Luxel Service Manual PDF

LUXEL V/VX-SERIES
PLATESETTER
ENGINEERS REFERENCE GUIDE
6800101004
FUJIFILM Electronic Imaging Ltd.

Fujifilm House
Boundary Way
Hemel Hempstead Tel: 01442 213440
Hertfordshire HP2 7RH Fax: 01442 343432
England Registered Number: 3244452
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IMPORTANT: Fujifilm products are so designed and constructed as to be safe without risk to health when
properly used (in accordance with the supplied documentation) and when the safety precautions contained in
this document are fully observed.
This product must not be copied without prior written authorization and is subject to change without notice.
For further information, contact the Custiomer Support Manager at the address given on the front page of this
manual.
CAUTION: FUJIFILM Electronic Imaging Limited cannot be held responsible for any loss or damage
to customers data by unauthorised third parties accessing the system. In the event that Fujifilm be-
comes aware of any computer virus which will or is likely to affect the system it will take reasonable
steps to bring this to the attention of customers but advises customers to take their own precautions
against unauthorised access.
WARNING: All precautions mentioned in this document must be strictly observed at all times. Person-
nel must read the contents of any documentation supplied and used with this product BEFORE com-
mencing any work with equipment described in this document.
This product must not be copied without prior written authorization and is subject to change without notice.
For further information, contact the Customer Support Manager at the address given on the front page of
this manual.
The manual was written and illustrated using the best possible information at the time of publication. Any
differences between the manual and equipment reflect improvements introduced after publication of the man-
ual. Changes, technical inaccuracies and typographic errors will be corrected in subsequent editions. As
part of our policy of continuous improvement, we reserve the right to alter design and specifications without
further notice.
WARNING: All precautions mentioned in this document must be strictly observed at all times. Personnel
must read the contents of any documentation supplied and used with this product BEFORE commencing any
work with equipment described in this document.
NOTE: Measured noise level for this product is less than 65 dBa.
TRADEMARKS and COPYRIGHT: The name Fujifilm and the Fuji logo are trademarks of Fuji Photo Film
Co., Ltd., Tokyo; Luxel, Celix, FineScan, Celsis, C-dot, C-Scan, Quattro, Lanovia, ColourKit and Celebrant
are trademarks of FUJIFILM Electronic Imaging Ltd; Adobe, Accurate, PageMaker, Illustrator, PostScript,
Photoshop and Type Manager are trademarks of Adobe Systems Inc. that may be registered in certain juris-
dictions; Windows and Windows NT are trademarks of Microsoft Corporation that may be registered in cer-
atin jurisdictions; All other company names, products or brand names are trademarks of their respective
holders.
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About this Guide

This Guide provides qualified Luxel service engineers with sufficient information to maintain all
variants of the Luxel V/Vx-Series 9600 (B1) and 6000 (B2) CTP system. It assumes the engineer
has attended an authorised training course and is familiar with laser safety, product features and
service procedures required to ensure the long-term operation of the equipment.
The Guide is divided into three volumes:
Volume 1 - System Overview. Describes the main product features, configurations, modules
and principles of operation.
Volume 2 - System Description. Describes the modules and assemblies in more detail and
shows how they are interconnected.
Volume 3 - System Replacements. Shows how to remove and replace field replaceable units
(FRUs), and carry out any set ups.
System faults are reported as error codes that appear on the MMI console. An up to date listing of
the code numbers, fault descriptions and recommended recovery steps are in a regularly updated
Guide called Luxel V/Vx-Series Error Codes. This is available as a Manual from the FFEI Service
Information Online site.
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TABLE OF CONTENTS
Volume 1 Chapter 1 Introducing The Luxel System
Luxel CTP Features ..................................................................................................1-1
Introducing the Luxel CTP Configuration ...........................................................1-2
Introducing the Luxel Modules ...........................................................................1-3
Autofeeder ...............................................................................................................1-5
Elevator.................................................................................................................1-6
Trolley and Cassette..............................................................................................1-6
Plate Transport Module (PTM) .............................................................................1-7
Interleaf Bin ..........................................................................................................1-7
Plate Handling Mechanisms .................................................................................1-7
Air Knife ...............................................................................................................1-7
Imaging Engine .......................................................................................................1-7
Optics Base and Periscope ....................................................................................1-7
Loading Platform..................................................................................................1-8
Traverse Carriage .................................................................................................1-8
Drum and Input/Output Modules .......................................................................1-8
RFI Box .................................................................................................................1-8
Man-Machine Interface (MMI) Console................................................................1-8
Purified Air System ..............................................................................................1-8
Drum Vacuum System..........................................................................................1-9
Buffer........................................................................................................................1-9
Plate Processor ........................................................................................................1-9
Plate Stacker ............................................................................................................1-9
Volume 1 Chapter 2 Introducing Luxel Modules

Luxel System - Modules and Variants .................................................................2-1
Introducing Plate Handling ...................................................................................2-3
Plate Handling Board (FHMB) ..............................................................................2-5
FHMB Operation ..................................................................................................2-7
Stepper Motors: ................................................................................................2-9
Introducing Traverse Scanning ...........................................................................2-10
Traverse Board (STB)............................................................................................2-11
STB Main Functions............................................................................................2-12
Cassette and Media Database Control ...............................................................2-15
Plate Processor Interface Commands .................................................................2-16
Introducing Image Expose ...................................................................................2-17
Image Expose Modules and Operations ............................................................2-17
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Image Data and Optical Path ..............................................................................2-20

Optics Base Module Control ...............................................................................2-22
Optical Motor Control (VBOMB)........................................................................2-22
CAN Control Interface: ..................................................................................2-24
Diagnostics: ....................................................................................................2-24
MPU: ..............................................................................................................2-24
Flash Memory:................................................................................................2-24
Voltages and Drives: ......................................................................................2-24
Motor Drivers.................................................................................................2-25
EOD Control .......................................................................................................2-25
EODHV Operation .........................................................................................2-25
Introducing Luxel Power and Control ..............................................................2-28
Luxel System Board (LSB) ...................................................................................2-28
LSB System Control ............................................................................................2-28
LSB Image Data Path ..........................................................................................2-30
CAN Network Control ........................................................................................2-33
Power Distribution Control .................................................................................2-35
Volume 1 Chapter 3 Servicing Safety Practice

Health and Safety at Work (All Variants) ..........................................................3-1
Warnings and Cautions .........................................................................................3-1
Clothing and Jewellery ..........................................................................................3-2
Equipment and Tools .............................................................................................3-2
Site Safety Rules ......................................................................................................3-2
Laser Safety ................................................................................................................3-2
Manual Shutter Control .........................................................................................3-2
General Laser Warnings ........................................................................................3-3
Safety Warnings ......................................................................................................3-4
A DLA Room ........................................................................................................3-4
A DLA Curtain .....................................................................................................3-5
Mains Rating Labels ...............................................................................................3-5
Drum and Traverse Warning Labels ....................................................................3-6
Optics Base Warning Labels ..................................................................................3-8
RFI, Interlock and Filter Box Warning Labels .....................................................3-9
Drum Vacuum Pump Warning Label ................................................................3-12
Interlocked Warning Labels (Automatic Only) .................................................3-13
Plate Transport Module Warning Labels ...........................................................3-14
Autofeeder Warning Labels ................................................................................3-15
Safety Devices .......................................................................................................3-17
Unattended Equipment .......................................................................................3-17
Dust Prevention ....................................................................................................3-18
Electrical Safety .....................................................................................................3-18
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Mechanical Safety .................................................................................................3-18

Chemical Safety ....................................................................................................3-19
Spinner Safety .......................................................................................................3-19
Moving Parts Safety............................................................................................3-19
Acoustic Noise Safety .........................................................................................3-19
Safety Interlocks (All Variants) ...........................................................................3-19
Interlocked Covers ...............................................................................................3-20
Locked Covers ......................................................................................................3-21
Emergency Stop Circuit ........................................................................................3-22
Emergency Stop Operation.................................................................................3-22
Mechanical Safety ...................................................................................................3-24
At the Autofeeder (Automatic Only)..................................................................3-24
At the Plate Transport Module (Automatic Only) ............................................3-24
Inside the Drum (All Variants)............................................................................3-24
Antistatic Precautions (All Variants) .................................................................3-24
Field Service Antistatic Kit ..................................................................................3-25
Volume 2 Chapter 1 Platesetter Diagnostics

Introducing Luxel CTP Diagnostics .....................................................................1-1
Booting the Platesetter .............................................................................................1-2
Boot Sequence and Initialisation ...........................................................................1-4
Introducing Main Diagnostics ...............................................................................1-6
Introducing Diagnostic Tests .................................................................................1-7
System Self-Test Error Codes ................................................................................1-7
System Self-Test Descriptions ...............................................................................1-8
ROM Test..............................................................................................................1-8
RAM Test..............................................................................................................1-8
Interrupt Tests ......................................................................................................1-8
Registry Check......................................................................................................1-8
PSU Voltage Supply Check...................................................................................1-8
NVRAM Integrity Test..........................................................................................1-8
Stepper Motor Tests..............................................................................................1-8
Datum Tests......................................................................................................1-8
Full Travel Tests ...............................................................................................1-9
Plate Handling Motors .....................................................................................1-9
DC Motor Assembly Tests ....................................................................................1-9
Spinner Checks .....................................................................................................1-9
Optics Checks .......................................................................................................1-9
Output Data Path Checks .....................................................................................1-9
Processor Comms Checks .....................................................................................1-9
MMI Test Images ....................................................................................................1-9
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Describing MMI Error Codes .............................................................................1-10

Types of Errors......................................................................................................1-10
Fatal Error Closedown Sequence ........................................................................1-11
Error Logging ........................................................................................................1-11
Using the SaveLog Utility ....................................................................................1-11
How to Use Main Diagnostics .............................................................................1-12
Setting up a Terminal Window ...........................................................................1-12
Accessing Diagnostics ..........................................................................................1-13
Main Menus........................................................................................................1-13
Obtaining the Diagnostics Menu ........................................................................1-13
Entering Diagnostic Commands .........................................................................1-13
Using Global Commands ....................................................................................1-14
Using Verbose .......................................................................................................1-15
Running Soak Tests ..............................................................................................1-16
Using the Debug Utility......................................................................................1-16
ddbg ...............................................................................................................1-17
edbg................................................................................................................1-17
ddeb................................................................................................................1-17
Using Script Commands.....................................................................................1-18
recordscript ....................................................................................................1-18
showscript ......................................................................................................1-18
runscript .........................................................................................................1-18
deletescript .....................................................................................................1-18
listscripts ........................................................................................................1-18
zeroscripts ......................................................................................................1-18
Obtaining Command Line Help .........................................................................1-18
Running Main Diagnostics ...................................................................................1-19
Using Log Utils Menus .........................................................................................1-19
log_utils menu ......................................................................................................1-20
log_utils/configuration menu ............................................................................1-22
log utils/nvram menu..........................................................................................1-23
Using Test Menus ...................................................................................................1-27
test/basic menu ....................................................................................................1-27
test/registry menu ...............................................................................................1-27
test/optics_motors menu ....................................................................................1-28
test/traverse menu ...............................................................................................1-29
test/spinner menu ................................................................................................1-29
test/optics menu...................................................................................................1-30
test/processor menu ............................................................................................1-30
Using Service Menus .............................................................................................1-30
service/memory menu ........................................................................................1-31
service/evt menu..................................................................................................1-31
service/remote menu ...........................................................................................1-32
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service/optics menu .............................................................................................1-32

service/optics/laser menu..................................................................................1-32
service/optics/motors menu..............................................................................1-35
service/optics/motors/move_motors (optics)...............................................1-36
service/optics/motors/simulate menu..........................................................1-37
service/optics/optics_mmi setup screensM.......................................................1-37
service/motors menu (stepper) ..........................................................................1-37
service/sensors menu ..........................................................................................1-39
service/time menu ...............................................................................................1-43
service/traverse menu .........................................................................................1-43
service/spinner menu ..........................................................................................1-45
service/actuators ..................................................................................................1-45
service/disk menu ................................................................................................1-46
service/disk/dfs menu.......................................................................................1-47
service/testpatns menu .......................................................................................1-48
service/job_mgr menu .........................................................................................1-50
service/image_mgr menu...................................................................................1-52
service/medproc/ ................................................................................................1-53
service/medtran menu ........................................................................................1-54
service/dbases menu ...........................................................................................1-58
service/dbases/cassette......................................................................................1-58
service/dbases/elevator.....................................................................................1-59
service/utils menu ...............................................................................................1-60
Checking Config and NVRAM Data..................................................................1-60
Introducing Configuration Data Files ................................................................1-60
Board Config Files ................................................................................................1-62
ID Data................................................................................................................1-63
History Data .......................................................................................................1-63
System Config Files ..............................................................................................1-63
ID Data................................................................................................................1-63
Revision Data......................................................................................................1-63
History Data .......................................................................................................1-63
System Registry Files............................................................................................1-64
HDD Data Files .....................................................................................................1-64
NVRAM Data ........................................................................................................1-65
Updating the System Registry.............................................................................1-65
Using Display_Registry ......................................................................................1-66
Using Update_Registry.......................................................................................1-66
Upgrading Embedded Firmware .......................................................................1-66
Setting Up Persistent Images ...............................................................................1-67
Creating a PI (Celebrant RIP) ..............................................................................1-67
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Deleting and Editing a PI (Celebrant RIP) .........................................................1-68

Creating a PI (Rampage RIP) ..............................................................................1-68
Running MMI Self-Tests .......................................................................................1-69
Using Media Tools .................................................................................................1-70
Fully-Automatic ....................................................................................................1-70
Manual and Semi-Automatic ..............................................................................1-70
Volume 2 Chapter 2 Plate Handling Control

Plate Handling Control Modules..........................................................................2-1
Autofeeder...............................................................................................................2-1
PTM ......................................................................................................................2-4
Imaging Engine .......................................................................................................2-7
Buffer .....................................................................................................................2-11
Plate Handling Assemblies ..................................................................................2-13
Plate Handling Sensors ........................................................................................2-13
Opto-Reflective Sensors......................................................................................2-13
Opto-Slotted Sensors ..........................................................................................2-15
Reflective/Diffused Sensor.................................................................................2-16
Micro-switch Sensor ...........................................................................................2-16
Magnet Reed Sensor ...........................................................................................2-16
Inductive Sensor .................................................................................................2-16
Plate Handling Motors .........................................................................................2-16
Stepper Motor .....................................................................................................2-16
DC Motor............................................................................................................2-17
Synchronous Motor ............................................................................................2-17
Plate Handling Solenoids ....................................................................................2-17
Plate Handling Operation and Sequence ..........................................................2-18
Autofeeder Operation.........................................................................................2-18
PTM Operation ...................................................................................................2-18
Engine Operation................................................................................................2-19
Buffer Operation.................................................................................................2-20
Plate Handling Control Sequence .......................................................................2-21
At the Autofeeder ...............................................................................................2-21
At the PTM .........................................................................................................2-22
At the Engine (Fully-Automatic with Punch) .....................................................2-26
At the Engine (Non-Punch with Large Plates)....................................................2-32
At the Engine (Non-Punch with Small Plates) ....................................................2-37
At the Buffer (B1 Variants Only).........................................................................2-42
Reversing the Cassette (Fully-Automatic) ..........................................................2-43
Recovering from Plate Errors (Fully-Automatic) ................................................2-45
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Plate Handling Flowcharts ..................................................................................2-46
Volume 2 Chapter 3 Plate Handling Modules

Introducing Plate Handling Modules ..................................................................3-1
Plate Handling Modules and Variants .................................................................3-2
Autofeeder ...............................................................................................................3-3
Plate Transport Module .........................................................................................3-4
Engine ......................................................................................................................3-5
Buffer........................................................................................................................3-7
Autofeeder Plate Handling Modules ...................................................................3-8
Autofeeder Control Assemblies ............................................................................3-8
Elevator Control Box.............................................................................................3-9
RFI Filter .............................................................................................................3-10
Inverter ...............................................................................................................3-11
Error Codes ....................................................................................................3-13
Contactor ............................................................................................................3-14
Elevator Interlock Controls .................................................................................3-14
Elevator Control PCB .........................................................................................3-16
Elevator Distribution PCB ..................................................................................3-18
Cassette Door Lock Solenoid ..............................................................................3-20
Trolley Docking Indicator...................................................................................3-20
Z-Direction Arm .................................................................................................3-21
Absolute Limit Safety Switch..............................................................................3-22
Autofeeder Motors..............................................................................................3-22
Elevator Motor/Gearbox (BM26) ...................................................................3-22
Autofeeder Solenoids..........................................................................................3-22
Autofeeder Sensors.............................................................................................3-23
Autofeeder Mechanical Assemblies ...................................................................3-24
Main Frame Assemblies......................................................................................3-25
Multi-Cassette Housing Assembly .....................................................................3-25
Cassette Loading Door........................................................................................3-26
Elevator Frame....................................................................................................3-26
Sensor Vane ........................................................................................................3-27
Elevator Drive Assemblies..................................................................................3-27
Trolley.................................................................................................................3-29
Trolley Assemblies .........................................................................................3-29
Trolley Operation ...........................................................................................3-29
Cassette...............................................................................................................3-30
Cassette Assemblies........................................................................................3-30
Plate Transport Modules ......................................................................................3-33
PTM Control Assemblies ....................................................................................3-33
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FHMB PCB (2) Assembly....................................................................................3-34

PTM Distribution PCBs ......................................................................................3-43
Sensor Distribution PCB .................................................................................3-43
24 V Distribution PCB (New) .........................................................................3-44
Cassette ID PCB..............................................................................................3-45
Motor Assemblies and Operations .....................................................................3-46
PTM Solenoids and Relays .................................................................................3-47
PTM Sensors .......................................................................................................3-47
PTM Mechanical Modules ...................................................................................3-51
X-Direction Door ................................................................................................3-51
Cassette Forward ................................................................................................3-52
Cassette Forward Assembly ...........................................................................3-52
Cassette Forward Operation...........................................................................3-53
Stack (Height) Increment ....................................................................................3-54
Feed Head...........................................................................................................3-55
Antistatic Brush ..................................................................................................3-56
Retard Pad ..........................................................................................................3-57
Interleaf Diverter and Drive Roller .....................................................................3-58
Plate Transport Guides .......................................................................................3-59
Engine Plate Handling Modules .........................................................................3-61
Engine Control Assemblies .................................................................................3-61
Engine Distribution PCBs ...................................................................................3-71
Sensor Distribution PCB (Output) ..................................................................3-72
Sensor Distribution PCB (Input).....................................................................3-73
24V Distribution PCB (New) ..........................................................................3-73
Registration Pin Isolation PCB............................................................................3-74
Motors ................................................................................................................3-75
Solenoids and Relays ..........................................................................................3-77
Sensors................................................................................................................3-77
Mixer Fan............................................................................................................3-81
Engine Mechanical Modules ...............................................................................3-81
Plate Loading Platform .......................................................................................3-86
Input Module......................................................................................................3-87
Output Module ...................................................................................................3-88
Drum ..................................................................................................................3-90
Transport Push Bar (Spring) ...............................................................................3-91
Punch, Registration and Centerer (New Billows) ...............................................3-93
Using Punch Diagnostic Commands ..............................................................3-94
Punch Mechanism Assembly .........................................................................3-94
Punch Mechanism Operation .........................................................................3-95
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Registration Mechanism Assembly ................................................................3-95

Registration Mechanism Operation ................................................................3-96
Centerer Mechanism Assembly......................................................................3-96
Centerer Mechanism Operation .....................................................................3-96
Punch Configurations .........................................................................................3-96
Punch, Registration and Centerer (Fuji)..............................................................3-98
Registration Module ...........................................................................................3-99
Swing Roller Module ........................................................................................3-100
Chad Tray (Punch Only)...................................................................................3-101
Buffer Plate Handling Modules ........................................................................3-102
Buffer Control Assemblies .................................................................................3-102
Buffer Control Modules ....................................................................................3-102
Buffer Assemblies (New) ...................................................................................3-104
Inter-Module Connections and Control ..........................................................3-105
Autofeeder-to-PTM Interconnections ...............................................................3-105
PTM-to-Engine Interconnections ......................................................................3-105
Buffer-to-Engine Interconnections ....................................................................3-106
Volume 2 Chapter 4 Traverse Scan Modules

Introducing the Traverse Scan Modules .............................................................4-1
Beam Assemblies ....................................................................................................4-1
Traverse Carriage Assemblies ...............................................................................4-2
Traverse PCB ........................................................................................................4-5
Location ............................................................................................................4-5
LEDs and Links ................................................................................................4-5
Traverse PCB Connectors .................................................................................4-5
Connector Pin Descriptions ..............................................................................4-6
Test Points ........................................................................................................4-6
Traverse PCB Functional Description ...................................................................4-6
MPU Controller ................................................................................................4-6
Media Scan System Description ............................................................................4-7
Scanning Overview ................................................................................................4-7
Mixer Fan and Baffles ...........................................................................................4-8
Traverse PCB Imaging Control .............................................................................4-8
Scan Interlock Protection ......................................................................................4-8
Traverse Diagnostics.............................................................................................4-8
Umbilical Interface................................................................................................4-8
Spinner Control Subsystem ...................................................................................4-8
Spinner Encoder ...................................................................................................4-9
Spinner Controller ................................................................................................4-9
Spinner Diagnostics ..............................................................................................4-9
Spinner Condition Sensing and Braking...............................................................4-9
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Current Limit....................................................................................................4-9
Braking .............................................................................................................4-9
Traverse Motor Control Subsystem ....................................................................4-10
Linear Encoding .................................................................................................4-10
Linear Scale ....................................................................................................4-11
Readhead........................................................................................................4-11
Traverse Servo................................................................................................4-12
Traverse Amplifier .........................................................................................4-13
Traverse Motor Assemblies ............................................................................4-13
Traverse Actuators .........................................................................................4-13
Carriage Position Encoder ..............................................................................4-14
Home Actuator...............................................................................................4-15
Index Actuator (Reference Mark) ...................................................................4-15
Overspeed and Braking ..................................................................................4-16
Optical/Traverse Synchronisation .....................................................................4-16
Traverse Diagnostics...........................................................................................4-17
Traverse Initialisation Sequence .........................................................................4-17
Edge Detect System Description .........................................................................4-18
Module Assemblies ..............................................................................................4-18
Edge Detect PCB .................................................................................................4-18
Operation...............................................................................................................4-19
Volume 2 Chapter 5 Media Expose Modules

Media Expose System ..............................................................................................5-1
Optics Base Modules ..............................................................................................5-1
Laser Module ........................................................................................................5-5
Laser Module Assemblies.................................................................................5-5
Photo Diode (PD) PCB..........................................................................................5-8
Laser Diode (LD) PCB ..........................................................................................5-9
Laser Air Temperature and Humidity Control.....................................................5-9
Beam Shifter........................................................................................................5-10
Waveplate...........................................................................................................5-11
Electro-Optic Deflector (EOD) ............................................................................5-11
Beam Combiner ..................................................................................................5-12
Neutral Density (ND) Filter ................................................................................5-12
Position Detector (POD) .....................................................................................5-13
Focus Adjust .......................................................................................................5-14
Aperture Control (Spot Size) ..............................................................................5-15
Optics Lenses .....................................................................................................5-16
Optics Mirrors ....................................................................................................5-16
Motors and Sensors ............................................................................................5-17
EODHV Module .................................................................................................5-17
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EODHV PCB...................................................................................................5-17
HV Transformer .............................................................................................5-19
Optics System Configurations.............................................................................5-20
Periscope Assemblies and Operation .................................................................5-20
Top Mirror (M1) Assembly .................................................................................5-21
Laser Power Detector (LPD) Assembly...............................................................5-21
Bottom Mirror (M2) Assembly............................................................................5-22
Spinner Assembly and Operation.......................................................................5-23
Fast Photo Detect (FPD) .......................................................................................5-25
Optical Motor Control PCB (VBOMB) ...............................................................5-26
Optical Motor Control PCB Assembly ................................................................5-26
Location ..........................................................................................................5-26
Connectors......................................................................................................5-26
Fuses...............................................................................................................5-27
Links...............................................................................................................5-28
Optics Base Cabling ..............................................................................................5-28
Media Expose Control and Operation ...............................................................5-29
Expose Sequence ...................................................................................................5-29
System Calibration ...............................................................................................5-29
Expose Control Functions ....................................................................................5-29
EOD Deflection ...................................................................................................5-30
Laser Aging Control ...........................................................................................5-30
Power Balance.....................................................................................................5-32
Beam Coincidence...............................................................................................5-32
Drum Coincidence..............................................................................................5-33
Exposure Calibration ..........................................................................................5-33
Volume 2 Chapter 6 Power and Control Modules

Introducing Power and Control Modules ..........................................................6-1
Accessing Engine Assemblies ...............................................................................6-1
System Power Distribution ....................................................................................6-2
AC Mains Power Pre-Requirements.....................................................................6-2
Mains Filter Box ......................................................................................................6-3
System AC/DC Cable Distribution ......................................................................6-3
System DC Cable Distribution ..............................................................................6-4
Interlock Box Modules ............................................................................................6-6
Interlock Box Functions .........................................................................................6-6
External I/O Interconnections ..............................................................................6-7
Mains Input and Emergency Stop Control ..........................................................6-9
Mains Input Control Assemblies ..........................................................................6-9
Emergency Stop Control...................................................................................6-9
Emergency Stop Replacements.......................................................................6-11
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Drum Vacuum Control ........................................................................................6-11

Interlocks Control .................................................................................................6-11
Interlock Box Assemblies ...............................................................................6-11
Interlock Replacements ..................................................................................6-12
Interlock Checks .............................................................................................6-12
Interlock Operation ........................................................................................6-12
External Interlocks..........................................................................................6-16
RFI Box Modules ....................................................................................................6-16
RFI Box Layout and Assemblies .........................................................................6-16
RFI Box External I/O Connections .....................................................................6-18
RFI Box - DC Power Modules..............................................................................6-19
PSU 1 ......................................................................................................................6-19
Fan Assemblies .....................................................................................................6-20
Fan Assembly .....................................................................................................6-20
System Control Fusing .........................................................................................6-20
Power Filter PCB ..................................................................................................6-21
Power Filter Assembly........................................................................................6-21
Location..........................................................................................................6-21
Connectors......................................................................................................6-21
Connector Pin Descriptions ............................................................................6-21
Power Filter PCB Operation ...............................................................................6-22
RFI Box - Image Processing Modules ................................................................6-23
Electro-Optical Deflector Driver (EODD) PCB..................................................6-23
EODD PCB Assembly .........................................................................................6-23
Location..........................................................................................................6-24
Connectors......................................................................................................6-24
Fuses...............................................................................................................6-24
LEDs and Links ..............................................................................................6-24
Test Points ......................................................................................................6-24
EODD PCB Operation ........................................................................................6-25
EOD DIFF Deflector .......................................................................................6-26
System Board (LSB) PCB......................................................................................6-26
System PCB Assembly ........................................................................................6-26
Location..........................................................................................................6-26
Connectors......................................................................................................6-26
Fuses...............................................................................................................6-27
ICs (Main Devices) .........................................................................................6-27
LEDs ...............................................................................................................6-28
Links...............................................................................................................6-28
Test Points ......................................................................................................6-29
Dongle ................................................................................................................6-29
Hard Disk Drives (HDD) .....................................................................................6-29
Disk Drive Assembly ..........................................................................................6-29
P RELIMINARIES
MMI and External Alert ........................................................................................6-30

Man Machine Interface (MMI) ............................................................................6-30
Fuses...............................................................................................................6-31
External Alert Control ..........................................................................................6-33
Volume 2 Chapter 7 Vacuum and Air Control

Vacuum and Contamination Control ..................................................................7-1
Drum Vacuum and Drum Blow............................................................................7-1
Contamination Control ..........................................................................................7-1
Contamination Managementl ...............................................................................7-3
Drum Vacuum and Drum Blow............................................................................7-4
Drum Configurations .............................................................................................7-4
Drum with Manifolds ...........................................................................................7-4
Drum with Chambers ...........................................................................................7-5
Drum Vacuum and Blow Assemblies ..................................................................7-6
Drum Vacuum and Blow System .........................................................................7-7
B1 Fully-Auto and Manual (without a Punch)......................................................7-8
B1 Fully-Auto (with a Punch) .............................................................................7-12
B2 Semi-Auto and Manual (without a Punch) ....................................................7-16
Air Knife ..................................................................................................................7-18
Air Knife (Compressor)........................................................................................7-18
Air Knife (Fan Blower) .........................................................................................7-19
Servicing the Air Knife .........................................................................................7-20
Fan Blower ..........................................................................................................7-20
Control Relay (BV23) ..........................................................................................7-21
Air Purifier (PAT) ...................................................................................................7-21
Servicing the PAT .................................................................................................7-22
Service Filtering for the Optics Base ...................................................................7-22
Volume 2 Chapter 8 System Cabling Descriptions

Cable Pin Descriptions ............................................................................................8-1
I/LOCKS_MAINS (9970-0119) ..............................................................................8-1
MAINS_RFI_IN (9970-0122) ..................................................................................8-2
DISK_PWR (9970-0129) ..........................................................................................8-2
EOD (9970-0135) .....................................................................................................8-2
CAN2 (9970-0138) ...................................................................................................8-3
MMI (9970-0139) .....................................................................................................8-4
INT_S41/S42 (9970-0140) .......................................................................................8-5
ENG_INT (9970-0142) ............................................................................................8-5
INT_STAT (9970-0143) ...........................................................................................8-7
P RELIMINARIES
CAN5_ENG (9970-0145) ........................................................................................8-8

ENG_FHMBPWR (9970-0146) ...............................................................................8-8
CAN3_ENG (9970-0147) ......................................................................................8-10
PUMP/PTM_PWR (9970-0150) ...........................................................................8-11
FEED_INT (9970-0152) .........................................................................................8-11
CAN5_INT (9970-0155) ........................................................................................8-12
PWR3_INT (99700156) .........................................................................................8-12
CAN3_INT (9970-0157) ........................................................................................8-13
ENG_M7 (9970-0159)............................................................................................8-14
RIB/RIB2 (9970-0161) ...........................................................................................8-15
BUFF_M7 (9970-0168) ..........................................................................................8-15
INT_S62/S71 (9970-0177).....................................................................................8-16
INT_S56/57/65 (9970-0178) ................................................................................8-16
ENG_S4 (9970-0183) .............................................................................................8-17
INT_S49/S50 (9970-0186).....................................................................................8-17
ENG_S5 (9970-0187) .............................................................................................8-18
INT_S52 (9970-0188) .............................................................................................8-18
ENG_S10/11 (9970-0190) .....................................................................................8-18
ENG_S14/12/3 (9970-0194) .................................................................................8-19
ENG_S8/S9 (9970-0195) .......................................................................................8-20
INT_M22ASSY (9970-0198) .................................................................................8-21
INT_S55/59 (9970-0210) .......................................................................................8-22
INT_S66/S53 (9970-0214).....................................................................................8-22
INT_OUT (9970-0216) ..........................................................................................8-23
RIB7 (9970-0219) ...................................................................................................8-24
ENG_DIAGS (9970-0221) .....................................................................................8-26
ALERT (9970-0223) ...............................................................................................8-26
INT_MAINS (9970-0226) .....................................................................................8-27
RIB8 (9970-0229) ...................................................................................................8-27
ELV_CTRL (9970-0230) ........................................................................................8-28
MAINS_ELV_IN (9970-0231) ..............................................................................8-29
ELV_IN (9970-0236) ..............................................................................................8-29
ELV_LOCK (9970-0237) .......................................................................................8-30
ELV_CON_24V (9970-0238) ................................................................................8-31
ENG_PROC (9970-0239) ......................................................................................8-32
MAINS_INT_PUMP (9970-0240) ........................................................................8-32
MAINS_DIST (9970-0243) ....................................................................................8-33
INT_EMERG (9970-0246) .....................................................................................8-33
I/LOCK_DC (9970-0252) .....................................................................................8-34
I/LOCK_EMERG (9970-0253) .............................................................................8-36
P RELIMINARIES
INT_M20/M27 (9970-0255) .................................................................................8-37

INT_M25/M21 (9970-0256) .................................................................................8-37
ENG_M1 (9970-0281)............................................................................................8-38
ENG_M2 (9970-0282)............................................................................................8-38
ENG_M4 (9970-0283)............................................................................................8-38
INT_S45ASSY (9970-0284) ...................................................................................8-39
INT_S76 (9970-0285) .............................................................................................8-40
I/LOCK_PUMPCTRL (9970-0287)......................................................................8-40
BUFF_S19/20 (9970-0288) ....................................................................................8-41
ENG_S19/20 (9970-0289) .....................................................................................8-41
ENG_S21 (9970-0291) ...........................................................................................8-42
ENG_S79 (9970-0292) ...........................................................................................8-42
MIX_FAN (9970-0295) ..........................................................................................8-43
MFAN (9970-0296) ................................................................................................8-43
BUFF_LOCK (9970-0298) .....................................................................................8-43
PROC_COMMS (9970-0306) ................................................................................8-44
PSU_I/LOCK (9970-0310) ....................................................................................8-44
ELV_TLOCKSOL (9970-0379) .............................................................................8-45
ENG_BLOW (9970-0380)......................................................................................8-45
ENG_S3/S12 (9970-0406) .....................................................................................8-46
ENG_S109/110 (9970-0390) .................................................................................8-46
ENG_S100/103 (9970-0392) .................................................................................8-47
MAINS_PSU (9970-0420) .....................................................................................8-48
PSU (9970-0421) ....................................................................................................8-48
DISK DATA (9970-0423) ......................................................................................8-50
MAINS_DIST (9970-0424) ....................................................................................8-50
CAN1 (9970-0425) .................................................................................................8-51
VBOMB_PWR (9970-0427) ...................................................................................8-51
24V_ENG (9970-0428)...........................................................................................8-52
EDGE_LASER (9970-0434) ...................................................................................8-52
VBOMB_SENSORS (99700435) ...........................................................................8-53
VBOMB_LPD (9970-0436) ....................................................................................8-54
VBOMB_LPDM (9970-0437) ................................................................................8-55
VBOMB_APM (9970-0438) ..................................................................................8-55
VBOMB_NDM (9970-0439)..................................................................................8-56
VBOMB_FOCM (9970-0440) ................................................................................8-56
PSU_CTRL (9970-0442) ........................................................................................8-57
VBOMB_POD (9970-0443) ...................................................................................8-57
I/LOCK_MAIN (9970-0444) ................................................................................8-58
ENG_S6/S15 (9970-0445) .....................................................................................8-59
P RELIMINARIES
ENG_BLOW (9970-0446) .....................................................................................8-59

I/LOCK_DC (9970-0447) .....................................................................................8-60
EDGE_DETECT (9970-0448) ................................................................................8-63
LSB_DATA_VBOMB (9970-0449) .......................................................................8-63
VBOMB_IHPEN (9970-0450) ...............................................................................8-64
REG_PIN (9970-0451) ...........................................................................................8-65
REG_FHMB (9970-0452) ......................................................................................8-65
COMP_PANEL (9970-0453) ................................................................................8-66
COMP_MAINS (9970-0454) .................................................................................8-66
ILOCK_COMP (99700-455)..................................................................................8-66
ILOCK_CTRL (9970-0456) ...................................................................................8-67
SOL_CTRL (9970-0457) ........................................................................................8-67
RIB3 (9970-0458) ...................................................................................................8-68
ENG_S1/2 (9970-0459) .........................................................................................8-68
VAC (9970-0460) ...................................................................................................8-69
ENG_M6 (9970-0461)............................................................................................8-70
ENG_M38 (9970-0462) ..........................................................................................8-70
ENG_S118 (9970-0463) .........................................................................................8-70
ENG_M10 (9970-0464) ..........................................................................................8-71
ENG_M11 (9970-0465) ..........................................................................................8-71
ENG_S114/116/113 (9970-0466) .........................................................................8-71
ENG_M3/5 (9970-0467) .......................................................................................8-72
ENG_M36/37 (9970-0468) ...................................................................................8-73
INV_MOT (9970-0471) .........................................................................................8-73
VBOMB_FAN (9970-0472) ...................................................................................8-74
CAN_FHMB1_4 (9970-0473) ...............................................................................8-74
PUMP (9970-0479) ................................................................................................8-75
ENG_FHMB_PWR (99700480) ............................................................................8-76
ILOCK_LINK (99700481) .....................................................................................8-76
BUFF_LINK (9970-0482) ......................................................................................8-77
ENGB1_S118 (9970-0490) .....................................................................................8-77
ENGB1_M10 (9970-0491) .....................................................................................8-77
ENGB1_S1/S2 (9970-0492) ..................................................................................8-78
ILOCK_LINK (9970-0493) ....................................................................................8-78
ENGB1_M11 (9970-0494) .....................................................................................8-79
ENGB1_S114/116/113 (9970-0495).....................................................................8-79
ENG_1BHP_S3/S10/S14 (9970-0497) .................................................................8-80
ENG_IHP_M3/5 (9970-0498) ..............................................................................8-81
ENG_FPD_S21 (9970-0499) ..................................................................................8-82
MAN_STOP (9970-0500) ......................................................................................8-82
P RELIMINARIES
SEMI_S109/110 (9970-0501) ................................................................................8-82

SEMI_M36/37 (9970-0502)...................................................................................8-83
BV41PUNCH_LINK (9970-0503) ........................................................................8-83
BV41WEB_LINK (9970-0504) ..............................................................................8-84
EXT_M11 (9970-0505) ...........................................................................................8-84
FRONT_SENSOR_EXT (9970-0506) ....................................................................8-85
B1_FRONTSENSOR (9970-0507) .........................................................................8-86
B2_FRONTSENSOR (9970-0508) .........................................................................8-87
B2_M11 (9970-0509) ..............................................................................................8-87
B1_M11 (9970-0510) ..............................................................................................8-88
INT_STAT (9970-0511) .........................................................................................8-88
ENG_BLOW_AUTO_WEB (9970-0512) .............................................................8-89
ENG_BLOW_AUTO_PUNCH (9970-0516)........................................................8-89
AIRKNIFE_VAC (9970-0517) ..............................................................................8-90
XBLW3_IPWR (9970-0518) ..................................................................................8-91
Volume 2 Chapter 9 System Cabling Views
Volume 3 Chapter 1 Routine Maintenance

Field Service Tools....................................................................................................1-1
Overriding the Interlocks .......................................................................................1-2
Opening Service Covers ..........................................................................................1-3
Manual and Semi-Automatic ................................................................................1-3
Fully-Automatic ......................................................................................................1-3
Maintenance Schedule.............................................................................................1-4
Cleaning Procedures ................................................................................................1-5
Cleaning the Spinner Mirror and L6 Lens ...........................................................1-5
Focusing Lens (L6)................................................................................................1-5
Cleaning the Traverse Assemblies ........................................................................1-6
Linear Scale and Drive Rail...................................................................................1-6
Readhead ..............................................................................................................1-7
Drive Rail Wiper ...................................................................................................1-7
Cleaning the PTM Assemblies ..............................................................................1-7
Feed Head ........................................................................................................1-7
Retard Pad ........................................................................................................1-7
Guides and Surfaces .........................................................................................1-7
Air Knife ...........................................................................................................1-7
Cleaning the Engine Assemblies ...........................................................................1-8
Drum ................................................................................................................1-8
Input and Output Modules ..............................................................................1-8
Punch................................................................................................................1-8
P RELIMINARIES
Push Bar (Cleaning)..........................................................................................1-8

LPD ..................................................................................................................1-8
MMI Touchpanel ..............................................................................................1-8
FPD Filter Lens .................................................................................................1-8
PAT Air Filter ...................................................................................................1-8
Cleaning the Module Interior ................................................................................1-9
Cleaning the Cassette .............................................................................................1-9
Cleaning the Elevator .............................................................................................1-9
Maintenance Procedures ........................................................................................1-9
Interlock Checks .....................................................................................................1-9
Punch Checks ..........................................................................................................1-9
Push Bar Flake Containment Checks .................................................................1-10
Drum Blow Checks...............................................................................................1-10
Laser Extinction Level Checks ............................................................................1-10
Pre-Cautionary Checks ........................................................................................1-11
Absolute Limit Sensor Check ..............................................................................1-12
Trolley and Cassette Checks ...............................................................................1-12
Trolley ............................................................................................................1-12
Cassette ..........................................................................................................1-12
Paper Detect Sensor Check ..................................................................................1-13
Light-Tight Checks ...............................................................................................1-13
Modules ..............................................................................................................1-13
Cassette...............................................................................................................1-13
Checking the Traverse ...........................................................................................1-14
Aligning the Carriage and Ball Cage ..................................................................1-14
Engine Traverse Level Check ..............................................................................1-14
Checking the Platesetter Output .........................................................................1-16
All Platesetter Variants ........................................................................................1-16
Check Image Form Adjustment ..........................................................................1-16
Check Expose Tint Quality .................................................................................1-16
Check Image Quality ..........................................................................................1-17
Platesetters Fitted With a Punch .........................................................................1-17
Check Plate Load in Drum..................................................................................1-17
Check Image Position and Skew.........................................................................1-19
Check for Punch Crop Accuracy.........................................................................1-19
Check Punch Centering ......................................................................................1-20
Set Image Traverse Centre Position ....................................................................1-21
Set Image Base Offset..........................................................................................1-22
Platesetters Fitted Without a Punch ...................................................................1-23
Check Image Skew Accuracy..............................................................................1-23
Check Edge Detect Function...............................................................................1-24
Check Image Start and Edge Accuracy ...............................................................1-24
P RELIMINARIES
Set Image Base Offset..........................................................................................1-25

Set Image Edge Sensor Offset .............................................................................1-26
Volume 3 Chapter 2 Plate Handling Service Procedures

Starting the Service Procedures.............................................................................2-1
General Plate HandlingReplacements..................................................................2-1
Sensor (Reflective-Opto PCB) Removal ................................................................2-1
Sensor (Opto-Slotted) Removal.............................................................................2-2
FHMB Replacement..............................................................................................2-3
Autofeeder Servicing ...............................................................................................2-4
Accessing Autofeeder Assemblies ........................................................................2-4
RFI Filter Replacement..........................................................................................2-4
Inverter Replacements ..........................................................................................2-5
Inverter Fault-finding .......................................................................................2-5
Inverter Replacement .......................................................................................2-6
Contactor Replacement.........................................................................................2-7
Elevator Control PCB Replacement ......................................................................2-7
Elevator Distribution PCB Replacement ...............................................................2-7
Setting Up the Elevator Shelf/Rail Alignments ....................................................2-7
Cassette Door Lock Replacement........................................................................2-11
Docking Lamp Replacement...............................................................................2-11
Docking Sensor Replacement .............................................................................2-12
Z-Direction Control Removal .............................................................................2-12
Z-Direction Control Replacement .......................................................................2-12
Absolute Limit Safety Switch Replacement ........................................................2-12
Elevator Motor (BM26) Replacement..................................................................2-13
Chain Tensioner Spring Replacement.................................................................2-13
Plate Transport Module Servicing ......................................................................2-15
Accessing PTM Assemblies .................................................................................2-15
PTM Sensor Replacements and Setups ..............................................................2-16
BS55 Sensor Setup...............................................................................................2-16
BS51 Sensor Setup...............................................................................................2-17
X-Direction Door ..................................................................................................2-18
X-Direction Door Replacement ...........................................................................2-18
Motor (BM27) Removal.......................................................................................2-19
Cassette Forward ..................................................................................................2-19
Cassette Forward Removal .................................................................................2-19
Cassette Forward Replacement...........................................................................2-19
Motor (BM20) Removal.......................................................................................2-20
Drive Belt Removal .............................................................................................2-20
P RELIMINARIES
Stack Increment ....................................................................................................2-20

Stack Increment Removal ...................................................................................2-20
Stack Increment Replacement.............................................................................2-21
Motor (BM21) Removal ......................................................................................2-21
Drive Belts Removal ...........................................................................................2-21
Feed Head .............................................................................................................2-21
Feed Head Removal............................................................................................2-21
Feed Head Replacement .....................................................................................2-22
Stack Height Position Check ..........................................................................2-23
Motor (BM23) Removal ......................................................................................2-24
Motor (BM22) Removal ......................................................................................2-24
Retard Pad .............................................................................................................2-24
Retard Pad Removal ...........................................................................................2-24
Retard Pad Replacement.....................................................................................2-25
Interleaf Diverter and Drive Roller.....................................................................2-25
Interleaf Diverter Removal .................................................................................2-25
Interleaf Diverter Replacement...........................................................................2-25
Interleaf Drive Rollers Removal..........................................................................2-26
Interleaf Drive Roller Replacement.....................................................................2-26
Transport Plate Guides ........................................................................................2-26
Pre-Diverter Plate Guide Removal .....................................................................2-26
Post-Diverter Plate Guide Removal ....................................................................2-27
Engine Interface (Output) Plate Guide Removal ................................................2-27
Engine Servicing .....................................................................................................2-27
Accessing Engine Assemblies .............................................................................2-27
Removing the Drum End Caps...........................................................................2-28
Loading Platform ..................................................................................................2-29
Loading Platform Removal (Manual) .................................................................2-29
Input Module ........................................................................................................2-31
Input Module Removal (All Variants) ................................................................2-31
Roller and Drive Belt Removal ...........................................................................2-31
Output Module .....................................................................................................2-32
Output Module Removal....................................................................................2-32
Fully-Automatic: ............................................................................................2-32
Semi-Automatic and Manual:.........................................................................2-33
Output Guide Removal ......................................................................................2-33
Transport Push Bar (Mark 2) ...............................................................................2-33
Removing the Push bar.......................................................................................2-33
Replace the Spring Shoes................................................................................2-34
Replacing the Push Bar .......................................................................................2-35
Aligning the Push Bar ....................................................................................2-35
P RELIMINARIES
Setting up the Push Bar.......................................................................................2-35

Drum Gear Segments ...........................................................................................2-36
Gear Segment Replacement ................................................................................2-36
Punch, Registration and Centerer (Billows) ......................................................2-37
Accessing Punch Assemblies ..............................................................................2-37
Complete Punch Removal ..................................................................................2-37
Accessing the Assembly .................................................................................2-37
Removing the Assembly.................................................................................2-39
Complete Punch Replacement............................................................................2-39
Punch Adjustments and Checks .........................................................................2-40
Visual Plate Punch Check...............................................................................2-41
Punch Mechanism Check ...............................................................................2-41
Registration Mechanism Check ......................................................................2-42
Centering Mechanism Check..........................................................................2-42
Punch Pin Checks ...............................................................................................2-42
Adjust Punch Pins ..........................................................................................2-42
Punch Checks .................................................................................................2-43
Registration Mechanism Replacements ..............................................................2-44
Motor (BM5) ...................................................................................................2-44
Sensors (BS10/11)...........................................................................................2-44
Registration Mechanism Checks.........................................................................2-44
Centerer Mechanism Replacements....................................................................2-44
Motor (BM3) and Gear Head ..........................................................................2-44
Sensors (BS14).................................................................................................2-44
Checking the Centerer Mechanism .....................................................................2-45
Adjusting the Centerer Mechanism ................................................................2-45
Punch Mechanism Replacements .......................................................................2-45
Motor (BM4) ...................................................................................................2-45
Sensors (BS8/9) ..............................................................................................2-45
Sensor (BS3) ....................................................................................................2-45
Punch Pins, Dies and Guides..........................................................................2-46
Punch Crop Depth Adjustment ......................................................................2-46
Drag Chain and Wiring Loom Removal .........................................................2-46
Registration Mechanism Replacements ..............................................................2-47
Motor (BM5) ...................................................................................................2-47
Sensors (BS10/11)...........................................................................................2-48
Registration Mechanism Checks.........................................................................2-48
Centerer Mechanism Replacements....................................................................2-48
Motor (BM3) and Gear Head ..........................................................................2-48
Sensors (BS12/13)...........................................................................................2-48
Sensors (BS14).................................................................................................2-49
Checking the Centerer Mechanism .....................................................................2-49
Punch, Registration and Centerer (Fuji) .............................................................2-49
Accessing the Assembly......................................................................................2-49
Removing the Assembly .....................................................................................2-49
Complete Punch Replacement............................................................................2-51
P RELIMINARIES
Punch Adjustments and Checks .........................................................................2-51

Visual Plate Punch Check...............................................................................2-52
Punch Checks .................................................................................................2-52
Replacing the Punch Pins ...............................................................................2-52
Removing the Punch Motor ...........................................................................2-53
Replacing the Chad Wipers ............................................................................2-54
Swing Roller Module (SRM) ...............................................................................2-55
Swing Roller Module Replacements ...................................................................2-55
Swing Roller Module Checks..............................................................................2-56
Registration Module .............................................................................................2-57
Registration Module Replacement......................................................................2-57
MMI .......................................................................................................................2-57
MMI ReplacementM ...........................................................................................2-57
Buffer Servicing ......................................................................................................2-57
Lowering the Buffer .............................................................................................2-57
Accessing the Buffer Assemblies ........................................................................2-60
Removing the Upper Cover (Skin) .....................................................................2-60
Motor, Gear and Sensors .....................................................................................2-61
Motor Replacement ............................................................................................2-61
Gear Replacement...............................................................................................2-61
Drive Belts and Rollers.........................................................................................2-62
Drive Belt Replacement ......................................................................................2-62
Roller Replacement.............................................................................................2-62
Buffer Alignment Check ......................................................................................2-62
Volume 3 Chapter 3 Traverse Scan Service Procedures

Starting Scan System Replacements .....................................................................3-1
Accessing Traverse Scan Modules ......................................................................3-1
Traverse Carriage Access .......................................................................................3-2
Replacing Traverse Assemblies.............................................................................3-4
Baffle Assemblies ....................................................................................................3-4
Traverse PCB ...........................................................................................................3-6
Traverse Motor .......................................................................................................3-6
Drive Rail Wiper .....................................................................................................3-7
Umbilical Cable ......................................................................................................3-8
Spinner .....................................................................................................................3-9
Ball Cage Assembly ..............................................................................................3-11
Readhead ...............................................................................................................3-11
Edge Detect PCB and Laser Diode .....................................................................3-13
Check Edge Detect Function...............................................................................3-13
Replacing the Edge Detect PCB ..........................................................................3-14
P RELIMINARIES
Replacing the Laser Diode ..................................................................................3-15

Edge Detect Setup Procedure..............................................................................3-16
Volume 3 Chapter 4 Optics Service Procedures

Starting Optics Module Replacements ................................................................4-1
Accessing Expose Modules....................................................................................4-2
Optics Replacement Setups ....................................................................................4-3
Find LPD Position...................................................................................................4-5
Update Laser Parameters.......................................................................................4-6
Clear Laser Aging Statistics ...................................................................................4-7
Set up Laser Current Limit and Start Aging Log ................................................4-8
Check Power Balance (2-Beam Only) ...................................................................4-8
Set Laser Extinction ................................................................................................4-9
Reset Beam Coincidence (2-Beam Only) ............................................................4-10
Run Beam Coincidence (2-Beam Only) ..............................................................4-10
Set up and Locate FPD .........................................................................................4-11
Set up ND Characterisation .................................................................................4-12
Reset Spinner Contamination Checks ................................................................4-12
Run Exposure Calibration ...................................................................................4-12
Set up Auto Focus .................................................................................................4-12
Set up Auto ND Wedge (2-Beam Only) .............................................................4-12
Set up Auto Threshold Wedge (2-Beam Only) ..................................................4-13
Set up Auto Coincidence Y & X (2-Beam Only) ................................................4-13
Run Auto Deflection Abs Phase (2-Beam Only) ................................................4-13
Run Auto Deflection Amp Y&X (2-Beam Only)................................................4-13
Adjust Image Form ...............................................................................................4-13
Run Expose Calibration .......................................................................................4-14
Image Base Offset .................................................................................................4-14
Edge Sensor Offset/Traverse Centre Position...................................................4-14
Check Image Quality ............................................................................................4-14
Optics Base Replacements ....................................................................................4-15
Optics Base Sensors ..............................................................................................4-15
Replace Optics Base Sensors ...............................................................................4-15
Setup Optics Base Sensors ..................................................................................4-15
Optics Base Motors ...............................................................................................4-16
ND Filter Assembly (Including SM1) .................................................................4-16
Replace ND Filter Assembly...........................................................................4-16
Setup ND Filter Assembly ..............................................................................4-16
SM2 (Focus Adjust).............................................................................................4-17
Replace SM2 ...................................................................................................4-17
Setup SM2.......................................................................................................4-18
P RELIMINARIES
SM3 (Aperture Control)......................................................................................4-18

Replace SM3 ...................................................................................................4-18
Setup SM3.......................................................................................................4-19
Laser Diode ...........................................................................................................4-20
Replace the Laser Diode .....................................................................................4-20
Setup the Laser Diode.........................................................................................4-22
Electro-Optic Deflector (EOD) ............................................................................4-22
Replace EOD Module .....................................................................................4-22
Setup the EOD ....................................................................................................4-22
Position Detector (POD) ......................................................................................4-23
Replace the POD PCB .........................................................................................4-24
Setup the POD PCB ............................................................................................4-24
Electro-Optics Deflector High Voltage (EODHV) .............................................4-25
Replace EODHV PCB .........................................................................................4-25
Setup EODHV PCB.............................................................................................4-25
Replace the HV Transformer ..............................................................................4-25
Setup the EODHV Transformers ........................................................................4-25
Laser Power Detector (LPD) ................................................................................4-26
Replace the LPD PCB..........................................................................................4-27
Setup the LPD .....................................................................................................4-28
Replace the Motor (SM4) ....................................................................................4-28
Setup the Motor (SM4)........................................................................................4-28
Replace the Sensor (S6) .......................................................................................4-28
Setup the Sensor (S6) ..........................................................................................4-29
Optics Motors Board (VBOMB) ..........................................................................4-29
Replace the VBOMB ...........................................................................................4-29
Setup the VBOMB...............................................................................................4-30
Fast Photo Detect (FPD) Sensor ..........................................................................4-30
Replace the FPD..................................................................................................4-30
Setup the FPD .....................................................................................................4-30
Exposing Test Strips ..............................................................................................4-31
Introducing the Test Strip Macros ......................................................................4-31
Using the Optics_MMI Options ..........................................................................4-32
Accessing Options ..............................................................................................4-32
Navigating Between Options..............................................................................4-32
Optics Test Pattern Setup Screen ........................................................................4-33
Final Values Screen.............................................................................................4-33
Machine Setup Screen.........................................................................................4-34
Extra Options Screen ..........................................................................................4-34
Selecting Options from Test Pattern Setup .........................................................4-35
Running Test Strips ..............................................................................................4-37
P RELIMINARIES
Manual and Semi-Automatic Machines (B1 & B2)..............................................4-37

Starting the Tests ................................................................................................4-37
Running Tests Strips.......................................................................................4-37
1: Auto Focus..................................................................................................4-38
2: Auto ND Wedge Density ............................................................................4-41
3: Auto Threshold Wedge Density .................................................................4-42
4: Auto Coincidence Beams Y.........................................................................4-42
5: Auto Coincidence Beam X ..........................................................................4-44
6: Auto Absolute Phase...................................................................................4-45
7: Auto Deflection Amplitude Beam Y ...........................................................4-47
8: Auto Deflection Amplitude Beam X ...........................................................4-49
Check Raster Quality .............................................................................................4-50
Calibrate Exposure Level ......................................................................................4-51
B1 and B2 Image Form Adjustments .................................................................4-54
Creating a Film Comparison Ruler .....................................................................4-55
Determining Horizontal Error ............................................................................4-56
Correcting Horizontal Error ...............................................................................4-57
Determining Vertical Error ..................................................................................4-59
Correcting Vertical Error ....................................................................................4-61
Set up ND Characterisation .................................................................................4-63
Volume 3 Chapter 5 Power and Control Service Proce-

dures
Starting the Service Procedures.............................................................................5-1
RFI Box .....................................................................................................................5-1
Engine Service Side ................................................................................................5-1
Accessing the Assemblies ......................................................................................5-1
Replacing RFI Box Modules ...................................................................................5-2
Power Supply Module (PSU1) ..............................................................................5-2
LSB Fan Replacement ...........................................................................................5-3
Power Filter PCB Replacement .............................................................................5-3
EODD PCB Replacement..................................................................................5-4
System PCB Replacement .....................................................................................5-4
HDD Replacement................................................................................................5-5
Replacing Interlock and Power Modules ............................................................5-6
Mains Filter Box ......................................................................................................5-6
Interlock Box ...........................................................................................................5-6
Volume 1 Chapter A Quick Reference Data

Useful Service Commands .................................................................................... A-1
Useful Service Sensor Tests ................................................................................... A-2
Sensor Listing ........................................................................................................... A-2
P RELIMINARIES
Solenoid Listing ....................................................................................................... A-4

Motor Listing ............................................................................................................ A-4
Volume 1 Chapter B Guide Technical Updates

Luxel System PCB Replacement .......................................................................... B-1
Laser Temperature and Humidity Control ....................................................... B-4
Operation................................................................................................................ B-4
Module Replacement ............................................................................................ B-5
Aperture Control Replacement ............................................................................ B-6
Preparation ............................................................................................................. B-6
Replacement Procedure ........................................................................................ B-6
Setting up Procedure ............................................................................................. B-7
Punch, Registration and Centerer (Fuji)............................................................. B-9
Punch Assembly Removal .................................................................................... B-9
Accessing the Assembly ...................................................................................... B-9
Removing the Assembly ...................................................................................... B-9
Complete Punch Replacement........................................................................... B-11
Punch Adjustments and Checks ........................................................................ B-11
Visual Plate Punch Check.............................................................................. B-12
Punch Checks ................................................................................................ B-12
Replacing the Punch Pins .................................................................................. B-12
Removing the Punch Motor............................................................................... B-13
Replacing the Chad Wipers ............................................................................... B-14
Vacuum and Air Control ..................................................................................... B-16
P RELIMINARIES
1-1
Volume-Chapt er
INTRODUCING THE LUXEL

SYSTEM
This chapter introduces the main features and modules of the Luxel platesetter system:
4
4
Luxel CTP Features .................................................................................................... 1-1
Introducing the Luxel Modules ................................................................................. 1-3
1.1 Luxel CTP Features

The Luxel CTP belongs to the Fujifilm family of Luxel platesetters for scanning
directly from computer-to-plate using photopolymer plates. It operates as a sin-
gle- or dual-laser expose system with a range of three system variants and mod-
ules for loading plates up to a maximum size of B1 or B2:
Fully-Automatic (B1 and B2): modules include - Autofeeder, Plate Transport
Module, Imaging Engine, Buffer, Processor and Stacker - see Figure 1.2 and
Figure 1.3.
Fully-automatic systems are either with or without a punch.
Semi-Automatic (B1 and B2): modules include - Imaging Engine (with load-
ing platform), Buffer (B1 versions only), Processor and Stacker - see
Figure 1.4.
All Semi-automatic machines are without a punch (web).
Manual (B1 and B2): modules include - Imaging Engine (with loading plat-
form).
All Manual machines are without a punch (web).
A flow of job images is sent directly across a SCSI bus from the RIP and held in a
queue on the Engine which serves as the main scanning module. While expos-
ing images to plate, the Engine can continue to receive and store new jobs from
the RIP.
The Luxel CTP uses an internal drum with plate vacuum, plate punching (fully-
automatic only) and a high-speed spinner to scan media with modulated laser
light. It processes RIPped data for fast optical scanning, controls plate handling
to the output, and runs system software for managing all the main operations.
Overall control of the machine is by the operator using an MMI touchpanel dis-
playing sets of menu screens as icons and selectable button options.
VOLUME 1 (1-2) INTRODUCING T HE LUXEL SYSTEM
A typical Luxel CTP system has the following standard and optional features:
A separate Raster Image Processor (RIP) server and optional client worksta-
tions.
Scanning to photopolymer plates.
A choice of RIP software applications with a Graphics User Interface (GUI).
Dual-laser beam system or an upgrade path from a single to dual-beam sys-
tem.
Variable resolutions from 48 l/mm (1219 dpi) to 144 l/mm (3657 dpi).
Media database on the Engine holding editable or seletable media data on
the plate types.
Comprehensive diagnostic self-tests and error screens for the user and engi-
neer.
1.1.1 Introducing the Luxel CTP Configuration

A typical site configuration, shown in Figure 1.1, would normally allow the RIP
server to accept images from a number of networked desktop sources. Network
links are:
Ethernet: an example of a typical protocol between the RIP server and DTP
systems.
RS232: diagnostic data is sent from the main System PCB on the Engine to
the PC for review by the engineer.
SCSI: RIPed image data sent from the PC to the engine.
RS232: communication link for controlling the flow of plates to the Proces-
sor.
L UXEL P LATESETTER VOLUME 1 (1-3)
RIP SOFTWARE IMAGES FROM

DESKTOP SYSTEMS
ETHERNET
RIP SERVER *
DIAGNOSTIC IMAGE
DATA DATA
MULTI-CASSETTE
HOUSING
ENGINE
BUFFER PLATE
PROCESSOR
AUTOFEEDER
PTM
STACKER
* SEE YOUR PROCESSOR NOT
RIP USER'S GUIDE COMMS SHOWN
Figure 1.1 Typical Luxel CTP configuration: fully-automatic
1.2 Introducing the Luxel Modules

The platesetter equipment modules are shown in Figure 1.2. to Figure 1.5 with
each variant module listed in Table 1.1.
Table 1.1 Main Luxel equipment modules

B1 Variants B2 Variants
Main Fully-Auto Manual Semi-Auto Manual Semi-Auto Fully-Auto
Modules:
Autofeeder: a a
Trolley a a
Cassette a a
PTM a a
Imaging a a a a a a
Engine
Buffer a a a a
Table 1.1 Main Luxel equipment modules (Continued)

PAT a a a a a a
Processor a a a a
NOTE: the B1 and B2 semi- and manual machines can be upgraded to fully-automatic.
MULTI-CASSETTE
HOUSING
BUFFER
SERVICE SIDE
AUTOFEEDER
PLATE
ENGINE USER SIDE
TRANSPORT
MODULE
(PTM)
PROCESSOR
Figure 1.2 Luxel 9600 CTP platesetter modules: B1 fully-automatic
MULTI-CASSETTE
HOUSING
BUFFER
SERVICE SIDE
AUTOFEEDER
PLATE
ENGINE USER SIDE
TRANSPORT
MODULE
(PTM)
PROCESSOR
Figure 1.3 Luxel 6000 CTP platesetter modules: B2 fully-automatic

BUFFER
PROCESSOR
ENGINE
LOADING
PLATFORM
Figure 1.4 Luxel 9600 CTP platesetter modules: B1 semi-automatic
PROCESSOR
LOADING
ENGINE
PLATFORM
Figure 1.5 Luxel 6000 CTP platesetter modules: B2 semi-automatic
1.2.1 Autofeeder
See Figure 1.2.
The Autofeeder consists of a moveable elevator frame and a set of control sys-
tems that allow a cassette to be aligned with the PTM plate feed mechanisms.
See Volume 2 Section 3.2 which describes the module in more detail.
1.2.1.1 Elevator
An elevator frame (with shelves and cassettes) moves vertically up/down to
align an MMI-selected cassette with the PTM plate feed. A gear/motor and a set
of chains and pulleys raises and lowers the elevator, with space at the top pro-
tected by a multi-cassette housing assembly.
1.2.1.2 Trolley and Cassette

See Figure 1.6.
Cassettes are always transported on a trolley for loading and installing in the
Autofeeder. Loading the cassette is carried out in a safelight area, usually sepa-
rate from the platesetter room which operates under normal lighting conditions.
Cassettes are never manually lifted by the operator or engineer.
Each cassette has:
an (ID)entity label read by the PTM
a removeable top cover for plate loading
a front lid that opens when the cassette is forwarded to the PTM feed head.
Cassettes and trolleys require periodic maintenance.
CASSETTE
TROLLEY
Figure 1.6 Trolley and cassette: general view
The trolley has two plate loading positions: horizontal and vertical, set from a
lever handle at one end. Its main function is to move the cassette from a safe-
light loading area to the Autofeeder cassette door where it docks into a set posi-
tion. This allows the operator to push the cassette onto to an empty shelf.
1.2.2 Plate Transport Module (PTM)

The module consists of an interleaf bin and the plate handling mechanisms used
to advance the cassette from the Autofeeder, and remove plates and interleaf
paper from the cassette before the plate is conveyed to the drum.
1.2.2.1 Interleaf Bin

Interleaf paper between the plates is diverted to a waste bin area that is periodi-
cally emptied by the operator. System software keeps a count of the removed
sheets and sends an alert to the MMI.
1.2.2.2 Plate Handling Mechanisms

A set of seven plate handling mechanisms inside the PTM carry out the follow-
ing operations:
secure the cassette to the shelf: X-direction door
pull the cassette from the shelf to the feed head: cassette forward
raise the plate pack to the correct height for plate nudging: stack increment
nudge the plate and take it away from the pack: feed head
prevent plate multi-feeds during the takeaway: retard pad
divert and drive the interleaf sheet to a bin: interleaf diverter/drive
guide and support the plate on route to the drum: plate guides.
1.2.2.3 Air Knife

An Air Knife system removes dust particles from the plate as it passes into the
drum.
1.2.3 Imaging Engine

The Engine is responsible for receiving and storing job data from the RIP,
processing image data for drum scanning (by deflecting and modulating two
laser beams), driving the traverse carriage, managing the interlocks and gener-
ating the DC supply voltages for all other modules. It also houses the MMI
(Man Machine Interface) console used by the operator to control production
workflow.
1.2.3.1 Optics Base and Periscope

Laser image processing is carried out in the optics base that generates a single
laser beam split into two separate beams and then recombined into two co-inci-
dental beams. Laser beam processing includes operations and modules run
from the optics base:
generate a laser beam: laser module
filter light beam intensity: neutral density (ND) filter
deflect beams for spinner rotation: electro-optic deflector (EOD)
detect beam misalignments: position detector (POD)

correct focus for plate thickness: focus adjust
adjust spot size on a plate: aperture (NA) control.
Other optics operations and modules are:
Optics motor control, laser current limits, temperature limits and image data
drive: violet optics motor board (VBOMB).
beam deflection drive control: electro-optic deflector drive board (EODD)
A `periscope' arrangement, consisting of two mirrors, bends the beams from the
optics base towards the spinner. An intervening assembly moves across the path
of the beams detects their laser power.
1.2.3.2 Loading Platform

Manual and Semi-Automatic machines have a loading platform allowing the
operator to manually load a single plate for each job. Two versions are available
for B1 and B2 sized plates.
See Volume 2 Section 3.4.2.1 which describes the module in more detail.
1.2.3.3 Traverse Carriage

A traverse carriage, housing the spinner and mirror, moves across a central
beam and drive rail using a frictionless drive shaft and a ball cage. Local control
from a traverse PCB reads the current position of the shaft, the spinner rotation
rate (encoder) and drives the traverse motor.
See Section Volume 2 Section 4.1 which describes the module in more detail.
1.2.3.4 Drum and Input/Output Modules

Two band roller modules on the drum input and output move the plate from the
PTM to the drum, and from the drum to the Buffer. After the plate has dropped
into the drum from the input side, a push bar moves it towards the punch where
it is held in position for centering and punching. After scanning, the push bar
moves the plate to the output module where it is conveyed to the Buffer.
1.2.3.5 RFI Box

A separate box, housed inside the Engine, generates the system DC voltages dis-
tributed to other modules, and contains the main system and optics control
PCBs.
1.2.3.6 Man-Machine Interface (MMI) Console

An MMI console on the Engine displays a set of menu screens with icons and
buttons that the operator selects to control the platesetter. MMI menus are
described in the Luxel Platesetter Operator's Manual.
1.2.3.7 Purified Air System

Clean air from a PAT module passes into the engine and optics base to ensure
positive air pressure.
1.2.3.8 Drum Vacuum System

Provides the vacuum for conforming plates to the drum and air blow for releas-
ing the plate.
See Volume 2 Section 7.1 which describes the system in more detail.
1.2.4 Buffer
The Buffer module, which operates as a band roller, holds the plate in transit
until the Processor is ready to develop the next job.
1.2.5 Plate Processor

A Plate Processor is closely-coupled to the Engine output so that both units
operate in daylight conditions. The Engine and Processor share the same com-
munication (comms) protocol: as plates are sent to the Processor, the two
machines pass commands, for instance, to check if the Processor is ready. Com-
munications can be enabled or disabled from the MMI; for maximum produc-
tion purposes the link is normally enabled.
The Processor is supplied separately from the other platesetter equipment and
has its own Service Guide.
1.2.6 Plate Stacker

An optional Stacker, shown in Figure 1.7, collects developed plates from the
Processor and stacks them in an upright position for the next production stage.
Unlike the Processor, the stacker operates independently using a sensor to
detect the arrival of a plate. Power is supplied from the Processor.
The Stacker (from Global Graphics) is supplied separately from the other plate-
setter equipment and has its own Service Guide.
Figure 1.7 Plate Stacker

1-2
Volume-Chapt er
INTRODUCING LUXEL
MODULES
This chapter introduces the main Luxel modules and variants, and briefly describes how
they function and operate.
4
4
Luxel System - Modules and Variants ...................................................................... 2-1
4
Introducing Plate Handling ........................................................................................ 2-3
4
Introducing Traverse Scanning............................................................................... 2-10
4
Introducing Image Expose....................................................................................... 2-17
Introducing Luxel Power and Control .................................................................... 2-28
2.1 Luxel System - Modules and Variants

Section 2.2 shows the main platesetter modules and their operations. A func-
tional view of the system is shown in Volume 2 Figure 9.1.
Platesetter modules are broadly grouped into five functional sub-systems:
Plate Handling - plate handling describes how plates are physically trans-
ported to the platesetter output. The main modules and assemblies are:
4 Plate Handling Motor PCBs (FHMBs 1 to 4)
4 Motors.
4 Sensors.
4 Solenoids and relays.
See Chapter 2.2 and Chapter 2.3 (Description) and Chapter 3.2 (Replacements).
Image Exposing - image exposing explains how image data is processed and
converted to laser data for scanning. The main modules are:
4 Optics Base modules - laser diode (pen), neutral (ND) density filter, electro-
optic deflector (EOD), focus adjust, EOD High Voltage (HV) module.
4 Periscope.
4 Laser power detector.

VOLUME 1 (2-2) INTRODUCING L UXEL M ODULES
4 Violet Boxer Optics Motors Board (VBOMB).
4 Electro-optic deflector driver (EODD).

See Chapter 2.5 (Description) and Chapter 3.4 (Replacements).
Traverse Scanning - traverse scanning explains how the traverse carriage
moves across the drum for plate scanning. The main modules and assem-
blies are:
4 Spinner.
4 Traverse PCB (STB).

4 Traverse motor.
4 Readhead and linear scale.

System and Power Control - overall management of the platesetter is from the
Luxel System PCB, housed in the RFI box. The main modules are described
as:
4 Luxel System Board (LSB).
4 CAN Bus.
4 PSU 1.
4 AC/DC distribution.
4 Interlocks and emergency stop control.

4 Power Filter PCB.
Vacuum and Contamination Control - a set of modules that generate and con-
trol vacuum, drum blow and purifying air:
4 PAT.
4 Valve Cage Solenoids.

4 Air Knife.
4 Compressors (drum blow).
See Chapter 2.7 (Description).
2.2 Introducing Plate Handling

Figure 2.1 and Figure 2.2 show a top-level view of the plate handling systems.
Plate handling is a sequential set of machine operations for transporting plates,
one at a time, between the variant plate loading system and the processor. It
uses the following modules:
Autofeeder (fully-automatic): houses cassettes (with plates) on elevator
shelve(s) for feeding into the PTM.
PTM (fully-automatic): feeds plates from a cassette to the engine and removes
interleaf paper.
Engine (all variants): holds a plate in a drum for centering, exposing and
punching (if the punch is fitted).
Buffer (fully-automatic): transports plates from the engine to the processor.
Plate handling operations are carried out by plate transport mechanisms (roll-
ers, push bars, etc) locally controlled by motors and sensor devices. Local man-
agement is from software routines running on a local FHMB PCB. Overall
system management is from the LSB that sends commands (and receives data)
to the FHMB.
PROCESSOR
8 DEVELOP
SEMI-AUTOMATIC ONLY
IMAGE
7 CONVEY
BUFFER
PLATE
PLATE
6 SCAN
IS NOT SKEWED
4 CHECK PLATE
OUTPUT
5 VAC PLATE
TO DRUM
PLATE TO
REG PINS
ENGINE
PUSH
3
INPUT
2
PLATE
1 LOAD
Figure 2.1 Plate handling modules (semi-automatic and manual)

AUTOFEEDER PTM ENGINE BUFFER PROCESSOR
4 NUDGE &
CASSETTE ON SHELF TAKEAWAY PLATE 11 CONVEY 12 DEVELOP
CASSETTE OPENS PLATE IMAGE
INPUT
OUTPUT
PUSH
PLATE TO
REG PINS
9 PUNCH
6 PLATE *
2 FORWARD 3 RAISE
CASSETTE STACK
10 SCAN
5 REMOVE PLATE
INTERLEAF
1 SELECT CASSETTE 7 CENTRE
PLATE
8 VAC PLATE
TO DRUM * IF PUNCH IS FITTED
Figure 2.2 Plate handling modules and operations (B1 fully-automatic)

Note that plate handling and optics devices described in this manual use the
following notation:
Sensors: BS [Number], for example, BS51
Solenoids: BV [Number], for example, BV22
Motors: BM [Number], for example, BM3.
2.2.1 Plate Handling Board (FHMB)

Four plate handling motor PCBs are fitted on the platsetter:
FHMB 2 and 3 fitted to the PTM
FHMB 1 and 4 fitted to the Engine.
Each FHMB operates using the same on-board functions and are replaced using
the same procedure. Differences between PCBs depend on local I/O device con-
nections for the variant machine and the on-board control firmware.
A description of each FHMB interface to their devices is given in the following
sections:
FHMB 1 (Engine): see Volume 2 Section 3.4.1.1.
FHMB 2 (PTM): see Volume 2 Section 3.3.1.1.
FHMB 3 (PTM): see Volume 2 Section 3.3.1.2.
FHMB 4 (Engine): see Volume 2 Section 3.4.1.2.
Figure 2.3 and Figure 2.4 show all the sensor inputs and motor/solenoid drives
for plate handling for the main platesetter variants.
SENSOR INPUTS MOTOR/SOLENOID OUTPUTS
INPUT MODULE (ENTRANCE/EXIT) FRICTION BAND INPUT MODULE (DC)

FHMB (1)
PUNCH (DC)
MIXER FAN DETECT
MIXER FAN (SOL)
ENGINE
PUNCH MOTOR (ON/OFF) POSITION ALERT CONTROL (RELAY)
INTERLEAF DOOR OPEN CASSETTE FORWARD (DC)

CASSETTE IDS 15
XDIRECTION DOOR (DC)
CASSETTE FWD/REV LIMIT
FHMB (2)
VECTOR DRIVE OVERLOAD/ALARM DOCKING LIGHT (SOL)
ELEVATOR SENSOR SHELF (1-3)
ELEVATOR (SYNCH)
ELEVATOR SENSOR (TOP/BOTTOM) PTM
CASSETTE AT NUDGER ZDIRECTION CONTROL (DC)
XDIRECTION DOOR (UP/DOWN)
CASSETTE DOOR LOCK (SOL)
CASSETTE DOOR CLOSED (SCHMER)
PLATE AT PRE-DIVERTER
STACK HEIGHT (DC)
STACK HEIGHT (HOME/TOP)
RETARD (UP/DOWN/MADE) NUDGER & TAKEAWAY (DC)
PAPER TENSIONER FHMB (3) NUDGER LIFT (DC)

PARK POSITION (PRE-INPUT)
24 V FOR DISTRIBUTION BOARD
CASSETTE EMPTY
PTM
NUDGER DETECT INTERLEAVE DRIVE (DC)
NUDGER LIMIT (UP/DOWN) AIR KNIFE FAN (RELAY)

PAPER POST DIVERTER (TOP/UNDER)
RETARD DROP (STEP)
INTERLEAF NIP CLEAR
PLATE PAST DIVERTER DIVERTER (SOL)
REG MOTOR (IN/OUT) POSITION PUSH BAR CARRIAGE (STEP)

CENTERING (RH/LH) DETECT
BUFFER FEED TO PROCESSOR (STEP)
CENTERING HOME
FHMB (4) CENTERING (STEP)
OUPUT MODULE (ENTRANCE/EXIT)
PLATE IN PUNCH REGISTRATION PINS (DC)
PUSH BAR FWD LIMIT/HOME ENGINE

VAC SOL (BV30, 40, 41)
BUFFER (ENTRANCE/EXIT)
FRICTION BAND OUTPUT MODULE (DC)
CHAD TRAY HOME
COMPRESSOR CONTROL
FAST PHOTO DETECT
SWING ROLLER (HOME/IN) DRUM VACUUM CONTROL
REG PIN CONTINUITY (NON-PUNCH ONLY) SWING ROLLER (DC) (NON-PUNCH ONLY)
Figure 2.3 FHMB Input/output devices (B1 and B2 fully-automatic)

SENSOR INPUTS MOTOR/SOLENOID OUTPUTS
INPUT MODULE (ENTRANCE/EXIT) FRICTION BAND INPUT MODULE (DC)

FHMB (1)
PLATE LOAD PUSH (HOME) MIXER FAN (SOL)
MIXER FAN DETECT PLATE LOAD CENTRE/PUSH (STEP)

ENGINE
PLATE LOAD CENTERING FRICTION BAND INPUT (DC)
PUNCH MOTOR (ON/OFF) POSITION ALERT CONTROL (RELAY)
REG MOTOR (IN/OUT) POSITION PUSH BAR CARRIAGE (STEP)
CENTERING (RH/LH) DETECT BUFFER FEED TO PROC (STEP) (SEMI ONLY)
CENTERING HOME FHMB (4) CENTERING (STEP)
OUTPUT MODULE (ENTRANCE/EXIT) REGISTRATION PINS (DC)
PUSH BAR FWD LIMIT/HOME ENGINE

VAC SOL (BV30, 40, 41)
BUFFER (ENTRANCE/EXIT) (SEMI ONLY)

FRICTION BAND OUTPUT MODULE (DC)
FAST PHOTO DETECT

COMPRESSOR CONTROL
SWING ROLLER (HOME/IN) DRUM VACUUM CONTROL
REG PIN CONTINUITY SWING ROLLER (DC)
Figure 2.4 FHMB input/output devices (semi-auto and manual)
2.2.1.1 FHMB Operation

A block view of the PCB is shown in Figure 2.5.
This section describes the main common functions on FHMBs (1 to 4).
Each FHMB operates as a local node under the system management of the LSB
that sends and receives high-level media handling commands and status mes-
sages. Plate handling control is distributed across the CAN bus and effectively
operates in real-time. It allows devices (sensors, motors, solenoids, relays and
fans) to switch on/off in the required sequence for moving plates to the proces-
sor or output.
FHMB functions are summarised as:
Interfacing for sensors connected directly or indirectly (via distribution
boards).
Control of motor drives associated with each sensor.
Control of local solenoids to various devices (relays, etc).
interconnect PCBs for the CAN bus network.
All four PCBs are identical in build, but the tasks they perform depends on the
devices they control. Because the handling software routines are configured for
each device, it is not possible to interchange FHMBs. Service engineers can
check the configuration (software issue levels, etc) from a separate utility, or
dump and restore configuration parameters to a local hard disk. On-board

NVRAM values for plate handling can also be accessed and stored to the engine
disk.
FHMB PCB
SOL 0
DRIVERS SOL 5
SM 0
SM 3
DC 0
DC 2
to
to
to
SOLENOID
STEPPER
DRIVERS
DRIVERS
MOTOR
MOTOR
DC
(CAN OUT AND STB
POWER +24V/+36V)
SOLENOID
CONTROL
CONTROL
CONTROL
STEPPER
MOTOR
MOTOR
DC
UMBILICAL
AND EXTERNAL
PCB DEVICES
SENSORS
MEMORY
MPU
REG
+5V
CAN BUS
TX/RX
CAN
MPU
A TO D
REGISTER
& SYNCH.
PULSING
SENSOR
SENSOR
RS232
S27
S0
to
SENSOR
CAN IN
(1 & 2)
I/F
+24V
(FHMB
1 TO 4)
+36V
(FHMB 4
ONLY)
SENSORS
Figure 2.5 FHMB operation - block view
Diagnostic facilities are included to test the functionality and status of each
FHMB from the Main Diagnostics (via the LSB). These carry out device tests,
and allow the service engineer to manually control I/O devices in the following
ways:
A) motors on/off and move a set distance
B) sensors on/off
C) solenoids on/off.
The CAN bus interconnections for the FHMBs (and STB) is based on the daisy-
chain arrangement shown in Figure 2.19. CAN bus data and power to the STB is
conveyed through an umbilical cable attached to FHMB (4).
A full description of the CAN bus system is in Volume 1 Section 2.5.2.
Voltages, Filters and Interlocks:
Voltages generated by the FHMB from an external +24 V source are:
+5 V - digital/analogue circuits and CAN (supplied by on-board switched
mode, 150 KHz, regulated from +24 V).
+18 V - FPD (regulated from +24 V) on FHMB(4) only.
Two inductors on the FHMB filter the +24 V supply.
Note that the +36 V is routed through FHMB (4) to the STB is not used by the
other FHMBs.
On-Board Fusing:
The board has built-in fuse protection for the output and switching circuits, plus
spare fuses available for the service engineer. Fuses are deployed as follows:
A) one fuse for each stepper and dc motor
B) one fuse for each high-power solenoid
C) one fuse to cover all the low-power solenoids
D) four spare fuses held in holders distributed around the board.
Output Controls and Driving:
Plate handling motors and solenoids are controlled and driven from the FHMB.
Solenoids, Relays and Fans:
A single FHMB is able to drive:
High-power solenoids or relays at 24 V (2 A peak).
Low power solenoids or relays at 24 V (500 A peak).
A constant +24 V to local fans.
DC Motors:
DC motor controller/drivers can deliver up to 2.5 A peak (2 A continuous) at
24 VDC to motors via a control register.
Stepper Motors:
Stepper motor control is provided for a set of plate handling stepper motors.
Two TPU (Timer Processor Unit) channels from the MPU provide the step clock-
ing edges to each motor controller: the even channel steps the motor while the
odd channel serves as a feedback path to the TPU for pulse counting. The step-
per control circuitry provides the correct stepping sequence for each motor.
Control registers, selected by the MPU, determine the type of holding current,
motor enable and motor direction.
2.3 Introducing Traverse Scanning

The traverse scan system is managed by the LSB using position data passed
from the Traverse system. Its main assemblies are housed on a traverse beam
and a traverse carriage.
A cast aluminium beam supports the traverse carriage and includes the follow-
ing sub-assemblies:
V-groove rail: provides a sliding surface for the ball cage.
Ball cage: a precision assembly of ball bearings that allow the carriage to slide
along the V-groove. Both carriage and cage need to be physically aligned. A
separate software utility checks for `creep' (that is, the two assemblies grad-
ually become misaligned as the system constantly traverses)
Drive rail: provides a drive rail for the traverse motor spindle and a base for
the linear scale.
Linear scale: runs along the drive rail to provide position coding for the read-
head encoder.
Actuators: All position measurements are offset from two actuators that indi-
cate the exact reference (Index) and coarse reference (Home).
The carriage assembly is motor-driven to run along the beam drive rail from its
Home position on the Service side. A traverse motor, which moves the carriage,
is controlled directly from the Traverse PCB. Position feedback is provided by a
readhead sensing micro positions on the linear scale; commands from the Sys-
tem Board, via the Traverse PCB, control the position and direction of the car-
riage.
Traverse PCB: This PCB runs local software handling routines for operating
the traverse carriage mechanisms.
Spinner: The spinner (Speedring type) includes an encoder that returns an
Index signal for each revolution and a rotating mirror for reflecting the laser
beams onto the plate.
Baffles: two baffles are fitted: removable and fixed.
Traverse Motor: a DC motor drives a spindle along the drive rail. The motor
assembly includes a casting.
Readhead: an encoder with sensors for reading the micro positions on the lin-
ear rail.
Umbilical: An umbilical ribbon cable from the Traverse PCB to FHMB4 con-
nects the CAN control/status signals and the power voltages. The cable is
positioned along a tray and flexes as the carriage traverses the drum.
The carriage is removed from the engine using two extenders fitted to the beam.
Most service procedures are completed while the carriage is located on the
extenders.
Main Diagnostic tests and utilities are available for the Service Engineer to
check and move the traverse.
2.3.1 Traverse Board (STB)

See Figure 2.6.
The Traverse PCB controls the spinner and traverse mechanisms, and also pro-
vides the drive currents for the spinner and traverse motors.
The main functions located on this PCB are described below. Refer to Section 2.3
for more information on how the Traverse PCB operates as part of the media
scanning subsystem.
READHEAD
TRAVERSE
ENCODER
ENCODER
SPINNER/
MOTOR
SCALE
HALL SENSE
DC
3-PH DRIVE
POSITION SIGNALS/TRAV INDEX/HOME

+36V
OUTPUT
DRIVE
COMMUTATION)
OUTPUT
DRIVE
(AND
REF
CLK
DAC
SPIN INDEX
19.2 MHz
DATA A
13.6 MHz
CONTROLLER
480 KHz
SPINNER
CONTROLLER
PRECISION
MOTOR
FAULT
LOCK/
ENABLE
INDEX/
HOME
TRAV
MPU
+5 V
5 V
MEMORY
CAN BUS
DCDC
RS232
STB
TO SSB
(VIA FHMB4)
EDGE DETECT
TO SSB
(VIA FHMB4)
+36V
+24V
Figure 2.6 Traverse PCB - block view

2.3.1.1 STB Main Functions

MPU Controller
The main functions of the MPU (Motorola 68376) are:
To control the Traverse PCB locally by receiving and interpreting high-level
commands sent from the System Board over the CAN bus. These commands
typically include, for example, Spinner Start/Stop, Traverse Datum, Fans On/
Off.
Initialise the Precision Motion (PM) Controller that operates the closed-loop
position feedback system for the traverse control.
Pass control and position data to the PM controller.
Control the flow of diagnostic data to a local VDU.
Precision Motion Controller
See Figure 2.7.
An LM628 Precision Motion (PM) Controller, operating in position mode, is
dedicated to controlling the traverse servo mechanism. The device provides
multiplexed 6-bit position data to a 12-bit D-to-A controller that drives the DC
traverse motor.
The PM controller is programmed with position, velocity and acceleration
parameters appropriate for the image size, number of optical beams and resolu-
tion. Two values to the PM controller are compared to give a digital error signal
that is converted to a drive voltage.
PLL reference frequency at 13.62 MHz divided down into two different
clock frequencies (4.55 and 6.82 MHz), depending on the resolution and
number of beams.
Digital encoded signals from the readhead.
The drive signal is produced by comparing two sets of numerical values:
4 The desired position trajectory (in microns depending on the optical speed) cal-
culated by the PM controller.
4 Feedback of incremental position pulses from the linear encoder to an accumula-
tor in the PM controller.
A digital error signal is then developed as a numerical value that is passed to
the DAC for driving the motor.
When error or limit conditions are detected, the PM controller is also able to
interrupt the MPU.
TRAVERSE
MOTOR
COMPENSATION
CIRCUIT
DC
AMP
READHEAD
DAC
DIFF
PM CONTROLLER
+
LINEAR POSITION ENCODED SIGNALS

CALCULATEED
POSITIONS
POSITIONS
CURRENT
GENERATOR
REGISTER
SUM
6.8MHz REF
TRAVERSE MONITOR
4.5/
DIVIDER
FREQ SEL
MHz
13.6
19.2MHz
REF
CLK
MPU
PLL
Figure 2.7 Traverse position control
Spinner Controller
See Figure 2.8.
The spinner circuitry is designed to drive the spinner motor at a constant speed
with the minimum amount of fluctuation. This control is regulated by an optical
encoder, mounted on the spinner shaft, that provides incremental spinner posi-
tion data.
REF FREQ
(480 Khz) TP11 TP9
ANALOGUE PULSE
PHASE PAL
SERVO WIDTH
DETECTOR LOGIC
MODULATOR
DATA A SENSE
+36 V
POWER
TP9 OUTPUT SPINNER OUTPUT
3-PHASE
166 microseconds
+36 V
TP11 OUTPUT
DEMAND ON MOTOR
STARTUP WINDINGS
RUNNING
DEMAND
LOWER SWITCHES
CLOSED FOR
BRAKE ON
Figure 2.8 Spinner speed control circuit
Spinner controller circuitry on the Traverse PCB is composed of five separate

functions detailed below.
The phase detector compares the phase and frequency of
1: Phase Detector.
DATA A from the encoder with a reference frequency of 480 KHz (or 160 KHz
when the spinner is idling at 10, 000 rpm). This allows any deviations of spinner
speed to be determined.
2: Analogue Servo. An analogue servo, consisting of an integrator and a phase
advance circuit, ensures that the spinner is phase-locked to the reference signal
(that is, DATA A and reference edges are co-incident). A filter sets the overall
bandwidth of the control loop.
3: Pulse Width Modulator. This function turns the analogue servo signal into a 60
KHz pulse train with a duty cycle proportional to the analogue signal level. This
signal has an offset, so 5 V represents 0% and 10 V represents 100%.
4: PAL. A PAL logic stage uses the PWM signal to drive the spinner motor with
a power level proportional to the level demanded by the analogue servo stage.
It also sequences the power stage outputs (3-phase) so that the spinner motor is
driven correctly. The logic stage handles control functions, for example, check-
ing that the spinner speed is within normal limits.
5: Power Output. The power stage takes the six signals from the previous stage
and uses these to control the six MOSFET transistors which switch to energise
the motor windings. Hall sensors around the rotor indicate the position of the
rotor, and their outputs are decoded for switching MOSFETS in the correct
sequence to start the motor.
Spinner Braking:
When a Stop command is sent, or the PSU is interrupted, the top winding
switches are opened and the bottom switches are closed. This type of braking is
regenerative and effectively short-circuits the motor windings. Braking time for
the spinner is less than 20 secs.
Reference Clock Generation:
A single 19.2 MHz crystal generates all the reference frequencies for the spinner
and traverse. Dividers and a PLL provide the clocking signals used by the spin-
ner controller and the PM controller respectively. Synchronised clocking
between the spinner and traverse subsystems is important for obtaining exact
resolutions and image start positions.
Diagnostics:
The MPU manages the local traverse diagnostic/utility routines for checking
the presence of the linear encoder, traverse motor and amplifier. These diagnos-
tics are available from the (Main>) prompt.
Voltages and Drives:
The Traverse PCB is supplied with a single +36 V and an auxiliary +24 V from
the CAN umbilical. A separate +5 V is also supplied for exclusive use by the
CAN interface. Voltage used on the PCB are:
+5 V - digital/analogue circuits and traverse motor drive (supplied by on-
board DC-DC device converting +36 V supply).
-5 V - analogue circuits (via an on-board charge pump).
+15 V - for analogue circuits.
+36 V - spinner drive.
Analogue signal from the traverse DAC is converted to current by a linear push-
pull amplifier that is disabled by the Brake command. The traverse current is
also available for diagnostic checks.
Temperature Monitor:
A temperature device on the Traverse PCB is monitored and, if the reading is
above a set limit, triggers an error code.
2.3.2 Cassette and Media Database Control

See the Luxel Platesetter Operator's Manual and also Figure 2.9.
A hard disk (HDD) on the Engine stores downloaded job images for scanning,
persistent images for plate quality tests, and holds the following MMI database
information:
Media: media details (plate size/thickness, type), including the default
number of plates for a pack. This database is downloaded from the RIP. The
number of plates is an editable value.

Cassette: the cassette ID is identified on the database when it is pulled into
the PTM. Each cassette holds details of the loaded media type selected by
the operator from the MMI.
Elevator: holds the cassette ID only and is updated when the cassette is
added or removed.
ID MEDIA TYPE QTY

ID#3
#3 LP-NV 1030 12
#4 LP-NV 745 40
#7 LP-NV 724 60
SELECT
ID#3 MMI
SELECT TYPE & QTY
ACTIVE ID#3
CASSETTE
DATABASE
ON DISK
MEDIA
TYPES
ON RIP
IMAGING JOB
AUTOFEEDER PLATE ENGINE
TRANSPORT IMAGE
DATA
RIP
INTERFACE
Figure 2.9 Cassette and media database operation
Media details are downloaded from the RIP application to the database after the
user adds new plate types and sizes to the RIP memory.
An active cassette is read by the system for its ID number allowing the MMI to
display the cassette's media details currently held on the database. Cassettes are
selected for advancement from the database details on the required type and
size of plates for the next job downloaded in the queue.
A single cassette with an ID can be refilled with the same type and size of media
and recognised immediately by the database. Cassettes loaded with a different
type or size of media need to have their database entry modified by the user
from the MMI before the system can start to use the installed plates.
2.3.3 Plate Processor Interface Commands

The Processor and Engine use a common set of interface commands to commu-
nicate information on machine status and readiness across an RS232 bus while
the system is running. This communications link is enabled or disabled from the
TOOLS menu on the MMI (see the Luxel Platesetter Operator's Manual.)
A set of basic commands control the transfer of an imaged plate from the Buffer
to the Processor. Plates are held in the Buffer until the Processor develops the
previous plate and requests the next plate. While the communication link is ena-
bled, production flow is maximised; if the link is disabled, production will still
continue but is likely to be slower and more prone to plate transfer errors.
2.4 Introducing Image Expose

Image expose system (data flow and control) functions are shown in Figure 2.10.
Job image data is downloaded from the RIP server, stored as a queue on the
engine hard drive disk (HDD) and processed into optical streams (X and Y) for
exposure on a plate.
Once the engine has stored a complete image (at least one separation) from the
RIP, it is held in a queue for plate exposure. The plate size and type is selected
by the platesetter from the RIP job details.
Laser beams X and Y are generated, focused, adjusted for density and checked
for correct alignment and power settings from the optics base.
2.4.1 Image Expose Modules and Operations

Image exposure is generated and controlled by the following:
RIP - two-way communication between the RIP server and the platesetter is
via a differential SCSI link to the LSB. A diagnostics RS232 channel allows
the engineer to interrogate the results of embedded test routines on the LSB.
Luxel System Board - the System Board is overall imaging manager that con-
trols the expose sequence via the CAN bus. It receives image data from the
RIP, stores it onto engine HDD and converts it into two streams for the X
and Y beams.
Electro-optic deflection is based on data supplied by the LSB.
VBOMB - the Violet Optical Motor Board controls the optics motors on the
optics base for the ND density, focus adjust, aperture control and laser
power detection. Control is monitored from the sensor signals returned by
these devices.
The VBOMB also controls the laser diode temperature, provides power limit
protection and the current control for image data switching.
Volume 2 Section 5.17 describes the operation of the VBOMB in more detail.
EODD - the Electro-Optic Deflector Driver board generates the sine and
cosine waveforms for the EOD deflectors from data supplied across the
EODD interface bus from the LSB. Waveforms are passed to the EODHV
board for further amplification.
EODHV - the Electro-Optic Deflector High Voltage board takes the sine and
cosine waveforms from the EODD and converts them into high voltage sig-
nals suitable for the Electro-Optic deflectors (EODs). It also allows a DC bias
to be applied to the deflectors to allow beam coincidence to be achieved.
Optics Base - this consists of modules that generate the two laser beams,
deflect them to a parallel swathe on the plate, adjust focus, illumination and
spot size.
It also houses lens for collimating the beam and a power detection to ensure
the two beams are aligned.
Periscope - an arrangement of mirrors that divert a laser beam from the optics
base to the spinner mirror. It also includes a laser power detector (LPD),
inline with the light path, to provide accurate samples of power readings for
each beam.
Two angled mirrors, M1 (top) and M2 (bottom), redirect the laser beams.
Only M2 mirror is field-adjustable using two fine-adjuster screws.
Spinner - rotates a mirror to divert the laser beams to a plate. It also includes
an encoder that provides SPIN INDEX and DATA A CLOCK signals to the
LSB for closed-loop spinner speed control.
SPINNER
CAN TO LUXEL
M2 STB SYSTEM
BOARD
LPD TO DRUM SURFACE
VBOMB POSITION
APERTURE FOCUS DETECTOR
M1 (POD)
PERISCOPE ND WEDGE
FILTER
VBOMB VBOMB VBOMB
OPTICS
LASER EOD BEAM
BASE
(X) (X) COMBINER
LASER EOD
(Y) (Y)
TRANSFORMERS
X/Y
PD AND LD IMAGE
DATA & PD AND LD
PCB PCB
CONTROL EODHV
DRIVE/POWER CONTROL
APERTURE
FOCUS POD TEMPERATURE/

LPD ND HUMIDITY
SENSOR BOARD
VBOMB EODD
CAN IMAGE DATA
CAN LUXEL CONTROL

STB SYSTEM
BOARD
RFI BOX
IMAGE DATA SCSI

DIAGNOSTICS
(RS232)
RIP SERVER
Figure 2.10 Platesetter system: image data flow and control

2.4.2 Image Data and Optical Path

Data for each image is compressed, stored, decompressed and converted to a
serial stream on the LSB and passed to the laser module as a switched data
stream, see Figure 2.13.
Two laser sources (LD1 and LD3) generate respective polarised beams (X or and
Y). deflected for position by an electro-optic device (EOD). The two beams,
when combined, run directly on the same axis, appear visually as a single beam.
Each beam provides a range of focused spot sizes for high speed scanning and
productivity. Resolutions available (at l/mm) are: 47, 48, 71, 72, 94, 96, 100 and
144.
LASER IMAGE DATA/EOD DATA M1 MIRROR

(FACTORY ADJUSTED
ONLY)
VBOMB
(OPTICS MOTOR OPTICS BASE
CONTROL)
LASER POWER
DETECTOR
COLLIMATING
LENS (L5) PERISCOPE
SPINNER
L6
COLLIMATED LASER
BEAMSALONG DRUM AXIS M2 MIRROR
(FIELD ADJUSTABLE)
LASER BEAMS
FOCUSSED AT
DRUM SURFACE
Figure 2.11 Media expose system - main modules
The beam deflection system is based on a set of axes shown in Figure 2.12. The
axes are defined at the output of the optics base as:
X - where the beam is deflected horizontally.
Y - where the beam is deflected vertically.
Z - where the beam is along the axis of the drum.
Y
OPTICS BASE
DRUM
X
Z
Z
X
BEAM
DIRECTION
SPINNER
ROTATION
SCAN
DIRECTION
Y
USER
END
Figure 2.12 Optical beam axis around drum
See Figure 2.13.

An optics base, located on the rear of the engine (user side), generates and mod-
ulates two laser beams split into X and Y data channels.
1. X Channel: when viewing the optics base, the X beam is the upper light path.
Deflection is in the horizontal plane when the beam exits the optics base just
before M1.
2. Y Channel: the Y beam is the lower light path in the optics base. Deflection is
in the vertical plane when the beam exits the optics base.
30 mW O/P POWER
DRIVE
CURRENT
(SWITCHED BY
IMAGE DATA)
BIAS
CURRENT
IMAGE DATA FLOW
A)
IMAGE
DATA FEEDBACK
BIAS
AND
DRIVE
CURRENT
ONE FULL SPINNER REVOLUTION

B)
Figure 2.13 Image data and current levels
2.4.3 Optics Base Module Control

Optics control for imaging is set from the:
VBOMB (see Volume 1 Section 2.4.3.1)
EODD (see Volume 1 Section 2.4.3.2).
2.4.3.1 Optical Motor Control (VBOMB)

See Figure 2.14.
The VBOMB controls the motor drives to the optics base motors based on sig-
nals received from local sensors, indicating Home and Limit positions, and the
LSB. As a CAN node it operates under the supervision of the System Board.
EXTERNAL
MODULES
LASER
LASER
DIODE
DIODE
POD
LPD
POD I/F
LPD I/F
LASER
LASER
I/F
I/F
TEMP AND
CONTROL
LASER
MPU
VOLTAGES
CONTROL
DRIVERS
SENSOR
DRIVES
MOTOR
DATA
CAN
AND
I/F
I/F
I/F
CAN
+5V
+/-15V
+24V
WEDGE
FOCUS
APERTURE
POD LPD
LIMIT/
HOME
SENSORS
LSB IMAGE DATA

LSB
OPTICS
BASE
Figure 2.14 VBOMB - block view
VBOMB functions are summarised as:

Provides bias and data level current for image data switching.
Receives and interprets commands from the LSB across the CAN bus.
Drives four low-power stepper motors for the following:
A) ND Filter wheel
B) Focus adjustment
C) Aperture (beam converter)
D) Laser power detection.
Monitors sensor inputs for accurate motor positioning.

Provides memory storage for local optics operation and set-up information.
Controls and protects laser diode temperature and power limits.
Optics devices (ND, focus, aperture and LPD) are moved by stepper motors to
their Home position and a set number of steps in either direction from Home.
Sensors associated with the devices are:
ND Filter Home (S1)
Focus Limit/Home (S2 and S3)
Aperture Control Home (S5)
Laser Power Detector Home (S6)
Three detector PCBs are controlled from the VBOMB:
1. Position Detector (POD): a two dimensional position detector that is used to
measure the relative alignment of the laser beams. This detector is calibrated
in conjunction with the ND wheel to obtain the optimum level of light
power.
2. Laser Power Detector (LPD): used as a reference for setting the output drive
level. The LPD is calibrated to ensure that the laser beam is aligned with the
centre of the detector.
CAN Control Interface:

Real-time CAN signals are received and transmitted from a transceiver. CAN
power (+5 VDC) is supplied to the VBOMB from the CAN connector.
Diagnostics:
Routines run on the VBOMB generate error messages which are read by the
diagnostic software on the System Board.
MPU:
An MPU, clocked at 10 MHz, runs the local drive and control routines for the
optics sensors, motors and laser controls. High-level commands are received
across the CAN bus and VBOMB status messages are sent back to the System
Board. Commands move the motors to a certain position; VBOMB reports to the
System Board on whether the motors can be moved or not.
Flash Memory:
A 512 K x 8 FLASH EEPROM holds the optics control code and board diagnos-
tics. New firmware code is downloaded from the RIP server via the System
Board.
Voltages and Drives:

The supplied voltages, +24 VDC (drives stepper motors), +5 VDC (digital
devices) and +15 V (drives lasers), are monitored by the MPU for providing
environment information.
Laser Power Detector

Power levels for each beam are measured from the LPD.
Position Detector
The two beams are aligned by the VBOMB (from POD data) to be co-incidental
during the non-scanning stage.
Motor Drivers
Low power (unipolar) stepper motors are driven from separate drivers control-
led by the Timer Processor Unit (TPU) channel levels on the MPU.
2.4.3.2 EOD Control

Calibrated media expose control is based on a set of co-operating functions that
operate before and during an expose scan:
EOD deflection: deflects X and Y beams before they reach the rotating spinner
mirror.
Laser module monitoring: the module returns data on the current laser power
and temperature outputs which are digitised and passed to the VBOMB.
Beam coincidence alignment: beams X and Y are aligned, one on top of the
other, for beam coincidence on the drum.
EODHV Operation
The EODHV provides each EOD module (X and Y) with the high voltage sine/
cosine waves required for beam deflection. The EODD supplies a single differ-
ential control voltage that consists, for each deflector, of a 667 Hz AC compo-
nent on a DC bias voltage for 40,000 spinner revolutions. The AC (sinusoidal)
part is used for beam deflection, and is synchronised with the spinner mirror
rotation. The DC part compensates for fixed angular mis-alignments in the EOD
assemblies detected by the POD and is adjusted during beam coincidence.
The EODD provides two supply voltages:
+24 VDC (and Return): EODHV PCB supply.
+12 VDC: EODHV reference voltage.
For each channel (X and Y), the composite input signal from the EODD is sepa-
rated into DC and AC components using a filter circuit. The DC component sets
a bias voltage of up to +750 V on the deflector. A bridge circuit drives each trans-
former primary using the AC component recovered from the filter. The AC volt-
age at the EOD deflectors can be varied in the range +2 Kv (pk-pk).
Figure 2.15 shows each of the EODX DIFF input signals with respect to Ground
and the signal obtained across the two EOD inputs. The voltage values are only
shown as an example.
+1350 VAC
EODX+
1kV PK-PK
+750V
+350 VAC
+500 VAC
EODX-
1 kV PK-PK
(ANTIPHASE)
0 VDC
-500 VAC
+1850 VAC
ACROSS
EODX
INPUT
+850 VDC
150 VAC
Figure 2.15 EOD drive voltage
A status signal is fed back to the EODD to indicate that the +24 VDC connection
is available and the HV to both channels exceeds 250 V. If the `HV-OK' signal is
LOW, then the +24 V and the HT supplies are OK; if not, an error flag is passed
from the EODD to the LSB.
HT+
DC - DC PUSH-PULL BK
+24V AMP
DC BIAS (PART OF)
+24V GND
-1 VIOL
Figure 2.16
+12V
EOD DATA BLUE
EODD
AC MODULATION TO EOD
FILTER (X OR Y)
X OR Y DATA WHITE
(AC + DC)
+1 YEL
HV STATUS
HT+
PUSH-PULL BN
AMP
DC BIAS (PART OF)
EODHV PCB (ONE CHAN ONLY)
EODHV (X or Y channel) - block view

2.5 Introducing Luxel Power and Control

2.5.1 Luxel System Board (LSB)
See Volume 2 Section 6.1.
The LSB acts as the overall manager of the system and performs the top-level
control and processing tasks using resident firmware that is down-loadable.
Some of the main functions and features of the LSB are:
an interface to image data from the RIP server
motherboard control for beam dongle facility
provides the drive and iconic translation for the MMI display
I/O connection to external modules (Processor, CAN node boards and RIP
server)
image data store and processing before exposure
holds the deflection LUTs and NVRAM parameters used for dynamic EOD
deflection control
provides system control for the plate handling and optics motors.
Platesetter system control and inter-node communications is across a CAN
(Controller Area Network) bus that can also operate with the LSB as the master
node. A description of this network (adapted for Luxel) is in Section 2.5.2.
Functions on the System PCB are divided into two working areas:
LSB System Control (see Section 2.5.1.1)
LSB Image Data Path (see Section 2.5.1.2).
2.5.1.1 LSB System Control

See Figure 2.17.
System control, based on the MPU (Motorola 68376), acts as an intelligent super-
visor for the Luxel system to receive high level commands from the CAN net-
work and transmit commands for driving the other electronic sub-systems.
Overall control is based on the the bussing, interface and MPU arrangement
shown in Figure 2.17.
DATA CONTROL
LBUS
I/F
RTC
CAN BUS (TO SOMB/FHMB)
MBUS
I/F
DATA CONTROL
MEMORY
TEMP
FLASH/
SRAM
IC
(BRIDGE)
PCI
I/F
MPU
TO AOMD MODULE
CPU BUS
AOMD
I/F
TO CONTROL
CONSOLE
MMI
I/F
CONTROLLER
SERIAL
RS232
TO INTERLOCKS
INTERLOCKS
I/F
DIAGNOSTICS
PROCESSOR
S/W DEBUG
Figure 2.17 System Board control functions
FLASH and SRAM Memory

Application, boot and diagnostic code files for the MPU are stored in (non-vola-
tile) FLASH memory before transfer to the MPU on power-up or user request.
Two MBytes of FLASH PROM (512 Kbyte devices) are fitted as standard, with
provision for a further 1 MByte at a later stage.
The contents of the FLASH memory can be updated at any time from a utility
running on the RIP server. This facility is used for on-site software and configu-
ration updates. The firmware level on the LSB must match the other node PCB
firmware levels for the system to operate correctly.
SRAM (512 Kbytes devices) is used (alongside FLASH memory) to provide wri-
table storage for the MPU.
LSB Temperature Monitoring

The LSB monitors its own temperature and generates an in-range or out-of-
range signal from a dedicated thermostat on-board device. Temperature status
signals are periodically read by the LSB which stops scanning and reports a fail-
ure to the MMI as an error code if the reading is out-of-range.
Voltages and Drives
The LSB operates with the following voltages supplied from the PSU:
+5 V - used by digital and analogue devices.
+15 V - used by the PLL and regulated down to +12 V for use by the disk
drives.
LSB Diagnostics
The MPU is able to run a set of on-board checks for the memory and registers
from commands and on power up.
Real-Time Clock
An embedded R-T clock is used by the system for date and time stamping. The
clock is set from an engineering utility.
NVRAM
NVRAM on the LSB stores the system-specific parameters for controlling the
optics, plate handling, etc. Volume 2 Section 1.8 explains how to view and tem-
porarily store the parameters.
2.5.1.2 LSB Image Data Path

Figure 2.18 shows the image data route and functions on the LSB from the RIP
image data input to the laser modulator.
Data Path Operation
See Figure 2.18.
The basic sequence for processing image data by the LSB is as follows:
1. An image file (page/picture) is sent from the RIP via the PCI SCSI link.
2. Data is transferred, via the PCI bus, to a compression circuit in consecutive
16-bit wide words. Direct memory access (DMA) and a first-in first-out
(FIFO) buffer provide optimum transfer rates.
3. Compressed data is transferred to a buffer memory in consecutive words
using DMA/FIFO. From here, image data is stored to the SCSI disk.
4. Steps 2. to 3. are repeated until a the complete image is received.
5. When an image is to be exposed, the SCSI bandwidth is allocated on a prior-
ity basis to the output process.
6. Steps 2. to 3. are reversed. Data is taken off the image storage disk, decom-
pressed, and transferred to the output formatter/serializer by the DMA and
FIFO buffer.
7. The serializer synchronises data to an absolute position on the drum, and
passes data to the EODD.
The data path is capable of receiving image data from the RIP while transferring
TO SSB
SYSTEM CONTROL
LBUS
I/F TO SSB
SYSTEM CONTROL
LBUS
data to the optics system.
MBUS
I/F
MBUS
DMA/FIFO BUFFER DMA/

PCI/ PCI DATA DMA/ OUTPUT
COMPRESSION DECOMPRESSION FORMATTER SERIALISER
SCSI FIFO MEMORY FIFO
BRIDGE
RIP IMAGE DATA

MBUS
MBUS
PATTERN SPIN
Figure 2.18 System Board data path

DISK
DRIVES GENERATOR INDEX
SCSI (FROM
MBUS STB)
INTERNAL PIXEL
DATA A
TO EODD
SCSI CLK
I/F (FROM STB)
GEN
Data Compression/Decompression
See Figure 2.18.
Data interfaces for compression/decompresssion devices are set at 16 bits for
maximum performance. A separate DMA controller manages the transfer of
data from the compressor to the FIFO and from there to the buffer memory on
the Mbus. Up to 16 transfers can be completed before the bus is released. The
compression technique applied is LZW. Compression/decompression data
transfers are increased in speed by DMA control of the bus and I/O FIFO buff-
ers.
1. A compression (C-FIFO) input on the DMA controller interfaces to the com-
pressor and accepts data at its the maximum rate while space exists in the
FIFO. The input data pat is 32-bits wide.
2. A compression (C-FIFO) output on the DMA controller provides a master
interface to the Mbus and the buffer memory. The output data path is 16-bits
wide.
3. The D-FIFO function for the decompression DMA controller operates in the
same way as the compression DMA controller explained in steps 1. and 2.
The length of the compressed record depends on a calculated setting for multi-
ples of input data lines. This calculation is also used by the decompressing proc-
ess.
A dual decompressor system strips alternate records from the buffer for transfer
to the output formatter.
Buffer Memory
This function provides intermediate DRAM storage between the data compres-
sion/decompression devices and the disk drives. The size of the buffer is 8
MBytes and the data burst rate is 80 Mbytes/sec. Buffer management is based
on four data streams:
odd/even compression records from the compressor are written to disk
odd/even records from the disk are written to the decompressors.
Internal SCSI Bus and Drives
A complete image is loaded into two disk drives that operate with separate SCSI
busses in order to improve performance. Each bus conforms to the single-ended
narrow standard that is also SCSI 3 (Ultra SCSI) compliant.
Output Formatter
The formatter receives decompressed data and stores it into two line-oriented
buffers (one buffer per beam) before transfer to the serialiser. Each decompres-
sor has its own set of line buffers to cater for a minimum of 90 lines of the output
image. The actual number of scan lines that the buffer holds is calculated by a
formula at the compression stage.
Data is passed to the serialiser by alternating the output from the buffer of each
decompressor. Once the requested number of lines have been written to the
buffer, and the output buffer is empty, the buffers are flipped for the next set of
decompressed lines.
Serialiser
The serialiser takes the two beam streams from the output decompression buff-
ers and converts them into data streams for the laser diode drivers. It uses all
the data from the output buffers on the first decompressor before switching to
the alternate output buffer on the second compressor. To avoid position errors,
and determine the start of image, a clock feeding the serialiser is synchronised
to the INDEX signal from the spinner encoder.
2.5.2 CAN Network Control

See Figure 2.19.
System control messages are exchanged over an industry-standard CAN (Con-
troller Area Network) bus distributed between the seven slave node PCBs:
System (SSB) - this operates as a master to download embedded firmware to
the other slave nodes.
FHMBs (1, 2, 3 and 4)
Traverse (STB)
VBOMB.
CAN network bussing is based on interlinking cables, daisy-chained between
boards. Each board is linked to the network as a node that can transmit or
receive messages to any other node. The CAN standard is a serial data interface
used for real-time control signals where the machine environment calls for
robust and reliable internal communications.
The CAN network model for data transfer is especially useful in that nodes can
be added, swapped or removed after the network mapping tables have been
modified. Also, it provides a system with extra network management features
and extensive real-time error checking and recovery procedures.
On a CAN network, system data (sensor data, motor commands, etc) is passed
between nodes as a frame messaging system where the signal content is labelled
by an identifier that is unique throughout the network. All nodes receive trans-
mitted messages and perform an acceptance test to detect whether the message
is relevant.
The message frame typically consists of fields denoting Start/End of Frame,
Data, Control, Acknowledgements and CRC Error Bits. Other frames, control-
ling the network for bus errors and overloads, are also transmitted between
nodes. Typical messages between the SSB and node boards would include, for
instance, an SSB supervisor command to start a motor and a node response that
the motor has started or failed to start after a timeout.
Error handling routines, built into the CAN software, automatically attempt a
recovery procedure depending on the type of error reported. All messages on
the bus are checked by each node and acknowledged if they are correct. Bus
errors will cause the frame to be retransmitted, or (in the case of persistent fail-
ures) for error reporting to the system user via the diagnostics.
CAN2 CAN3
LSB FHMB(1) FHMB(2)
CAN1 CAN4
VBOMB FHMB(3)
CAN5
UMBILICAL
TRAVERSE FHMB(4)
CAN
Figure 2.19 CAN node interconnection - (B1 and B2 fully-automatic)
CAN2 CAN_FHMB1_4
LSB FHMB(1)
CAN1
VBOMB
UMBILICAL
TRAVERSE FHMB(4)
CAN
Figure 2.20 CAN node interconnection - (manual and semi-automatic)
CAN controller devices on node PCBs are tightly coupled to their board MPUs
which manage local board processes, and include a CAN interface.
The CAN protocol operates as peer-to-peer, but for certain tasks also operates as
master-slave when, for instance, the SSB constantly receives and transmits
frames as the master. Local data is sent from a node to the SSB. The SSB returns
high-level control signals to the nodes for synchronising the optics, scanning
and plate handling sub-systems.
The system employs a high-speed CAN version (CAN-H) where signal levels
are set at 2.75-4.5 V (HIGH) and 0.5-2.25 V (LOW). Terminations (at 120 ohms)
are provided.
2.5.3 Power Distribution Control

See Figure 2.21 and Volume 2 Section 6.2.
Platesetter power is generated and routed as follows:
PSU 1: supplies +5 V, +24 V, +36 V, +15 and -15 V from the RFI box
Power Filter: filters DC supply before it is routed from the RFI box.
Vacuum Pump: AC mains is controlled via a relay so that vacuum is switched
on during imaging.
Emergency Power Stop: a separate PSU supplies +24 V to emergency buttons
on the PTM (Fully-automatic) and Engine (manual).
Interlock Control: the main voltages for the spinner, laser and plate handling
motors are switched off by an interlock system operated by opening a cover.
PAT, Stacker and Processor: these modules are powered separately from the
Engine.
Elevator: AC power is routed via the PTM for the elevator motor.
ELEV
MOTOR
VAC PUMP AC AC
PUMP INVERTER
AC AC COMPRESSOR
AC BOX
ENG_FHMBPWR
FHMB1 CTRL
DC DC
x2
INTERLOCK DC INT_EMERG
BOX FHMB2
MAINS_DIST PWR3_INT
AC VACUUM
DC
FHMB3
PWR2 FHMB4
AC MAINS_RFI_IN
DC
IEC
CTRL FOR
DC LASER AUTOFEEDER
RFI BOX DIST
LSB
24V_ENG
I/LOCKS (x4) +15V/-15V I/LOCK (x1) I/LOCK (x1)

VBOMB
ENG_INT
EXT I/LOCK ENG_INT
Figure 2.21 System power distribution and control (B1 and B2 fully-automatic)
ENGINE PTM BUFFER
1-3
Volume-Chapt er
SERVICING SAFETY PRACTICE

This chapter MUST be read before starting work on a service procedure for the automatic, semi-
automatic and manual platesetters:
4
4
Health and Safety at Work (All Variants) .................................................................. 3-1
4
Laser Safety ................................................................................................................ 3-2
4
Safety Interlocks (All Variants)................................................................................ 3-19
4
Emergency Stop Circuit ........................................................................................... 3-22
4
Mechanical Safety .................................................................................................... 3-24
Antistatic Precautions (All Variants)....................................................................... 3-24
CAUTION: This chapter must be read before working on the equipment where there are
risks from overridden interlocks.Service and installation engineers for a Luxel CTP must
be trained on the product engineering course before working on a platesetter system.
The minimum requirements for site safety, before installing the machine, are set
out in the Luxel Platesetter Pre-Installation Manual.
Operator Safety Information is included in the Luxel Platesetter Operator's Man-
ual.
Safety information in this chapter is for all three variants (Automatic, Semi-
Automatic and Manual) platesetters.
3.1 Health and Safety at Work (All Variants)

This section applies to the Automatic, Semi-Automatic and Manual variants.
All personnel are advised to familiarise themselves with any local or national
legislation relating to health and safety at work. Particular attention should be
given to those sections covering personal responsibility regarding safe working
practices which must be strictly observed at all times.
This chapter explains the safety conventions used in this manual and highlights
safety practices specific to the product.
3.1.1 Warnings and Cautions

There are two types of safety notices in this Guide:
VOLUME 1 (3-2) S ERVICING S AFETY P RACTICE
1. WARNINGS are displayed for conditions which may endanger life.
WARNING: The instructions in a warnings must be followed precisely. They are given to
avoid serious injury.
2. CAUTIONS are displayed for conditions which may cause damage to equip-
ment or materials.
CAUTION: The instructions given in cautions must be followed to avoid damage to equip-
ment or materials.
3.1.2 Clothing and Jewellery

Do not wear clothing or jewellery which could be hazardous when in contact
with any part of the equipment, or which could reflect laser light into an eye.
3.1.3 Equipment and Tools

Use the approved service tools, listed in Volume 3 Section 1.1, and wear the pro-
tective garments which are specified in this Guide.
3.1.4 Site Safety Rules

Most accidents can be avoided if you follow these simple rules.
Familiarize yourself with the location of mains supply On/Off switch on the
Engine, the two emergency cut-off switches on the PTM, the wall-mounted
On/Off isolator switch and all other equipment switches.
Always obey the warnings, cautions, and any other instructions included in
this Guide, and in other relevant equipment manuals associated to the
equipment.
Never attempt to perform procedures that are not included in this Guide.
3.2 Laser Safety

CAUTION: Use of controls or adjustments, or performance of procedures other than

those specified herein, may result in hazardous radiation exposure.
Since the Luxel CTP uses lasers it is labelled as a Class I laser product when all
the covers are closed. While the covers are opened and the interlocks defeated,
the machine is a Class IIIB laser source. Light is emitted in the violet spectrum at
405 nm. Maximum power output from the laser source is classified as Class IIIB.
3.2.1 Manual Shutter Control

A manually-operated safety shutter is fitted on the periscope assembly (laser
power detector) and is closed to prevent laser beams entering the drum. See
Figure 3.1 below on how to open and close the shutter.
DANGER
Laser radiation when open
AVOID EYE OR SKIN EXPOSURE TO
DIRECT OR SCATTERED RADIATION
OPEN CLOSED
LASER POWER
DETECTOR
ASSEMBLY
SHUTTER
Figure 3.1 Manual laser safety shutter
3.2.2 General Laser Warnings

Laser light, because of its special properties, poses safety hazards not associated
with other light sources. The use of lasers requires that all service engineers and
everybody near the laser system, are aware of the dangers involved. Laser
safety depends on the engineer being familiar with the instrument and the prop-
erties of coherent, intense beams of light.
Laser beams can ignite volatile substances, such as alcohol or other solvents and
damage light-sensitive elements in, for instance, photodiodes. Reflected beams
can also cause damage.
Note the following laser radiation warnings:
WARNING: Never look directly into a laser beam. This could cause serious damage and
possible blindness.
When working on a Class IIIB laser source, always wear goggles capable of attenuating
the beam to a Class II level if there is the slightest risk of direct reflection
The voltages used in the laser circuits, and power supplies, are potentially hazardous.
Exercise extreme caution while servicing the platesetter with its interlocked covers
removed.
Never place a mirror or other reflective material in the laser beam. This action can reflect
hazardous light to others working in the general area.
Laser current and beam power are always set at the factory from the optics
NVRAM parameters supplied with each laser or as part of a laser upgrade/
replacement procedure. If a laser needs replacing, only the recommended
parameters given in the supplied datasheet are entered. These parameters
include maximum power levels that need to be set for the laser.
Do not power up the platesetter with a laser disconnected.
Remove the protective lid of the optics base only in accordance with the
instructions given in the service procedure.
Attenuating laser safety goggles must be used where there is a risk of direct
reflection from a laser beam. Where there is no such danger, and when
observing diffused reflected spots from screens and targets, it is permissible
to work without attenuating laser safety goggles. Extreme care must be
taken when working with lasers.
The protective cover of the laser module should never be removed.
3.2.3 Safety Warnings

Laser safety warnings must at all times comply with local and national regula-
tions.
While the laser is being serviced, it may be necessary to operate the platesetter
with certain covers removed and the safety interlocks over-ridden using the
approved method shown in Volume 3 Section 1.2. Under these circumstances,
only the service engineer shall be in the Designated Laser Area (DLA). The DLA
may be a room, a curtained area, or a purpose-built DLA tent.
3.2.3.1 A DLA Room

All other personnel should be warned of the hazard by:
A laser warning notice attached to the door(s) leading to the room. An
example is shown in Figure 3.2.
A red warning light, positioned above the door(s) leading to the room, illu-
minated whenever there is a laser radiation hazard, see Volume 2 Section
6.7.
LASER CLASS 3B OPERATIONS

WHEN WARNING LIGHT IS ON
LASER CLASS IIIb OPERATIONS NO ENTRY TO UNAUTHORISED
PERSONNEL
WHEN WARNING LIGHT IS ON
EUROPEAN
NO ENTRY TO UNAUTHORISED
PERSONNEL
U.S.A.
Figure 3.2 Typical laser warning signs
3.2.3.2 A DLA Curtain

Local legislation may permit the following alternative:
Isolation of the platesetter by means of a curtain. The curtain must be
opaque to violet light (405 nm) and must extend from floor to a height of at
least 2.1 m (82.7 in).
Warnings placed, where required, to ensure that personnel are aware of the
laser radiation hazard inside the curtained area. Safety Notices and Hazards
Safety labels are fitted to the equipment to warn you of potential hazards. These
labels must not be defaced or removed. Typical warning labels, fitted within the
platesetter, are shown in Figure 3.1 to Figure 3.15.
3.2.4 Mains Rating Labels

The serial number and model type appear on a mains rating label fitted to the
rear panel. This is shown in Figure 3.3.
ETL LISTED
CONFORMS TO
UL STD 1950
C US CERTIFIED TO
92206 CAN/USA STD C22.2 NO. 950
Product: LUXEL
Model No: V-9600CTP
Serial No:
Volts 230 50/60Hz ~
Max Current: 15A

Manufactured:
This device complies with Part 15 of the FCC rules

and is subject to the following two conditions:
1.This device may not cause any harmful
interference.
and
2.This device must accept any interference
received including interference that may
cause undesired operation.
IMAGING ENGINE This Class A digital apparatus meets all the
(REAR) requirements of the Canadian Interference-Causing
Equipment Regulations.
Cet appareil numrique de la classe A respecte
toutes les exigences du Rglement sur le matriel
brouilleur du Canada.
This laser conforms to the applicable requirements of
NOTE: MANUAL AND SEMI-AUTO 21 CFR Sub chapter J.
PLATESETTERS ARE RATED AT 10 A FUJIFILM ELECTRONIC IMAGING LTD.
MAX PETERBOROUGH
ENGLAND CLASS 1 LASER
LASER KLASSE 1
LASER DE CLASSE 1
7550 854D 02
Figure 3.3 Mains input - typical rating label
3.2.5 Drum and Traverse Warning Labels

Figure 3.4 illustrates the laser and spinner risks for the engineer when the drum
end caps are removed and the interlocks are defeated.
DANGER

WARNING
HIGH SPEED SPINNER ROTATION
KEEP CLEAR
Figure 3.4 Drum end cap - laser and spinner rotation warning labels
Figure 3.5 illustrates the spinner, laser and moving parts risks to the engineer
after the drum end caps are removed and the interlocks are defeated.
Note that the laser radiation warning in Figure 3.5 only applies to a non-punch
machine.
CAUTION
WARNING LASER RADIATION
DO NOT STARE INTO BEAM
HIGH SPEED SPINNER ROTATION
KEEP CLEAR
AVOID EXPOSURE
NOTE: LABEL ON BOTH 1250-45 BCamCP2
0.8mw 670nm
Laser radiation
Emitted from Aperture
ENDS OF BAFFLE To EN60826-1, 21CFR Part 1040.10
VECTOR
TECHNOLOGY
5794 0004 1002 LIMITED
WARNING MOVING PARTS

KEEP LOOSE CLOTHING, HAIR AND
JEWELLERY ETC. CLEAR.
Figure 3.5 Drum user side - spinner and moving parts warning labels
3.2.6 Optics Base Warning Labels

Figure 3.6 shows the areas of risk for the engineer from exposed laser beams and
high tension voltage when the optics base lid is removed.
DANGER

Attention!
high tension
Vorsicht!
Hochspannung
Prcaution!
haute tension
LASER RADIATION - AVOID EYE Precaucin!
OR SKIN EXPOSURE TO DIRECT alta tensin
OR SCATTERED RADIATION
WAVELENGTH & MAX OUTPUT

405 nm/45 W
CLASSIIIB LASER PRODUCT
Figure 3.6 Optics base - laser and high tension warning labels
3.2.7 RFI, Interlock and Filter Box Warning Labels

Figure 3.7 shows the area of risk from high-tension voltage after the RFI box lid
is removed.
VOLUME 1 (3-10) S ERVICING S AFETY PRACTICE
RFI BOX
Attention!
high tension
Vorsicht!
Hochspannung
Prcaution!
haute tension
Precaucin!
alta tensin
Figure 3.7 RFI box - high-tension warning label
Figure 3.8 shows the area of risk from high-tension voltage after the interlock
box lid is removed.
Danger
Disconnect the
mains supply before
removing this cover
Figure 3.8 Interlock box - high-tension warning labels
Figure 3.9 shows the area of risk from high-tension voltage after the mains filter
box lid is removed.
WARNING: Both the mains filter box and the interlock box contain LIVE components
when the circuit breaker ON/OFF is in the OFF position.
Danger
Disconnect the
mains supply before
removing this cover
MAINS FILTER BOX
ENGINE
(SERVICE SIDE)
Figure 3.9 Mains filter box - high-tension warning label
3.2.8 Drum Vacuum Pump Warning Label

Figure 3.10 shows the risk of hot running temperatures from the Busch drum
vacuum pump.
Figure 3.10 Drum vacuum pump (Busch) - hot warning label

3.2.9 Interlocked Warning Labels (Automatic Only)

Figure 3.11 and Figure 3.13 show the areas of laser beam risk to the engineer
when the interlocked covers are opened and the interlocks are defeated.
DANGER - Laser radiation when open

and interlock defeated



Figure 3.11 Interlock cover - interlocked warning label (Automatic)



SERVICE SIDE
USER SIDE


Figure 3.12 Interlock cover - interlocked warning label (semi-auto and manual)
3.2.10 Plate Transport Module Warning Labels

Figure 3.13 shows the areas of risk from moving parts on the PTM when the top
cover is opened and the interlocks are defeated.

Figure 3.13 PTM - moving parts warning label
3.2.11 Autofeeder Warning Labels

Figure 3.14 show the areas of risk from moving parts on the Autofeeder when
all the covers are opened and the interlocks are overridden.

AUTOFEEDER
(SERVICE SIDE)
WARNING
ENSURE MAINS SUPPLY DISCONNECTED
BEFORE SERVICING
Figure 3.14 Autofeeder - moving parts warning label
Figure 3.15 warns the engineer about the risks of removing a cassette from the
Autofeeder without first locating a trolley under the cassette door.
Figure 3.15 Autofeeder - Àlways Use Trolley' warning label
3.2.12 Safety Devices

Read all warning labels. Make sure that all safety controls, such as those listed
below, are present and working correctly:
Circuit breakers.
Covers and doors.
Guards.
Panel indicators.
Safety interlocks.
Unless essential for commissioning or servicing, and under prescribed condi-
tions, never override, negate, or bypass any of the above safety devices.
3.2.13 Unattended Equipment

Never leave equipment unattended unless in a safe condition with respect to the
following hazards:
Electrical.
Mechanical.
Laser Radiation.
Chemical.
Spinner.
Pneumatics.
3.2.14 Dust Prevention

To avoid dust contamination of the machine, it is important to restrict to a mini-
mum any operation with covers, lids or doors removed or open.
3.2.15 Electrical Safety

WARNING: Do not remove panels, lids or covers, unless instructed to do so by this or
other related manuals. Hazardous mains voltages are present behind panels.
Regularly verify that mains supply cables are not worn or damaged.
Make sure that water and other liquids do not come into contact with the
equipment.
Do not attempt to operate the equipment when flammable or volatile sub-
stances are present in the atmosphere.
Avoid leaving electrical cables trailing where anyone may trip over them.
3.2.16 Mechanical Safety

WARNING: .Do not attempt to lift heavy equipment or assemblies by yourself.
The following basic precautions apply to the platesetter system. More specific
mechanical safety risks, when the safety interlocks are over-ridden, are
described in Section 3.5.
Always close and lock equipment access covers to prevent internal access
from the service side of the Engine, PTM and on the Autofeeder.
The platesetter consists of assemblies that are excessively heavy for one
engineer to lift. If a replacement or installation procedure requires that one
of these assemblies needs to be moved or lifted at any point, then make sure
assistance is available.
The platesetter has a number of motor-driven moving parts that could
present a risk to the service engineer. Make sure you are familiar with the
main areas of danger listed below, and how to carry out a recommended
service procedure when the interlocks are over-ridden.
A) elevator chain pulley system
B) spinner
C) cassette and plate transport mechanisms
D) plate push bar
E) punch and centerer.
3.2.17 Chemical Safety

The guidelines below must be followed when storing or handling highly flam-
mable liquids.
Store bulk supplies in a metal cabinet marked with a `flammable liquid'
label of an approved design.
For use in the work area, decant the liquid to a container with a maximum
capacity of 250 mL. The use of a safety dispenser is recommended.
Do not use the liquid near to non-flameproofed electrical equipment.
Do not use the liquid near to a naked flame. DO NOT SMOKE.
3.2.18 Spinner Safety

3.2.18.1 Moving Parts Safety
While the interlocks are over-ridden, a high-speed spinner mirror presents a
danger for the service engineer.
NOTE: At idle speed, spinner rotation is a direct multiple of some interior lighting fre-
quencies. This could make the spinner mirror appear as stationary.
WARNING: The spinner rotates at very high speeds and can cause serious injury if acci-
dentally touched. Make sure the spinner has stopped rotating before accessing a drum
with the interlocks defeated.
Use the Main Diagnostics (diagnostics/service/spinner/stop) command to halt

the spinner.
3.2.18.2 Acoustic Noise Safety

While the spinner is running and the covers on the Engine are removed, there is
a sound level of up to 65 dBA.
WARNING: Always use appropriate ear protection devices before working on or around a
rotating spinner.
3.3 Safety Interlocks (All Variants)

This section applies to all variants. See Volume 2 Figure 9.10 and Volume 2 Sec-
tion 6.3.3 which describes the interlock system.
The platesetter system includes two safety control facilities for protecting the
operator and engineer from mechanical, laser and electrical hazards. These are:
An interlocked cover system on the covers and doors used by the operator. See
Volume 2 Section 6.4 describing the controls and wiring, and Section 3.3.1
showing the location of the covers. Note that the covers on the service side
and Autofeeder are locked and must only opened by a FFEI-approved and
trained engineer.
An emergency stop system for the operator to rapidly switch off power to all
motors, the laser and spinner. See Section 3.4.
3.3.1 Interlocked Covers

Figure 3.16 shows a set of six protected covers that operate as interlocks to
switch off power to the media handling motors, spinner and laser.
6
5 4
2
Figure 3.16 Interlocked covers (automatic)
The following covers are interlocked on an automatic platesetter (see

Figure 3.16):
1. Buffer: top
2. Engine: top output side
3. Engine: user side
4. Engine: service side
5. Engine: top input side
6. Plate Transport Module: top
The following covers are interlocked on a semi-automatic and manual plateset-
ter (see Figure 3.17):
1. Engine: user side cover
2. Engine: top input cover
3. Engine: top output cover
4. Engine: service side cover.
2
4
3
SERVICE SIDE
(FOR SERVICE
ENGINEER ONLY)
USER SIDE
(FOR OPERATOR)
Figure 3.17 Interlocked covers (semi-auto and manual)
WARNING: If the platesetter has to be run with a cover open and the interlocks overrid-
den, extreme care must be taken to avoid the following hazards: rotating spinner, laser
beam, moving plate motors.
All unqualified personnel must be prohibited from the area, while the machine is in the
overridden state and the Laser Safety Officer informed.
NOTE: The cassette door is part of the elevator interlock system. Controlled from the
MMI, the door lock switches off the elevator motor when it is opened.
Use the approved method (key-switch) for over-riding the interlocks. The
switch is located behind the Engine (service side) cover, with the facility
explained in Volume 3 Section 1.1.
Once the interlocks are defeated, there are a number of hazards that the service
engineer needs to be aware of before starting an installation or service proce-
dure.
3.3.2 Locked Covers

All covers fitted on the service side of the Engine and PTM, and all covers on the
Autofeeder are locked with screw fixings described in Volume 3 Section 1.3.
After completing a service visit, make sure that the removed covers are securely
locked again. This is to ensure that the operator can only access plates from the
openings shown in the Operator and Safety Manuals.
3.4 Emergency Stop Circuit

This section applies to Automatic and Manual variants.
See also Volume 2 Section 6.3.3 which describes the emergency stop circuit.
Emergency stop switches are accessible on the:
PTM (Automatic) - see Figure 3.18.
Engine (Manual) - see Figure 3.19.
As soon as the stop switch is pressed, an emergency relay immediately removes
all electrical supply to the laser, traverse and plate handling mechanisms.
Emergency stops are fuse-protected and are only able to be overridden by an
approved service engineer.
3.4.0.1 Emergency Stop Operation

WARNING: AC Mains supply is still live at the mains filter and interlock box when the
emergency stop has been pressed. Make sure the AC supply is removed or switched off
at the mains outlet before accessing the Engine.
PRESS DOWN
TO STOP
AUTOFEEDER PTM
Figure 3.18 Location of emergency stop switches (Fully-Automatic)

Figure 3.19 Location of emergency stop switch (Manual)
When pressed, the two emergency stop buttons, located on the top of the PTM,
automatically remove AC power to the system (except for the mains filter and
interlock box). This facility is operated if there is an immediate risk of human
injury or machine damage and is reset to allow the supply of AC voltage after
the emergency has been cleared.
The emergency stop circuit control is housed in the interlock box and operates
as follows:
1. While the system is operating normally, the 240 VAC mains input supply to
the RFI box, vacuum pumps and elevators generates a 24 VDC steady cur-
rent to a contactor coil on the emergency safety contactor. The contactor
(type 1026-1BB40) is closed while DC supply is available.
2. Pressing on the stop button opens the 24 V circuit at the PTM, de-energises
the coil which opens the two contacts (live and neutral) for the AC supply to
the RFI box, PTM and Autofeeder. A drop in voltage to the circuit breaker is
sensed and causes the breaker to switch off.
3. Engineers also have the option of removing AC via the safety isolators at the
mains distribution box next to the platesetter.

4. Supply is not restarted until the steps below are completed in the following
order:
A) The emergency stop button is reset by turning the red button in the indicated
direction. This resumes the 24 VDC supply and re-energises the emergency stop
contactor.
B) The ON/OFF circuit breaker is switched on again.
3.5 Mechanical Safety

This section details the main mechanical areas of risk for the service engineer
when the covers are removed and the interlocks are defeated.
3.5.1 At the Autofeeder (Automatic Only)

WARNING: Autofeeder mechanisms potentially present a risk of injury from moving
assemblies when the interlocks are defeated.
The Autofeeder is an elevator system with a mechanical set of chains and pul-
leys that move shelves to their required position for online cassette loading.
With the top and side covers open, and the interlocks defeated, there are a
number of potential hazards for the service engineer to be aware of:
hand trapping by a moving chain
trap hazard between the elevator and the frame.
3.5.2 At the Plate Transport Module (Automatic Only)

A plate feed mechanism between the Autofeeder and the Engine pulls the cas-
sette forward using two motor-driven arms.
3.5.3 Inside the Drum (All Variants)

A motor-driven push bar moves the plate from the input module to the punch.
3.6 Antistatic Precautions (All Variants)

CAUTION: Do not handle exposed electronics. The components may be electrostatically

damaged leading to equipment errors.
The Luxel CTP contains electronic components which are susceptible to static
damage. When clearing jams, cleaning a device, or performing routine mainte-
nance tasks, care should be taken not to touch any exposed electronics.
Before handling a board, all antistatic precautions must be followed.
CAUTION: Do not place a board on an unearthed surface after removing it from its protec-
tive wrapper. Do not place it on the wrapper, the outside of which could be electrostati-
cally charged.
When removing the board from its antistatic wrapper, take care not to touch any
of the board components or connector pins.
Use a Fujifilm field service antistatic kit or, if this is not available, a disposable
antistatic wrist-strap as detailed in this section.
3.6.1 Field Service Antistatic Kit

See Figure 3.20.
The following figure shows the recommended on-site service station using a
field service antistatic kit.
CAUTION: Use the disposable antistatic wrist-strap. Failure to do so may result in dam-
age to the board.
A disposable wrist strap is used to connect the engineer to an earthed (ground)

point on the equipment (usually the chassis). To achieve this, the wrist strap is
adhesive-backed. The equipment must be plugged into an earthed socket (but
not switched on) to ensure a path to ground.
The main antistatic recommendations are as follows:
Always ensure a wrist-strap is connected to earth.
Only personnel that are static-protected should touch boards or exposed
internal components.
Any board to be fitted should be kept within its antistatic enclosure until
needed.
If a board is removed, always pack it in an approved static-safe bag and seal
the opening to provide a Faraday enclosure.
CONDUCTIVE MAT
EARTH STRAP
CLIPPED TO
EXPOSED
CHASSIS CHASSIS
ANTISTATIC
POWER FIELD SERVICE KIT
OFF (9998-7920)
MAINS
PLUG
EARTH WRIST STRAP
Figure 3.20 Antistatic handling station

2-1
Volume-Chapt er
PLATESETTER DIAGNOSTICS
This chapter describes how to use the test and utility commands in Main Diagnostics
required for a service visit.
4
4
Introducing Luxel CTP Diagnostics .......................................................................... 1-1
4
Booting the Platesetter .............................................................................................. 1-2
4
Introducing Main Diagnostics ................................................................................... 1-6
4
Introducing Diagnostic Tests ....................................................................................1-6
4
Describing MMI Error Codes ................................................................................... 1-10
4
How to Use Main Diagnostics ................................................................................. 1-12
4
Running Main Diagnostics ......................................................................................1-19
4
Using Log Utils Menus .............................................................................................1-19
4
Using Test Menus ..................................................................................................... 1-27
4
Using Service Menus ............................................................................................... 1-30
4
Checking Config and NVRAM Data......................................................................... 1-60
4
Upgrading Embedded Firmware ............................................................................. 1-66
4
Setting Up Persistent Images ..................................................................................1-67
4
Running MMI Self-Tests ........................................................................................... 1-69
Using Media Tools ....................................................................................................1-70
NOTE: Platesetter diagnostics may be modified and expanded as new firmware for the
System Board is released. Check the CD Release Notes of new firmware issues for the
latest changes to error codes.
1.1 Introducing Luxel CTP Diagnostics

Features of the Luxel Violet diagnostic system are:
Runs a set of POST checks on application start up.
Runs as embedded firmware on the System Board with an RS232 link to a
VT100 terminal or a PC HyperTerminal.
Uses a set of Log Utilities, Test and Service menus, under Main> diagnostics
prompt, that present selectable commands for field service diagnostics.
VOLUME 2 (1-2) P LATESETTER D IAGNOSTICS
Detects system and media handling errors which are reported on an MMI
console.
Allows the engineer or operator to run a set of automated self-tests for the
system (electronics, traverse, etc).
Allow the engineer to run tests on media handling devices (sensors, motors,
etc) and move discrete mechanisms.
Includes a persistent (permanent) set of test images held on the Hard disk
and selectable from the MMI.
Allows the engineer to access PCB and system configuration files, and edit
system configuration data in a registry file whenever there is a hardware or
software change.
Allows access to the error log files held in Flash memory.
Once the application is running, the following diagnostic tools are available:
Main Diagnostics
A suite of tests and utilities for the service engineer. They run under a hierarchi-
cal menu system that include global commands.
See Section 1.3 and Section 1.6.
MMI Self-Checks
These are a suite of system tests on machine modules (PCBs, motors, optics, etc)
that give a pass/fail result. Self-tests are controlled from the MMI and initiated
by the engineer or operator.
See Section 1.14.
MMI Test Images
A set of persistent images are available for checking image quality and for com-
missioning the system.
See Section 1.5.
MMI Media Tools
A facility on the MMI that allows the operator or engineer to select/park a cas-
sette and advance/eject single plates without scanning.
See Section 1.15.
MMI Error Codes
These are a set of codes that appear on an Error handling screen when a subsys-
tem (optics, spinner, traverse, etc) reports an error.
See Section 1.5.
1.2 Booting the Platesetter

Figure 1.1 shows the system software sequence for booting up and starting the
machine application. See Section 1.5 for details on MMI errors codes and Section
1.4 which describes the tests in more detail.
BOOT SYSTEM
POWER UP
FAIL BOARD SHUTS

CPU DIAGNOSTICS
DOWN
CHECK FLASH
CODE
IF FLASH
CODE CORRUPTS REMAIN IN
OR CONTROL+C PRESSED BOOT MODE
OR TOUCHSCREEN (READY TO
PRESSED DOWNLOAD F/W)
SETS UP HDD
AND NVRAM
CONTROL + C
RUN
FOR BY-PASS
DIAGNOSTICS
MODE
APPLICATION SYSTEM
RUN POST CHECKS

(SYSTEM)
DISPLAY ERROR
START APPLICATION
READY TO SCAN
Figure 1.1 System Bootup sequence
Figure 1.1 shows where you can press [Ctrl-c] to enter by-pass mode and run
diagnostics or modify laser parameters without affecting customer jobs.
NOTE: Enter Start to resume the application when the system is in boot mode.
1.2.1 Boot Sequence and Initialisation

The system boot sequence runs as follows:
Boot Sequence
1. When power is switched on, each CAN node PCB (System, VBOMB, STB
and FHMB) resets its firmware application code.
2. Start-up code provides the system with a minimum level of operating func-
tionality for the application to run. Some of these start-up operations
include:
4 Running initial board self tests.
4 Starting the MMI.

4 Check for the presence of a diagnostic terminal monitor.
4 Initialise hardware without switching on the lasers or motors.
4 Initialise the CAN bus.

3. Start-up code on the System PCB continues to:
4 Establish CAN communications with all node boards.
4 Build configuration records and log differences.
4 Initialise the top level software modules.
SYSTEM OPTICS TRAVERSE DRUM I/P DRUM O/P PROCESSOR

(FHMB1) (FHMB4) NOT READY
ELEVATOR PLATE O/P
(FHMB2) (FHMB3)
Figure 1.2 Boot screen - startup icons (fully-automatic)

Application Sequence
4. Each of the node boards executes a self test on power-up to check whether
the application code is able run. The following POST (Power On Self Test)
routines automatically check:
4 operation of ROM, RAM and processor interrupts
4 communication to the node boards: System Board, FHMBs, STB and VBOMB.
4 power supply line voltages
4 integrity of NVRAM configuration files

4 integrity of System Registry
5. If no errors are found during the POST checks, each PCB confirms its status
to the System PCB and its Boot screen icon turns from grey to bold. If a PCB
check fails, its screen icon remains greyed-out. See also Figure 1.2 and Step
9. below.
Initialisation Sequence
6. Each node PCB initialises its subordinate modules independently of the Sys-
tem Board. Because all the hardware and mechanical dependencies vary
with type of machine configuration, the order of module start-up is resolved
locally.
7. During the initialisation stage:
A) The System Board builds a record of the machine's configuration (board IDs,
serial numbers, etc) and checks whether this matches the previous configuration.
Configuration data is held in NVRAM.
B) If a platesetter cover is open (with the interlocks enabled), power to all the PCBs
is lost except on the System Board, so only a partial initialisation is completed.
C) A plate left in the machine is ejected if the trailing edge has passed BS50;
otherwise it is reversed back into the cassette.
D) A cassette left in the PTM is withdrawn into the Autofeeder.
E) Plate processor is checked for connection and on/off status.
Initialisation Homing Sequence
8. Initialisation also includes assembly homing and limit checks:
A) Push bar is moved down and up again to check motor operation.
B) Traverse carriage creep is checked by moving the carriage to the user end.
C) Spinner rotates at maximum speed.
D) All the optics motors are checked for home datum positioning and travel limits.
E) Traverse carriage moves back to start of scan position at the service end.
F) laser calibration check commences when the traverse is aligned with the Fast
Photo Detect sensor (FPD).
9. If an error is found, an error symbol appears in the Error Handling screen
showing:
4 the location of the module at fault (optics base, spinner, etc)
4 an error code.
10. Errors are either fatal or non-fatal:
fatal error indicates a problem where the platesetter cannot continue to scan
until the fault is removed
non-fatal error indicates a transient fault or an alert but allows the platesetter
to scan.
1.3 Introducing Main Diagnostics

Main Diagnostics consists of a suite of tests and utilities that are run from a
menu system shown in Figure 1.3 below:
MAIN
START STAND ALONE

(R&D USE ONLY) (R&D USE ONLY)
DEVELOPMENT
DIAGNOSTICS LOG
(R&D USE ONLY)
LOG UTILS MENU TEST MENU SERVICE MENU
Figure 1.3 Main Diagnostics - menu map
The following menus are available from Main Menu:

Development Menu
This menu is only available to R&D and service engineers. Use with caution.
Diagnostics Menu
This is password-protected for the service engineer and includes all the com-
mands considered useful for field sites. It has three submenus:
Log Utils: these are commands for editing/displaying files, and saving/
restoring files to the Hard disk (see Section 1.8).
Test: these are test commands that can be selected individually from the
diagnostics> menu or run automatically as:
Boot-up tests (see Section 1.4 for a description).
MMI Self-tests (see Section 1.14 for a description).
Service: these are utility commands that can be selected individually (see
Section 1.10).
Log Menu
All the software error logs for each node PCB are held in local Flash memory
and downloaded to the Hard disk for checking by the engineer.
NOTE: The `Start' and `Standalone' menu options are for R&D use only.
1.4 Introducing Diagnostic Tests

The platesetter performs a set of System self-tests when the Run Diagnostics but-
ton on the MMI TOOLS menu or Error Handling menu is pressed. These
extended tests include all of the boot-up tests.
The SIO online Luxel V/Vx-Series Error Codes Guide describes all the MMI error
codes in detail, including the System tests (codes 1000 to 1999)
1.4.1 System Self-Test Error Codes

System tests are run in the following sequence producing the following error
codes:
1. Check processor core: ROM, RAM, Interrupts, NVRAM storage and slave
boards to give Error Codes.
4 ROM: 1001
4 RAM: 1002
4 Interrupts: 1003
2. PSU rails. Error Code: 1006.
3. Hard disk drive operation. Error Code: 1027.
4. NVRAM integrity on the System Board. Error Code: 1004.
5. System Registry. Error Code: 1005.
6. CAN network checks between the System PCB and node slave boards. Error
Code: 1028
7. All optics stepper motors can operate from a datum. Error Code: 1008.
8. All optics stepper motors are able to fully travel and limit detectors are
checked to give Error Codes:
4 LPD motor: 1009
4 ND motor: 1010
4 Beam converter motor: 1011
4 Focus motor: 1012

4 Focus sensor: 1013.
9. All DC motor assemblies. Error Code: 1007.
10. Spinner runs up to speed and is able to maintain lock. Error Code: 1018.
11. Optical recalibration check on all optical sensors.
1.4.2 System Self-Test Descriptions

This section describes the following system self-tests that run from the MMI and
from Main Diagnostics:
1.4.2.1 ROM Test

This addresses Flash memory and checks data over the data bus. A CRC is per-
formed in two areas of Flash: the boot system and the application system.
1.4.2.2 RAM Test

This checks RAM and data over the data bus. If an error is found a fatal error is
flagged.
1.4.2.3 Interrupt Tests

This checks that the interrupt lines to the processor are not held active. If an
error is found a fatal error is flagged.
1.4.2.4 Registry Check

This checks if the system configuration has been modified.
1.4.2.5 PSU Voltage Supply Check

The FHMB checks that the +24, +5 and +15 VDC lines are within tolerance.
1.4.2.6 NVRAM Integrity Test

This checks that the configuration files contain data that is specific to the sys-
tem. The data is compared to a checksum. If the data is corrupt, the data is
restored to its default. The engineer can load backup data from the hard disk if
default data is not possible.
1.4.2.7 Stepper Motor Tests

Datum Tests
This checks that the optics motors Home correctly by driving each motor to its
datum position:
Focus motor
Laser power detector motor
Aperture control motor
ND filter motor.
The above motors are driven from the VBOMB. A fatal error is flagged if a
motor does not turn or a detector does not respond.
Full Travel Tests

This checks that the optics motors can be stepped freely over the length of the
drive rail by driving each motor to its end stop and returning to zero position.
The zero position is compared to the datum sensor to check that no steps are
missing.
Plate Handling Motors

The plate handling motors for the FHMBs are checked as part of the system self-
tests.
1.4.2.8 DC Motor Assembly Tests

This checks that the plate handling DC motors move to an initial position, one
other position and return again:
A fatal error is flagged if no output is detected from the limit sensor after a set
period of time. The check cannot determine if the sensor or the motor is at fault.
1.4.2.9 Spinner Checks

This checks that the spinner can run at full and idle speed. It is run at each speed
for 30 seconds to check that phase lock is maintained.
1.4.2.10 Optics Checks

The optics stepper motors are checked for home datum position and travel lim-
its. A beam coincidence check is described in Section 1.10.4.1.
1.4.2.11 Output Data Path Checks

This checks the digital data path from the HDD to the serialiser. The serialiser
CRC circuit is initialised. A test image is loaded from the disk and the CRC
value of its data is read at a point just before the optics base and compared with
its known value.
1.4.2.12 Processor Comms Checks

If the Processor operates with the same protocol interface as the platesetter, the
check ensures there is a communication connection.
A loopback test to verify data output requires a loopback connector to be fitted.
1.4.3 MMI Test Images

When the Run Test Image option is selected from the MMI Maintenance menu, a
set of persistent images (PI) on the Engine hard disk drive (HDD) can be chosen
as a test output. When selected, the platesetter automatically exposes the image
and ejects it. Standard PIs are:
Grid for Registration checks
Tint at 50 %
4 x S&T CMYK.
For a platesetter, the image will not adjust to fit whatever plate width is loaded.
Exposure levels are set from the most recent calibration settings on the RIP.
You can move an image from the RIP to the engine and scan it as a persistent
image using the procedure in Section 1.13. Alternatively, you can create an
image using a DTP application and download it as a PI to the engine.
Test strips are also exposed directly from the Engine (not downloaded from the
RIP) using the Service (optics mmi) menu.
1.5 Describing MMI Error Codes

1.5.1 Types of Errors
See the SIO online Luxel V/Vx-Series Error Codes Guide for a list of code descrip-
tions and recovery steps for the service engineer. Errors and their recovery pro-
cedures for the user are explained in the Luxel Platesetter Operator's Manual.
Error codes appear on an MMI Error Handling screen whenever a machine or a
plate transport failure is detected.
Errors are one of two types:
FATAL: these faults prevent the platesetter from operating. When a fatal
error occurs, the operator should follow a recommended recovery proce-
dure. Failure of the machine to recover automatically will cause the same
Error Handling screen to reappear.
NON-FATAL: these are temporary faults that should not prevent the
machine from operating but may have caused the current image to fail. The
system will continue to scan other images on the queue. Non-fatal errors are
also cause by system alerts calling for maintenance attention.
Fatal and non-fatal error codes are arranged into the following groups:
1. Optics: 100 - 199. Optical module and alignment errors.
2. Traverse: 200 - 299. Traverse errors.
3. Spinner: 300 - 399. Spinner errors. (Note that error group 400 to 499 is reserved).
4. Environment: 500 - 599. Temperature, chad tray and cover errors.
5. Input Data Controller: 600 - 699. IDC errors on image data from the RIP
server to the HDD.
6. Output Data Path: 700 - 799. OPD errors on image data from the HDD to the
optics base module. (Note that error group 800 to 899 is reserved).
7. Media Processor: 900 - 999. Processor and comms link errors to the Engine.
8. Diagnostic Self Tests: 1000 - 1999. Diagnostic error reports run from the
MMI.
9. Media Transport: 1200 - 1299. General media transport control errors.
10. Elevator: 1300 - 1399. Elevator errors.
11. Plate Feed (PTM): 1500 - 1599. Module and media jam errors on the PTM.
12. Input Module: 1600 - 1699. Module and media jam errors on the input mod-
ule.
13. Drum: 1700 - 1799. Punch, push bar, registration, chad tray, centering and
vacuum errors.
14. Output Module and Buffer: 1800 - 1899. Module and media jam errors on
and around the Buffer and output module.
NOTE: The enabled error codes depend on the machine variant and configuration.
1.5.2 Fatal Error Closedown Sequence

Detected FATAL errors force the system into a controlled state that allows the
machine to recover automatically and provide adequate information for the
operator or service engineer to fault-find.
As soon as a FATAL error occurs, the system starts an automatic set of controlled
closedown operations that leave the machine in a state where remaining plates
are not at risk of accidental `fogging'. After a closedown has finished, the
machine is in a safe state for the operator to access the problem area.
Closedown operations are described fully in the Luxel V/Vx-Series Error Codes
Engineer's Guide available on SIO.
1.5.3 Error Logging

If a fatal error occurs it is automatically logged on the HDD as an error log
(Elog) file called elogNew.txt. Note that the name is case-sensitive. Alterna-
tively, an Elog file can be generated (and saved to disk) at any prompt in the
diagnostic/service menu by entering:
elog [Return]
You can view and capture an Elog file for further analysis by:
1. List all the files on the HDD by entering:
dfs> ls
2. Scroll down to find the elogNew.txt file.
3. Enter the R&D menu from the main> prompt (password boxer.dev).
4. Enter the following:
streams [Return]
5. Enable Hyperterminal text capture from the Transfer menu and type more off
to avoid the need to keep pressing the spacebar.
6. To display the file, enter:
read general/elogNew.txt
1.5.4 Using the SaveLog Utility

The current set of NVRAM parameters and logged statistics for assessing
machine history can be transferred as a file from the Engine HDD to a floppy
disk on the RIP PC.
1. Make a note of the pathname to the RIP PC floppy drive.
2. Run this facility from the Windows Start menu as (or equivalent):
Program / FUJIFILM Electronic Imaging Ltd / Recorder Utilities / SaveLog

to open a window from where you can select the required data from the menu:
0 Error/Status
2 NVRAM Test
4 SCSI Log
99 All
3. Insert a floppy disk and save the selected data by entering a menu number and
the pathname.
1.6 How to Use Main Diagnostics

Main Diagnostics is designed to provide a set of tests (go/no go) and useful util-
ities for rapid confirmation of the system's operation. If you encounter any
problems while running Main Diagnostics, call FFEI Customer Support (UK).
1.6.1 Setting up a Terminal Window

Main Diagnostics are run from any terminal (PC, laptop, RIP server, etc) that is
able to present a HyperTerminal or VT100 type emulation window. These utili-
ties and tests are embedded on the System PCB allowing the service engineer to
enter diagnostic commands and read return data from the main modules.
Before commencing Main Diagnostics, check that:
an RS232 connection from the terminal to the RFI box (DIAGS port) is fitted.
the platesetter is switched on.
Use the following method to set up the communications link between the plate-
setter and a HyperTerminal on the RIP server.
1. Open a terminal window from the desktop Start button:
Programs 4FUJIFILM4RecorderUtilities4Diagnostic Terminal
2. Set the Properties options for the platesetter comms link to the terminal as
follows:
4 Connect: COM1 or 2
4 Settings: Autodetect
4 Configuration: 9600 bits per sec; 8 data bits; None parity; 1 Stop bit; No flow
control.
3. If you need to transfer scrolled text to a selected file from the HyperTerminal
window, switch on the Capture Text from the Transfer menu.
To obtain a suitable width for the terminal window, set the Properties, Terminal
Settings box to 132 column mode.
NOTE: You may need to uncheck and recheck the 132 column mode box for this setting
to take effect.
1.6.2 Accessing Diagnostics

1.6.2.1 Main Menus
To enter Main Diagnostics carry out the following:
1. Power up the platesetter from the Engine on/off switch.
2. Open a terminal window, for instance, HyperTerminal on a PC.
3. Once the application has loaded, the main> prompt appears (press [Return] if
it is not displayed). Enter the following global command to view the diag-
nostic options as a formatted screen of menus (if required):
main> mode 1
Or enter the mode as 0 to obtain full screen text. Pressing [Tab] [Tab] displays
the current options available.
1.6.2.2 Obtaining the Diagnostics Menu

Diagnostic tests and utilities for the service engineer are available by entering:
main>diagnostics
Enter password: **** (example 'uk1')
TIME ...
DATE ....
Date & Time Correct? (y/n) : y
diagnostics>
Valid passwords are issued from FFEI Customer Support (UK).
1.6.3 Entering Diagnostic Commands

There are two types of command:
those which directly select tests or utilities
those which select another group (or sub-menu) of commands and have the
suffix
/.. When a command is entered, the screen displays all the available command
options.
To navigate between menus, enter the command name and press Return to move
down a menu level, or .. Return to move up a menu level.
After entering the first two or three letters of a command from any prompt and
pressing the [Tab] key, the remainder of the command name is displayed.
Where a boxed list shows `More ->', press the [Tab] [Tab] to display the additional
commands. The screen needs to be in unboxed mode before the commands are
listed.
Other commands require extra parameters to be entered in the form of numbers
or letters.
If a command is not entered without the required parameter(s), a ÙSAGE' mes-
sage appears showing a list of valid parameters for the command.
Commands can be invoked using its pathname; for instance, Diagnostics> service/
optics/laser.
1.6.4 Using Global Commands

Global commands do not appear in the menu structure and are displayed with
the Help command. They can be entered regardless of the current menu position.
All the global commands, along with the menu items available for the current
menu level, are displayed as a list by typing
help [Return] or [?] [Return]
To select a command, type its name, followed by:
[Return] or [Enter]
The global commands and their functions are shown in Table 1.1. Note the fol-
lowing:
All diagnostics commands are case independent. For example, HELP, help or
HeLp, all select the same command.
Diagnostics commands can be abbreviated. For example, to select the Help
command you can enter h, he, hel or help.
You can enter the first few letters of a command and press [Tab] to finish the
entry.
If several commands begin with the same letters, then sufficient letters must
be typed to make the selection unique.
For example, if there are two commands, help and hello and he is entered, the
system responds with a command entry error.
Some commands can be modified by adding subsidiary commands. For
example, enter:
soak soe
and the soak command is modified so that it Stops On an Error.
Certain commands require responses to questions.
Table 1.1 Global commands

Global Command Description
break A forced breakpoint for debugging
ddeb Display debug files
edbg <num> enables debug
ddbg <num> Disables a specific debug
repeat Executes the command string count times
showscript <name> Displays the contents of a specified script
runscript <name> Runs name script
star Enables/disables the rotating star activity indica-

tor
deletescript <name> Deletes named script
zeroscripts Erases all script files
record <name> Records the command lines into a script file

Table 1.1 Global commands (Continued)

verbose Selects the level of messages for display
run <name> Run executable file
help Lists all menu items currently available and dis-

plays details about tests
? Lists all menu items currently available and dis-

plays details about tests
soak <test> <num> Soak a test or a submenu of tests
sys_status Displays machine status problems
enable <command name> Enables individual tests or submenus for soak

testing
disable <command name> Disables individual tests or submenus for soak

testing
find <command name> Locates a command within the menu structure
path Displays the current menu path
mode <1/0> Enter Monitor mode (boxed/unboxed)
deletscript <name> Deletes a script
evt/ Enters the evt menu
../ Returns cursor to parent menu
quit/ Returns cursor to parent menu
zeroscripts Erases all scripts
hreset Hard reset
sreset Soft reset
1.6.5 Using Verbose

The verbose command controls the messages appearing on the Log file during
soak tests. On its own, this command reports the status of the Verbose function
(on or off).
Use verbose on and verbose off to switch the function on and off respectively.
When Verbose is on, all messages are displayed and messages beginning
with: **, --, ++ and ^^ are logged to RAM (if RAM logging is enabled).
NOTE: Only error messages (indicated with**) are logged to Flash memory.
When Verbose is off, only error messages are displayed and logged to appli-
cation, RAM or Flash.
NOTE: For troubleshooting, always select the Verbose ON option.

1.6.6 Running Soak Tests

The soak command runs all tests that are soak enabled in all sub-menus below
the current level.
Tests and sub-menus that are soakable are indicated by an S suffix to the com-
mand name.
If the S is in bold, the test is enabled. If the S is not bold, the test is not enabled.
To soak all soakable tests and sub-menus, use the soak command. By selecting
soak soe the diagnostics will run each soakable test once and will stop when an
error occurs.
To soak more than once, use: soak x where x is the required number of repeti-
tions.
To soak an individual test or sub-menu, enter soak x name, where x is the name
of the test or sub-menu and name is the number of repeats.
To select the stop-on-error code use the suffix soe. For example, soak 10 soe initi-
ates a soak on all enabled tests 10 times and the tests will stop on any error
** An error stopped the soak test! [test name] To stop a soak test press [Ctrl-c].
If a soak test fails and the stop-on-error (SOE) flag has been set, then a message
is displayed on the monitor:
where [test name] is the name of the test which failed.
To select the loop-on-error code use the suffix loe. For example soak 10 loe initi-
ates a soak on all enabled tests 10 times and the tests will loop indefinitely on
any error.
The enable command enables soak tests.
Individual tests can be enabled. For example enable test3 enables command Test3
for soak testing. If enable all is entered then every command in all sub-menus
will be enabled.
The disable command disables soak tests.
Individual tests can be disabled. For example disable test3 disables command
Test3 for soak testing. If disable all is entered then every command in all sub-
menus will be disabled.
Test results can be logged to application, RAM, or Flash memory for subsequent
examination.
Time information can be optionally added to the error log using the command
time_stamp.
Temperature information may be also added to the error log using the com-
mand temp_stamp.
1.6.6.1 Using the Debug Utility

The Debug utility allow you to switch diagnostic information on/off for each of
the machine software tasks and display the sequence of events as they occur on
the system.
NOTE: Always make sure that the Debug facility is disabled before the system is returned
to normal production scanning. The system operates at a slower speed when Debug is
enabled.
ddbg
Disables the diagnostic output from a machine software task. The parameter is
<software task number (see Table 1.2)>. For example, ddbg 8 disables output
from the AODs.
edbg
Enables the diagnostic output from a machine software task. The parameter is
<software task number (see Table 1.2)>. For example, edbg 8 enables information
output from the AODs.
ddeb
Enter ddeb to display all the debug task switch numbers shown in Table 1.2. This
will also indicate if the switch flags are ON or OFF.
Table 1.2 Debug task numbers

Number Debug Check Number Debug Check
0 Event logging 21 Calibration info
1 Std processing 22 Test pattern generator
2 Std exits 23 Spinner contamination
3 Event timers 24 Laser
4 CAN driver 25 System Board temp sense handling
5 Input data controller 26 Delay detector
6 Output data controller 27 EODD port control
7 Local disk debug switch 28 Media transport
8 EOD info 29 Not used
9 MMI GUI 30 Not used
10 Exposer 31 Characterisation using LPD
11 Spinner running to idle speed 32 Expose calibration
12 APC 33 Calibration files
13 SCSI 34 O/P event log text to terminal
14 NVRAM 35 Not used
15 Media management 36 Enable dump of function calls elog
16 Not used 37 LSB control register dump
17 Traverse 38 SCSI - specific setter detail
18 EOD circling 39 Laser environment details

Table 1.2 Debug task numbers (Continued)

19 Beam coincidence 40 Laser Aging details
20 Media processor 41 Not used
- - 42 Laser Dew Point detail
1.6.6.2 Using Script Commands

A script allows you to create a sequence of Main commands and parameters and
run them as an executable file. This facility means that you can generate useful
repetitive routines without having to constantly re-enter command lines. All
scripts are held in a separate script file.
recordscript
Use recordscript to create a new script, for example, `sol':
recordscript sol
actuators/set 10 on
time/sleep 150
actuators/set v 10 off
time/sleep 100
script end (Ctrl-X adds this line automatically)
You can use any of the commands and parameters detailed in this chapter. Type
[Ctrl-x] to terminate the script and the line `script end' appears.
showscript
Displays the text of a specified or the currently loaded script, for example, show-
script sol
runscript
Executes the currently loaded script or a specified script, for example:
runscript sol.
To run a script more than once, enter, for instance:
repeat sol 12
deletescript
Deletes the latest copy of a script name from the script file, for example:
deletescript sol
listscripts
Lists all the scripts available in the script file.
zeroscripts
Erases all scripts in the scripts file.
1.6.6.3 Obtaining Command Line Help

If you are working from a service menu, use the global Help command to obtain
further text details on each command in the menu.

To obtain details on parameters for a command, enter the command name and
press [Return]. This gives a usage line showing each parameter; for instance if
you enter:
diagnostics/service/cassette_dbases> addm
the required parameters are displayed on the following line:
Usage: addm <name> <width> <height> <init quant> <thickness> <type>
Alternatively, you can obtain full usage details of the command by entering ?
before the command name, for example:
diagnostics/service/optics/move_motors> ? beam_re_pos
1.7 Running Main Diagnostics

Main Diagnostics are divided into the three submenu options shown in
Figure 1.4.:
1. Log Utils: allows you to check and modify parameters for NVRAM, registry
values, machine statistics and errors, and copy the configuration files to the
Engine HDD.
2. Test: allows you to run a set of test commands to check, for instance, if the
motors are operating correctly. Some of these tests are also run as POST
checks during system initialisation.
3. Service: provides a set of useful software utilities for checking equipment.
For instance, moving actuators (motors and solenoids), displaying the cur-
rent state of actuators and sensors, etc
.
Figure 1.4 Diagnostics menu
1.8 Using Log Utils Menus

.
Log_utils menu provides a set of commands forr displaying the machine statis-
tics, accessing and updating the Registry/Configuration files and accessing the
NVRAM parameters.
1.8.1 log_utils menu

disp_stats
Displays machine statistics as shown in Figure 1.5:
Parameters: [raw] to obtain a plain ascii file.
Cassette selects 295 Punches since chad 120

Cassette failures 1 Compression(1-1.5) 3
Shelf selects 391 Compression(1.5-2) 17
Elevator failures 0 Compression(2-2.5) 51
Plates Loaded 1786 Compression(2.5-3.5) 11
Plates Retracted 11 Compression(3.5-5) 82
Paper Sheets Handled 1755 Compression(5+) 3143
Exposes 2426 Lowest Comp x 100 87
Fast Spinner Time 180390 Highest Comp x 100 9811
Spinner Failures 0 Image(500mmx500mm) 1138
Media Used(width < 520mm) 126 Image(500mmx750mm) 1223
Media Used(width >= 1050mm) 153 Image(960mmx500mm) 2737
Punches 989 Image(960mmx750mm) 490
Media Jams (Feeder) 2 Image(960mmx1000mm) 1213
Media Jams (Paper Bin) 0 Image(960mmx1162mm) 1346122834
Media Jams (Drum) 4 Total Op Time Secs 13484016
Media Jams (O/P Buff) 9 Total Scan Time Secs 308433
Paper Past Diverter 0 ND_FULL_POWER_POD 167
Feeder Faults 3 BEAM_CO_X_POSN_FULL_POWER 123
Drum Vacuum Secs 165562 BEAM_CO_Y_POSN_FULL_POWER -129
Auto-Feeder Pump Secs 107592 EODD_LB_X_OFFSET_FULL_POWER 1984
EODD_LB_Y_OFFSET_FULL_POWER 2256
Laser On Time Secs 0
Figure 1.5 disp_stats screen
edit_stats
Allows you to edit the machine statistics fields using the cursor keys to move
down each field.
Use the cursor key to move up/down the column and the arrow key to delete.
Press [Return] to obtain the question:
Write change statistics back [y/n]
Parameters: [None]
save_stats
Writes the Statistics file to HDD, see Section 1.11.
Parameters: [None]
updateSysLogs
Writes the System Configuration log files for each node slave board to the HDD.
Parameters: [None]
save_nvram
Saves the System NVRAM parameters to the HDD, see Section 1.11.
Parameters: [None]
disp_nvram
Displays the current NVRAM parameters and their values.
disp_nvram <parameter name> - displays a specific parameter.
disp_nvram - lists all the parameters.
disp_nvram *trav* - allows you to enter wild cards for displaying all the
parameters related to a shortened syntax word.
restore_nvram
Writes the NVRAM parameters from the Hard disk (HDD) to the System PCB.
Reboot the system after restoring the NVRAM.
Make sure that the correct NVRAM configuration is currently stored on disk by
checking the Sysnvram.bin file, see Section 1.10.11.1.
Parameters: [None]
init_nvram
Initialises all the NVRAM parameters to their default values. Do not use unless
advised by FFEI (UK) Customer Support.
Parameters: [A (all parameters)]
disp_conf
Displays the System Configuration file for each node PCB, see Section 1.11. This
shows details of the main node PCBs and gives details of their serial numbers,
test dates, PCB part numbers.
Parameters: [None]
display_registry
Displays the system, slave board or HDD details held on the System Registry
showing the system serial number, build, test date, install date, change history
and change details.
Parameters: [board | system | hdd]; for example, enter display_registry board.
display_errors
Shows the number of times an error has occured, for example:
Error 139 occured 5 times
Parameters: [None]
reset_error_stats
Sets the error statistics to zero.
Parameters: [None]
configuration/
Opens the Configuration menu, see Section 1.8.2.
nvram/
Open the NVRAM menu, see Section 1.8.3.
laser_x_stat
Shows the date and operating current for the laser X installed date and subse-
quent increases of current values to offset aging. It records the history of the
laser operating current with the date of when any current increases by 10 %
from the previous recorded value.
The first entry is the installed or field replacement date; each entry afterwards is
a 10% increase of current. Entries are updated by running the laser_aging com-
mand or when the application runs the diagnostic every 24 hours.
Use this data to predict when the laser will fail by determining when the operat-
ing current is 50% higher than the initial operating current value.
Parameters: [None].
diagnostics/log_utils>clear_laser_x_stat
diagnostics/log_utils>laser_x_stat
Date Laser current.

Oct 28 16:04:17 2002 1174
Jan 1 12:00:00 1998 0
Jan 1 12:00:00 1998 0
Jan 1 12:00:00 1998 0
Jan 1 12:00:00 1998 0
Jan 1 12:00:00 1998 0
laser_y_stat
Displays the statistics for laser Y showing date and time and laser current. See
laser_x_stats above.
Parameters: [None].
clear_laser_x_stat
Clears the laser statistics file. Use this commande when a laser is replaced on an
installed machine.
Parameters: [None].
clear_laser_y_stat
Clears the laser statistics file. See the command above.
Parameters: [None].
1.8.2 log_utils/configuration menu

Use the Configuration menu to save and restore configuration files to the HDD
to avoid the loss of data. These commands are normally used by the factory.
save
Saves a copy of board NVRAM data or configuration data to the HDD.
Parameters: [nvram | config]; enter, for example, save nvram.
dump
Displays all the NVRAM details on the HDD to the monitor.
Parameters: [nvram | config]; enter, for example, dump nvram.
restore
Restores the board NVRAM data or config data from the HDD to a target board.
Do not restore NVRAM data to the boards from HDD unless you are certain
these are correct for the machine configuration.
Parameters: [nvram | config]; enter, for example, restore_nvram.
writeData
This facility allows you to display and edit board Configuration files before they
are saved to the registry. The circumstances where you may need to modify
these files are exceptional; normally, the files on a site machine are updated
automatically on startup. Use the following parameters for each board:
A) <ssb_config> <REGISTRY_SSB_ID>
B) <stb_config> <REGISTRY_STB_ID>
C) <vbomb_config> <REGISTRY_VBOMB_ID>
D) <fhmb1_config> <REGISTRY_FHMB1_ID>
E) <fhmb2_config> <REGISTRY_FHMB2_ID>
F) <fhmb3_config> <REGISTRY_FHMB3_ID>
G) <fhmb4_config> <REGISTRY_FHMB4_ID>
Use the Up/Down Arrow to move between fields.
readData, wrDataArray, rdDataArray, wrCircArray, rdCircArray, init_registry
These commands are not used by service engineers, unless requested by FFEI
(UK) Customer Support.
1.8.3 log utils/nvram menu
Use this menu to view NVRAM parameters and edit values used for the:
laser module
read and write the traverse centre position

read and write the image offset value on the plate
enter a new cage creep utility number of traverses and the interval in hours
between the fast laser contamination checks.
LCPD_params
This command stores the original parameters for the laser when it was first
manufactured. The modified working values are stored in NVRAM after laser
aging, power balance and extinction ratio are setup.
It allows you to display/edit the NVRAM laser parameters for a replaced laser
module. Enter lcpd_params to display the current parameter values for the laser
module. Alternatively, enter lcpd_params change to display the parameters for
editing before they are automatically saved to NVRAM. Revise the parameters
as follows (from top to bottom):
Enter new decimal values supplied with the laser module data sheet, see Vol-
ume 3 Section 4.3.3.
Laser drive power
Laser bias current
Laser current limit
Laser wavelength.
The laser drive power is always 1000 and the other values are specified on the
laser module label.
ORIGINAL DRIVE DAC X VALUE (DEC)

ORIGINAL BIAS DAC X VAL (DEC)
ORIGINAL CURRENT LIMIT DAC X VAL (DEC)
ORIGINAL DRIVE DAC Y VALUE (DEC)
ORIGINAL BIAS DAC Y VAL (DEC)
ORIGINAL CURRENT LIMIT DAC Y VAL (DEC)
LASER X WAVELENGTH (DEC)
LASER Y WAVELENGTH (DEC)
Use the cursor Arrow-Down key to move down each field, use Update to make the
change and press [Return] to exit from the menu.
fog_time
Sets the maximum time a plate can be exposed to ambient light on a Manual
machine. The current maximum setting is 6 mins on both the input and output
to the processor on a Manual machine.
Parameters: [num of minutes on input] [ num of minutes on output].
setter_to_processor
Sets the distance (in mm) for the leading edge of a plate to pass the last Engine
sensor (BS5) on a Manual machine.
Parameters: [num of mm].
set_punch
Use this command to indicate to the machine that a punch is fitted.
Parameters: [0 (not fitted) | 1 (fitted)].

dew_protection
This should be set to 1 if the dew protection Temperature and Humidity Sensor
PCB is fitted, otherwise it is set to 0.
Parameters: [0 (not protected) | 1 (protected)].
exposure_calibration
Set this to 1 to enable a fixed energy level on the plate using the MMI exposure
calibration facility.
Parameters: [0 (disabled) | 1 (enabled)].
spinner_contamination
Controls the operation of the spinner contamination check.
Parameters: [ 0 (disabled) | 1 (enabled)].
temperature_compensation
R&D use only. Do not use.
Parameters: [0 (not compensated) | 1 (compensated)].
reset_spin_clean_level
A new spinner contamination clean level is set up the next time exposure cali-
bration is executed. Do not run this command unless the spinner is changed.
Parameters: [None].
rd_centre_posn
Reads the traverse centre position (in microns) from NVRAM, see also Volume 3
Section 1.8.2.5.
Parameters: [None].
wr_centre_posn
Writes the traverse centre position (in microns) to NVRAM, see also Volume 3
Section 1.8.2.5.
Parameters: [value = microns].
rd_edge_sensor_offset
Reads the NVRAM edge detect sensor offset in microns.
Parameters: [None].
wr_edge_sensor_offset
Writes the NVRAM edge detect sensor offset in microns.
Parameters: [microns]
rd_image_offset
Displays the current image base offset value from the centre of the punch hole,
see also Volume 3 Section 1.8.2.6.
Parameters: [None].
wr_image_offset
Writes a new image base offset position to NVRAM.
Parameters: [value (mm)].
power_control
R&D use only. Do not use.
cage_creep
Use this command to view/set the cage creep number of scans for checking end
positions. The default number of traverses is 35. See Volume 3 Section 1.7.2.
bearing_hold
Use to view/edit the spinner bearing hold time (in seconds). This is the time
from when an image has been exposed to when the spinner has stopped.
Parameters: [None].
nd_correction
Allows the addition of the ND correction values to the ND wedge position
passed from the RIP jobfile.
Parameters: [1 = enable | 2 = disable].
pfa_disklog
Enables/disables the post-failure analysis disk logging to the RIP SaveLog file.
The PFA_DISKLOG_ENABLED parameter is normally set as 1 to enable error
logging. Error logging creates an ASCI log file on the Engine which records the
current software status of the machine at the time of a fatal error.
Check also that the parameters PFA_DISKLOG_LEVEL and
PFA_DISKLOG_DELAY are set to 0.
Parameters: [1 = enable | 0 = disable].
pfa_disklog_level
Shows the level of error logging. The default setting is 0.
Parameters: [0 = standard | 1 = in]
preload_plate
Controls the preloading of a plate to the pre-diverter position. Normally, the
MMI media tools are used for this operation.
Parameters: [0 = do not preload | 1 = preload].
contam_chk_interval
R&D use only.
elog_evt
Defines the number of machine events to be logged by elog. A typical value is
10000.
Parameter: [value].
1.9 Using Test Menus
Test menus allow you to select and run tests for the devices and data paths
listed in Figure . The test results only indicate a PASS or FAIL; you need to
switch on Verbose (global command), to obtain more information about the test
results.
Typical test outputs are shown below. Test outputs show Error Code numbers, if
the tests are applicable to the System tests, and the time and date.
1.9.1 test/basic menu

psu
The PSU_TEST is executed and the result shown as `PASSED' or `FAILED'.
Parameters: [None].
nvram
Checks for NVRAM integrity.
Parameters: [None].
clock
Tests for the correct date and clock output for the set time zone.
Parameters: [None].
1.9.2 test/registry menu

reg_powerup
Use this utility to check if the hard/soft/firmware revisions made on the system
are compatible with the existing configuration. This command also runs as part
of the POST checks on startup.
Parameters: [HDD | system].
display_registry
Displays the system, slave board or HDD details held on the System Registry,
see Section 1.11.
Parameters: [board | system | HDD]; for example, enter display_registry board.
update_registry
Used to modify data in the System Registry after a hard/soft/firmware modifi-
cation, see Section 1.11.
Parameters: [system | HDD]; enter, for example, update_registry system. Only use
HDD for tests.
Toggle the `N' default to `Y' with the [Left/Right Arrow] keys and press [Return] to
exit, then enter Y to confirm.
If you have changed both the System Board and HDD, then the following
appears:
sysSerialNum
sysBuildDate
finalTestDate
Enter revised details (using the cursor keys to navigate) if you have changed
both the System Board and the HDD. Enter the system serial number for pro-
duction machines as PXXX. Press [Return] to exit and Y to confirm. If you have
not made any changes, a message No update to Registry required is dis-
played.
Now check that the revised details are valid by running the Reg_power test:
registry> reg_powerup
1.9.3 test/optics_motors menu

all_home
Checks that each optics stepper motor (focus, low power detector, beam con-
verter and ND filter) reach their datum position, see Section 1.4.2.
Parameters: [None].
LPD_motor
Checks the LPD motor.
Parameters: [None].
beam_conv_motor
Checks the beam converter motor.
Parameters: [None].
ND_motor
Checks the neutral density motor.
Parameters: [None].
focus_motor
Checks the focus motor.
Parameters: [None].
1.9.4 test/traverse menu

datum
Moves the carriage to the traverse datum position at the user end.
Parameters: [None].
trav_test
To confirm the level of the platesetter, run trav_test which moves the carriage
along the service end of the traverse for the number of traverses set by the
cage_creep command. The default number is 10 which allows you to check if
creep has exceeded the specification of 1 mm. To check the user end, enter the
command as trav_test r. See Volume 3 Section 1.7.2 for the levelling procedure.
This test takes several minutes to execute.
Parameters: [r (starts at right - user end)].
1.9.5 test/spinner menu

spin_test
Runs the spinner tests, see Section 1.4.2.
Parameters: [None]
contamination
Runs the spinner contamination check to indicate the percentage of degradation
from a reference level. A large decline (30% or greater) would also be seen as a
reduction in expose quality on the plate. The check requires a correctly set up
FPD, see Volume 3 Section 4.3.9.2. Run reset_cont_lvl before running contamina-
tion.
Parameters: [None].
reset_cont_lvl
Initilises the reference level for the contamination check.
Parameters: [None].
locate_FPD
Obtains the center position from the two edges of the FPD. The result is entered
into the NVRAM parameter: TRAV_HIGH_SPEED_POS.
Parameters: [None].
chart_FPD_resp
Obtains the FPD and LPD response data. This information is only useful for
FFEI (UK) Customer Support.
Parameters: [None].
1.9.6 test/optics menu

beam_coincidence
Runs the BEAM_COINCIDENCE_TEST to set beam deflection alignment. Any
failures, where beam_co is unable to align the beams, results in an optical error
code.
The test will automatically run a macro to:
enable the debug command, edbg 19
switch on the laser.
If there is a problem in running beam_co, then run the above macro commands
separately and re-run beam_co.
Parameters: [None]
deflector_check
Runs a set of tests to check X and Y beam alignments, deflector gains, beam
crossing and angles on the POD. Outputs the results as PASS/FAIL:
4 Deflectors crossed (X and Y cables crossed)
4 X and Y deflector x/y positions on the POD at midrange.
Parameters: [None]
1.9.7 test/processor menu

status
Runs the PROCESSOR_COMMS_TEST to check the Engine communication link
with the Processor.
Parameters: [None]
1.10 Using Service Menus
Commands useful for running service utilities are available from the menu
shown in Figure .
1.10.1 service/memory menu

NOTE: These commands are only used when directed by FFEI CustomerServices Ltd.
dmem
Displays the contents of System Board logical memory addresses for the appli-
cation firmware. Enter ? command for details of the parameters.
verify
Verifies the address pattern. Enter ? command for details of the parameters.
smem
Sets the memory contents. Enter ? command for details of the parameters.
sverify
Sets the memory to a pattern and then verify. Enter ? command name for details
of the parameters.
cmem
Copies memory from one address to another. Enter ? command for details of the
parameters.
compare
Displays the differences between the 1st and 2nd blocks of memory. Enter ? com-
mand name for details of the parameters. Enter ? command for details of the
parameters.
search
Displays occurrences of a specified value within a defined area of memory.
Enter ? command for details of the parameters.
1.10.2 service/evt menu

The software process system runs about fifty multiple system tasks called STDs
(State Transition Diagrams) which co-operate with each other by passing mes-
sages (or Events) along channels. EVT commands are normally used by R&D to
display and manage these communications as a method of determine the cause
of failure if the machine `hangs up'.
NOTE: Service engineers are advised not to use the EVT commands, except for those
listed below.
ini
Event processing is normally initialised on machine startup.
Parameters: [None].
getstate
Displays the current state of each STD task on the System board. These mes-
sages are numerous and will only make sense to R&D. Capture the full display
of text output and consult FFEI Customer Support (UK).

Parameters: [None].
sequence
This shows how the system reached its current state as a sequence of events. Use
the following command: sequence -1 1000 to get the last 1000 state changes. Save
the full display to a floppy disk as a text file and email the results to FFEI Cus-
tomer Support (UK).
Parameters: [std number | number of entries].
1.10.3 service/remote menu

tip
R&D use only.
rcmd
Executes a single command on a remote node.
Parameters: [remote system ID | command to execute].
rlogin
This allows you to login and display data directly from an intelligent slave
board without routing via the System Board.
Use Help to check the list of commands available on each board. When starting
rlogin, make a note of the messages to obtain information for exiting from the
board main> prompt.
Parameters: [ssb | stb | vbomb | fhmb1, etc]; enter [Ctrl-e] to close the session.
1.10.4 service/optics menu
Opening the optics submenu reveals the options shown above.
1.10.4.1 service/optics/laser menu

simlaser
R&D use only.
appl_status
R&D use only.
power_balance
Runs power balance at 48, 72 and 96 resolutions.
Parameters: [Resolution].
check_eodd_ok
Displays the eodd_ok status to indicate if the interlocks are overridden.
Parameters: [None].
x_beam_enable
Sets the X-beam data to 1. This gives a laser output if the laser is enabled using
the lenable command (see below).
Parameters: [None].
x_beam_disable
Sets the X-beam data to 0. This will stop the laser output.
Parameters: [None].
y_beam_enable
Sets the Y-beam data to 1. This gives a laser output if the laser is on using the len-
able command (see below).
Parameters: [None].
y_beam_disable
Sets the Y-beam data to 0. This will stop the laser output.
Parameter: [None].
set_clear_film_density
R&D use only.
set_start_patch_number
R&D use only.
set_end_patch_number
R&D use only.
set_bias_level
Displays or edits the laser bias level to set up laser extinction (see the command
measure_extinction_ratio below).
Working Laser X/Y bias DAC values are changed using the backspace and
numerical keys:
4 to increase the extinction ratio of a laser you need to decrease the bias current
4 to decrease the extinction ratio of a laser you need to increase the bias current.
Increase or decrease the Working Laser bias current DAC values by 1 unit at a
time.
Changing the bias current by a large value (greater than 5) may damage the
laser.
Press [Return] then use the side keys to select UPDATE, the press [Return] to exit.
This will update all the working laser bias values in NVRAM.
Parameters: [change].
Changing values
Working Laser X bias dac value (dec) 563

Working Laser Y bias dac value (dec) 526
Remember Incorrect Values can cause damage

dec hex
Working Laser X bias dac value (dec) 563 233
Working Laser Y bias dac value (dec) 526 20e
Confirm Change UPDATE

Updating Values
lcpd_params
Changes the laser setup. See Section 1.8.3.
laser_stats
R&D use only.
lenable
Enables a laser module for continuous drive or bias. laser Ids are 1 (X) and 3 (Y);
insert the values in LCPD_params for full bias and drive; resolutions available
are 48, 1200, 72, 1800, 96, 100, 2400, 144.
Parameters: [laser id] [bias | drive] [resolution]
ldisable
Disables a laser module from continuous drive or bias.
Parameters: [laser id]
lstatus
Shows the status of the two X and Y laser module PCBs: Photo Diode (PD) and
Laser Diode (LD) head boards. Use to check the connection between the lasers
and the VBOMB.
laser_aging
Resets the laser current limit values and gives some guidance on when it needs
to be replaced. A more useful command to check for laser aging is laser_X_stats
or laser_Y_stats which show the rate of current change from the date of installa-
tion.
For example, the module is close to end of life when:
1. the read x current value is greater than or equal to end of life current value
2. the actual +ve rate of change is greater than the max rate of change. This pro-
duces a fatal error requiring a change of module when 7 has been exceeded.
Use enable debug 40 global command beforehand.
Parameter: [None].
edbg 40
diagnostics/service/optics/laser>laser_aging
Original x current = 1212 read x current = 1260 end of life percentage = 50

End of life current 1818
Original y current = 1157 read y current = 1174 end of life percentage = 50
max rate of change = 7
about to do the x actual_rate calc.
last x current = 1259 read x current = 1260 actual +ve rate of change 0
about to do the y actual_rate calc.
last y current = 1175 read y current = 1174 actual +ve rate of change 0
previous x current limit = 415 new_current_limit x = 415
previous y current limit = 387 new_current_limit y = 387
ddbg 40
measure_extinction_ratio
Measures the extinction ratio of both laser modules. Use set_bias_level to adjust
the extinction ratio.
The extinction ratios should be between 180 and 220 for both lasers (if fitted).
Parameter: [None].
diagnostics/service/optics/laser>measure_extinction_ratio
Laser X extinction ratio = 205.442322

Laser Y extinction ratio = 193.664627
1.10.4.2 service/optics/motors menu

The Motor menu is divided into move_motors and simulate.
service/optics/motors/move_motors (optics)
full_pod_power_pos
Moves the ND wedge to the full POD power position.
Parameters: [None].
half_pod_power_pos
Moves the ND wedge to the half POD power position.
Parameters: [None].
nd_res_pos
Moves ND wedge to a specified resolution position.
Parameters: [48 | 72 | 96 | 100 | 144 | 1200 | 1800 | 2400].
max_nd_pos
Moves ND wedge to a maximum transmission position.
Parameters: [None].
min_nd_pos
Moves ND wedge to a minimum transmission position.
Parameters: [None].
beam_res_pos
Moves beam converter and aperture control to a resolution position.
Parameters: [48 | 72 | 96 | 100 | 144 | 1800 | 1200].
focus_res_pos
Moves the focus to a resolution position for a plate thickness in microns.
Parameters: [48 | 72 | 96 | 144 | 100 | 2400 | 200 | 240 | 1800 | 1200| 200 | 240
| 300].
close_pos_lpd
Moves LPD to its close position.
Parameters: [None].
open_pos_lpd
Moves LPD to its open position.
Parameters: [None].
home_optics_motors
Moves all the optics motors to their Home positions.
Parameters: [None].
motors_to_scan_posn
Moves all the optics motors to their scan positions.
Parameters: [None].
service/optics/motors/simulate menu
These commands are mainly for use by R&D. Refer to Customer Support (UK)
for information on their use at an installation.
nd_simulate
Simulates the ND motor.
Parameters: [1 = on | 0 = off].
focus_simulate
Simulates the focus adjust motor.
beam_simulate
Simulates the beam converter motor.
lpd_simulate
Simulates the LPD motor.
1.10.4.3 service/optics/optics_mmi setup screensM

Use this command to open a setup screen for automatically generating and
exposing test strips from a set of editable default values. Each strip differs from
the previous one by a `step value', enabling the operator to determine the opti-
mum step position and store its 'final value' into NVRAM.
Volume 3 Section 4.4 describes how to use this facility in more detail.
1.10.5 service/motors menu (stepper)
This menu reveals a set of utilities for operating the stepper motors for optics
and plate handling. Before running these commands you first need to set the
current motor using the setmotor command.
init
Initialises the stepper motors.
Parameters: [None].
setmotor
Enter motor name to set the current motor for the other commands, for example,
setmotor nd.
Parameters: [motorname]. See Table 1.3 for a list of motor names.

getmotor
Displays the currently selected motor name.
Parameters: [None].
move
Use this command to move the currently selected motor a number of steps at a
specified speed.
Parameters: [distance of the move (in steps) | f = forwards; b = backwards |
speed (steps per sec)]; for instance, move 80 f 400.
stop
Use this command to stop the currently selected motor.
Parameters: [e = motor stopped with a holding current applied | d = motor
stopped without a holding current applied].
movemore
Moves the currently selected motor a further number of steps after the move
command has been invoked. Parameters: [steps]; enter, for example, as
movemore 20.
offstation
Moves the currently selected motor to a specific position relative to its Home
sensor, for example: offstation 60 400.
Parameters: [position (in steps) | move in steps (per sec) | d (optional) = motor
moves to the required position without passing through Home].
movetillsen
Moves the currently selected motor towards a sensor until an edge (rising or
falling) is reached, for instance, movetillsen 80 f 400 bs41 f.
Note that the transition detection capability for the required sensor and edge
must have been previously enabled using the en_trans command on the /sensor
menu. .
Parameters: [num = max number of steps to move if the edge is not detected | f
or b = move direction | speed (steps/secs) | sensor number | f or r = select the
edge transition to stop the motor (rising or falling)].
shpos
Shows the position of the current motor.
Parameters: [None].
shcond
Shows the status of the current motor.
Parameters: [None].
show
Displays the list of motor names, see Table 1.3.
Parameters: [None].
Table 1.3 Stepper motor names

Setmotor Name Description of Motor
focus Focus
beam_converter Beam Converter
nd ND Wedge
slow_speed LPD
stack_height stack height
push_bar push bar
centerer centerer
bridge_feed buffer
output_mtr BM38 on output module
p_pusher platen pusher
wait
Wait for the currently selected motor to stop.
Parameters: [None].
1.10.6 service/sensors menu
Sensors can have long names (for instance, punch_motor_off_position) or short

names (for instance bs2).
read_sensor
Use to read the on/off condition of an individual sensor, for example,
read_sensor bs9.
Parameters: [Sensor name].
eslog
Enables sensor timelines for event logging (elog). This allows you to check the
status of a sensor during a sequence of machine events.
Parameters: [None]
dslog
Disables sensor timeline logging.
Parameters: [None}
dgslog
Enables sensor logging for a group of sensors called limit, input and output.
Parameters: [group]
shslg
Shows a list of sensor groupings.
Parameters: [None].
en_debounce_rd
Enables or disables debounced sensor reading. When enabled, all subsequent
sensor reads return the software-debounced value; when disabled, all sensor
reads return the current instantaneous value.
Parameters: [y or n = determines whether the subsequent sensor read returns the
debounced value (y) or the instantaneous value (n)]. The default is (y).
simulate
Enables simulation of the value returned when a sensor is read. A sensor can be
simulated at either the client node (the board running the utility) or the server
node (the board controlling the sensor).
Parameters: [c or s = for client or server local simulation | the number of the sen-
sor, for example, bs8 | the value to be returned whenever the sensor is read
where (on or off = discrete sensor; num = analogue sensor)].
This command has limited field use.
dis_simulate
Turns off sensor simulation and returns a previously simulated sensor to normal
operation.
Parameters: [c or s = to match the previous sensor parameter | sensor number,
bs8].
en_trans
Enables a sensor rising/falling transition edge for a discrete sensor.
Parameters: [b (both); r (rising); f (falling) | sensor number]; for instance, enter:
en_trans r bs11.
en_limits
Enables the limits detection on analogue sensor.
Parameters: [sensor name | lower limit | upper limit].
dis_evt
Disables the event generation for sensors (discrete and analogue).
Parameters: [sensor number].
show
Lists all the system sensor names if accessed from the System board.
Parameters: [None]
envsim
Controls the simulation of all environment monitoring sensors.
Parameters: [on = all sensors will be simulated to within the standard operating
ranges; off = all sensors returned to normal operation]. Enter the command
without a parameter to indicate if the simulation is currently enabled or not.
environ
Displays the temperature sensor reading on the System Board in units of 0.1C.
There are three thresholds defined by the software.
Parameters: [None].
read_con
Opens a screen showing the continuous condition of all the input and output
plate handling sensors while the machine is operating, see Figure 1.6 and
Figure 1.7.
Most of the sensors indicate YES when the sensed object (plate or motor opto-
slot sensor tab) is present and NO when it is absent. The cassette ID sensors
indicate if they are detecting BLACK or WHITE blocks.
Parameters: entered for the input and the output sensors:
read_con [fhmb1] to obtain the Manual/Semi input sensor screen, see
Figure 1.6.
read_con [fhmb4] to obtain the Manual/Semi output sensor screen, see
Figure 1.7.
read_con [ip] to obtain the Fully-Automatic sensor screen for the elevator
and PTM.
read_con [op] to obtain the Fully-Automatic sensor screen for the drum and
buffer.
Figure 1.6 Read_con (input sensors) screen (fully-automatic)
Figure 1.7 Read_con (output sensors) screen (fully-automatic)
Press [Ctrl-c] to EXIT from a submenu or select the following options (see
Figure 1.8):
All ERR: select All ERR to switch off (remove) the displayed sensors with
error reports; reselect the option to redisplay the sensors.
Exit: to exit from the Read_con screen.
Specific Sensor: select a specific sensor to switch off (remove) the displayed
sensor output; reselect the option to redisplay the sensor output.
All XXX: select All XXX to switch off (remove) the displayed sensors with
indeterminate reports; reselect the option to redisplay the sensors.
Figure 1.8 Read_con submenus
1.10.7 service/time menu

set_time
Allows you to set the real-time clock on the machine.
Parameters: [YY | MM | DD | hh | mm | ss].
now
Displays the current time.
Parameters: [None].
sleep
Use to add a machine pause in milliseconds, for example, sleep 100.
Parameters: [mS].
gtime
Gets the VRTX time in (ticks).
Parameters: [None].
1.10.8 service/traverse menu
init
Initialises the traverse servo motor.
Parameters: [None].
datum
Moves the traverse carriage to the datum position on the service side.
Parameters: [None].
wait_datum
Use after entering the datum command to prevent any other diagnostic com-
mand from running while the carriage is reaching datum.
Parameters: [None].
goto
Moves the carriage to a position on the traverse set in microns.
Parameters: [position (in microns)]; for example, goto pos=- 610000 for approxi-
mate centre beam position.
wait_stop
Use after entering the stop command to prevent any other diagnostic command
from running while the carriage is stopping.
Parameters: [None].
stop
Stops the carriage traversing by operating as a smooth brake.
Parameters: [None].
halt
Stops the carriage traversing by operating as an abrupt brake.
Parameters: [None].
pos
Reports the position of the traverse.
Parameters: [None].
medirq
Continously monitors the edge detect interrupts. Enter Ctrl-c to abort the moni-
tor.
Parameters: [Number of edges detected].
status
Reports if the traverse is moving or stationary.
Parameters: [None].
rd_centre_posn
Reads the traverse centre position (in microns) from NVRAM.
Parameters: [None].
wr_centre_posn
Writes the traverse centre position (in microns) to NVRAM.
Parameters: [Value (microns)].
1.10.9 service/spinner menu

reset
Initialises the spinner control circuitry.
Parameters: [None].
start
Starts the spinner and runs it up to full speed.
Parameters: [speed (33 or 40)].
idle
Runs the spinner at idle speed.
Parameters: [None].
stop
Stops the spinner - braking takes approximately 20 seconds (max).
Parameters: [None].
index
R&D use only.
rd_image_offset
Displays the current image base offset value from the centre of the punch hole.
Parameters: [None].
wr_image_offset
Writes a new image base offset position to NVRAM.
Parameters: [new value (mm)].
1.10.10 service/actuators
set_drv
Sets the solenoid (BV) and the motor (BM) drivers to on, off and disabled.
Parameters: [actuator name | on, off, disable]; enter, for example, set_drv bm28 on.
See also Figure 1.9.
set
Sets the current actuator and solenoid.
Parameters: [actuator name ] [ on, off, disable, no, sweep]; where no = no change.
cond
Reads the current state of the solenoids or actuators as on or off.
Parameters: [actuator name]; enter, for example, cond bv1.
show
Displays all the actuator (solenoid and motor) names, see also Figure 1.9.
Parameters: [None].
Figure 1.9 Actuator names displayed (fully-automatic)
1.10.11 service/disk menu

If there are two Hard disk drives, they are selected as SCSI unit numbers 0 and 1.
Unit 0 matches CHAN 1 drive; Unit 1 matches CHAN 2.
unit-no
Returns the SCSI number of the drive unit as (odd = 1; even = 0) if a parameter is
not entered.
Parameters: [0 | 1] to set the default unit for operating the commands below; for
instance, unit-no 1.
scsi-id
Displays the device SCSI ID and default unit number.
Parameters: [SCSI ID No] for instance, scsi_id 0.
test-unit-rdy
Returns the state of the default unit(s) and checks whether the unit is ready to
run. Enter as test-unit-rdy after setting the unit number (unit-no). The test report
indicates unit ready (++), unit, unit number and SCSI ID.
Parameters: [None]
capacity
Indicates the status and size (in bytes) of the disk drive memory blocks of a
default unit without a parameter. Also displays the blocks of logical addresses
and block banks in byte decimals for free and used memory.
Parameters: [SCSI ID no] for instance, capacity 0.
inquiry
Without a parameter, displays all the drive details (SCSI ID, vendor ID, product
ID, etc) and completes checks on the default drive status.
Parameters: [SCSI ID no] for instance, inquiry 0.
start-stop
Parameters: [1 (stop) | 0 (start)] to start and stop the default disk rotating. Enter a
second parameter to select the unit. A report indicates whether the stop/stop
operation is successful.
reset
Installs the SCSI driver for the default unit.
Parameters: [SCSI ID no] for example, reset 1
dfs/
Opens the disk file system utility below.
1.10.11.1 service/disk/dfs menu
Opening the disk/dfs menu reveals the options shown above.

mountall
Mounts a new file system. If the system is already mounted, it is unmounted
first. Make sure the dfs is initialised as part of the startup.
Parameters: [None].
un-mountall
Unmounts the file system.
Parameters: [None].
format-low
Scans the disk drive and checks all sectors for damage. Note that the complete
check takes about 55 minutes.
Parameters: [SCSI ID No].
sys-format
This reformats (i.e. repartitions) the drive and removes all unwanted files and
images. Make sure that the Media/Cassette databases, NVRAM, PIs and Con-
figuration data are regenerated on the new disk space. Record the existing data-
base details on paper from dbase/dump and restore from on the MMI; use the
Configuration options to save/restore NVRAM data; use the Registry options to
display/update config data.
Parameters: [None].
ls
List files in the current HDD directory; for instance, ls /general/* to list all files in
the general folder.
Parameters: [filename] or without a parameter lists all files.
cd
Changes the file system default partitions to be either odd or even.
Parameters: [filesystem].
mv
Renames a file on a partition.
Parameters: [old filename | new filename].
rm
Deletes matching files on one or more partitions.
Parameters: [filename].
od
Displays the contents of a file.
Parameters: [filename].
partition-info
Displays information on the disk partitions as odd, even and general.
Disk information is shown as disk name, address, partition size, sector size and
sector cluster.
Parameters: [odd | even | general] to display the disk number, partition address
and size; section size; section cluster numbers; FAT size; sectors FAT.
diskspace
Displays the partition usage on the odd, even, general disk partitions. Displays
the total area (in Mbytes) for the area used and area free.
Parameters: [odd | even | general].
cmp
Compares two files on the disk.
Parameters: [number of edges].
cp
Copies a file to a directory.
Parameters: [filename | directory].
1.10.12 service/testpatns menu
NOTE: Testpatns commands are entered using hyphens (-) and not underscores(_).
Test pattern outputs generated by /testpatns are from direct calls to the machine
hardware and not to the application exposer/plate handling software modules.
Use the optics_mmi facility described in Volume 3 Section 4.4 to create and out-
put a test pattern. Test strip generation from this facility include an automatic
and manual set of tests followed by a media eject.
test-patn-edit
Entering this command displays the line:
1 Beam Res 48 l/mm Vertical Lines 1 On 1 Off
Use the arrow keys to move between each setting and toggle to a new pattern
setup.
Parameters: [None].
image-params
Use the arrow keys to move up/down the menu and edit the settings. Press
Return to exit.
Parameters: [None].
power-con
Displays and edits the power control value.
Parameters: [None]
beam-buffer-select
Allows you to select beams X and Y and a buffer.
spinner-on-off
Indicates the spinner rotation is on or off.
Parameters: [None].
image-bias-posns
Displays and edits the image bias positions.
Parameters: [None]
apc-setup
Displays or edits the APC setup.
Parameters: [None].
Run
Output a test pattern.
Parameters: [None]
dump-buffers
Not used for field servicing unless requested by FFEI (UK) Customer Support.
fill-buffers
Not used for field servicing unless requested by FFEI (UK) Customer Support.
1.10.13 service/job_mgr menu

This facility allows you to create, delete or display the status of a media job on
the Hard disk. As an alternative method, the service engineer can create jobs
from the RIP and delete jobs from the Manage Job Queue option on the MMI
Maintenance menu.
There are two types of jobs: Expose and Media. Expose jobs are linked to transient
or persistent images (PI). Transient (i.e. RIP) images are deleted once scanned; PI
images remain on disk until explicitly deleted.
NOTE: To exit from job_manager, enter quit.
init
Initialises the Job and Image Manager software.
Parameters: [None].
piejob
Use this command to create a persistent image expose job (i.e. a job linked to a
specified persistent image name is created and added to the Expose queue.
Use the procedure in Section 1.13 to create a persistent image.
Parameters: [image name | e]. The optional [e] parameter allows you to edit the
job parameters.
delete
Remove a job from the expose queue.
Parameters: [job ID].
expose
Simulates expose of all jobs on the queue. Jobs need to be queued before start-
ing.
Parameters: [None].
qhold
Holds the expose queue.
Parameters: [None].
qrelease
Releases the expose queue.
Parameters: [None].
jhold
Holds a job from the expose queue.
Parameters: [job id].
jrelease
Releases a job from the expose queue.
Parameters: [job id].
media
Displays the current media details on the active shelf.
Parameters: [None].
qstat
Dumps the job queue status that includes the progress, parent and sub job IDs.
Includes a history list of jobs.
Parameters: [None]
stat
Enter stat to display the status of queued jobs as a test for the Job Manager func-
tion on the MMI.
download job id: job IDs of any expose jobs
expose job id: job IDs of any downloading jobs
queued jobs: total of jobs on the Expose queue
media held jobs: number of jobs held for media
job held: held job at head of queue
queue held: job queue is held.
dumpjob
Dumps the job description if it has not been processed.
Parameter: [job ID].
1.10.13.1 service/image_mgr menu

init
Initialises the Job Manager and Image Manager.
Parameters: [None].
rm
Deletes an image.
Parameters: [job ID].
dumpimage
Displays the image descriptor settings.
Parameters: [image name].
dir
Lists all the images (persistent and RIP transient) held on Engine HDD.
Parameters: [None].
editjob
Opens a screen from where you can edit the default job parameters for a persist-
ent image.
This facility allows you to select an expose image and edit parameters. For
instance, a set of commissioning pages (persistent images), installed on the
platesetter Hard disk for scanning as test jobs where local parameters may need
to be adjusted. These images are exposed directly from the MMI and not the RIP.
A standard set of reference PIs are preloaded on the HDD to include:
grid
S&T page (CMYB).
tint - 50% for tint prediction
A spare set of PIs are also available on the Boxer CD.

1. Enter the utility, and:
image_mgr> dir
to list all the persistent images on Hard disk.
2. Now enter:
image_mgr> editjob <image name>
which lists the following image parameters:
4 eject len(gth): post eject length
4 punch: punch on/off
4 x pos(ition): horizontal image offset on plate

4 y pos(ition): vertical image offset on plate
4 wedge pos(ition): wedge position

4 laser power: not available
4 repeats: not available

4 media name: target media types and size.
3. Scroll down to the required field and edit the settings as required with the
cursor keys.
4. Press [Return] to confirm and enter y to save the new value to the default job
file on the HDD.
NOTE: In some cases, image names can be entered as (*) wildcards; they have a maxi-
mum length of 17 alpha-numeric characters.
editimage
Allows you to edit the image descriptors (pos/neg).
1.10.14 service/medproc/
status
Obtains the status (busy, etc) of the processor.
Parameters: [None].
takemedia
Sets the processor to expect plates.
Parameters: [None].
stop
Stops the Processor rollers.
Parameters: [None].
restart
Restarts the processor after a stop.
Parameters: [None].
thickness
Sets the plate thickness (microns) for the Processor as follows:
4 0.2 plate: enter 200
4 0.24 plate: enter 240

4 0.3 plate: enter 300.
1.10.15 service/medtran menu

The media transport options allow the engineer to move the elevator to a set
position and move the plate through the machine.
Figure 1.10 Media transport menu (manual and semi-auto)
init
Initialises the media transport software variables, clears any error status set-
tings, etc, without moving any motors.
Parameters: [None].
abort
Stops any active media transport.
Parameters: [None].
chkdrum
Checks for a plate in the drum by running the push bar up and down.
Parameters: [None].
prepplate
Prepares a plate at the top of the stack by removing paper.
Parameters: [None].
plateintodrum
Moves a top plate into the drum if the drum is empty.
Parameters: [None].
plateintoindsens
Moves a plate to the inductive sensor (BS50) if the plate has been advanced to
the nudger.
Parameters: [None].
remove_paper
Removes paper from the feeder.
Parameters: [None].
returnplate
Returns a plate in the feed head to the cassette.
Parameters: [None].
prepdrum
Prepares the drum for a plate load.
Parameters: [None].
eject
Ejects the plate from the drum.
Parameters: [None].
clear
Moves the plate from the Buffer to the Processor.
Parameters: [None].
conform
Conforms the plate to the drum by advancing it to the punch sensor, centering it
and operating the vacuum.
Parameters: [None].
prepstack
Prepares the stack by moving it to the correct position for removing a top plate.
See also Volume 3 Section 2.3.5.2 to adjust stack height.
Parameters: [None].
set_stack_height
Displays current stack height to align cassette and feeder for loading plates.
Parameters: [None].
updatefeeder
Updates the feed head status by reading the feed head sensors.
Parameters: [None].
inputstat
Displays the current status of the input module at the last update (ie whether or
not it contains a plate).
Parameters: [None].
feederstat
Displays the feed head status at the last update (ie whether or not it contains a
plate and its location).
Parameters: [None].
drumstat
Displays the current drum status at the last update (ie whether or not it contains
a plate or is ready to receive a plate plus details of a plate already in the drum).
Parameters: [None].
bufstat
Displays the current Buffer status at the last update (ie whether or not it con-
tains a plate and if it is waiting for the Processor).
Parameters: [None].
setup_push_bar
Use to calibrate the distance between the push bar Home sensor and the regis-
tration pins. See Volume 3 Section 2.4.5.3 for a description of the setup proce-
dure.
Parameters: [plate height (in mm)] [plate thickness (eg 0.15)]
[reg_pin_push_bar_offset (in mm)].
medtransim
Shows or sets the media transport simulation mode.
Parameters: [1 to enable simulation or 0 to disable]. Shows the status without a
parameter.
bridgesim
Shows and sets the Buffer simulation mode.
Parameters: [1 to enable simulation or 0 to disable].
paperbin
Shows the paper bin status, indicating the number of waste sheets and whether
it is empty, full or nearly full.
Parameters: [None].
chadtray
Shows the chad tray status, indicating the number of punch chad waste and
whether it is empty, full or nearly full.
Parameters: [None].
init_elev
Sets the elevator software to expect 1, 3 or 5 shelves.
Parameters: [1 | 3 | 5].
access_door
Displays the current state of the cassette door.
Parameters: [None]. Use while media transport is being simulated; displays
locked or open.
loading
Sets or clears the internal flag used to indicate if a media load is in progress.
Parameters: [1 = sets | 0 = clear]

selecting
Sets or clears the internal flag used to indicate that a cassette select operation is
in progress.
returning
Sets or clears the internal flag used to indicate that a cassette is being returned to
its shelf.
xdoor
Shows the status of the X-direction door as open or closed with no parameters
entered.
Parameter: [None] to simulate the state of the door as either closed or open.
load_cassette
Advances the cassette from the shelf to the plate load position.
Parameters: [None]
unload_cassette
Reverses the cassette back from the plate load position to the elevator.
Parameters: [None]
display_cassette_status
Displays the cassette position, contents and ID.
Parameters: [None].
move_elevator
Moves the elevator up/down to the required shelf position for advancing the
cassette.
Parameters: [n = 0, 1, 2, 3, 4,]; enter as: move_elevator <shelf_1> (where shelves a =
0 top shelf; b = 1; c = 2; d = 3; e = 4 bottom shelf). For instance, move_elevator a
moves the elevator to the top shelf.
GetElevatorShelfStatus
R&D use only.
1.10.16 service/dbases menu

These options modify the cassette and elevator databases held on the HDD.
1.10.16.1 service/dbases/cassette
init
Initialises the database.
Parameters: [None].
dumpc
Displays the entire contents of the cassette database, showing the cassette ID in
each bay.
Parameters: [None].
update
Updates the media and cassette databases with the current values found for
each shelf.
Parameters: [cassette ID | plate name | number of plates | empty (0 = no, 1 =
yes].
reduce
Reduces the number of plates on the database.
Parameters: [cassette id | number of plates].
dumpm
Displays the entire contents of the media database, showing the type of plate
and the remaining number of plates, etc.
deletem
Delete a media database entry.
Parameters: [entry number].
addm
Add a new media database entry.
Parameters: [media name | width | height | init quant | thickness | type].
1.10.16.2 service/dbases/elevator
init
Initialises the database.
Parameters: [None].
dumpe
Displays the entire contents of the elevator database.
Parameters: [None].
update
Updates each shelf with the current cassette details.
Parameters: [shelf (A..E) | cassette ID].
1.10.17 service/utils menu

nd_char
This utility creates a HDD file called ND_char. The utility sets up characterisa-
tion tables of the LPD readings against the ND settings required for exposure
calibration. The file is obtained by switching on Y-beam only, setting the resolu-
tion at 96 lpmm and measuring the power at the LPD.
It is setup at the factory and only needs to be recreated if a laser or the HDD is
replaced. For other uses, refer to (Volume 3) Table 4.1 on page 3. During initiali-
sation, the system checks if the file exists, and displays the error code 139 if it is
not found.
Parameters: [None].
restore_nd_char
Restores the ND Character table to HDD. Enable debug 33 to check operation
during the process and disable afterwards.
Parameters: [None].
find_lpd_posn
Updates the NVRAM with the new LPD parameter by evaluating and storing
the position of the maximum laser power for the LPD. Run this command after
replacing the LPD, HDD, SM4 motor or LPD sensor. See Volume 3 Section 4.2.1.
Parameters: [Value (-270 to -294]
power_margin
R&D use only.
optics_efficiency
R&D use only.
nd_repeatability
R&D use only.
setup_fpd_offset
Automatically measures the FPD offset and sets up the NVRAM parameter,
FPD_OFFSET.
Parameters: [None].
1.11 Checking Config and NVRAM Data

1.11.1 Introducing Configuration Data Files
Configuration (Config) data for all the CAN node boards (System board,
VBOMB, STB and FHMBs), the overall system and the NVRAM for each board
are held on the platesetter as four types of files:
1. Board Configs: data files (board serial number, etc) for each node board.
2. System Configs: System data (System ID, etc).
3. System Registry: board configuration data that needs to be updated if a hard-
ware or software change is made.

4. NVRAM: current parameters copied from the System board to the Hard
disk.
The platesetter stores copies of the configuration data files on the System Board
and Hard Disk (HDD) as backup data. Useful data for board IDs, revision and
history are copied from the Config files and held on a System Registry file that
allows service engineers to check and record changes of the system configura-
tion. Figure 1.11 outlines the organisation of the data files and the type of data
they store.
Service engineers are able to replace node boards with new boards that have dif-
ferent revision levels, download new versions of firmware, update the system
registry and run registry checks to ensure that the various versions of hardware
and software installed on the system are compatible.
If a System board is being replaced, its NVRAM parameters can be copied onto
the Hard disk, and restored to the new board, see Section 1.11.7.
BOARD CONFIG
SERIAL NUMBER
BUILD DATE
PCB PART No. ID DETAILS
MACHINE BUILD
PCB MANUFACTURER
FINAL TEST DATE
CHANGES MADE
(SYS, F/W, S/W)
MULTIPLE HISTORY
RECORDS DETAILS
DATE (NOTE) DETAILS NOTE: INCLUDES SYSTEM
(20)
ENGINEER ID SERIAL NUMBER OR
F/W, S/W USER No.
HDD SSB
GENERAL\ FHMB1-4
CONFIG
TMPREG.TXT
SOMB
GENERAL\ STB
NVRAM
REGISTRY.TXT
CONFIG
GENERAL\ SYSTEM
SYSCONFIG.TXT REGISTRY NVRAM
GENERAL\
SYSNVRAM.BIN SYS CONFIG
SYSTEM CONFIG
SYSTEM ID
BUILD DATE ID DETAILS
TEST DATE
SSB SERIAL No.

STB SERIAL No.
MULTIPLE SOMB SERIAL No.
RECORDS FHMB1 SERIAL No. REVISION
(6) FHMB2 SERIAL No. DETAILS
FHMB3 SERIAL No.
FHMB4 SERIAL No.
H/W CHANGED
MULTIPLE DETAILS (NOTE) HISTORY NOTE: DETAILS OF H/W
RECORDS DATE DETAILS CHANGED INCLUDING
(10) ENGINEER ID HDD. DETAILS INCLUDE
SERIAL No.
Figure 1.11 Configuration and Registry files - structured view
1.11.2 Board Config Files

Each CAN node board (System Board, VBOMB, STB, FHMB1 to 4) stores the fol-
lowing board data (as a maximum number of characters) in a local Board Config
file:
1.11.2.1 ID Data
4 serial number (16 chars)
4 build date (5)

4 PCB part number (16)
4 machine build (1)
4 PCB manufacturer (2)

4 final test date (8).
1.11.2.2 History Data

4 software, firmware and system changes (5)
4 installation dates (8 - taken from the machine Time/Date)
4 installer names. (8 - the password of the installer)

From each board, Config data is passed to the System Board for storage as sets
of multiple records that are displayable as ASCII data. In the case of History
records, the last entry is shown first for up to 20 entries. This data can be
accessed by the service engineer either for information purposes or for updating
whenever the configuration of the board is changed.
The current Config data for each board is displayed on a terminal from Main
diagnostics after obtaining the Registry menu as follows:
diagnostics> tests
sysdiag> registry
registry> display_registry board
1.11.3 System Config Files

In addition to the multiple board Config data files, the System Board also holds
a similar set of system data files.System config data shows which boards make
up the system, allowing the engineer to track board changes. System config data
is held separately on the System Board and HDD as the following items:
1.11.3.1 ID Data
4 system ID (16 chars)
4 build date (8)

4 tests date (8).
1.11.3.2 Revision Data

4 board serial numbers (System Board, STB, FHMB1 to 4, VBOMB)
1.11.3.3 History Data

4 H/W changed
4 details of change
4 date of change
4 ID of engineer that made the change.
For revision data the last 10 system changes are tracked and the last 6 system
configurations are stored.
1.11.4 System Registry Files

The System Registry is a set of Config data files for all the node boards in the
platesetter and is held on System Board Flash memory, with a copy automati-
cally generated on the HDD. Its purpose is to provide a quick view to the cur-
rent software, firmware and hardware status of each board, and also the history
of any changes made to the software and hardware in the system.
Each board has a set of board data files comprising an ID file, a Revision file and
a History file, see Section 1.11.4 for details of the ID Data, Revision data and His-
tory Data.
The History file is automatically updated when the Revision file is changed.
Whenever software, firmware or hardware is changed on the system, the engi-
neer must update the System Registry. The next time the system is booted up,
the ID, Revision and History files in all of the node boards are compared with
the same files in the System Registry by a utility called 'Reg_Powerup' held in
the Registry directory.
If a difference between any two files is detected, a warning symbol appears
(Error Code 1005) on the MMI. This is a non-fatal error allowing the system to
continue scanning; however, it will reappear until the registry has been updated
using the utility 'Update_Registry', see Section 1.11.7.
The current System Registry on the System Board is displayed from Main Diag-
nostics after obtaining the registry menu:
diagnostics> tests
sysdiag> registry
registry> display_registry system
1.11.5 HDD Data Files

Hard Disk Drive (HDD) configuration data, held as backup files, is interchange-
able with the data on the System Board. Configuration data is held on the HDD
in four file areas:
1. generalmp.txt: temporary data from System Registry on the System Board
used for checking compatibility levels after a board or software change.
2. generalegsyslog.txt: a copy of the System Registry on the System Board.
3. generalysconfig.txt: system configuration data from the System Board.
4. generalysnvram.bin: all the NVRAM values from each board are stored via
the System Board.
NOTE: The registry data held on the HDD will only be different to that stored on the Sys-
tem Board if either one has been replaced.
The current registry data held on HDD is displayed on Main diagnostics after
obtaining the registry menu as follows:
diagnostics> tests
sysdiag> registry
registry> display_registry HDD
1.11.6 NVRAM Data

NVRAM values, held by the System Board, are stored for backup on the Hard
disk. Engineers can save and restore NVRAM values between the System board
and the HDD.
The Save and Restore functions are available after obtaining the Configuration
menu by entering:
diagnostics> log_utils
log_utils> configuration
configuration> save _nvram
The Save command takes all the NVRAM board files and copies them to HDD.
configuration> restore _nvram
NOTE: Avoid using the command `restore board' unless you are sure the NVRAM config-
uration on the HDD is the correct version.
1.11.7 Updating the System Registry

If a node board is replaced, or new software is downloaded, then the System
Registry data on the System Board and HDD must be updated and checked for
hardware/software incompatibilities, see Section 1.11.7.2. This is automatically
carried out by the check, Reg_powerup, that automatically runs when the sys-
tem is booted up after the change. The Reg_powerup test can also be run as an
explicit command from:
registry>reg_powerup
The result from this test is either:
A compatibility failure shown as an Error Handling screen on the MMI with
an Error code of 1005.
A pass allowing the MMI scan mode screen to appear.
If a software change is made, the registry test is completed and (if successful)
allows the system to enter scan mode Where there are non-software changes,
then the test will automatically fail requiring the engineer to update the registry
using the Update_registry utility, see Section 1.11.7.2.
If the System Board or HDD are replaced, data from one device is automatically
copied to the new device. However, a problem occurs when both the HDD and
System Board are changed. In this case, note the system configuration details
and update the registry with the new serial, build and final test data, see Section
1.11.7.2.
1.11.7.1 Using Display_Registry

1. Obtain the prompt (registry>) from:
diagnostics/tests/registry
2. Enter:
registry> display_registry system
for the System Registry
registry> display_registry board
for all the boards.
1.11.7.2 Using Update_Registry
1. Obtain the prompt (registry>) from:
diagnostics/tests/registry
and enter:
registry> update_registry system
2. Start to reply to the following set of questions:
Figure 1.12 Update_registry screen
3. If you have changed the System Board and the HDD, then the following
appears:
sysSerialNum
sysBuildDate
finalTestDate
Enter revised details (using the Arrow keys to navigate) if you have changed
both the System Board and the HDD. Enter the system serial number for
production machines as PXXX. Press Return to exit and Y to confirm.
4. Now check that the revised details are valid by running the Reg_power test:
registry> reg_powerup
1.12 Upgrading Embedded Firmware

New firmware downloads for the application (including diagnostics) and boot
files are supplied on a CD disk installed from the RIP server. Use the procedure
below:
1. Make sure you have saved a copy of the current NVRAM settings to HDD in
case you need to revert to the previous firmware version. The firmware
update could include new or old NVRAM parameters set to new default
values which immediately take effect once the system is restarted. Use the
following command:
log_utils> save_nvram
2. Insert the CD disk and read the appropriate firmware Release Notes. This is
accessed from the directory `SW/docs/'.
3. Shut down the system from the MMI and reboot from the power on/off
switch.
4. Press firmly the MMI screen immediately the following message appears:
Touch panel to abort
A successful abort gives the message:
Aborted
Remaining in Boot Mode
5. Close down the RIP application on the RIP server, if it is already running.
6. Open the Recorder Utilities window as a PC desktop application:
Program / FUJIFILM Electronic Imaging Ltd / Recorder Utilities / Start
7. Highlight the platesetter name in the box.
8. Select Device/Utilities Download Firmware... to open the [Platesetter Name]
Firmware window. This gives you two options for loading new (V1_xx)
.HEX files from the `SW/New Release' folder on the CD disk:
4 Full: opens a Select Folder window allowing you to access and automatically
load all the new release files, as a group, from the selected CD disk folder. Note
that the files are not displayed in this window when the directory is opened.
4 Custom: opens the Select File to Download window allowing you to select
(highlight) specific release files from the CD disk folder. Do not download any
new Boot files unless this is requested in the Release Notes.
9. Press Select Folder or OK to close the selection window, confirm the selections
when asked, and follow the set of messages that appear as files download to
completion.
10. Restart the platesetter and launch the RIP application. If there have been any
Boot sector changes then a second reboot is necessary.
11. Carry out a machine recalibration after changing the firmware.
12. When the machine is working correctly, save the new NVRAM settings
using the command:
log_utils> save_nvram
1.13 Setting Up Persistent Images

1.13.1 Creating a PI (Celebrant RIP)
The Engine HDD is able to store diagnostic and calibration PIs selected from the
MMI as exposed jobs for customer and service use. These images are persistent
because they not deleted after imaging. If the HDD is reformatted, make sure
that these images are restored to the PC and downloaded to the Engine. You can
download any RIP image as a PI but note that too many PI files on the HDD are
likely to mean a smaller page buffer for normal jobs.
Use the following procedure to create a PI image:
1. Close the RIP application.
2. Open the File Manager and search for the file òutput.cml' from the Win-
dows Find file option. The default pathname is:
Program Files/Fujifilm Electronic Imaging/output.cml
Open the file with any editor (Notepad, etc).
3. At the end of the file, add a new line as:
ImageName="xxxxx" (without spaces where "xxxxx" is any text name.)
4. Save the file and close down the File Manager.
5. Open the RIP Application again and select a job that you wish to use as a PI
image. This is normally a typical customer job or a large image that can be
used for testing purposes.
6. Download the job to the Engine and check in the Log that it has not exposed.
If it has started to expose, then it will not appear as a PI image.
7. Check from the MMI that the image name has appeared on the Run Test
Image window in the TOOLS menu.
8. Shutdown the RIP application.
9. Make sure the entered text line in the òutput.cml' file is removed or is con-
verted into a comment.
To convert into a comment add:
Rem ImageName="xxxxx"
1.13.2 Deleting and Editing a PI (Celebrant RIP)

1. Enter the following Main Diagnostics menu:
service/disk> dfs
and delete the five files for each PI image: odd, even, id, jd and erl. Use the
command rm to remove each file.
2. To edit a PI, enter:
service/image_mgr> editjob XXXXX
1.13.3 Creating a PI (Rampage RIP)

1. Edit the environment variable, JOB_NAME, to page name, where the page
name is the name of the PI image.
2. Put the page in the plot queue. Note that this page will download to the
Engine HDD but will not image.
3. Reset the environment variable to the next page name and follow step 2)
above.
4. When all the pages have been downloaded, delete the environment variable,
exit from the Rampage Shooter application and restart the application.
If the media size is smaller than the PI a possible Shooter error could appear. To
avoid this problem, resize the image from the diagnostics image_mgr utility
making sure that the parameter field media name is left blank. This will ensure
that the PI images on any sized plate.
1.14 Running MMI Self-Tests

MMI System Self-tests are run from the TOOLS menu to check devices on all the
modules, except for the Processor. These diagnostic tests are described in Sec-
tion 1.5 on page 1-10. Run the tests as follows:
1. Once the Image Not Downloading icon appears on the TOOLS screen, select
Run Diagnostics from the menu:
Alternatively, select Run Diagnostics from an Error Handling screen (if the
option is active).
2. This function runs all the platesetter System diagnostics and displays a
Splash screen showing the tests running in each of the control sub-systems
(node PCBs):
SYSTEM OPTICS TRAVERSE FHMB2 FHMB1 FHMB3 FHMB4 PROCESSOR

NOT READY
Figure 1.13 Recorder Self-Tests - diagnosing screen
4 System - System Board check

4 Optics - VBOMB PCB and optics base modules checks
4 Traverse - carriage motors and Traverse PCB checks
4 Elevator - Autofeeder and FHMB2 checks
4 Drum Input - PTM and FHMB4 checks

4 Plate Output - Buffer and FHMB4 checks
4 Drum Output - Module and FHMB1 checks

4 Processor - ready/not ready check.

3. If all the tests pass, then the display shows a Tick icon on the Pass screen
4. Press Return to reboot and commence scanning. If a self-test fails, the Error
Handling screen for the Error Group appears.
1.15 Using Media Tools

1.15.1 Fully-Automatic
Media Tools allows you to select a cassette and output a single unexposed plate
for inspection using the following options:
advance a single, unexposed plate into the drum
eject a single, unexposed plate from the drum
swap on-line cassettes feeding the drum
park an on-line cassette back into the Autofeeder.
Select Media Tools from the PAUSE top-level menu to open the Media Tools
screen:
ADVANCE PLATE PARK CASSETTE EJECT PLATE
ADVANCING
PLATE
MEDIA INFO RETURN SWAP CASSETTE
Figure 1.14 Media Tools screen (fully-automatic)
1.15.2 Manual and Semi-Automatic

Manual and semi-automatic machines have the following media Tools options:
advance a single, unexposed plate into the drum
eject a single, unexposed plate from the drum
swap media types.
ADVANCE PLATE EJECT PLATE
ADVANCING
PLATE
MEDIA INFO RETURN SWAP MEDIA
Figure 1.15 Media Tools screen (manual and semi-automatic)

2-2
Volume-Chapt er
PLATE HANDLING CONTROL

This chapter introduces the main plate handling modules and how they control the
movement of plates through the system.
4
4
Plate Handling Control Modules ...............................................................................2-1
4
Plate Handling Assemblies ......................................................................................2-13
Plate Handling Operation and Sequence ...............................................................2-18
2.1 Plate Handling Control Modules

This section briefly introduces the main plate handling control assemblies for all
Luxel platesetter variants and shows their approximate location.
2.1.1 Autofeeder
Figure 2.1 outlines the main Autofeeder control assemblies and their connec-
tions.
The Autofeeder consists of a frame cage, and an elevator with five cassette
shelves that move up and down as a cassette plate type is selected for forward-
ing.
Overall control of the Autofeeder and elevator movements is from FHMB2, with
AC motor drive fed through from the Engine. A separate interlock mechanism
ensures AC power to the elevator motor is switched off when:
A) the cassette loading door is open or unlocked
B) the frame travel safety limits at the top and bottom are exceeded.
VOLUME 2 (2-2) P LATE H ANDLING C ONTROL
ELEVATOR
MOTOR
BM26
CONTROL MOTOR (BM28)
BASE
DOOR LOCK
DOCKING LIGHT
CASSETTE
ELEV ABS
(BS68/69)
(BV22)
ZDIRECTION
LIMITS
(BV25)
A1
CONTACTOR
+24V
CASS DOOR LOCK
LOCK
+24V
FHMB(2)
W
U
V
MOT DSBLD
BS73
TO
H
(BS74/75)
ALARM/
OLOAD
BS78
INVERTER
ELEVATOR CONTROL PCB
CONTROL
MOTOR
P24V
BS77
FWD/REV
FST/RST
(BM26)
N
L
+24V
+24V
+24V
+24V
FILTER
CONTACTOR
ELEV CTRL SOL
BASE
BM28
BV25
BS72
BV22
BS73
E
L
SAFETY
RELAY
FHMB(2)
FHMB(2)
MAINS
INPUT
FHMB(2)
FHMB(2)
Figure 2.1 Autofeeder controls and power
See Figure 2.2

Elevator Control PCB: houses a set of relays that switch, under FHMB2 con-
trol, to drive the elevator motor drive in the FWD/RST/REV/FAST modes.
Elevator Distribution PCB: uses three sensor detectors and three linear verti-
cal vanes (attached to the moving elevator frame) to provide feedback about
the current vertical position of the shelf.

Inverter and contactor: the inverter provides power control to the elevator
motor, and the contactor halts the motor (BM26) if an interlock signal is
received when a cover is opened, or the operator selects the MMI option to
open the cassette door.
Cassette door lock: a solenoid door lock is under control of the MMI to open
the cassette door when installing or removing a cassette.
FHMB 2 PCB: the main elevator control PCB linked by the CAN bus to the
SSB (System PCB).
Sensors: Autofeeder sensors provide feedback to FHMB2 on shelf positions,
trolley alignment at the cassette door and the status of the cassette door lock.
See also Volume 2 Section 3.2.1.14.
Motors: motors (controlled by FHMB2) drive the following plate handling
assemblies on the PTM:
4 AC elevator motor/gear assembly (BM26) - drives the elevator frame
4 Z-direction arm (BM28) - moves the arm up and down
4 cassette door lock (BV22) - opens the cassette door.

Relays and Solenoids: solenoids (controlled by FHMB2) drive the following
plate handling assemblies on the PTM:
4 Cassette Door Lock (BV22) - locks and unlocks the cassette door
4 Absolute Limit Top and Bottom - indicates limit travel of elevator.

SENSOR VANE
SHELF SENSING
ELEVATOR
A: YNN
TOP
ABS B: YYN
SHELF 5
LIMIT C: NYN
D: NYY
E: NNY
4
SENSOR DISTRIBUTION PCB
BS31(BOTTOM)
ELEVATOR 3
FWD/REV
SLOW/RST BS32 BS33 BS34
BS30 (TOP)
2
1
BOTTOM
ABS
LIMIT
BS BS
AC SUPPLY
74 75 INVERTER
BM26 CONTACTOR
ELEVATOR MOTOR
KEY
CASSETTE DOOR LOCK
BS (SLOTTED)
BS BV
72 22 BS (REFLECT)
BS63 BS (REED)
ELEVATOR BS70 BM28 BS (SWITCH)

CONTROL CASSETTE DOOR ENTRY
PCB BV (SOLENOID)
ZDIRECTION ARM
BM (MOTOR)
BS77 BS78
DOCKING LH DOCKING RH
FHMB2
Figure 2.2 Autofeeder plate handling control assemblies
2.1.1.1 PTM
Figure 2.3 shows the main control and drive signals to the PTM plate handling
devices.
TO AUTOFEEDER
ENGINE ELEVATOR
(MAINS SUPPLY) MOTOR
CAN5 AIR KNIFE TO INPUT MODULE

FHMB(4) FAN
SENSOR PLATE FEED

DIST
See Figure 2.4

PWR SENSORS
ENGINE FHMB(3)
(PWR DIST)
24V PLATE FEED
DIST SENSORS
PLATE FEED
MOTORS
drive to the local motors.

CAN4
CASSETTE ID SENSORS
CASS
ID CASSETTE FWD/REV SENSORS
CASSETTE/X-DIRECTION SENSORS
CASSETTE/X-DIRECTION MOTORS
FHMB(2)
ELEVATOR MOTOR
ELEVATOR SOLENOIDS
CAN3 (CONTROL PCB)
FHMB(1)
ELEVATOR SENSORS
Figure 2.3 PTM plate control and drive

ENGINE EMERGENCY STOPS
(INPUT SUPPLY)
ENGINE +24V CONTACTOR

(SAFETY RELAY)
sensor status signals from PTM moving assemblies and provide the 24 V
Sensors: PTM sensors are used to determine limits, home positions and the
FHMB 2/3 PCBs: two motor handling PCBs run software routines that accept
KEY
BS (SLOTTED)
BS (REFLECT)
NUDGER NUDGER AND FEED HEAD BS (REED)
LIFT TAKEAWAY
(BM23) (BM22) BS (SWITCH)
BS46 VIEW ON A BS47 BS46 BS47
BS (INDUCTIVE)
BS45
BV (SOLENOID)
A
BM23 BS45
BM (MOTOR)
NUDGER
BS48
BS43 BM22
BS51
BS43 TAKEAWAY INPUT
DIVERTER
ROLLER
CASSETTE AND PLATES BS55

BS48 BS49 BS50 BS66 BS59 BS52
BS36 40 BS56 BS53 BV20
BS65
BS57
VACUUM
BM24 TUBE
BM25
CASSETTE ID RETARD
INTERLEAF
BS61 ROLLER
BS62 BS71 CASSETTE
FORWARD
BS44 INTERLEAF
BM27 BS41 BS42 BIN DOOR
Figure 2.4 PTM plate handling control assemblies

X-DIRECTION STACK
BM21
ing. See Volume 2 Section 3.3.1.6 for a description of the sensors.
DOOR BM20 INCREMENT

BS76
presence of plates or interleaf paper while the PTM assemblies are operat-
Motors: motors drive the following plate handling assemblies on the PTM:
4 X-Direction door (BM27) - moves the door flap up and down when a new cas-
sette is installed.
4 Cassette forward (BM20) - drives the two arms that pulls the cassette into the
PTM
4 Stack Increment (BM21) - drives the leadscrew mechanism to increment the
stack in small steps to activate the stack height sensor.
4 Nudger and takeaway (BM22) - drives the nudger and takeaway rollers
4 Nudger lift (BM23) - lifts and lowers the nudger roller to remove the top plate on
the stack
4 Interleave drive (BM24) - drives the two rollers that push the interleaf paper into
a bin.
Relays and Solenoids: drive the following plate handling assemblies:
4 Air Knife Control (BV23) - switches on/off the air knife
2.1.2 Imaging Engine

Figure 2.5 shows the main control and drive signals to the Engine plate han-
dling devices.
See Figure 2.6.
FHMB 1/4 PCBs: provide local control (as firmware routines) for accepting
sensor signals and switching plate handling motors on/off.
Sensors: Engine sensors are used to determine limits, assembly positions and
the presence of plates while Engine assemblies are operating. See also Vol-
ume 2 Section 3.4.
Motors: motors drive the following plate handling assemblies on the Engine:
4 Input module (BM1) - drives the band rollers for conveying plates into the drum.
4 Push bar (BM2) - drives the push bar to forward plates into position for imaging
4 Centering (BM3) - drives the two centering arms for aligning the plate (along the
horizontal drum axis) before punching.
4 Punch (BM4) - drives the punch pins.
4 Registration (BM5) - drives the registration pins that operate as a mechanical
`stopper' at the leading edge to hold the plate in position for imaging.
4 Output module (BM6) - drives the module rollers for conveying plates out of the
drum.
4 Buffer Feed to Processor (BM7) - drives buffer rollers.
4 Plate Centering (BM10) - centres the plate on the manual load platen.
4 Plate Pushing (BM11) - pushes the plate from the platen to the drum.
FHMB PWR
FHMB 2/3
VACSOLS/COMPR (BV31)
EXT
I/LOCK CENTRING/REG/OUTPUT
SENSOR SENSORS
DIST
I/LOCKS CAN5 (O/P) BUFFER SENSORS
4
FPD
4
BUFFER/OUTPUT/
REGISTRATION/
FHMB(4) SWING CENTRING MOTORS
plate.
ROLLER
POWER SENSORS
PWR2 24V
FILTER PUNCH SENSORS
DIST
REG
PIN
PUSH BAR
REG PIN CONT SENSORS
INTERLOCK
BOX UMBILICAL
TRAVERSE CARRIAGE
ID1
CAN ID
FHMB PWR SENSOR

PLATE/PUNCH
DIST
ID0 SENSORS
(I/P)
CAN3
INPUT/PUNCH
MOTOR
BV3 MIXER
FHMB(1) (EXHAUST)
SOL 4 (BM41) - controls air blow to the air knife and vacuum blow.
CAN2 RTN
BV8 EXT
Figure 2.5 Engine plate control and drive (B1 and B2 fully-automatic)
ALERT
Swing Roller Motor (BM37) - operates the SRM to hold the leading edge of the
RTN
Solenoids: these drive the following devices:

4 Mixer Fan (BV3) - switches the mixer fan on/off during an expose.
4 Drum Vacuum (BV5) - switches the drum vacuum motor on/off before and after
an expose.
4 Error Light (BV8) -
4 SOL 1 (Divert Valve - BV 30) - diverts air to the drum.
4 SOL 2 (Compressor relay - BV31) - switches the vacuum compressors on/off.
4 SOL 3 (Leading Edge - BV40) - solenoid for vacuum leading edge.

4 SOL 4 (BV41) - controls air to the vacuum blow and the air knife.
INPUT OUTPUT
MODULE MODULE
BM6
PTM BS5
DRUM
BM1
BS52 BS1
BS4
BS6 PUNCH/ BM5 (REGISTRATION)

REGISTRATION/
CENTERER
MODULE
BS2 A
PUSH
BAR BM3 (CENTERER)
BM2
BM4
(PUNCH)
BS15
BS8
BS9
VIEW ON A
BS14
BM5
BM4
BS12 BS3 BM3 BS13
PUNCH/REGISTRATION/CENTERER MODULE
(BILLOWS) KEY
BS (SLOTTED)
B BS (REFLECT)
BS (MICRO SW)
BS11 BS10
BV (SOLENOID)
VIEW ON B
(UNDERNEATH) BM (MOTOR)
Figure 2.6 Engine plate handling control assemblies (B1 fully-automatic with
punch)
INPUT OUTPUT
MODULE MODULE
BM6
PTM BS5
DRUM
BM1
BS52 BS1
BS4
BM37 BS109/110
BS6
REGISTRATION
SWING MODULE
BS2 ROLLER
PUSH MODULE
BAR BM36
BM2
BS100/103
BS15
KEY
BS (SLOTTED)
BS (REFLECT)
BM (MOTOR)
Figure 2.7 Engine plate handling control assemblies (B1 and B2 fully-automatic
and manual without punch)
2.1.3 Buffer
Figure 2.8 shows the main Buffer drive controls and assemblies. Two types are
currently available on installed machines: old (used on early production Violet
machines) and new.
New Buffers now have the following servicing features:
Can be lowered from the Processor, in the same way as the old Buffer, to
access the rear of the engine.
The exterior cover can be removed while the Buffer is in-situ to access Buffer
parts.
No longer includes a labyrinth or height adjuster.
BUFFER EXIT
ENTRANCE
INTERLOCK (B1 MANUAL INTERLOCK
BUFFER
(BS19)
(BS20)
TO PROCESSOR
BUFFER FEED
IS LINKED OUT)
DIRECTION
PLATE
(BM7)
BUFF_S19/20
BUFF_S19/20
BUFF_M7
BUFFER
ENG_INT
DISTRIBUTION
(OUTPUT)
SENSOR
PCB
RIB1/2
FHMB(4)
CONTROL
CAN
IMAGING ENGINE
INTERLOCK
BOX
TO SSB
Figure 2.8 Buffer plate control and drive
See Figure 2.9.

Sensors: BS19 and BS20 indicate if the Buffer has received a plate and ejected
a plate.
Motor: BM7 drives the Buffer band roller under control of FHMB4.
BS19
BS20
TO
PROCESSOR
BM7
BAND
ROLLER
KEY
BS (REFLECT)
BM (MOTOR)
Figure 2.9 Plate handling mechanisms and controls - Buffer
2.2 Plate Handling Assemblies

This section describes the standard assemblies used to control the transport of
plates for all modules:
Plate handling sensors: see Section 2.2.1.
Plate handling motor and solenoids: see Section 2.2.2.
2.2.1 Plate Handling Sensors

Plate handling sensors are mainly used to initiate on/off switching for a plate
handling motors, indicate a plate jam or check for mechanical limits. There are
five types of sensors typically used on the platesetter:
1. Opto-reflective switch: flags the exact position of a plate leading/trailing edge
on the media path.
2. Reflective/diffused: senses reflective light (plate) or diffused light (paper).
3. Opto-slotted switch: detects a limit tab on a motor-driven mechanism.
4. Micro-switch: opens and closes by a moving mechanism.
5. Inductive: detects the metallic or non-metallic presence of plates or paper.
NOTE: The method of removing and replacing these sensors is very similar. A descrip-
tion is given in Volume 3 Section 2.1.1.
2.2.1.1 Opto-Reflective Sensors

These are opto switches which emit light and detect the same light from a reflec-
tive surface. The sensor output is +5V when light is reflected back to the detec-
tor (reflective plate is present). The sensor output is 0V when light is not
reflected (reflective plate is not present). Note that these levels are inverted for
software purposes at the sensor registers.
Light emitted from opto-reflective sensors used in the plate handling paths are
switched on and off by a train of pulses to reduce any fogging of the plate. They
are typically switched on for 200 microseconds and off for 3 ms. While a plate is
stationary, the sensors are turned off to reduce the risk of `fogging'. Where this
type of sensor is not used for detecting plates it is not pulsed.
Opto-reflective sensors detect a change of reflected light from a surface or a
passing edge. They are especially useful for determining plate presence and
lengths along a path, and are generally very sensitive to plate angle and dis-
tance.
Fixings and mountings for these sensors are mechanically set on the platesetter
so that you only need to ensure that a replacement is fitted in exactly the same
position as the old device. On replacement, reflective sensors may require cali-
bration to find the minimum level of LED drive to allow detection. Normally, a
replacement setup is not required.
Voltage supply to the sensor is set at +5 VDC and the type of switching is:
A) Plate Not Detected = LOW output.
B) Plate Detected = HIGH output.
C) Fault Condition = OFF.
Opto-reflective sensors are fitted on the Cassette ID, the Opto-Reflective Sensor
PCB and the Paper Plate Sensor PCB:
Cassette ID PCB:
Sensors read the reflective ID codes (1-31) on the cassette once it is advanced to
the feed head.
A) Light not Detected = ON
B) Voltage supply: 4.5 to 16 VDC
On fitting opto-reflective sensors, note the following:
1. As the angle of the sensor to the plate increases, the detection distance
reduces.
2. The plate angle for the reflective underside should be >45 with an allowa-
ble sensing range of 4 to12 mm.
3. The emulsion side gives a more diffused reflection with a decrease in maxi-
mum detection distance. This effect is even more evident with interleaf
paper.
4. For emulsion side and interleaf paper, the allowable sensing range is 4 mm
to 8 mm.
Opto-Reflective Sensor PCB:
This PCB (called Reflective-Opto) mechanically houses the sensor device and
detects the arrival of plate at set points on the media path, see Figure 2.10. The
PCB houses a single sensor and includes a cathode with two parallel resistors in
series.
R1
33R
R2
33R SW1
EE-SY313
PL1
1
2 5 3
ANODE VCC
3 C1 2
4 OUT
4 1
CATHODE GND
0.1u
25V
Figure 2.10 Reflective-opto sensor board layout
Paper Plate Sensor PCB:

This PCB is similar to the Reflective-opto PCB and is used to detect the presence
of a plate or interleaf sheet. The PCB is calibrated at the factory using an on-
board potentiometer. Adjustments should not be made once the device is fitted.
2.2.1.2 Opto-Slotted Sensors

These sensors are used by the software to detect the position of a mechanism,
notably for travel limit sensing or position detection. A small vane, fixed to the
moving mechanism, interrupts the slot light, indicating to the software the cur-
rent position of the mechanism.
Opto (or interrupt) switches emit and detect light between two integral posts.
The sensor output is +5 VDC when light is detected (vane is not interrupting a
light beam). The sensor output is 0 VDC when light is not detected (vane is
interrupting a light beam).
SUPPLY
VOLTAGE
GND
SLOT FOR FLAG

OUT
Figure 2.11 Opto-slotted sensor connectors (side view)
Voltage supply to the sensor is set at +5 VDC and the type of switching used is:
A) Light not detected = LOW output = read ON.
B) Light detected = HIGH output = read OFF.
2.2.1.3 Reflective/Diffused Sensor

These sensors operate as an integral emitter and a detector for detecting
whether light has been reflected from the plate surface (without the interleave
paper) or diffused (when the interleaf has failed to be removed). Examples of
these sensors are:
4 BS51
4 BS55.
Voltage supply to the reflective/diffused sensor is set at +24 VDC. The sensor
output is attenuated on the +24 V Distribution PCB before being passed as a
+5 V signal to the FHMB.
These sensors are setup for correct detection.
2.2.1.4 Micro-switch Sensor

Micro-switches are used to detect a moving assembly and operate as:
4 Absolute Limit: detects the end of travel at both ends by the Autofeeder frame
(trip sensor).
4 Chad tray: detect presence of tray.
4 Cassette at nudger: detects the presence of the cassette at the nudger.
4 Centering detect: left and righthand side.
2.2.1.5 Magnet Reed Sensor

Two reed sensors inside the Autofeeder cassette door operate when the pin
inserts on the trolley buffer locate in the correct position. The sensor includes a
3-way plug:
A) Pin 2: +24 VDC
B) Pin 3: GND.
2.2.1.6 Inductive Sensor

An inductive sensor detects either paper (non-metallic) or plate (metallic). After
replacing inductive sensors on the PTM follow the instructions on the setup pro-
cedure.
Voltage supply to the inductive sensor is set at +24 VDC. The sensor output is
attenuated on the +24V Distribution PCB before being passed as a +5 V signal to
the FHMB.
An example of this sensor is:
4 BS50.
2.2.2 Plate Handling Motors

2.2.2.1 Stepper Motor
Stepper and 5:1 Gear: A 2-phase unipolar motor used on the push bar.
Stepper and 3:1 Gear: A continuous +24 VDC used for the stack increment.
Stepper (200 Steps): The Buffer motor includes a dual-ratio gearbox that
drives at two speeds when the stepper is in forward and reverse mode.
2.2.2.2 DC Motor
24 VDC 33 RPM: A +24 VDC used for the retard mechanism and the inter-
leaf roller. Pin 2 on the motor terminal is the supply voltage.
24 VDC 120:1 Worm: A +24 VDC used for the X-direction door.
24 VDC 7:2 Gear: A variable speed motor used for cassette forward.
24 VDC 66 RPM: Used on the output and input modules.
2.2.2.3 Synchronous Motor

Used to drive the elevator on the Autofeeder.
2.2.3 Plate Handling Solenoids

24 VDC: Used on the push bar latch. Includes 3-w plug
4 pin2 = +24 V
4 pin3 = GND.
24 VDC Rotary: Used on the diverter, it includes double shaft and return
spring.
2.3 Plate Handling Operation and Sequence

This section describes the operation of each module as plates are conveyed
towards the Processor. Refer to Section 2.3.1 for a description of how motors and
sensors operate during a plate transfer.
2.3.0.1 Autofeeder Operation

See also Figure 2.2 and Section 2.3.1.1.
NOTE: This sequence applies to fully-automatic platesetters with and without a punch.
The Autofeeder module allows the operator to load and install optionally 1-to-5
cassettes that are automatically selected by the RIP, depending on the job and
plate type required. Each cassette is housed on one of the shelves tiered inside
an elevator frame that moves up and down under the control of the RIP job selec-
tions or the operator.
Plates are loaded into cassettes in a safelight area and conveyed to the Auto-
feeder on a trolley. Normally, cassettes are ALWAYS located on a trolley or on an
Autfeeder shelf to avoid being lifted manually.
Two front corner buffers on the trolley have magnetic pins detected by sensors
BS77 and BS78 as the trolley docks. If both sensors are actuated, then the trolley
is aligned at the door and the docking light turns ON.
Plates of one type are loaded into a cassette that has a designated ID number
from #01 to #31. When the cassette becomes active (selected by the RIP and
advanced to the PTM) the ID is read by a set of photo sensors on the PTM, indi-
cating to the system software the media type and size available for each of the
downloaded jobs.
2.3.0.2 PTM Operation

See Figure 2.4 and Section 2.3.1.2.
NOTE: This sequence applies to fully-automatic platesetters with and without a punch.
The two cassette forward arms advance the active cassette towards the feed
head and reverse the cassette back into the Autofeeder when it is no longer
required. As the cassette moves forward, its front cover lifts up using a ramp
and wheel mechanism.
Once the cassette is in position under the feed head, the nudger roller drops
down to come into contact with the top plate or interleaf sheet. The stack incre-
ment lifts and drops the leading edge of the plate stack in increments while
checking BS47. The system checks that the cassette is not empty.
The nudger drives the plate into the takeaway nip using a combination of fric-
tion and normal force. Once detected in the nip, the nudger roller lifts clear and
stops. The takeaway roller uses friction and the force of the sprung pad under-
neath to continue removing the plate or interleaf.
In normal operation, if there is more than one plate or interleaf nudged into the
takeaway, the retard mechanism uses a sprung slope to `retard' and prevent a
multifeed. This works by using the friction of the retard pad surface against the
multifed sheet to overcome the friction between the top required sheet and and
the sheets underneath.
2.3.0.3 Engine Operation

See Figure 2.6 (fully-automatic with punch) and Section 2.3.1.3. For a descrip-
tion of the vacuum/drum blow system, see Volume 2 Section 7.2.
NOTE: For the description below the terms:

LE refers to the Leading Edge of a plate.
TE refers to the Trailing Edge of the plate.
Fully-Automatic (with Punch)

See Volume 2 Figure 3.49 showing the main plate handling modules on a drum
with a punch and Figure 2.6.
REGISTRATION/
CENTERER
PUSHBAR
PUNCH
LEAD EDGE VAC
LONG BLOW
MAIN VAC
SHORT BLOW
Figure 2.12 Drum plate handling modules (with punch)
Fully-Auto, Manual and Semi-Auto (without Punch)

See Volume 2 Figure 3.50 showing the main plate handling modules on a drum
without a punch and Figure 2.4.
Engine plate sequence depends on whether the plates are large or small.
Large B1 (greater than 500 mm high): follow the sequence in Section 2.3.1.4
Small B2 Only (less than 350 mm high): follow the sequence in Section 2.3.1.5.
Loading a small plate (B2) causes two problems that are rectified by the de-
skew and conform sequence:
4 the LE of the plate jumps over the registration pins
4 the LE of the plate is scratched if there are drum imperfections.
Ejecting a small plate (B2) causes one problem that is rectified by the de-
skew and conform sequence:
4 small plates tend to jump over the registration pins when conform vacuum is
released.
REGISTRATION
MODULE
PUSH BAR
SWING ROLLER
MODULE (SRM)
LEAD EDGE VAC
LONG BLOW
MAIN VAC
SHORT BLOW
Figure 2.13 Drum plate handling modules (without punch)
The leading edge (LE) drum vacuum channel at the far output end has three
states:
1. Conform Blow: applied to prevent plate scratching, assist the plate TE into the
drum while being pushed, and assist with de-skew continuity.
2. Eject Blow: release the LE of the plate for ejection (at the same time as drum
blow occurs for the complete plate).
3. Conform Vacuum: to hold the plate in position for imaging.
2.3.0.4 Buffer Operation

See Figure 2.9 and Section 2.3.1.6.
NOTE: This sequence applies to all B1 platesetters with and without a punch.
Scanned plates from the Engine are conveyed (or held in transit) by the Buffer
until the Processor clears the previous plate and sends a `READY' command to
the Engine.
The Buffer band rollers operate at dual speed: fast speed to convey the plate
from the output module and slow speed to match the Processor.
2.3.1 Plate Handling Control Sequence

This section describes step-by-step how a plate is transported through the plate-
setter as far as the Processor. For a description of how the Processor operates,
refer to the supplied User's Guide.
See Figure 2.14 to Figure 2.17 for a flowcart description of plate sequencing for
loading, imaging and ejecting.
See Volume 2 Section 7.2.3 for a description of the vacuum operation during
imaging.
2.3.1.1 At the Autofeeder

See Figure 2.2 for the location of Autofeeder control devices.
Advancing a Cassette into the PTM:
1. Cassette with plate pack is installed onto a shelf and selected from MMI or RIP as active
cassette for loading.
Cassette door closes (BS72, cassette door closed), Z-direction arm up (BS63, Z-
direction up) and X-direction flap up (BS71, X-direction door up).
2. Elevator motor (BM26, elevator) moves shelf to correct position using readback
from BS32 to BS34.
2.3.1.2 At the PTM

1. Stack increment at Home position (BS44 on) and cassette forward in Home position
(BS42, cassette reverse limit).
X-direction flap moves down (BM27, X-direction door) and BS71 (X-direction
door down).
BM27
BM20 BM21
2. Cassette forward arm (BM20, cassette forward) rotates to pick up cassette.
3. Cassette arms rotate (BM20 on) to pull cassette into PTM until BS65 (cassette at
nudger) actuates.
BS41 (cassette forward limit) actuated indicates an error caused by missing

cassette or cassette not installed on shelf.
Cassette door on lid opens by ramping up on PTM side plates.
Cassette ID read from BS36 to BS40 (cassette ID 1-31).
4. Nudger roller drops down (BM23, nudger lift) and (BS45, nudger down limit).
Retard pad rises (BM25, retard drop, and BS56, retard up) as plate goes forward
(past the diverter) and paper is stopped.
Retard pad lowers for paper.
Nudger roller moves paper until takeaway roller and interleaf roller picks up
paper, then nudger roller lifts up. Only one roller moves paper at a time in order
to avoid a paper jam.
5. Stack rises (BM21, stack height) at quick speed to raise plates until BS47 (stack
height position) is actuated.
Stack drops and rises again slowly to re-actuate BS47.
Stack now in correct position. Only one attempt at raising the stack is carried out
before a plate feed.
BS43 (cassette empty) detects empty or loaded cassette. Empty cassette is moved
back to Autofeeder and error code is given.
6. Nudger (BM22, nudger and takeaway) starts to pick top plate or interleaf.
7. While raised, the retard pad operates from a spring and `retards' multifed sheets
from passing through to the takeaway roller.
If TE of top plate clears BS48 (nudger detect) and BS49 (retard made) the
takeaway motor (BM22) stops.
A plate jam causes the retard pad to lower (BS57, retard down).
8. Top LE of plate or interleaf moves (BM22, nudger and takeaway) towards

diverter. BS48 and BS49 are read.
If BS48 and BS49 are not detected after timeout, stack is raised slightly (once
only).
If BS48 and BS49 are still not detected, then an error code is given.
9. Plate passes BS49 and nudger (BM22) is stopped then lifted (BM23, nudger lift
and BS46, nudger up limit).
Takeaway roller is in contact with interleaf or plate.
Takeaway roller (BM22, nudger and takeaway) and interleave drive (BM24)
advance interleaf.
Diverter in Home (up) position (BV20 off).
10. Interleaf sheet: BS66 (interleave nip clear) or BS53 (paper tensioner) are actuated
as interleaf drives down into waste bin.
BS50 (plate at pre-diverter) is not actuated by interleaf sheet.
BS66 indicates TE of sheet clearing drive.
BS53 operates as lazy loop sensor to stop interleave drive if paper tightens.
BS53 actuated for 2.0 second pauses interleaf drive motor for 0.1 second.
The sequence is repeated until BS66 (interleave nip clear) indicates TE of sheet.
Nudger and takeaway (BM22) stops while interleaf drive (BM24, interleave
drive) remains on for 3 seconds.
11. Plate: BS50 (plate at pre-diverter) actuated to indicate a plate, diverter drops
down (BV20, diverter) and plates are driven by takeaway roller (BM22) towards
BS59 (plate past diverter).
Interleave drive stops (BM24, interleave drive).
BS51 (paper past-diverter top), and BS55 (paper past-diverter under) for paper
detect paper only.
Leading edge of plate at BS50 starts air knife.
Trailing edge of plate passes BS55 stops air knife.
12. LE of plate reaches BS52 (park position) and input module rollers (BM1, friction
and band input) start if drum is clear of previous plate.
If interleaf is under takeaway it is cleared into the bin.
If a plate is still under takeaway roller, it is held at BS50 (plate at pre-diverter).
Any errors in the drum causes nudger motor to reverse plate back into cassette
and reverse cassette into Autofeeder.
Plate TE moves past diverter which returns to Home up position.
2.3.1.3 At the Engine (Fully-Automatic with Punch)

NOTE: This sequence applies to fully-automatic platesetters with a punch using large B1
plates.

De-skew and Conform Sequence:
1. Plate LE reaches BS1 (input entrance) and BM1 (friction and band input) moves plate
into drum.
Push bar is in Home position (BS6, push bar home).
2. If the plate is large it may not clear BS2 (input exit), so push bar moves to Home
position and plate `jogging' commences:
Input module rollers turn and push bar moves down slightly.
Rollers turn again and push bar moves up and then down a little more. This is
repeated until BS2 is cleared.
If BS2 is not cleared by plate TE after 6 attempts an error code is given and plate
is recovered manually by turning the input module plate recovery handle at the
user side of the Engine.
Any plates in the PTM are reversed back into the Autofeeder after a failure
described above, see also Section 2.3.1.8.
3. Plate slides into drum and push bar moves to Home position (BM2, push bar
and BS6).
Registration pins are extended (BS11, registration motor in), punch pins are out
(BS9, punch pins out), centering fingers at Home (BS14, centering home) and
vacuum is off.
4. Push bar advances plate until LE is detected at punch (BS3, plate in punch).
Push bar moves back 10 mm.
5. Centering mechanism (BM3, centering) moves fingers inwards from 1174 mm

apart until BS12 (centering RH detect) and BS13 (centering LH detect) are on
when contact is made with plate at each side.
Push bar moves forward when electrical continuity between the two centering
fingers and plate is detected.
Centering fingers move back to Home (BS14, centering home) when plate is
centered. An error code is given if the plate cannot be centred.
6. Push bar goes forward again to mechanically conform plate.

Drum vacuum turns on.
Punch pins move in (BM4, punch) if required by job (BS8, punch motor in).
7. Push bar moves back 30 mm to clear plate for imaging.

Plate is held by vacuum and mixer fan switches on (BV3).
Plate is imaged.
Eject Sequence:
8. Punch pins move out (BS9, punch pind out), registration pins retract (BS10,
registration motor out) and vacuum switches off.
9. Output module motor starts (BM6, friction and band output) and push bar
moves forward to push plate into output rollers.
Eject blow is switched on.
Buffer rollers start (BM7, buffer feed to processor) when LE reaches BS4 (output
entrance).
10. Push bar returns to Home after BS4 and BS5 are actuated.
Switch off eject blow (non-punch) when TE reaches BS4.
Push bar is in home position (BS56 actuated).
BS4
2.3.1.4 At the Engine (Non-Punch with Large Plates)

NOTE: This sequence only applies to platesetters without a punch using plates larger
than 500 mm (height).
See also Figure 2.7 showing the main plate handling modules on a drum with-
out a punch.
De-skew and Conform Sequence:
into drum.
repeated until plate slides into drum.
and BS6).
Registration pins are extended (registration motor in).
Plate LE passes BS2 and leading edge vacuum switched on as conform blow, see
Section 2.3.0.3.
CONFORM BLOW ON
4. Push bar advances plate until LE reaches registration pins where it is checked
for continuity.
Swing Roller Module (SRM) is lowered and another check for continuity is
made.
5. If continuity across registration pins is made then the plate is not skewed and is
ready to be imaged.
Leading edge vacuum is switched on to conform vacuum mode and also main
vacuum.
SRM is raised.
CONFORM VAC ON
MAIN VAC ON
6. Push bar moves to clear plate for imaging.

Plate is imaged after a plate edge detect is completed at the user end.
Eject Sequence:
7. Leading edge conform and main vacuum are switched off.
Leading edge eject blow is switched on and registration pins retracted.
CONFORM VAC OFF

AND EJECT BLOW ON
MAIN VAC OFF
Buffer rollers start (BM7, buffer feed to processor) when plate LE reaches BS4
(output entrance).
BS4
9. Leading edge eject blow switches off when plate TE reaches BS4.
Leading edge of plate reaches BS5, plate speed slows to obtain approximately
300 mm of media at the output guide (to allow manual collection).
Push bar returns to Home after BS4 and BS5 are actuated.
BS5
BS4
EJECT BLOW OFF
2.3.1.5 At the Engine (Non-Punch with Small Plates)

NOTE: This sequence only applies to platesetters without a punch using plates smaller
than 350 mm (height).
See Figure 2.7 showing the main plate handling modules on the drum for a small
plate.
This sequence is followed in order to overcome the small plate loading prob-
lems described in Section 2.3.0.3.
De-skew and Confrom Sequence:
into drum.
repeated until plate slides into drum.
and BS6).
Registration pins are extended (registration motor in).
Plate LE passes BS2 and leading edge vacuum switched on as conform blow, see
Section 2.3.0.3.
CONFORM BLOW ON
4. Push bar advances plate to an intermediate position just before the registration
pins
As the Swing Roller Module (SRM) moves down, the plate is advanced slowly
towards the pins.
Just as the plate contacts the pins, the SRM touches the plate. This timing is
critical to prevent plate scratching.
5. If continuity across registration pins is made then the plate is not skewed and is
ready to be imaged.
Leading edge vacuum is switched on to conform mode and main vacuum is
switched on.
SRM is raised.
CONFORM MODE ON
MAIN VAC ON
6. Push bar moves to clear plate for imaging.

Plate is imaged after a plate edge detect is completed at the user end.
Eject Sequence:
7. SRM is down.
Leading edge conform vacuum and main vacuum are switched off.
CONFORM VAC AND

MAIN VAC OFF
8. SRM is raised and registration pins are retracted.

Leading edge eject blow is switched on and push bar starts to move plate.
EJECT BLOW ON
Buffer rollers start (BM7, buffer feed to processor) when LE reaches BS4 (output
entrance).
BS4
10. Leading edge eject blow switched off when plate TE reaches BS4.
Leading edge of plate reaches BS5, plate speed slows to obtain approximately
300 mm of media at the output guide.
Push bar returns to Home after BS4 and BS5 are actuated.
BS5
BS4
EJECT BLOW OFF
2.3.1.6 At the Buffer (B1 Variants Only)

Feeding a plate into the Buffer and Processor:
1. LE of plate reaches end of output module and BS5 (output exit) is actuated. Buffer band
rollers turn at a faster speed than the output module.
LE detected at BS19 (buffer entrance).
BS19
BS5
2. LE of plate reaches end of Buffer and BS20 (buffer exit) is actuated.

Plate is advanced a short distance before BM7 switches off.
Buffer waits for Ready signal from Processor.
BS20
3. Ready signal from Processor is received and BM7 restarts at a slower speed to
match Processor.
Processor rollers turn to accept plate.
BS20 actuates on plate TE and BM7 continues for a further 170 mm then stops.
2.3.1.7 Reversing the Cassette (Fully-Automatic)

See Figure 2.2 and Figure 2.4.
This section describes how a cassette is returned to the Autofeeder when a new
type of plate is required.

1. If there is a plate in the drum, it is ejected.
System checks if BS48 (nudger detect) is on or off.
If on, the retard pad and nudger roller are lowered.
Nudger drive motor reverses until BS48 is off.
2. System checks if BS49 (retard made) is on or off.

If BS49 (and BS48) is on, the system assumes there is still paper at the top of the
stack and starts to feed it towards the diverter and waste bin.
If instead BS50 (plate at diverter) detects a plate being fed from the stack, the
nudger motor reverses and puts the plate back into the stack.
3. Stack increment lowered to Home position (BS44 on), nudger to up (BS46 on)
and Z-direction arm to up (BS63 on).
4. Cassette forward mechanism reverses cassette back onto shelf.

Z-direction arm is down (BS70 on).
5. Elevator frame moves to next required position for advancing a cassette.

See Section 2.3.1.1 onwards for a description of how a cassette is forwarded.
2.3.1.8 Recovering from Plate Errors (Fully-Automatic)

An auto-recovery procedure returns the top plate automatically from the feed
head to the cassette if there is a fatal error. Note the following:
4 the top plate only returns if the fatal error has been caused elsewhere in the sys-
tem
4 the cassette is reversed back into the elevator
4 if there is still a plate in the drum then it is ejected.

The purpose of the auto-recovery procedure is to ensure that only the minimum
number of plates (one or less) is fogged if the operator has to carry out a manual
plate recovery.
1. The MMI displays a fatal Error Handling screen.
2. Retard pad and nudger roller is lowered.
3. Nudger roller (BM22, nudger and takeaway) reverses direction.

Step 2. in Section 2.3.1.7 is completed.
If the leading edge of the top plate has not passed BS59 (plate past diverter), it is
pushed back into the cassette (that is, a plate recovery procedure is not
attempted if the plate is too far into the feeder).
4. Nudger lifts up and the Z-direction arm moves up.

Stack drops to home position (BS44 on).
The cassette forward mechanism reverses direction to push the cassette back
into the Autofeeder.
5. If there is a plate in the drum it is ejected to the Buffer.
2.3.2 Plate Handling Flowcharts

Figure 2.14 to Figure 2.17 below show the main sequence of machine steps for
loading, imaging and ejecting plates from each of the platesetter variants.
No Check plate pusher and centerer are at Home

Any Jobs to Expose?
position
Yes
Move plate pusher and centerer to initial load position for job.
Pusher & centerer positions help operator to load the correct size of plate.
Plate description and orientation displayed on the MMI
After 10 minutes
No WARNING 1248
Is a plate loaded on the platen (BS118)?
TIMEOUT_WAITING_FOR_
SUPPORTED_MEDIA
Yes
When Input Fogging Timer expires give audible
Start Input Fogging Timer (6 mins)
alarm.
WARNING 1281
MEDIA_FOG_AT_INPUT_ALERT
Yes
Is Autoload ON (Operator Preference)?
Yes
No
Enable "media Confirm" button on MMI.
Has user pressed "Media Confirm"?
Yes
Plate centred on Input Platen

WARNING 1294
ERR_MEDIA_FEEDER_MEDIA_TOO_BIG
Centering is OK? No or WARNING 1295
Checks for correct media size ERR_MEDIA_FEEDER_REMOVE_PLATE
or WARNING 1296
Yes ERR_MEDIA_FEEDER_REPLACE_PLATE
No
Plate still detected by BS118 on Input Platen? WAIT (Offline Timeout)
Yes
No
Drum ready? ERROR 1707
Yes
Plate pushed into Input rollers
Clear Input Fogging Timer
Plate pusher continues to Home position
Plate trailing edge at BS1? No

ERROR 1640 or 1600 errors for a device fault
(Plate is clear of Platen)
Yes
Centerer guides move to Home position
No
Plate trailing edge past BS2? ERROR 1640 or 1600 errors for a device fault
Yes
Plate is now in the Drum

Start conforming plate
M l Pl t L dS f Pl t
Figure 2.14 Manual plate load sequence from platen
Edge Detect Expose
Expose is complete
Start "processing timer 1".

Plate must be processed within 15 minutes
If "processing timer " expires

Output rollers empty? No
WARNING
Yes
Tell the Processor the Plate thickness

(Semi-Auto only)
Eject plate from drum

Clear "processing timer 1"
Plate arrived at output rollers (BS4)? No ERROR
Yes
Plate arrived at output rollers (BS5)? No ERROR
Yes
Manual machine?
No, Semi-Auto Yes, Manual
Change to Slow speed

Change to Slow speed
Start 'Output Fogging Timer' (6 minutes)
Move plate to 'setter_to_processor' position
Move plate to Manual Pick Up position
Plate past o/p rollers Plate past o/p rollers

ERROR (plate jammed in output) No
entry sensor (BS4)? entry sensor (BS4)?
No
Yes Yes
Processor
ready?
Wait for operator to remove Plate.
Yes Drum is now empty.
Move plate into processor at processor speed

Drum is now empty.
If 'Output Fogging Timer' expires

Plate past o/p rollers Plate past o/p rollers
WARNING 1870 No
exit sensor (BS5)? exit sensor (BS5)?
MEDIA_FOG_AT_OUTPUT_ALERT
Yes Yes
Clear 'Output Fogging Timer'

Output rolelrs are now empty
Output Rollers are now empty
Figure 2.15 Plate eject sequence (manual and semi-automatic)

Check push bar is in Home position?
Yes
De-skew and almost conform plate using

Insert registration pins
push bar
Centerer and push bar backs off

Check plate in punch sensor (BS3) is clear?
Yes
Plate conforms slowly
Push bar pushes plate to 30 mm to registration pins
(fast operation)
Plate centering is OK?
Push bar pushes plate to pins for de-skew (slow

operation) Yes
Vacuum is applied
No, try again,

but only once
Check plate in punch (BS3) is set?
Plate is punched (if required by job ticket)

Yes
Push bar backs off 8-10 mm

(depends on plate size)
Push bar returns to Park position
(approx 30 mm before conform area)
Centerer moves nearer to plate.

Check for LH sensor.
Imaging starts
Centerer checks LH and RH sensor
Figure 2.16 Plate load and imaging (fully-automatic with punch)

Mixer fan off

Loading Blow ON
Push bar postion lookup table

Load plate into drum
from Input Module
Registration pins ON
Drum+offset(nvram)
Push bar
Yes
Approaches plate
Push bar de-skews plate
Wait 0.1 sec
Check Reg pin

Retry1 < 20 ?
continuity
No
Initial continuity failed
Yes
No Final de-skew tapping
by push bar
ERROR
Mixer fan on
If Plate Height > 350mm
Swing Roller Module
(SRM) DOWN
Note:
Check for continuity after
vacuuming. If it fails, try
Step push bar back Yes
again from the start. If it
fails again, continue
Push Bar forward - anyway
Plate Registered to pins Retry < 3 ?
If Plate Height < 350mm
Swing Roller Module
(SRM) DOWN
No, Continuity failed ERROR
after SRM moves DOWN
Check continuity
Yes
Loading Blow OFF

LE vacuum ON
Wait 0.1 sec
LE + Main Vacuum ON
Imaging starts
Ejection blow ON
Wait 1.5 sec (nvram)
Wait 1.0 sec (nvram)
Check continuity
Registration pins OFF
SRM moves UP Push bar moves to ejection

position
Push bar steps back

park position Ejection blow OFF
Figure 2.17 Plate load and imaging sequence (manual and semi-automatic)
2-3
Volume-Chapt er
PLATE HANDLING MODULES

This section describes the main modules (assemblies) used to transport plates for the
Fully-Automatic, Semi-Automatic and Manual systems. It also describes the sensors and
motors that operate with the assembly:
4
4
Introducing Plate Handling Modules ........................................................................3-1
4
Autofeeder Plate Handling Modules .........................................................................3-8
4
Plate Transport Modules ..........................................................................................3-33
4
Engine Plate Handling Modules ..............................................................................3-61
4
Buffer Plate Handling Modules..............................................................................3-102
Inter-Module Connections and Control ................................................................3-105
3.1 Introducing Plate Handling Modules

See Volume 2 Figure 9.1 showing the main modules for plate handling.
This section introduces the main plate handling assemblies fitted on each of the
following modules:
Autofeeder: see Section 3.2
Plate Transport Module: see Section 3.3
Engine: see Section 3.4
Buffer: see Section 3.5.
VOLUME 2 (3-2) P LATE H ANDLING M ODULES
3.1.1 Plate Handling Modules and Variants

Table 3.1 lists the all the main plate handling modules for the Luxel platesetter
variants.
Table 3.1 Plate handling modules: used on variants

Main Modules Fitted on: Fully-Auto Man Semi- Fully-Auto Man Semi-
(Punch/No (No Punch)
Punch
Autofeeder:
Trolley a a
Z-Direction Arm a a
Cassette a a
Elevator (with all assemblies) a a
Control Box Assemblies a a
Plate Transport Module:
FHMB (2 and 3) a a
Cassette Forward a a
X-Direction a a
Stack Increment a a
Nudger Lift a a
Retard a a
Nudger and Takeaway a a
Interleave Diverter and Drive a a
Transport Plates Guides a a
Antistatic Brush a a
Air Knife a a
Imaging Engine:
Input Module a a a a a a
Output Module (static tray) a a a a a
Output Module (driven tray) a
Traverse a a a a a a
Registration Module a(NP) a a a a a
Table 3.1 Plate handling modules: used on variants (Continued)

Main Modules Fitted on: Fully-Auto Man Semi- Fully-Auto Man Semi-
(Punch/No ual Auto (No Punch) ual Auto
Punch
Centering: a
Mechanical a(P)
Electrical Continuity a(P) a
Edge Detect a(NP) a a a a a
Punch:
Billows New Version a
Swing Roller Module a(NP) a a a a a
Transport Pushbar: a a a a a
Spring Pushbar a a a a a
FHMB (1 and 4) a a a a a a
Loading Platform (Platen) a a a a
Chad Assemblies a(P)
Vacuum System:
Compressor Box a a a a a a
Valve Cage a a a a a a
Sensors a a a a a a
Solenoids and Relays a a a a a a
Motors a a a a a a
Buffer:
Roller Transport a a a
Sensors a a a
Solenoids and Relays a a a
Motors a a a
3.1.2 Autofeeder
See Table 3.1 for platesetter variant details and Section 3.2 for a module descrip-
tion.
The Autofeeder consists of:
Trolley: transports cassettes between the safelight loading area and the
Autofeeder.
Sensors and motors used: BS77, BS78 (Docking).

Cassette: consists of a removeable lid with a plate access door that opens
automatically as the cassette is advanced towards the PTM. Plates of a single
type and size are loaded onto a platen and secured by sliding guides that
lock into position. See the Luxel Platesetter Operator's Manual for more infor-
mation on how to load and install a cassette. Each cassette has a dedicated
ID number (from 1 to 31) that is sensed at the PTM as the active cassette for
the media and cassette database on the Engine.
Sensors and motors used: BM28, BS63, BS70, BM28 (Z-direction); BS 43 (Cas-
sette Empty); BS 36 to 40 (Cassette ID1-5).
Elevator: a multi-cassette (5) system uses fixed shelves on an elevator frame
that moves up and down under software control. Cassettes are forwarded
from the shelf to the feed head assembly as required for a scan job, and
reversed back into the shelf when a new plate type is demanded. Shelf posi-
tions for software control of elevation are determined by three readhead sen-
sors that detect three vertical vanes, with scaled widths which provide an
encoded reading.
Sensors and motors used: BS32 to34 (Elevator Shelves); BS 30, BS31 (Elevator
Over Top/Bottom); BM26 (Elevator).
Z-direction Arm: in a vertical position it operates as a constraining arm to
align the cassette to the PTM entry; in a horizontal position it allows access
for the cassette to be pushed onto a shelf. It indicates an error if the cassette
is not fully pushed in during the shelf install procedure.
Sensors and motors used: BS63, BS70 (Direction Up/Down), BM28 (Z-Direc-
tion).
Control Assemblies: Elevator control is from FHMB 2 and the local Elevator
Distribution/Control PCBs.
3.1.3 Plate Transport Module

See Table 3.1 for variant details and Section 3.2 which describes the PTM mod-
ules in more detail
X-direction Door: this is a flap that moves up to the vertical position when
the cassette is installed into the Autofeeder. In the up position, it ensures the
cassette follows the shelf runners during a load from the trolley; when down,
it allows access to the PTM feed head. The door remains down until a new
cassette is installed.
Sensors and motors used: BS62, BS71 (Direction Door Down/Up), BM27 (X-
direction Door).
Cassette Forward: collects the cassette from the elevator shelf and pulls it
towards the feed head; also reverses the cassette back into the shelf.
Sensors and motors used: BS41, BS42 (Cassette Forward/Reverse), BS65 (Cas-
sette at Nudger); BM20 (Cassette Forward).
Stack Increment: raises the plate stack until BS47 is actuated. If the nudger
mis-feeds, it raises the stack in increments of 0.1 mm before the first plate is
nudged.
Sensors and motors used: BS44, BS61 (Stack height Home/Top Limit), BS47
(Stack Height Position); BM21 (Stack Height).
Nudger Lift: raises and lowers the nudger roller.
Sensors and motors used: BS46, BS45 Nudger Up/Down); BM23 (Nudger Lift).
Nudger and Takeaway: both rollers are driven by the same motor. The
nudger picks up the top plate/interleaf from the stack and the takeaway
nips the plate/interleaf and drives it forward. For jam clearance, the nudger
direction is reversed.
Sensors and motors used: BS48 (Nudger Detected), BS52 (Park Position); BM22
(Nudger and Takeaway).
Retard: a sloped pad, when raised during a plate feed, operates with an
adjustable spring mechanism to `retard' multi-fed sheets and prevent them
from passing through the takeaway nip roller. Only the required top plate/
interleaf is allowed to pass. During a plate/interleaf jam, the pad is lowered
from the takeaway roller to allow the top plate to be nipped back into the
cassette by the takeaway roller.
Sensors and motors used: BS56, BS57 (Retard up/down); BM25 (Retard Drop).
Interleaf Diverter: a solenoid-controlled assembly that is actuated to the
down position for a plate and remains in an up position (from a fixed counter
weight) when an interleaf is detected.
Sensors and motors used: BV20 (Diverter).
Interleaf Drive: interleaf sheets are fed from the takeaway and routed by the
diverter to the interleaf drive. Two drive rollers move the sheet towards a
waste bin.
Sensors and motors used: BS53 (Paper Tensioner), BS66 (Interleave Nip Clear);
BM24 (Interleave Drive).
FHMB (2 and 3): provides local control for the PTM and Autofeeder plate
handling mechanisms.
Plate Transport Guides: a set of plates on the PTM that provide a surface
for plates to slide across.
Air Knife: fitted on a fully-automatic machine, the air knife blows a stream
of air across the top of a plate as it advances into the engine. This reduces
plate dust and contamination entering the drum.
Sensors and motors used: BV23 (Air Knife Control).
NOTE: on later machines the air knife is fitted to the Engine instead of the PTM.
3.1.4 Engine
See Table 3.1 for variant details and Section 3.4 for a description of the module
assemblies.
Input Module: a set of friction rollers and a band roller, driven by a belt,
convey plates into the drum. Large plates that are unable to automatically
drop into the drum are `jogged' downwards by switching the rollers on/off
and moving the push bar up/down.
Sensors and motors used: BS1, BS2 (Input Entrance/Exit).

Drum: the drum allows the plate to be held and conformed before imaging.
A plate is pushed round the lower circumference of the drum by the push
bar as far as the registration pins, centered and then punched. Drum vac-
uum holds the plate in position while scanning occurs. Vacuum grooves on
manual and semi-automatic drums have a leading edge and main vacuum
zones.
Sensors and motors used: BS1, BS2 (Input Entrance/Exit); BM1 (Friction and
Band Input).
Punch Mechanism (B1 fully-auto only): these are a bridge-type punch that
allow the plate to pass through after the registration pins are retracted.
Punch build versions for Violet machines are currently New Billows. The
punch protocol configuration (Heidelburg, Komori, etc) depends on cus-
tomer preferences. On fully-automatic machines, the punch mechanism is
combined with the centering and registration mechanism as a single
replaceable module. Later machines may include the Fuji punch with design
modifications to improve chad removal.
Sensors and motors used: BS8, BS9 (Punch Motor On/Off), BS3 (Plate in
Punch); BM4 (Punch).
Centering Mechanism (B1 fully-auto only): centres the plate inside the
punch by moving two fingers from the Home position towards each other
until the sensor on each finger makes contact with the plate. Mechanical
centering only occurs on B1 fully-automatic machines with a punch; all non-
punch machines rely on the edge detect function to ensure the plate is not
skewed and the image is started at the correct traverse offset.
Sensors and motors used: BS12, BS13 (Centering Detect), BS14 (Centering
Home); BM3 (Centering).
Registration Mechanism (B1 fully-auto only): a set of motor-activated pins
that stop a plate in a reference position for imaging and punching. The pins
are withdrawn to allow the passage of the plate to the output module.
Sensors and motors used: BS10, BS11 (Registration Motor In/Out); BM5 (Reg-
istration Pins Motor).
Registration Module (non-punch only): stop the plate in a reference posi-
tion for imaging. A lack of electrical continuity between the two registration
pins and the plate indicates plate skew. An additional Registration Pin
Board sets the voltage for electrical continuity.
Sensors and motors used: BM36 (Registration Pins), BS100 (Registration Pin
Motor Home), BS103 (Registration Pin Motor In).
Edge Detect PCB: locates the precise position of the plates horizontal edge
in order to determine the start of image position.
Swing Roller Module: holds the plate leading edge against the drum sur-
face for imaging.
Registration Pin Isolation PCB: used by the plate centering system to iso-
late the two registration pins from chassis ground.
Sensors and motors used: BS104 (Registration Pin Continuity).
FHMB (1 and 4): provides control for the engine plate handling mecha-
nisms.
Transport Push Bar: while inactive, the bar remains in a Home position. The
bar moves the plate forward, around the drum, until the leading edge is
detected at the reistration pins. After imaging, the bar pushes the plate for-
ward to the output module and then returns to the Home position. Two ver-
sion of the push bar are available: the Mark 1 which includes a
polycarbonate blade and the Mark 2 (Spring) without a blade.
Sensors and motors used: BS6 (Push Bar Home), BS15 (Push Bar Forward
Limit); BM2 (Push Bar).
Output Module: a set of friction and band rollers to convey a plate from the
punch to the Buffer. The main assemblies are common assemblies but the
output guides differ depending on the variant.
Sensors and motors used: BS4, BS5 (Output Entrance/Exit); BM6 (Friction and
Band Output).
Plate Loading Platform: fitted on Manual and Semi-Automatic platesetters
to receive manually loaded plates that are centered and pushed into the
input module. The loading operation allows for two modes of loading:
autoload enabled (no need to confirm the load) and autoload disabled.
Sensors and motors used: BS113 (Plate Centering Home); BS114/115 (Plate
centering Continuity 1 and 2); BS116 (Plate Pusher Home); BS118 (Plate on
Platen Opto); BM10 (Plate Centering); BM11 (Plate Pusher).
Chad Assemblies (B1 with punch): diverts chad from the punch pin guides
to a channel at the rear of the drum and into a tray for removal. Note that the
number of punch operations are counted to provide an alert for the user on
when to empty the tray.
Sensors and motors used: BS 79 (Chad Tray).
3.1.5 Buffer
See Table 3.1 for variant details and Section 3.5 for a description of the module
assemblies.
Roller Transport: a set of bands driven by rollers convey plates from the
output module to the Processor. The speed of the rollers is adjusted from fast
speed (to convey the plate from the output module) to slow speed (to syn-
chronise with the processing speed) If the Processor is not ready, the plate is
held in transit by the Buffer. Drive control depends on plate leading edge
detection by the buffer/output module sensors and the Processor ready
state commands to the Engine.
Sensors and motors used: BS19, BS20 (Buffer Entrance/Exit); BM7 (Buffer
Feed).
3.2 Autofeeder Plate Handling Modules

.The Autofeeder consists of a frame cage, control assemblies and an elevator
with five cassette shelves that move up and down as a cassette plate type is
selected for forwarding.
Assemblies are divided between:
Control - see Section 3.2.1.
Mechanical - see Section 3.3.2.
3.2.1 Autofeeder Control Assemblies

See Figure 3.1.
Overall control of the Autofeeder and elevator movements is from FHMB2, with
AC motor drive fed through the PTM from the Engine.
TROLLEY
DOCKING
INDICATOR
CASSETTE
ELEVATOR Z-DIRECTION ARM DOOR LOCK
DISTRIBUTION PCB SOLENOID
ELEVATOR
CONTROL PCB
CONTROL ABSOLUTE
CABLES SAFETY
TO PTM SWITCH
(UPPER)
POWER
CONNECTION
TO MOTOR ELEVATOR MOTOR
CONTROL BOX
ABSOLUTE
SAFETY SWITCH
(LOWER) GEARBOX
Figure 3.1 Autofeeder controls - location of main control assemblies

A separate interlock mechanism ensures AC power to the elevator motor is

switched off when:
A) the cassette loading door is open or unlocked
B) frame travel safety limits at the top and bottom are exceeded.
Control assemblies are:
Elevator Control Box - the box includes:
4 RFI Filter
4 Inverter.
4 Contactor.
Elevator Interlock Controls.
Elevator Control PCB.
Elevator Distribution PCB.
Cassette Door - the cassette door includes:
4 Cassette Door Lock Solenoid.
4 Trolley Docking Indicator.

Z-Direction Arm.
Absolute Safety Switch.
Motors and Gears
Solenoids.
Sensors.
3.2.1.1 Elevator Control Box

Elevator motor control assemblies are housed in a control box shown in
Figure 3.1 and Figure 3.2.
MOTOR
CONTROL
CHASSIS COOLING
FINS
TERMINAL
BLOCK
FILTER
DIN RAIL
END
STOP
INVERTER
(SJ100) SURGE
SUPPRESSOR CONTACTOR
Figure 3.2 Elevator control box assemblies (filter/inverter/contactor)
3.2.1.2 RFI Filter

See Figure 3.3.
An RFI filter is used to suppress inverter spikes in both directions. This is
because the inverter is a switching module that generates external noise which
could affect motor control and outside equipment.
NEUTRAL
MAINS LIVE
SUPPLY
EARTH
AUTOFEEDER EARTH
FILTER
BASE
PLATE
EARTH
POINT
L
TO INVERTER N
CONTROLBOX PLATE
CONTROL
BOX LID
EARTH
MOTOR
Figure 3.3 RFI Filter connections
3.2.1.3 Inverter
An Hitachi SJ100 inverter uses a set of four switched relays on the Elevator Con-
trol PCB (see Section 3.2.1.6) to control multispeed power sequencing for the ele-
vator motor. Inverter switching ensures the correct torque for heavy loads.
Directions are for forward (FWD), reverse (REV), fast (FST) and reset (RST).
Mains supply from the inverter is converted to vector drive signals U, V and W
for the elevator motor (gearmotor).
Inverter module functions are programmed from a digital display and keypad
that allow the service engineer to run manual tests and check for error codes.
Service engineers are recommended NOT to alter the EEPROM for the motor
function control or adjust the frequency setting.
The main servicing features of the Inverter are:
Single-phase supply at 200 - 240 VAC (50/60 Hz) to a 4-pole gearmotor.
An alarm (BS74) and overload output (BS75), via the Elevator Control PCB,
to FHMB(2) if the module develops a fault or the temperature exceeds a set
level. Power to the motor is immediately switched off when the alarm/over-
load conditions are set.
When running, the inverter generates considerable heat that is dissipated by

a rear cooling fin. Make sure the module is properly ventilated and the cov-
ers are not blocked.
All switching relays on the Elevator Control PCB are supplied from +24 V
generated from the inverter.
a) ELEVATOR RED
RST
OR
FAST
YL
REV
BRN
ALARM GND ALARM I/P FWD
BLU&WH
P24V
BLK WH/BLU (2 WIRES)
ACCESS: OPEN TO ELEVATOR

FRONT L 6 5 4 3 2 1 P24 CONTROL PCB
PANEL (PL4)
H 0 01 L FM CM2 12 11
BLK O/LOAD
(BS75)
WHT
ALARM
BLK (BS74)
ACCESS: BEHIND ALARM
FRONT AL1 AL0 CONTROL
PANEL
BLU
ALARM I/P
WHT/BLU
ALARM I/P
b) ELEVATOR POWER
ACCESS: LOOSEN M4
SCREW TO L1 L2 L3/N T1/U T2/V T3/W
OPEN CASE
BLK
L (BRN) BLK TO
CONTACTOR
N (BLU) BLK
BR BL
MAINS SUPPLY
(FROM FILTER O/P)
Figure 3.4 Inverter connections (control/power)

Error Codes
The inverter shows a set of error codes to indicate the state of the motor circuit.
Table 3.2 Inverter error code conditions

Error Type Displayed Error Comment
Code
Over Current 01 to 04 Output of inverter is shorted,

motor is locked or the load is too
heavy. Inverter switches off.
Overload E 05 Motor overload is detected caus-
ing thermal trip. Inverter
switches off.
Braking Overload E 06 Overvoltage is detected and

inverter switches off.
Overvoltage Protection E 07 Motor overvoltage is detected
and inverter switches off.
EEPROM Error E 08 Memory has an error due to
noise or temperature. Inverter
switches off.
Undervoltage E 09 Decrease in input voltage to a

certain cut off point. Inverter
switches off.
CT Error E 10 Large noise source too close to
the inverter. Inverter switches
off.
CPU Error E 11 CPU malfunctions. Inverter
switches off.
External Trip E 12 Abnormal signal from external

equipment causes inverter to
switch off.
USP Error E 13 Power is turned on while the
inverter is running.
Ground Fault E 14 Ground fault detected between
inverter output and motor.
Input Overvoltage Pro- E 15 Input voltage is above a certain

tection limit. Inverter output is switched
off.
Thermal E 16 Temperature of inverter is too
high because cooling fan has
failed. Inverter is switched off.
PTC Error E 17 External thermistor is too large.
Inverter switches off when PTC
function is selected.
Waiting ---U Inverter receiving voltage has

dropped so output is off.
3.2.1.4 Contactor
A safety contactor (Siemens 3RT1016) isolates the gearmotor from the mains
supply when the elevator cassette door or an interlocked panel is opened. It
includes a surge suppressor to protect local circuits from coil switching back
emf.
WHT
MOTOR SUPPLY BRN WHT
(FROM INVERTER) BS73 (TO ELEV CONTROL PL1)
BLU RD
+24V (TO ABS LIMIT)
1 3 5 21 A1
NC
CONTACTOR
22
2 4 6 NC A2
BLU BLK
+24V RTN (TO ELEVATOR
TO MOTOR BRN WHT/OR CONTROL PCB PL1)
BS73
WHT
Figure 3.5 Contactor connections
3.2.1.5 Elevator Interlock Controls

See Figure 3.6.
Autofeeder control ensures that a local contactor removes power to the elevator
motor when:
one of the elevator absolute limit switches is tripped by the elevator passing
the upper/lower safety limits of travel
cassette door is unlocked or open
an interlocked cover is open.
See also Volume 2 Figure 9.10 for an overall view of the interlock system, includ-
ing the control assemblies on the Engine.
DOOR LOCK
KEY BV22 FHMB(2)
COIL SAFETY
+24V RELAY
CONTACTOR
FHMB(2)
SURGE
SUPPRESSOR A1 21
BV22
NC
DOOR SCHMERSAL
BS
LOCK SOLENOID LOCK
72
x2
A2 22
LOCK BS72 TO
RTN FHMB(2)
ABS
LIMIT (BS68)
TOP LIVE
MAINS
NEUTRAL INPUT
EARTH
ABS FILTER
LIMIT (BS69)
BOTTOM
NOTES: FHMB(2) SIGNALS VIA

ELEVATOR CONTROL PCB
L N E
INVERTER SEE ALSO SECTION 11.2.4.4
(BS74/75) FOR INTERLOCKS CONTROL
U V W
FHMB(2)
A1 1 3 5 21
NC CONTACTOR
BS73
A2 2 4 6 22
U V W
BS73 TOFHMB(2)
FHMB(2)
+24V RTN GEAR
MOTOR
(ELEVATOR)
Figure 3.6 Elevator interlocks - schematic view

3.2.1.6 Elevator Control PCB

Figure 3-3.7 shows the Elevator Control PCB layout.
PL3
ELV_CTRL SK1
(FWD/REV/ETC)
PL4
PL2
ELV_IN
PL1
ELV_CTRTL
(BS73)
Figure 3.7 Elevator Control PCB - layout view
Location
Mounted on the frame on the service side, see Figure 3.1.
Elevator Control Connectors
PL1: ELV_CTRL.
PL2: Not Used.
PL3: Not Used.
PL4: ELV_CTRL.
SK1: ELV_IN.
Connector Pin Descriptions
See Volume 2 Figure 9.9 showing the system cable interconnections.
Test Points
H1-H4: GND
Elevator Control PCB Operation
See Figure 3.8.
Drive control from FHMB2 is fed to the PCB where a set of relays are switched
to provide the drive + 24 V controls for the inverter. Two protection signals are
returned to FHMB2:
Overload: indicates the motor is overloaded and switches off power to the
motor.
Alarm: a fault has been detected on the inverter.
RELAY
(SW3-6)
+24V 4 1
SOL1-4
INVERTER
CONTROL BM2
(PL4) (SK1
REV/FAST/
RST/FWD 6 2
SOL1-4 RTN
BM26 (FWD/REV/FST/RST)
RELAY
(SW2)
+24V 1 4
ALARM_H
INVERTER
CONTROL SK1
(PL4)
ALARM 2 6
ALARM_L
BS74
RELAY
(SW1)
+24V 1 4
OLOAD_H
INVERTER
CONTROL SK1
(PL4)
OVERLOAD 2 6
OLOAD_L
BS75
Figure 3.8 Elevator control relays - pin arrangement

3.2.1.7 Elevator Distribution PCB

Figure 3.9 shows the PCB layout.
SENSOR VANE
BS31
BS32 BS33 BS34
BS30
PL5
PL1 PL2 PL3 PL4
Z-DIRECT Z-DIRECT RIB8

(UP) (DOWN)
ELV_LOCK
Figure 3.9 Elevator Distribution PCB - layout view
Location
Mounted on the elevator sensor vane bracket, see Figure 3.1 and Figure 3.16.
Elevator Distribution Connectors
PL1: Not used.
PL2: Not used.
PL3: ELV_LOCK (Z-Direct UP)
PL4: ELV_LOCK (Z-Direct Down)
PL5: RIB8.
See Volume 2 Figure 9.9 showing system cable interconnections.
Elevator Distribution PCB Operation
See Figure 3.10.
Shelf positions on the elevator are determined by three optical sensors (BS32-34)
that detect the presence of vanes attached to the moving elevator. Sensors BS30
and BS31 detect the top and bottom travel limit and issue a warning before the
final absolute safety limit sensors (BS77 and BS78) are switched.
SHELF A
SAFETY LIMIT VANE
CODE:
001
101
ELEVATOR
DISTRIBUTION
PCB AND SENSORS
SENSOR VANE
SHELF E
Figure 3.10 Sensor vane reading (5 shelves)
As the elevator and vanes move up or down through the sensors (BS32-34), a
gray scale code is generated indicating the elevator position, see Table 3.3.
Shelves are accurately positioned at the edge of the relevant sensor vane. The
elevator is driven at a FAST speed until the shelf and vane edge is above the sen-
sor, then drive down at a SLOW speed until the vane edge is detected, to give
accurate and repeatable shelf alignment.
An accurate mechanical alignment between the shelf rail and the PTM feed rails
is critical for correct operation of the cassette forwarding mechanism. The align-
ment is set during the installation using a specification and an alignment proce-
dure.
You can check the operation of the elevator sensors using the read_sensor com-
mand Main Diagnostics.
Table 3.3 Shelf and sensor encoding

Shelf Sensor 34 Sensor 32 Sensor 33
A (top) OFF ON ON
B OFF OFF ON
C ON OFF ON
D ON OFF OFF
E ON ON OFF
3.2.1.8 Cassette Door Lock Solenoid

A Schmersal safety lock (AZM170) operates from a solenoid (BV22) that is
released under software control for installing/removing the cassette. While the
door is in use, a switch sensor (BS72) indicates the status of the lock to the SSB.
The door has an actuating key that locks under MMI control.
DOOR AND KEY
RED BK
BV22
BS72
OR WH
12 11 A1 A2
RED GN
22 21
SCHMERSAL SOLENOID LOCK (AZM170-02Z)
Figure 3.11 Cassette door lock - lock wiring
3.2.1.9 Trolley Docking Indicator

A docking indicator is used by the operator to ensure that the trolley is correctly
aligned (square) with the cassette door before the cassette is installed into the
Autofeeder. Two magnetic reed switches (BS77 and BS78) on both sides of the
cassette door are made when both trolley buffer inserts are detected. This sensor
circuit is in series with the docking lamp to enable a +24V supply.
TROLLEY AND INSERTS
BS78 BS77
SWITCH SWITCH
+24V
DOCK
LAMP
RTN
Figure 3.12 Docking indicator control
3.2.1.10 Z-Direction Arm

See Figure 3.13.
A mechanical Z-axis arm with a guide roller is used to constrain the cassette
while it is loading into the PTM. Its position UP or DOWN) also indicates to the
software if the cassette is correctly installed before advancing. This mechanism
uses a dc motor/worm gear and wormwheel to move the arm.
M6 SCREW
GUIDE ROLLER
WORMWHEEL
SPACER BS63 SENSOR
Z-AXIS ARM
BEARING
RETAINER
BEARING
BRACKET
MOTOR (BM28)
COVER BRACKET
BS70 SENSOR
Figure 3.13 Z-direction control assembly

3.2.1.11 Absolute Limit Safety Switch

See Figure 3.1.
Two safety switches (upper limit and lower limit) are set to disable the elevator
if it travels beyond an upper and lower safety point. The switches are in series
with the interlock supply to the contactor which switches off the elevator motor,
see Figure 3.6. Once switched, the sensor must be reset by pulling out its yellow
button. These switches are a final hardware limit to the elevator travel in either
direction; normally, a software travel limit check will indicate an error before the
switch is triggered.
WARNING: Do NOT test a limit safety switch while AC power is applied to the elevator
motor. If a fault is suspected, then investigate the problem by isolating the switch assem-
bly from the Autofeeder.
3.2.1.12 Autofeeder Motors

The two Autofeeder motors (BM) are as follows:
BM26 Elevator
Location: see Figure 3.1.
Type: asynchronous motor and two-stage gearbox.
Operation: raises and lowers the elevator.
BM28 Z-Direction Control
Location: see Figure 3.1 and Figure 3.13.
Type: DC
Operation: moves up an arm, checks that a cassette is fully home and
that restrains the cassette while it is being pulled into the PTM.
Elevator Motor/Gearbox (BM26)

Elevator drive is from an asynchronous motor with a two-stage worm gearbox.
The gearbox is sealed and does not require maintenance.
CAUTION: Make sure all precautions are followed when servicing the elevator while the
frame is being lifted under motor control. If in doubt, lift the frame by turning the elevator
motor fan.
Rotate the fan at the top of the motor to move the elevator in either direction
over a very short distance. Main Diagnostics commands, described in this chap-
ter are also used to raise or lower the elevator.
3.2.1.13 Autofeeder Solenoids

Figure 3.1 shows the location of all the Autofeeder solenoids (BV) as follows:
BV22 Cassette Door Lock
Location: above the cassette door.
Type: solenoid
Operation: unlocks a door to allow a plate cassette to be loaded into the
Autofeeder.
BV25 Docking Light

Location: located above the cassette door, see Section 3.1.
Type: green lamp
Operation: controls supply to a lamp indicating that the trolley and cas-
sette is aligned correctly to the Autofeeder.
3.2.1.14 Autofeeder Sensors

The location, type and operation of all the Autofeeder sensors are as follows, see
Figure 3.1:
BS30 Elevator Top Limit
Location: rear of sensor distribution PCB.
Type: opto-slotted (wide).
Operation: indicates the elevator at the top limit position.
BS31 Elevator Bottom Limit
Operation: indicates the elevator at the bottom limit position.
BS32 Elevator Shelf 1
Operation: positioning shelf detector, binary 1.
BS63 Z-Direction Up Limit
Location: inside the cassette door, righthand side.
Type: opto-slotted.
Operation: detects when the Z-direction arm is raised.
BS70 Z-Direction Down Limit
Location: inside the cassette door, righthand side.
Type: opto-slotted.
Operation: detects when the Z-direction arm is lowered.
BS72 Cassette Door Closed
Location: inside of the cassette door lock.
Type: switch inside the Schmersal lock assembly.

Operation: monitors state of the cassette door and returns a signal to the
System PCB.
BS73 Elevator Motor Disabled
Location: part of elevator contactor.
Type: part of contactor.
Operation: monitors the state of the elevator contactor for removing
power to BM26 if the cassette door or an interlocked door is opened, see
Figure 3.6.
BS74 Vector Drive Alarm
Location: detected from the inverter, see Figure 3.8.
Type: inverter detector circuit.
Operation: vector drive output status from the inverter to stop the eleva-
tor.
BS75 Vector Drive Overload
Location: detected from the inverter, see Figure 3.8.
Type: inverter detector circuit.
Operation: vector drive output status from the inverter to stop the eleva-
tor.
BS77 Docking Made (RH)
Location: inside the cassette door (RHS) and fitted to trolley buffer, see
Figure 3.1.
Type: reed switch.
Operation: detects correct right-hand side engagement of trolley and
switches on docking light if BS78 is also actuated.
BS78 Docking Made (LH)
Location: inside the cassette door (LHS) and fitted to trolley buffer, see
Figure 3.1.
Type: reed switch.
Operation: detects correct left-hand side engagement of trolley and
switches on docking light if BS77 is also actuated.
3.2.2 Autofeeder Mechanical Assemblies

The main cassette/plate handling assemblies on the Autofeeder, shown in
Figure 3.14 are:
Main Frame - includes:
4 Multi-cassette Housing.
4 Cassette Loading Door
Elevator Frame - includes:
4 Sensor Vane.
Elevator Drive Assemblies - includes:

4 Elevator Motor, Gear and Drive Shaft.
Trolley.
Cassette.
BRACKET/CAM
FOLLOWER CASSETTE
LOADING DOOR
JACKING
SCREW
JACKING
PIN
FOOT
ADJUSTER
DRIVE
SHAFT
ELEVATOR
CONTROL BOX MOTOR
BASE GEARBOX FLOOR RESTRAINT BRACKET
Figure 3.14 Main frame assemblies (without elevator frame and multi-cassette
housing)
3.2.2.1 Main Frame Assemblies

A main outer frame, shown in Figure 3.14, houses the control modules and
mechanical assemblies.
The Autofeeder base locates the anchor feet and jacking castors at each corner.
The castors are only used to manoeuvre the module; the weight of the module is
always distributed on four anchor feet that are locked in position with the cas-
tors lifted.
Two floor restraints, at the outer ends of the main frame, prevent the Autofeeder
from moving when the trolley is pushed against the cassette door. Check that
the restraint brackets are securely fixed to the floor.
3.2.2.2 Multi-Cassette Housing Assembly

The housing assembly sits on top of the Autofeeder frame to allow room for
raising the elevator. A single version of the housing is available for a 5-shelf
frame. Once fitted, it is not normally removed for a service procedure, unless
there is a mechanical problem lifting the frame. To ensure a light-tight fit, the
housing is precisely positioned on the frame with locating dowels.
3.2.2.3 Cassette Loading Door

This door can only be opened from the MMI using the `Change Cassette'
options. See Section 3.2.1.8 which describes the door locking mechanism.
3.2.2.4 Elevator Frame

Figure 3.15 shows the main sub-assemblies fitted on the elevator frame:
Sensor Vane
Elevator Drive Assemblies.
A cam follower bracket aligns the elevator frame to the main frame and the
PTM. The alignment is factory-set. An adjustable bracket allows the follower
setting to be altered on either side, but this is only required if there is a problem
levelling all the shelves to the cassette guides on the plate feed.
ELEVATOR WALL
FRAME (DETAIL
ELEVATOR REMOVED)
SENSOR VANE CASSETTE
AND DISTRIBUTOR LOADING
PCB (SEE
FIGURE 5.22)
ROLLER
CAM
FOLLOWER
BRACKET
SHELF
CAM
LOCATION
CHANNEL
BASE CHAIN
PLATE
Figure 3.15 Elevator frame assemblies

3.2.2.5 Sensor Vane

The sensor vane is fixed to the elevator frame and moves through sensors fitted
on a PCB attached to a fixed bracket.
ELEVATOR
DISTRIBUTOR
PCB (ATTACHED TO
FRAME BRACKET )
ELEVATOR
SENSOR
VANE
Figure 3.16 Elevator Sensor Vane
Each vane is adjusted vertically to line up each shelf with the slotted sensor and
vane switching positions. Once factory-set, they do not need to be readjusted
unless the shelf-PTM rails become misaligned, causing an obstruction for the
cassette. If there is an alignment problem use the procedure in Volume 3 Section
2.2.1.6.
3.2.2.6 Elevator Drive Assemblies

The elevator frame is moved up/down by a gearmotor and chain pulley
arrangement shown in Figure 3.17. Each drive chain is identified with its
number of links. As an extra safety feature, the chains run on gear sprockets
with metal guard plates that ensure they engage with the sprockets if the ten-
sioner spring suddenly fails. The guard is factory-set and should not be
adjusted.
IDLER CHAIN (195)

IDLER SHAFT SPROCKET CAM AND CHAIN (189) ABSOLUTE
(SHORT)
BRACKET LIMIT
UPPER SENSOR IDLER SHAFT
ELEVATOR (LONG)
DISTRIBUTION
PCB
CHAIN (119)
ELEVATOR
SPROCKET MOTOR (BM26)/
BEARING GEAR
CHAIN PLATE
& TENSIONER
(FIGURE 5.24)
CHAIN (119)
CHAIN
GUARD DRIVE
SHAFT
CHAIN ADJUSTER
(FIGURE 5.24)
GEAR
ABSOLUTE
LIMIT
SENSOR LOWER SENSOR
VANE
Figure 3.17 Elevator drive assemblies
Chain links are internally self-lubricating and only need to be visually checked
during a service visit for signs of corrosion on the side plates where a machine is
operating in a humid environment.
If there are exterior signs of corrosion, carefully remove the corrosion then apply
a coating of thin oil to the affected area. The recommended lubricant is: Kluber
oil (4UH1-68) or, if this is unobtainable, any low viscosity (10-40) oil.
The chain is fixed at two points:
Adjuster end: this is adjusted by two locknuts to ensure the correct tension. A
pin at the bottom of the adjuster prevents the locknuts from coming loose.
The adjustment is factory-set and does not need to be retightened.
Tensioner end: a spring tensioner secures the chain to a fixed plate on the ele-
vator frame. This is a replaceable part.
TENSIONER
BUSH SPRING
PIN LINK
ASSEMBLY
SPLIT PIN
PULL OUT
TO REMOVE
LINK PLATE
MORE LINKS
Figure 3.18 Drive chain tensioner linking
3.2.2.7 Trolley
Trolley Assemblies
Figure 3.19 shows the main trolley assemblies.
Trolley Operation
The main function of the trolley is to transport a cassette between the plate load-
ing area and the Autofeeder. Cassettes are always stored either on a trolley or on
a free Autofeeder shelf. The trolley functions as follows:
A parking brake is switched on for loading and installing plates.
A trolley tray operates on a pivot mechanism that allows it to be in two plate
handling positions: horizontal and vertical.
In the vertical position it is possible to load plates located on the plate pack
support; the vertical position is offset slightly at an angle to prevent the
plates from slipping.
The Luxel Platesetter Operator's Manual explains in more detail how the trolley is
used.
RETAINER
AND SPRING
SPACER
ROLLER LATCH
PIVOT TRAY
ASSEMBLY
LATCH
STRIKER PLATE
LATCH
PIVOT ACTUATOR ROD
BRACKET
HANDLE
BUFFER
HANDLE
SUPPORT
BRAKE
FRAME
ASSEMBLY
CASTOR
Figure 3.19 Trolley assemblies - detail view
3.2.2.8 Cassette
CAUTION: Cassettes are always located on the trolley or inside the Autofeeder. They are
very heavy and, if handled or stacked on one side, could crack to break the light-tight
seal.
Cassette Assemblies
See Figure 3.20 (showing the cassette lid), Figure 3.21 (showing the cassette
body) and Figure 3.22 (showing the cassette platen).
The cassette assembly consists of:
A removable fibre-glass top lid with two sections: front and rear. The front
lid is held down by magnets and opens when the cassette is pulled towards
the feed head.
A platen sub-assembly that includes three plate guides (with clamps).
A body sub-assembly that provides the outside frame. The adjuster plates
for aligning the lid catches are factory-set, and must not be moved.
CASSETTE REAR LID
SNAP
CATCH
CASSETTE FRONT LID
Figure 3.20 Cassette lid assembly
If there are problems feeding plates into the feed head it could be caused by:
Loaded plates exceed the cassette capacity limit of 60.
The plate pack is not adequately butted against the datum edge.
The plate guides are too tight against the plate pack.
Cassette ID label is damaged or removed.
Appendix B describes the possible error codes and remedies for elevator, cas-
sette and plate advancing faults.
A cassette ID label is fitted in an exact location (marked by two dimples) on the
lower side of the cassette body shown in Figure 3.21. Spare labels with adhesive
backing are easily fitted by the customer.
If there are problems with feeding plates into the feed head, it could be caused
by:
1. Loading plates that exceed the capacity limit of 60.
2. The plate pack is not adequately butted against the datum edge.
3. The plate guides are too tightly held against the pack.
The cassette ID label is fitted in an exact location (marked by two pimples) on
the lower side of the body shown in Figure 3.21. Spare labels with adhesive
backing can be fitted by the customer. The new ID is read into the database as
normal.
See the Platesetter Operator's Manual for a description on how the cassette is
operated.
PLATEN
SUPPORT CASSETTE ID
LABEL
INTERNAL
GUIDE
LATCH
KEEPER
RAIL LIGHT SEAL
HANDLE GASKET
ADJUSTMENT
PLATE (FACTORY SET)
(LH LOWER) BUFFER
LABYRINTH
NOTE: CENTERING DOWELS, CASSETTE ADJUSTMENT BUFFER
SHELF BALLS AND FORWARD PLATE WASHER CORNER
CHANNELS ARE UNDERNEATH
Figure 3.21 Cassette body assembly
SHORT PLATE
GUIDE
PLATE AT
DATUM EDGE
SCALE
LONG PLATE
GUIDE CLAMP
HANDLE
Figure 3.22 Cassette platen assembly

3.3 Plate Transport Modules

The PTM consists of:
Control assemblies - see Section 3.3.1
Mechanical assemblies - see Section 3.3.2.
3.3.1 PTM Control Assemblies

The main control modules on a PTM are:
FHMB PCB (2).
FHMB PCB (3).
PTM Distribution PCBs.
PTM Motors
PTM Solenoids and Relays.
PTM Sensors.
Air Knife and Control Assemblies.
CASS ID PCB
SENSOR
DISTRIBUTION PCB
24V DISTRIBUTION
PCB
FHMB 2
SENSOR
DISTRIBUTION
AND 24V
DISTRIBUTION
PCBs
FHMB 3
Figure 3.23 Location of main PTM control assemblies

Two FHMBs (2 and 3) control the plate handling devices for the PTM and Auto-
feeder. These boards hold the local motor handling software routines initiated
under the high level control of the System board. Plate Transport control
depends on the sensor signals sent from the local FHMB to the System PCB.
3.3.1.1 FHMB PCB (2) Assembly

See Figure 3.24 showing the PCB layout and also Volume 1 Section 2.2.1 describ-
ing how the FHMB functions.
PL7 PL9 PL12 PL14 PL24 PL25 PL26

PL19 PL21 PL23
PL18
FS14
SK3
PL30
PL6 FS13
PL11
SK2 PL29
PL5
FS12
SK1
PL28
FS15
PL4 FS11
PL3 PL17
PL13
PL27
PL2
PL1
FS1 PL31
FS2 PL10 PL15 PL16 FS7 FS8 PL20 PL22 FS10

PL8
FS4 FS5
FS3 FS6 FS9
Figure 3.24 Motor PCB FHMB (2) layout

NOTE: Connector boxes shown as shaded in the figure above have fitted connectors.
Location
Mounted inside the PTM on the service side - righthand side PCB (see
Figure 3.23).
LEDs and Links
There are no LEDs or links.
Connectors
PL1: 8-way male Molex header type STR 6410. See Table 3.4.
PL2: 2-way male Molex 6410 straight header. Not used.
PL3: 4-way male AMP CT straight header. Not used.
PL5: 6-way male Molex straight header. Not used.
PL6: 8-way male Molex minifit Jr. Not used.
PL8: 3-way male AMP CT straight header. See Table 3.4.
PL11: 10-way male boxed header. Not used.
PL18: 26-way male header. RIB7 cable connection to Elevator Distribution
PCB.
PL19: 26-way male straight header. RIB6 cable connection to Box Cassette ID
PCB.
PL21: 4-way male AMP CT straight shrouded header. Not used.
PL27: 6-way male single in-line shrouded header top entry. Not used.
PL28: 6-way male single in-line shrouded header side entry. Not used.
PL31: 8-way Molex minifit Jr. PWR3 power connection.
SK1: 15-way female D-type. CAN3 bus connection from FHMB (1).
SK2: 45-way female R/A boxed header. Not used.
SK3: 5-way female D-type. CAN4 bus connection to FHMB (3).
See Volume 2 Figure 9.8 showing system cable interconnections.
Fuses
FS1: 2A for Elevator Control
FS2: 2.5A. for Cassette Door Closed.
FS3: 2.5A. Spare.
FS4: 2.5A for Docking Light.
FS5: 2.5A for Elevator Reset.
FS6: 4 A. Spare
FS7: 4A. Z-Direction Control.
FS8: 2.5A for X-Direction Door.
FS9: 2.5A. Spare.
FS10: 2.5A for Cassette Door.
FS11: 2.5A. Not used.
FS12: 2.5A. Not used
FS15: 2.5A. Spare.
Main ICs
U33: Electronic Programmable Logic Device. Controls and reads sensors.
U39: Electronic Programmable Logic Device. Solenoids and DC motors.
U42: Electronic Programmable Logic Device. Stepper motors.
U27 Firmware.
Test Points
TP1: CAN Ground.
TP2: Pulsed drive to opto-reflective sensors.
TP3: CAN +5V.
TP5: A-D Converter Ground.
TP6: A-D Converter +5V.
TP8: Digital Ground.
TP9: System Reset. Out of Reset = virtually zero volts when measured from
TP23.
TP13: +24V Ground.

TP18: +5V supply to DC motor drivers.
TP22: Sensor Latch 2.
TP24: +5V Digital supply rail.
TP30: Unprotected 5V.
TP31: +24V.
TP32: +24V Ground.
TP33: +24V Ground.
TP34: +24V Ground.
FHMB (2) Motor, Solenoid, Relay and Sensor Distribution
PCBs
Table 3.4 FHMB (2) Distribution PCB devices
Device ID Device Description FHMB (2) Distribution PCB
Plug No
Motors:
BM20 Cassette Forward 22 Not Used
BM26 Elevator - Fast 1 Not Used
BM26 Elevator - Fwd 1 Not Used
BM26 Elevator - Rev 1 Not Used
BM26 Elevator - Reset 15 Not Used
BM27 X-Direction Door 20 Not Used
BM28 Z-Direction Door 16 Not Used
Solenois and Relays:
BV22 Cassette Door Lock 8 Not Used
BV25 Docking Light (Indicator) 10 Not Used
Sensors:
BS30 Elevator Over Top 18 Elevator Dist
BS31 Elevator Over Run Bottom 18 Elevator Dist
BS32 Elevator Shelf 1 18 Elevator Dist
BS36 Cassette ID 1 19 Cass ID
Table 3.4 FHMB (2) Distribution PCB devices

Plug No
BS41 Cassette Forward Limit 19 Cass ID
BS42 Cassette Reverse Limit 19 Cass ID
BS62 X-Direction Door Up 9 Not Used
BS63 Z-Direction Up Limit 18 Elevator Dist
BS65 Cassette at Nudger 23 Not Used
BS70 Z-Direction Down Limit 18 Elevator Dist
BS71 X-Direction Door Down 19 Not Used
BS72 Cassette Door Closed 14 Not Used
BS73 Motor Disabled 14 Not Used
BS74 Vector Drive Arm 24 Not Used
BS75 Vector Drive Overload 26 Not Used
BS76 Front Door Open 19 Cass ID
BS77 Docking Made RH 18/21 Not Used
BS78 Docking Made LH 18 Not Used
FHMB (2) Motor, Solenoid, Relay and Sensor Variants
Table 3.5 FHMB (2) Variants: control device fitted

Device Fitted Variants
All devices in Table 3.4 above All Fully-Automatic machines

See Figure 3.25 showing the PCB layout and also Volume 1 Section 2.2.1 describ-
ing how the FHMB functions.
PL7 PL9 PL12 PL14 PL24 PL25 PL26

PL19 PL21 PL23
PL18
FS14
SK3
PL30
PL6 FS13
PL11
SK2 PL29
PL5
FS12
SK1
PL28
FS15
PL4 FS11
PL3 PL17
PL13
PL27
PL2
PL1
FS1 PL31

PL8
FS4 FS5
FS3 FS6 FS9
Figure 3.25 Motor PCB FHMB (3) layout
Location
Mounted inside the PTM on the service side - lefthand side PCB.
LEDs and Links
Connectors
PL1: 8-way male Molex header type STR 6410. See Table 3.6.
PL9: 8-way male AMP CT straight header. Limit links on a plug are fitted as
follows: Pins 3 and 4 linked; pins 7 and 8 linked. These links are pull
sensor inputs to GND for BM22.
PL18: 26-way male header. RIB4 input from pulsed sensor inputs via Vertical
Distribution PCB. See Table 3.6.
PL19: 26-way male straight header. RIB5 input from pulsed sensor inputs via
24V Distribution PCB PCB. See Table 3.6.
PL28: 6-way male single in-line shrouded header. Not used.
PL29: 6-way male single in-line shrouded header top entry. See Table 3.6.
PL31: 8-way Molex minifit Jr. PW3_INT connection.
SK1: 15-way female D-type. CAN4 connection from FHMB (2).
SK3: 15-way female D-type. CAN5 connection to FHMB (4).

See Figure 9.8 showing system cable interconnections.
Fuses
FS1: 2A for Platefeeder Pump/24V for sensor.
FS3: 2.5A. Spare.
FS4: 2.5A for Diverter.
FS5: 2.5A for Interleave Drive.
FS6: 4 A. Spare.
FS7: 4A. Retard Drop.
FS8: 2.5A for Nudger and Takeaway.
FS9: 2.5A. Spare.
FS10: 2.5A for Nudger Lift.
FS13: 2.5A. for Stack Height.
Main ICs
Test Points
TP1: CAN Ground.
TP3: CAN +5V.
TP23.
TP13: +24V Ground.

TP31: +24V.
TP32: +24V Ground.
TP33: +24V Ground.
TP34: +24V Ground.
Motor, Solenoid, Relay and Sensor Controls
Table 3.6 FHMB (3) distribution PCB devices
Plug No
Motors:
BM21 Stack Height 29 Not Used
BM22 Nudger and Takeaway 20 Not Used
BM23 Nudger Lift 22 Not Used
BM24 Interleave Drive 15 Not Used
BM25 Retard Drop 16 Not Used
Solenoids and Relays:
BV20 Diverter 10 Not Used
BV23 Air Knife Fan (Relay) 1 Not Used
BV24 24V for Sensor On/Off 1 On 24V Dist
Sensors:
BS43 Cassette Empty 18 Sensor Dist
BS44 Stack Height Home 12 Not Used
BS45 Nudger Down Limit 19 24V Dist
BS46 Nudger Up Limit 19 24V Dist
BS47 Stack Height Position 18 Sensor Dist
BS48 Nudger Detect 18 Sensor Dist
BS49 Retard Made 18 Sensor Dist
BS50 Plate at Pre Diverter 19 24V Dist
BS51 Paper Post Diverter 19 24V Dist
BS52 Park Position Pre Input Nip 18 Sensor Dist
BS53 Paper Tensioner (Lazy Loop) 18 Sensor Dist
BS55 Paper Post Diverter 19 24V Dist
BS56 Retard Up 18 Sensor Dist
Table 3.6 FHMB (3) distribution PCB devices (Continued)

Plug No
BS57 Retard Down 18 Sensor Dist
BS59 Plate Past Diverter 19 24V Dist
BS61 Stack Height Top Limit 7 Not Used
BS66 Interleave Nip Clear 19 24V Dist
Table 3.7 FHMB (3) Variants: control device fitted

Device Fitted Variants
All devices in Table 3.6 above All Fully-Automatic machines
3.3.1.3 PTM Distribution PCBs

A set of distribution PCBs optimise machine cable runs between each PTM sen-
sor device and its handling FHMB. There are three Distribution PCBs on the
PTM:
Sensor Distribution PCB
New 24V Distribution PCB
Cassette ID PCB.
Figure 3.26 shows the PCB mounting arrangement on the service side of the
PTM.
SENSOR 24V
DISTRIBUTION DISTRIBUTION
PCB PCB
FEEDER END PLATE

(PTM SERVICE SIDE)
Figure 3.26 Distribution PCB mounting arrangement (PTM)
Sensor Distribution PCB

Figure 3.27 shows the layout of the Sensor Distribution PCB for a fully-auto-
matic platesetter and Figure 3.23 shows its location on the PTM. The PCB sup-
plies +5V to each of the sensors and returns signals to FHMB 3.
BS43 BS49
PL1
BS48 PL5
BS52 PL3 PL4

PL2
RIB4/RIB5
BS56 PL7 PL8

PL6 PL10
BS57 PL11
PL9
PL12
BS47 BS53
Figure 3.27 Sensor Distribution PCB (FHMB 3) - layout view
24 V Distribution PCB (New)

Figure 3.28 shows the layout of the New 24V Distribution PCB for a fully-auto-
matic platesetter and Figure 3.23 shows its location on the PTM.
This PCB distributes +24 VDC to energise the following sensors on the PTM:
BS50 (plate in pre-diverter)
BS51 (paper post-diverter top)
BS55 (paper post-diverter bottom).
Pin connection power for the 24 V sensor plugs are:
A) pin 2 = +24 V
B) pin 4 = 0 V.
It also distributes +5 VDC to energise the following sensors on the PTM:
BS45: (nudger down limit)
BS46: (nudger up limit)
BS59: (plate past diverter)
BS66: (interleave nip clear).
A) pin 2 = +5 V
B) pin 3 = 0 V.
BS51 (FHMB3)
BS50 BS3 (FHMB4) SET CAN ID 1
24V I/P
PL11
PL8
BS55 (FHMB3)
BS18 (FHMB4)
PL3 PL12
PL5 PL7 PL10
FHMB (PL19)
PL2
PL1 PL4 PL6 PL9
BS46
BS45 BS66 BS59
Figure 3.28 New 24 V Distribution PCB (FHMB 3) - layout view
The New 24 V Distribution PCB includes circuitry to attenuate the +24 V sensor
signal (from BS50/51/55) to +5V before they are passed to the FHMB.
BV24 is an on-board relay switched by FHMB 3 to connect the +24 VDC supply
to sensors BS50, BS51 and BS55. This ensures the sensor photo lights are only on
at required times and do not cause plate `fogging' by being on continuously.
Volume 2 Figure 9.8 shows system cable interconnections and Volume 2 Section
8.1 describing the pin signals.
Cassette ID PCB
Figure 3.23 shows the location of the Cassette ID PCB for a fully-automatic
platesetter before the plate feed mechanism on the service side and Figure 3.29
shows the PCB layout. The main function of the PCB is to read the cassette ID
(SW1-5) as the cassette is advanced towards the plate feed. It also routes the cas-
sette forward/reverse limit (BS41/42) and front door open (BS76) sensors to
FHMB2.
FHMB
PL19 PL5
BS42
PL2 PL1
BS41 PL6
PL4 PL3
VIEW ON OPTO-REFLECTSWITCHES
SW5 (ID5) SW4 (ID4)
BS40 BS39
SW3 SW2 SW1

BS38 BS37 BS36
(ID3) (ID2) (ID1)
Figure 3.29 Cassette ID PCB (FHMB 2) - layout view
3.3.1.4 Motor Assemblies and Operations

The location and operation of all the PTM motors (BM) are listed as follows:
BM20 Cassette Forward
Type: DC with braking.
Operation: pulls and pushes the cassette in and out of the elevator.
BM21 Stack Height (Increment)
Type: stepper with 3:1 gearbox.
Operation: raises and lowers plate stack to nudger rollers.
BM22 Nudger and Takeaway
Type: DC (33 rpm).
Operation: drives top plate off the cassette.
BM23 Nudger Lift
Type: DC (33 rpm) with braking.
Operation: tilts the nudger assembly.
BM24 Interleave Drive
Type: DC (66 rpm) with one-way clutch.

Operation: drives the paper bin rollers.
BM25 Retard Drop
Type: DC (33 rpm) with braking.
Operation: pulls down the retard pad mechanism.
BM27 X-Direction Door
Type: DC.
Operation: raises and lowers the cassette guide door.
3.3.1.5 PTM Solenoids and Relays

PTM solenoids/relays (BV) are listed as follows:
BV20 Diverter
Type: solenoid.
Operation: lowers diverter when the plate is detected; springs back up
when power is removed.
BV23 Air Knife Fan
Location: service side, below air knife fan assembly.
Type: relay.
Operation: controls the +24 VDC switching supply for the air knife.
BV24 24 Volt for Sensor On/Off
Location: on New 24 V Distribution PCB.
Type: relay.
Operation: controls the switching of +24 VDC to BS50 and BS51.
3.3.1.6 PTM Sensors

The location of all the PTM sensors (BS) are listed as follows:
BS36 Cassette ID1
Type: opto-reflective
Operation: cassette ID1, binary 1.
BS37 Cassette ID2
BS38 Cassette ID3

BS39 Cassette ID4
BS40 Cassette ID5
BS41 Cassette Forward Limit
Type: Opto-slotted.
Operation: stops the motor in the clockwise direction.
BS42 Cassette Reverse Limit
Type: opto-slotted.
Operation: stops the motor in the anti-clockwise direction.
BS43 Cassette Empty
Operation: detects if the cassette is empty.
BS44 Stack Height (Increment) Home
Type: opto-slotted.
Operation: detects when the plate lifter is at Home (i.e. down).
BS45 Nudger Down Limit
Type: Opto-slotted.
Operation: monitors the position of the cam on BM23.
BS46 Nudger Up Limit
Type: opto-slotted.
Operation: monitors the position of the cam on BM23.
BS47 Stack Height (Increment) Position
Type: opto-slotted.
Operation: stops BM21 when the plate stack reaches position.
BS48 Nudger Plate Detect

Type: opto-reflective.
Operation: indicates a plate has been pulled from the cassette to the
nudger.
BS49 Retard Made
Type: opto-reflective.
Operation: indicates that the plate is now in the takeaway roller nip.
BS50 Plate at Pre-diverter
Type: Inductive.
Operation: Indicates either paper or plates (+24 V supply).
BS51 Paper Post Diverter (Top)
Location: feed head cross bar, attached to hinge and bracket above guide
plate, see Volume 3 Figure 2.10.
Type: reflective/diffused (+24 V supply).
Operation: checks for plate or paper. The device operates as an integral
emitter and a detector that senses light reflected from the plate surface
(without the interleave paper) or diffused (when the paper has failed to
be removed). See Volume 3 Section 2.3.2.2 for the setup procedure if this
sensor is replaced.
BS52 Park Position Pre-Input Nip
Operation: indicates that the next plate is ready.
BS53 Paper Tensioner (Lazy Loop)
Type: micro-switch.
Operation: monitors paper tension and stops the interleave drive rollers
for a period if actuated.
BS55 Paper Post Diverter (Under)
Type: Reflective/diffused (+24 V supply).
Operation: checks for plate or paper. The device operates as an integral
emitter and a detector that senses reflected light from the plate surface
(without the interleave paper), or diffused light (when the paper has
failed to be removed). See Volume 3 Section 2.3.2.1 for the setup proce-
dure if this sensor is replaced.
BS56 Retard Up
Type: opto-slotted.
Operation: checks position of motor driving retard.
BS57 Retard Down
Type: opto-slotted.
Operation: checks position of motor driving retard.
BS59 Plate Past Diverter
Operation: detects when the leading edge of the plate has reached a
point before the diverter is raised.
BS61 Stack Height Top Limit
Type: opto-slotted.
Operation: prevents stack stepper motor from over running.
BS62 X-Direction Door Up
Type: opto-slotted.
Operation: detects when the door flap is raised.
BS65 Cassette at Nudger
Type: micro-switch.
Operation: detects if the cassette has been fully pulled out to reach the
nudger.
BS66 Interleave Nip Clear
Location: see Volume 2 Figure 2.4.
Operation: detects if paper has failed to fully enter the bin.
BS71 X-Direction Door Down
Type: opto-slotted.
Operation: detects if the door flap is in the down position.
BS76 Front Door Open
Location: at the bottom of the interleaf bin cover.
Type: micro-switch
Operation: paper bin sensor to detect if the bin door cover is accidentally
open.
3.3.2 PTM Mechanical Modules

See Figure 3.30 showing the arrangement of the main assemblies.
The main plate handling assemblies feed plates from the cassette to the Engine
drum and divert paper interleaf sheets to a waste bin. Once the cassette is
installed (in the Z-direction) on the Autofeeder, these assemblies advance and
reverse cassettes (in the X-direction) between the feed head and the Autofeeder
elevator.
X-Direction Door.
Cassette Forward.
Stack Increment.
Feed Head.
Retard Pad.
Interleaf Diverter/Drive Roller.
Plate Guides.
INTERLEAF
DIVERTER
X-DIRECTION
DOOR ASSEMBLY
FEED HEAD
ASSEMBLY
RETARD PAD
ASSEMBLY
CASSETTE
FORWARD
ASSEMBLY
INTERLEAF DRIVE
ROLLER ASSEMBLY
STACK INCREMENT
ASSEMBLY
Figure 3.30 Plate handling assemblies - general view
3.3.2.1 X-Direction Door

See Figure 3.31.
The complete assembly is removed to access the sensors and motor. The assem-
bly consists of:

A) motor and worm gear: drives the flap up (cassette install) or down (cassette
advance)
B) flap and box section: the flap ensures the cassette is correctly aligned inside the
elevator.
C) sensors and vane: a vane rotates into two sensors to indicate the up/down
position of flap for the application software.
PIVOT R. H. SUPPORT
BLOCK BRACKET
SENSOR
BRACKET UP
SENSOR BS71
SENSOR BS62
FOLDED
FLAP
MOTOR
MOUNTING
BRACKET
SENSOR
SENSOR BRACKET DOWN
VANE
FOLDED BOX
SECTION
MOTOR BM27
Figure 3.31 X-Direction door - detail view
3.3.2.2 Cassette Forward

Cassette Forward Assembly
See Figure 3.32.
The complete assembly is removeable to access the sensors, motor and drive
belts. The assembly consists of:
A) Drive arm with cam follower: rotates to advance/reverse the cassette between
the elevator and the feed head.
B) Top plate: holds the assembly to the PTM mounting frame.
C) Eccentric idler: provides the belt tension.
D) Sensor plate and sensors: limit sensors to control arm travel for forward and
reverse directions.
E) Motor and gear: secured by a motor support plate.
F) Belt and pulleys: a set of drive/idler pulleys move a timing belt and drive
arms.
LH ARM ASSEMBLY
BEARING
DRIVE ARM BLOCK
RH ARM ASSEMBLY
BELT
FORWARD
SHAFT
ECCENTRIC MOTOR
IDLER/TENSIONER SUPPORT
PLATE
DRIVE
PULLEY
BEARING
AND CIRCLIP
CAM
FOLLOWER
DRIVE ARM
NOTE: TOP COVERING PLATE

REMOVED IN THIS SENSOR
DIAGRAM PLATE
SENSOR A
TAB
GEAR
MOTOR BM20
VIEW ON ARROW A
IDLER
IDLER/
SENSOR BS42 TENSIONER
SENSOR BS41
Figure 3.32 Cassette forward assembly - detail view
Cassette Forward Operation

See Figure 3.33.
Volume 2 Section 2.3 explains how the cassette forward mechanism operates.
The two arms advance/reverse the cassette as follows:
As the two arms rotate in the advance direction, the cams locate inside the
cassette grooves to pull in the cassette to the feed head.
As the two arms rotate in the reverse direction, the cams push the cassette
back into the elevator.

The drive arms rotate 270 from their home position to collect the cassette from
the elevator shelf by sliding cam followers into the cassette channels and pulling
the unit forward. After the cassette at nudger (BS65) sensor indicates the cas-
sette has reached the feed head the drive arms stop rotating.
A reverse rotation pushes the cassette back into the elevator, as shown in
Figure 3.33.
CASSETTE
FEED
CASSETTE POSITION
REVERSE
DIRECTION
CASSETTE
ADVANCE
DIRECTION
HOME
HOME CASSETTE
FORWARD
TOP PLATE
CASSETTE
ADVANCE
DIRECTION
CASSETTE
REVERSE
DIRECTION CASSETTE
FEED
POSITION
Figure 3.33 Cassette forward arm direction
3.3.2.3 Stack (Height) Increment

See Figure 3.34.
The complete assembly is removed to access the sensors, motor and drive belts.
The assembly consists of:
Lift bar: lifts the cassette feed end.

Leadscrew: drives the lift bar in increments.
Drive pulleys and timing belts: two belts (1500 and 410 length) connect at a
double pulley.
Idler pulley: provides tension for 1500 belt.
Motor and gears: motor on the support bracket provides 410 belt tension.
Sensors: for the top limit and home positions of the lift bar.
MOTOR (BM21) BEARING

AND GEARBOX (LEADSCREW AND
DRIVE SHAFT)
SENSOR
BS61 STACK
SENSOR
LIFT
BS44
BEARING
LIFT BAR BLOCK
BELT SENSOR
(T5/410) BRACKET
MOTOR
SUPPORT BELT
DOUBLE (T5/1500)
PULLEY
ECCENTRIC
PIN
STACK IDLER
IDLER BRACKET
PULLEY
Figure 3.34 Stack Increment assembly - detail view
3.3.2.4 Feed Head

See Figure 3.35.
The assembly consists of:
Motors: one motor lifts the nudger and the other drives the nudger/takea-
way rollers.
Nudger lift mechanism: operate as a cam that pushes down on the bar to lift/
drop the nudger roller. A load bar weight provides the friction force for
nudging the plate.
Stack height mechanism: adjusted to set the correct position of the plate stack
for nudging.
Takeaway mechanisms: chain drive for the two rollers with tension provided
by the sliding motor fixings.
Support plates: set of plates retaining the feed head mechanisms.
MULTI SENSOR MOUNTING ADJUSTING

SUPPORT BRACKET SENSOR BS46 SCREW SCREW (M5)
(NUDGER UP
LIMIT) SENSOR BS47
(STACK HEIGHT STACK HEIGHT SENSOR
NUDGER LIFT POSITION) ADJUSTING BRACKET
SENSOR VANE
SUPPORT BACKPLATE
L. H. END
PLATE R. H. END PLATE
FEED HEAD
NUDGER
INTERFACE
LIFT CAM
PLATE
SENSOR
BS48 DO NOT
(NUDGER TOUCH SCREW
DETECT)
FIXING
SENSOR BS45
(NUDGER
DOWN LIMIT) PLATE HEIGHT
SENSOR BS43 SENSOR VANE MOTOR
(CASSETTE EMPTY) BM22
ROLLER AXLE-
NUDGER LONG
LOAD BAR
TENSION DRIVE ROLLER
ROLLER CHAIN
BUSH STRIP
ROLLER AXLE- ROLLER CHAIN
SHORT
Figure 3.35 Feed Head - detail view
3.3.2.5 Antistatic Brush

An antistatic brush support assembly is fitted on the feed head support back-
plate to remove static from paper sheets as they pass through to the de-inter-
leaver.
SUPPORT
BACKPLATE
FEED HEAD
ANTISTATIC BRUSH
SUPPORT ASSEMBLY
Figure 3.36 Antistatic brush

3.3.2.6 Retard Pad

Figure 3.37 shows the retard pad assembly which consists of:
Pad: operates from a cam, shaft and actuating lever mechanism to raise and
lower the pad. A stainless steel paper guide (with black PE tape) forms an
ramp between the retard pad and the lead edge guide to prevent paper
sheets from binding on the retard pad.
PAPER
GUIDE RETARD MOTOR MOTOR
LEAD EDGE DOWN CAM AND GEAR
SPRING GUIDE SPRING PILLAR
LOCATOR RETARD BM25
PAD
SENSOR
BS57
SENSOR
BS65
FRONT VIEW
ADJUSTING
SCREW
MOUNTING
MOUNTING PAPER PLATE
SCREWS LEAD EDGE GUIDE
SENSOR
GUIDE RETARD
BS56
PAD
END PLATE
SENSOR
BS57
SENSOR
BRACKET
SENSOR
BS65
ACTUATING
LEVER
CENTERING
PIN
CAM SHAFT
RETARD
VIEW SHOWING RETARD DOWN CAM MOUNTING DO NOT
BACKPLATE REMOVED SCREWS TOUCH
SENSOR
VANE SENSOR RETARD
BS56 INTERFACE
Figure 3.37 Retard assembly - detail view
Spring locators and adjusters: the pad has a factory-adjusted spring mecha-
nism that is pre-set.
Centering pin: locates the cassette inline with the feed head.
Motor and sensors: includes a motor gear (BM25) to actuate the retard pad,
and sensors (BS56 and 57) to indicate the position of the pad. BS65 micro-
switch indicates if the cassette has reached the nudger.
Since the assembly is critical for the throughput of single plates and interleaf
sheets into the PTM, it is built and set very precisely at the factory and should
not need adjusting during a service visit. Any sub-assembly failure (including
the motor) is completed by replacing the complete module.
3.3.2.7 Interleaf Diverter and Drive Roller

Figure 3.38 shows the interleaf diverter and drive roller assemblies.
The diverter and drive rollers are two separate assemblies consisting of:
Diverter guide: normally in the up position for interleaf sheets.
Solenoid: drops the diverter guide for plates. It includes a coupling between
the device and the guide shaft.
Counter-weight: enables the guide to rise to its home position for interleaf
sheets. A new longer counter-weight is now fitted.
Rollers: drive roller and nip roller.
Bearings: these are not FRUs but they are removable.
ROTARY
SOLENOID
BV20
SOLENOID
COUPLING
STEADY
ROLLER
DIVERTER GUIDE
AND SHAFT
BEARING
RETAINER
BEARING
MOTOR/GEAR
BM24
PAPER
TENSIONER
BS53
STEADY
NIP ROLLER BRACKET
ROLLER
TUBE
DRIVE ROLLER
COUNTERBALANCE
WEIGHT
RETAINER END PLATE
COUNTERBALANCE
BLOCK
Figure 3.38 Interleaf diverter and drive rollers - detail view

3.3.2.8 Plate Transport Guides

See Figure 3.39.
The five plate guides are designed to be easily removed to access assemblies on
the PTM which require a service procedure. They provide a smooth travel sur-
face for transferring plates (driven by the takeaway motor) from the cassette to
the input module.
The guides are stationary plates fixed between the feed head and the input
module to provide a path for the plates and interleaf sheets. An air knife assem-
bly blows any surface contaminants back towards the Autofeeder.
Two Mylar deflection strips (short and long) are attached to the feed head with
adhesive backing. They are fitted to ensure that plates stay in contact with the
guides and activate sensor BS50.
PRE-DIVERTER DIVERTER
GUIDE (LH) SOLENOID BV20
FIXING BRACKETS (LH)
SENSOR BS50
SENSOR BS49
FIXING BRACKETS (RH)
POST-DIVERTER
SENSOR BS52
DIVERTER
SENSOR BS55
PRE-DIVERTER
GUIDE (RH)
SENSOR BS59
ENGINE INTERFACE
AIR KNIFE ASSEMBLY
A
BRACKET
COUNTER ROUTE TO
WEIGHT VALVE CAGE
(BV41)
AIR KNIFE
PRE-DIVERTER DIVERTER POST-DIVERTER ASSEMBLY
GUIDES
ENGINE
INTERFACE
SENSOR BS49 BRUSH
SENSOR BS50
PRE-NIP
MOTOR 24V DC
INTERLEAF LOWER
GUIDE (1) DRIVE ROLLER
INTERLEAF LOWER GUIDE (2)

VIEW ON ARROW A
Figure 3.39 Transport guides plates - assembly views
3.4 Engine Plate Handling Modules

The Engine consists of:
3.4.1 Engine Control Assemblies

Fully-Automatic: control and power from the Engine are routed to the Buffer and
PTM (and Autofeeder), see Volume 2 Figure 9.8. Note that the Engine must be
mechanically coupled with the PTM to avoid plate `fogging'. The Buffer forms a
bridge to the Processor ensuring there is no risk of light `fogging' plates.
Manual and Semi-Automatic: Engine and Buffer control and power is the same as
the fully-automatic for these variants.
NOTE: differences in control assemblies depend on whether the system is without a

punch (web) or with a punch.
24V DISTRIBUTION PCB

SENSOR
MMI PCB DISTRIBUTION PCB
(OUTPUT)
REGISTRATION
FHMB 4 PINS OPTO SENSOR
ISOLATOR PCB DISTRIBUTION PCB
(INPUT)
FHMB 1
DRUM
NOTE: TRAVERSE PCB's NOT SHOWN - FAST PHOTO

SEE CHAPTER 2-5 DETECT
RFI BOX
Figure 3.40 Location of engine plate control PCBs (fully-automatic)

See Figure 3.40 showing the location of the main plate control assemblies:
FHMB (1) PCB.
FHMB (4) PCB.
Sensor Distribution PCB (Output).
Sensor Distribution PCB (Input).
New 24V Distribution PCB
Registration Pin Isolation PCB (BS118).
Paper Plate Sensor PCB (see Plate Loading Platform).
Engine Motors.
Engine Solenoids and Relays.
Engine Sensors.
NOTE: The plate edge detect function is explained as part of the traverse mechanism.
Two FHMBs (1 and 4) control the plate handling devices for the PTM and
Engine. These boards hold the local motor handling software routines initiated
under the high level control of the Luxel System Board. See Figure 3.41 and
Figure 3.42 showing the PCB layouts and Volume 1 Section 2.2.1.1 describing
how the FHMB functions. Note the differences on how each variant uses both
boards - see Volume 2 Figure 9.5, etc.

Figure 3.41 shows the PCB layout.
FHMB (1) Location
Mounted inside the Engine, on the service side (see Figure 3.40).
FHMB (1) LEDs and Links
FHMB (1) Connectors
See Table 3.8 listing cable plug/socket connections to FHMB (1).
See Volume 2 Figure 9.5 to Volume 2 Figure 9.7 showing FHMB (1) cable intercon-
nections.
PL1: 8-way male Molex header type STR 6410.
PL2: 2-way male Molex 6410 straight header.
PL8: 3-way male AMP CT straight header.

PL18: 26-way male header. RIB3 to Sensor Distribution PCB (Input).
PL19: 26-way male straight header.
PL23: 4-way male AMP CT straight header. BS80 Mixer fan detect.
PL30: 6-way male single in-line shrouded header top entry. BM11 Plate pusher
(Man).
PL31: 8-way Molex minifit Jr. FHMB_PWR power supply
SK1: 15-way female D-type. CAN2 from LSB.
SK3: 15-way female D-type.CAN3 to FHMB92) for fully-automatic/CAN to
FHMB(4) for manual and semi-automatic.
FHMB (1) Connector Pin Descriptions
See Volume 2 Figure 9.5 to Volume 2 Figure 9.7 showing FHMB(1) cable inter-
connections and Volume 2 Section 8.1 listing cable connections and signals.
FHMB (1) Fuses
FS1: 2A for Mixer fan and remote Alert.
FS3: 2.5A. Spare.
FS4: 2.5A. Not Used.
FS5: 2.5A for Friction and Band Input motor.
FS6: 4 A. Spare.
FS7: 4A. Punch motor.
FS9: 2.5A. Spare.

FS15: 2.5A. Spare.
PL9 PL14 PL24 PL25 PL26

PL19
PL7 PL12 PL21 PL23
PL18
FS14
SK3
PL30
PL6 FS13
PL11
SK2 PL29
PL5
FS12
SK1
PL28
FS15
PL4 FS11
PL3 PL17
PL13
PL27
PL2
PL1
FS1 PL31

PL8
FS4 FS5
FS3 FS6 FS9
Figure 3.41 Motor PCB FHMB (1) layout view (fully-automatic)

FHMB (1) Main Device ICs

U27: Firmware.
FHMB (1) Test Points
TP1: CAN Ground.
TP3: CAN +5V.
TP7: Vacuum sensor signal voltage.
TP23.
TP13: +24V Ground.
TP31: +24V.
TP32: +24V Ground.
TP33: +24V Ground.
TP34: +24V Ground.
FHMB (1) Motor, Solenoid and Sensor Controls
Table 3.8 describes the devices connected directly to FHMB (1) or via a Distribu-
tion PCB.
See also Figure 3.46 showing the Sensor Distribution PCB layout and Volume 2
Figure 9.5 to Volume 2 Figure 9.7 showing the device connections for each vari-
ant, and Volume 2 Section 8.1 describing cable pin signals.
Table 3.8 FHMB (1) device connections

Device ID Device Description FHMB PL No Sensor Distribu-
tion (Input) PL No:
Motors:
BM1 Friction and Band Input 15 -
BM4 Punch 16 -
BM10 Plate Centering 28 -
BM11 Plate Pusher 30 -
BM38 Output (Stepper-Man/Semi) 27 -
Solenoids and Relays:
BV8 Error Warning Light (Alert) 1
BV3 Mixer Fan 1
BV40 SOL3 (Leading Edge) 10
Sensors:
BS1 Input Entrance - 4
BS2 Input Exit - 3
BS8 Punch Motor ON Position - 6
BS9 Punch Motor OFF Position - 9
BS80 Mixer Fan Detector 23 -
BS113 Plate Centering Home - 10
BS114 Plate Centering Continuity 1 14
BS115 Plate Centering Continuity 2 14
BS116 Plate Pusher Home 25
BS118 Plate on Platen 23

See Figure 3.42 showing the PCB layout describing the main FHMB functions.
FHMB (4) Location

Mounted inside the Engine on the service side, top of the traverse beam (see
Figure 3.40).
FHMB (4) LEDs and Links
FHMB (4) Connectors
connections and also Volume 2 Section 8.1 listing connections and signals.
PL1: 8-way male Molex header type STR 641.

PL4: 3-way male AMP CT straight header. To FPD.
PL6: 8-way male Molex minifit Jr. PWR2 connection for STB (+24 V and
+36 V).
PL18: 26-way male header. To RIB1 cable and Sensor Distribution PCB (Out-
put).
PL19: 26-way male straight header. To RIB2 cable to +24 V Distribution PCB
PL21: 4-way male AMP CT straight shrouded header. To BS5 (Output Exit).
PL27: 6-way male single in-line shrouded header top entry.
PL31: 8-way Molex minifit Jr. PWR2 connection.
SK1: 15-way female D-type. CAN5 from FHMB (3) for fully-automatic/
CAN_FHMB(1) for manual and semi-automatic.
SK2: 45-way female R/A boxed header. Connects +36V DC, and CAN signals
from FHMB(4) to the STB.
SK3: 15-way female D-type. Not used.
FHMB (4) Connector Pin Descriptions

connections and also Volume 2 Section 8.1 listing cables and signals.
PL9 PL14 PL24 PL25 PL26

PL19
PL7 PL12 PL21 PL23
PL18
FS14
SK3
PL30
PL6 FS13
PL11
SK2 PL29
PL5
FS12
SK1
PL28
FS15
PL4 FS11
PL3 PL17
PL13
PL27
PL2
PL1
FS1 PL31

PL8
FS4 FS5
FS3 FS6 FS9
Figure 3.42 Motor PCB FHMB (4) layout view
FHMB (4) Fuses

FS1: 2A for Drum Vacuum motor.
FS3: 2.5A. Spare.
FS5: 2.5A for Friction and Band O/P motor.

FS6: 4 A. Spare.
FS7: 4A. Registration Pins motor.
FS9: 2.5A. Spare.
FS11: 2.5A. Centering.
FS13: 2.5A. Push bar carriage.
FS14: 2.5A. Bridge Feed to Processor.
FS15: 2.5A. Spare.
FHMB (4) Main Device ICs
U27: Firmware.
FHMB (4) Test Points
TP1: CAN Ground.
TP3: CAN +5V.
TP23.
TP13: +24V Ground.
TP31: +24V.
TP32: +24V Ground.
TP33: +24V Ground.
TP34: +24V Ground.

FHMB (4) Motor, Solenoid and Sensor Control
Table 3.9 describes the devices connected directly to FHMB (1) or via a Distribu-
tion PCB.
See also Figure 3.46 showing the Sensor Distribution PCB layout and Volume 2
Figure 9.5 to Volume 2 Figure 9.7 showing the device connections for each vari-
ant.
Table 3.9 FHMB (4) devices connections

Device ID Device Description FHMB (4) Sensor Dist 24 V Distribu-
PL No: (Output) PL tion PL No:
No:
Motors:
BM2 Push Bar (Carriage) 29 - -
BM3 Centering (Punch) 27 - -
BM5 Registration Pins (Punch) 16 - -
BM6 Friction and Band Output 15 - -
BM7 Buffer Feed to Processor 30 - -
BM36 Reg Pin Mtr Continuity 22 - -
BM37 Swing Roller Motor 20 - -
Solenoids:
BV5 Drum Vacuum Motor Control 1 - -
BV30 SOL 1 (Divert Valve) 10 - -
BV31 SOL 2 (Compressor Relay) 8 - -
BV41 SOL 4 (Blow and Air Knife) 16 - -
Sensors:
BS3 Plate in Punch - - 2
BS4 Output Entrance - 2 -
BS5 Output Exit - 8 -
BS6 Push Bar Home 7 - -
BS10 Registration Motor OUT - 6 -
Position
BS11 Registration Motor IN - 9 -
BS12 Centering RH Detect - 10 -
BS13 Centering LH Detect - 11 -
BS14 Centering Home Position - 7 -
BS15 Push Bar Forward FWD 12 - -
Limit
Table 3.9 FHMB (4) devices connections (Continued)

Device ID Device Description FHMB (4) Sensor Dist 24 V Distribu-
PL No: (Output) PL tion PL No:
No:
BS19 Buffer Entrance - 4 -
BS20 Buffer Exit - 3 -
BS21 Fast Photo Detector 4 - -
BS79 Chad Tray Home - - 6
BS100 Reg Pins Motor (Home) - - 4
BS103 Reg Pin Motor (Out) - - 1
BS104 Reg Pins Continuity 25 - -
BS109 Swing roller (Home) 9 - -
BS110 Swing roller (In) 9 - -
BS112 Push Bar FWD 12 - -
BS118 Plate on Platen (Opto) 23 - -
3.4.1.3 Engine Distribution PCBs

See Volume 2 Figure 9.5 to Volume 2 Figure 9.7 showing the PCB interconnec-
tions for each variant.
A set of distribution PCBs are used to optimise machine cable runs between the
Engine sensor devices and their handling FHMB. There are three Distribution
PCBs on the Engine:
Service side drum mounting plate PCBs:
A) Registration Pin Isolation PCB (see Section 3.4.1.4)
B) Sensor Distribution (Input) PCB
RFI Box mounting PCBs:
A) Sensor Distribution (Output) PCB
B) New 24V Distribution PCB
NOTE: All Sensor Distribution PCBs on the Engine and PTM have the same layout and
circuit design. This is also the case with all 24V Distribution PCBs.
Figure 3.43 shows the layout of the PCB drum mounting plate above the drum
on the service side of the machine.
PCB DRUM MOUNTING PLATE
REGISTRATION PIN SENSOR DISTRIBUTION

ISOLATION (INPUT)
Figure 3.43 Distribution PCBs - on drum mounting plate
Figure 3.44 shows two additional Distribution PCBs attached to the top right-
hand side of the RFI box.
RFI BOX
(TOP)
SENSOR
DISTRIBUTION
(OUTPUT)
24V
DISTRIBUTION
Figure 3.44 Distribution PCBs - top of RFI box
Sensor Distribution PCB (Output)

Figure 3.45 shows the layout of the Sensor Distribution PCB and Figure 3.40
shows its location on the Engine. The PCB supplies +5V to each of the sensors
and returns signals to FHMB 4.
PL1
PL5
PL2 PL3 PL4
PL6 PL7 PL8
PL9 PL10 PL11
PL12
SET CAN ID 0
Figure 3.45 Sensor Distribution PCB (Output) - layout view
Sensor Distribution PCB (Input)

Figure 3.46 shows the layout of the Sensor Distribution PCB and Figure 3.40
shows its location on the Engine. The PCB supplies +5 V to each of the sensors
and returns signals to FHMB 4.
PL5
SET
CAN ID 0
PL4 PL8 PL11 PL12
PL3 PL7 PL10

PL1
PL2 PL6 PL9
Figure 3.46 Sensor Distribution PCB (Input) - layout view
24V Distribution PCB (New)

Figure 3.47 shows the layout of the New 24V Distribution PCB and Figure 3.40
shows its location on the Engine.
PL11
PL8
PL5 PL7 PL10 PL12
PL3
PL2
PL1 PL4 PL6 PL9
Figure 3.47 New 24V Distribution PCB (FHMB 4) - layout view
This PCB distributes +24 V to energise the following sensors on the Engine:
BS3 (plate in punch)
A) pin 2 = +24 V
B) pin 4 = 0 V.
It also distributes +5 V to energise the following sensors on the Engine:
BS79: (chad tray home).
A) pin 2 = +5 V
B) pin 3 = 0 V.
The 24 V Distribution PCB includes circuitry to attenuate the +24 V sensor sig-
nal to +5V before they are passed to the FHMB.
See Volume 2 Section 9.4 showing system cable interconnections.
3.4.1.4 Registration Pin Isolation PCB

See Figure 3.48
Location
See Figure 3.40. Located on the drum mounting plate (service side) for all non-
punch platesetter variants.
Operation
A check for plate skewing occurs when the plate contacts both registration pins.
Once electrical continuity is sensed between the two pins, the plate is de-
skewed.
The Registration Pin Isolation PCB provides electrical isolation between both
registration pins and chassis ground. An on-board PSU (5VDC to 5 VDC)
applies power across both pins in series with opto-isolators connected to FHMB
(4). This arrangement forms an electrical barrier that guarantees a completed
circuit when the pins and the plate are in contact.
PL1
PL2
PL3
Figure 3.48 Registration Pin Isolation PCB layout
NOTE: The registration pins must have clean oil-free surfaces to ensure electrical con-
tact.
Connectors
PL1: 8-way header to registration pin
PL2: 10-way header to FHMB (4).
PL3: 4-way header to registration pin.
See Volume 2 Figure 9.5 to Volume 2 Figure 9.7 showing the PCB interconnec-
tions for each variant and also Volume 2 Section 8.1 listing cables and signals.
3.4.1.5 Motors
See Volume 2 Figure 9.5 to Volume 2 Figure 9.7 showing the cable connections to
each motor.
Motors (BM) on the Engine are listed as follows:
BM1 Friction Band Input
Location: Input module - service side, see Figure 3.56.
Operation: drives the plate into the drum.
BM2 Push Bar (Carriage)
Location: transport push bar - service side, see Figure 3.59.
Type: stepper with 5:1 gearbox and 20 tooth pinion.
Operation: drives bar and plate around the drum to the punch.
BM3 Centering (Punch)
Location: centering mechanism beneath output module, see Figure 3.60.

Type: stepper (Billows).
Operation: drives centering arms IN and OUT.
BM4 Punch
Location: punch assembly - service side, see Figure 3.60.
Type: DC (Billows).
Operation: drives punch pins.
BM5 Registration Pins
Location: underneath Output module, see Figure 3.66.
Type: DC (Billows).
Operation: operates the registration pins on the punch.
BM6 Friction Band Output
Location: output module - service side, see Figure 3.57.
Operation: drives plates from the drum to the Buffer. Note that this
motor is replaced with a stepper motor (BM38) for Semi-Automatic
machines.
BM7 Buffer Feed to Processor
Location: buffer module - Engine side, see Figure 3.69
Type: stepper
Operation: drives plates from the Buffer to the Processor.
BM10 Plate Centering
Location: inside the plate loading platform, see Figure 3.55.
Type: stepper
Operation: centres the plate on the platen before loading.
BM11 Plate Pusher
Location: inside the plate loading platform, see Figure 3.55.
Type: stepper
Operation: pushes the plate towards the input module
BM36 Registration Pin
Location: operates the registration pins on the non-punch engine.
Type: DC
Operation: operates the registration pins.
BM37 Swing Roller Motor
Location: service side, inside the drum, see Figure 3.52.
Type: 24 VDC with 60:1 gearbox
Operation: operates roller in two directions to open and close spur
wheels against the plate and improve leading edge conformance.
BM38 Output (Stepper)
Location: motor replacing BM6 on the output transport, see Figure 3.57.
Type: stepper
Operation: provides more synchronised control between the output and
the processor.
3.4.1.6 Solenoids and Relays

See Volume 2 Figure 9.5 to Volume 2 Figure 9.7.
Solenoids and relays (BV) fitted on the Engine are listed as follows:
BV3 Mixer Fan
Location: underneath FHMB1
Type: 24 V Relay
Operation: switches the mixer fan on/off during a scan in order to pre-
vent thermal hot spots.
BV5 Drum Vacuum Control
Location: inside the interlock box, see Volume 2 Figure 6.7.
Type: relay.
Operation: controls the relay switching on 230 AC to the drum vacuum
pump.
BV8 Error Warning Light (Alert)
Location: attached to the RFI box, underneath the interlock box.
Type: relay
Operation: external alert indication for the operator. When the machine
ceases operation because the required media type is missing, the alert
relay switches an external buzzer or flashing light. This alert is fitted by
the customer as an option.
BV30 SOL 1 (Divert Compressor)
See Volume 2 Section 9.5
BV31 SOL 2 (Compressor Relay)
BV40 SOL 3 (Leading Edge)
BV41 SOL 4 (Blow and Air Knife)
3.4.1.7 Sensors
See Volume 2 Section 2.2.1 for a description of the sensor types. See also Volume
2 Figure 9.5 to Volume 2 Figure 9.7.
Sensors (BS) fitted on the Engine are listed as follows:
BS1 Input Entrance
Operation: detects leading edge of plate in input nip.

BS2 Input Exit
Operation: detects trailing edge of plate past push bar.
BS3 Plate in Punch
Operation: detects leading edge of plate in punch.
BS4 Output Entrance
Operation: detects plate in output.
BS5 Output Exit
Operation: detects trailing edge of plate has left output.
BS6 Push Bar Home
Location: on a bracket where the bar is held in the Home position, serv-
ice side, see Figure 3.52.
Type: opto-slotted.
Operation: detects when the push bar is at Home position (parked).
BS8 Punch Motor Limits (On)
Type: opto-slotted.
Operation: punch motor is ON and pins are IN (extended).
BS9 Punch Motor Limits (Off)
Type: opto-slotted.
Operation: punch motor is OFF and pins are OUT (retracted).
BS10 Registration Motor Out Position
Type: opto-slotted.
Operation: registration motor pins are OUT (retracted).
BS11 Registration Motor In Position
Type: opto-slotted.
Operation: registration motor pins are IN (extended).
BS14 Centering Home Position

Type: opto-slotted.
Operation: detects Home position.
BS15 Push Bar Forward Limit
Location: mounted on drum casting below and left of punch motor at
service end, see Figure 3.52. Punch Engine only.
Type: opto-slotted.
Operation: detects forward limit overrun.
BS19 Buffer Entrance
Location: Buffer, engine side, see Figure 3.69
Operation: leading edge indicates full buffer
BS20 Buffer Exit
Location: Buffer, processor side, see Figure 3.69
Operation: trailing edge indicates empty buffer.
BS21 Fast Photo Detect
Location: drum casting, service side, see Volume 2 Figure 5.16.
Type: photo-diode
Operation: samples laser light power for spinner contamination and
laser calibration.
BS79 Chad Tray Home
Location: underneath the tray and accessed from underneath the optics
base.
Type: micro-switch
Operation: indicates the presence of the tray.
BS80 Mixer Fan Detector
Location: B_FAN cable pin link.
Type: FHMB 1 interprets HIGH/LOW state if the B_FAN pin link has
been inserted.
Operation: detects if the fan cable has been re-connected after a service
procedure.
BS100 Reg Pin Motor Home
Location: Registration Module, see Figure 3.66.
Type: opto-slotted
Operation: indicates if the registration pins are retracted.
BS103 Reg Pin Motor Out
Location: Registration Module, see Figure 3.66.
Type: opto-slotted
Operation: indicates if the registration pins are extended.
BS104 Reg Pins Continuity
Location: Registration Module pins, see Figure 3.66.
Type: open/closed circuit detection
Operation: indicates when the plate is contacting both registration pins
and has been de-skewed.
BS109 Swing Roller Home
Location: swing roller, service side, lower sensor, see Figure 3.67.
Type: opto-slotted
Operation: detects if the plate spur rollers are up.
BS110 Swing Roller In
Location: swing roller, service side, upper sensor, see Figure 3.67.
Type: opto-slotted
Operation: detects if the plate spur rollers are down to hold the plate in
position on the drum.
BS112 Push Bar Forward
Location: drum casting, service side (Web/manual Engine only).
Type: opto-slotted
Operation: detects the travel limit of the push bar towards the output
end.
BS113 Plate Centering Home
Location: inside the loading platform, see Figure 3.55.
Type: opto-slotted
Operation: detects the return of the centering arm to the Home position.
BS114 Centering Continuity 1
Type: opto-slotted
Operation:
BS115 Centering Continuity 2
Type: opto-slotted
Operation:
BS118 Plate on Platen Opto
Location: inside the loading platform, Figure 3.55.
Type: opto-reflective sensor on the Paper Plate Sensor PCB. This PCB is
similar to the Reflective Opto PCB except that it is factory-calibrated to
detect the difference between a plate and paper. Do not adjust once it is
installed or replaced.
Operation: detects the presence of a plate only without attached interleaf
paper.
3.4.1.8 Mixer Fan

See Volume 2 Figure 9.5 to Volume 2 Figure 9.7.
The fan is fixed to a bracket that swings free from the service side end cap open-
ing and is switched on remove thermal hot spots during a scan.
Leaving the supply cable disconnected after a service procedure will initiate an
error code on power up. Sensor BS80 detects if the mixer fan lead cable has been
reconnected after a service visit.
3.4.2 Engine Mechanical Modules

Figure 3.49 to Figure 3.54 show the main Engine assemblies used for conveying
plates.
See Volume 2 Section 4.1 for more information on the traverse assemblies.
The main engine plate handling assemblies are:
Plate Loading Platform - see Section 3.4.2.1.
Input Module - see Section 3.4.2.2.
Output Module - see Section 3.4.2.3.
Drum - see Section 3.4.2.4.
Transport Push Bar - see Section 3.4.2.5.
Punch, Centerer and Registration Assemblies (Billows) - see Section 3.4.2.6.
Swing Roller Module - see Section 3.4.2.10.
Chad Tray (Punch Only) - see Section 3.4.2.11..
FROM PLATE
TRANSPORT
OUTPUT
TO PLATE FHMB4
MODULE
OUTPUT
FHMB1
INPUT
MODULE
BEAM
PUNCH
BS6
PUSH BAR
CENTERING AND
REGISTRATION
MODULES
CHAD TUNNELS
TO TRAY
BS15 DRUM AND

BASE
PUNCH
MOTOR
VACUUM SUPPLY
FOR DRUM
Figure 3.49 Main engine assemblies (B1 fully-automatic with punch)

OUTPUT
MODULE
OUTPUT INPUT
TRAY TO OUTPUT MODULE
FROM
PLATE
LOADER
BEAM
BS6
REGISTRATION
MODULE
PUSH
BAR
TRAVERSE
SWING ROLLER GEARS
MODULE
FPD
BS112
DRUM AND
BASE
Figure 3.50 Main engine assemblies (B2 manual without punch)

COMPRESSOR BOX
VALVE CAGE
BEAM
UMBILICAL
TRAY READHEAD
FLAT DRIVE
RAIL
V-RAIL
CENTERING
MOTOR
BALL CAGE FLYWHEEL
MOTOR
PUSH BAR
PUNCH
M2 MIRROR
OPTICS
BASE
USER END
BAFFLE
Figure 3.51 Engine section view - user end (B1 fully-automatic with punch)
DISTRIBUTION
PCB'S PCB MOUNTING
PLATE
FHMB1
HOME SENSOR
(BS6)
INTERLOCK
BOX PUSH BAR
MOTOR
PUNCH MOTOR
MIXER
FAN
TRAVERSE
LIMIT SENSOR PCB
(BS15)
SERVICE END
Figure 3.52 Engine section view - service end (B1 fully-automatic with punch)
COMPRESSOR
VALVE CAGE READHEAD BOX
BEAM
UMBILICAL
TRAY
FLAT DRIVE
RAIL
V-RAIL
FLYWHEEL
MOTOR
BALL CAGE
SWING ROLLER
PUSH BAR & REGISTRATION
MODULE
M2 MIRROR BAFFLE
USER END
Figure 3.53 Engine section view - user end (manual and semi-automatic)
SERVICE END
FHMB 1
INTERLOCK
BOX HOME SENSOR
(BS6)
PUSH BAR
REGISTRATION MOTOR
MODULE
RFI BOX
MIXER FAN
SWING ROLLER
MODULE (SRM)
TRAVERSE PCB
LIMIT SENSOR
(BS112)
Figure 3.54 Engine section view - service end (manual and semi-automatic)
3.4.2.1 Plate Loading Platform

See Figure 3.56.
RACK SHORT
BS113
LINEAR TRACK BS116

SHORT
BM10
LH CENTRING
ARM RACK SHORT
BS114
BS118
LINEAR TRACK
LONG RH CENTRING
ARM
DRAG
CHAIN
LINEAR TRACK BS115
SHORT
PLATE LIFT
ROLLER
RACK LONG
BM11
PLATE LIFT
CARRIAGE
Figure 3.55 Loading platform view
The plate loading platform has two build versions:

B1 Manual and Semi-Automatic
B2 Manual and Semi-Automatic.

Both platforms have similar design and assemblies except for the differences in
size for handling B1 and B2 plates.
The loading plateform consists of:
Racks (long and short) and a pinion for centering
Centering arms
Rack for driving the plate pusher motor.
Sensors and motors: see Figure 3.55.
3.4.2.2 Input Module

This module has three different build versions for:
B1 Automatic
B2 Manual and Semi-Automatic
B1 Manual and Semi-Automatic.
Figure 3.56 shows the B1 Fully-Automatic input module. For servicing puposes,
all three builds are similar.
An air knife/curtain provides a stream of compressed air across the plate before
it passes into the drum. Contaminants on the plate are removed before they
enter the drum. A description of plate contamination control is in Volume 2 Sec-
tion 7.3.
Air is supplied from the compressor box with the flow controlled from the sole-
noid (BV41) located on the valve cage.
NOTE: AIR KNIFE FITTED ON AIR KNIFE

MOTOR BM1
PTM FOR FULLY
AUTO MACHINES A
SENSOR BS1
FROM
PTM
ROLLER
(IDLE)
BEARING
INPUT
BELT
DUCTING
PIPE ROLLER
(FRICTION)
BV41 ROLLER
(IDLE)
SENSOR BS2
TO DRUM
SIDE PLATE VIEW ON ARROW A
ROLLER
(DRIVEN)
GEAR
MANUAL
PLATE
VALVE CAGE FORWARD
(SEE CHAPTER 2-7) GEAR PULLEY
TENSIONER
Figure 3.56 Input module - general view (B1 fully-automatic)
3.4.2.3 Output Module

This module uses a common assembly with different output guides for the main
variants shown in Table 3.10.
The module consists of:
Sensors: BS4 and BS5.

Motor: for more precise control in moving a plate, a stepper output motor
(BM28) is fitted on the Manual and Semi-Automatic machines instead of a
DC motor (BM6).
Output Guide: there are different versions of the guide, depending on the
variant. See Table 3.10.
Rollers and belts: the rollers are held to the side plate by removable bearings.
These can be removed in-situ.
Table 3.10 Output guide plates and variants

Variant Output plate description
B1 fully-automatic Output guide with Buffer module

B1 semi-automatic Output guide with Buffer module
B1 manual Output guide with output tray
B2 semi-automatic Output guide with driven output tray (buffer)
B2 manual Output guide with output tray
SPUR GEAR CROWN

(76T) ROLLER
OUTPUT
BELT OUTPUT
FRICTION
BELT OUTPUT
PLATE LH
SENSOR BS5
SENSOR BS4
MOTOR BM6
TENSIONER
FRICTION ROLLER
(1 PULLEY)
Figure 3.57 Common output module (without output guide) - detail view
B1 Auto/Semi/Manual
B2 Semi
B2 Manual
Figure 3.58 Variant output module guides - detail view
3.4.2.4 Drum
See Figure 3.50.
The drum assembly is an aluminium casting fixed to the Engine base. Since it
has an anodised surface that prevents corrosion, it does not require servicing
except for periodic cleaning to remove plate dust and punch swarf. Note that
the drum surface should be cleaned after every service visit and the customer
reminded of the importance of this maintenance task.
For imaging purposes, the axes of the drum are usually defined as:
4 Slow: traverse direction
4 Fast: spinner rotation direction.
Drum functions are:
Conforming a plate for imaging: drum vacuum/air blow is across sets of
grooves directly connected to a manifold and valve system. Note that for
non-punch machines there is a leading edge zone which has three states: LE
conform blow, LE eject blow and LE vacuum conform. Pipe connections to
the drum are factor-fitted and should not normally be checked unless there
are conformance problems.
Supporting the traverse carriage: a top beam supports the carriage that holds
the spinner. To ensure that the carriage and its ball cage are properly
aligned, the drum (and Engine) must be level across the traverse axis.
NOTE: Follow the drum cleaning procedure in Volume 3 Section 1.5.4.
3.4.2.5 Transport Push Bar (Spring)

See Figure 3.59.
The spring bar (Mark 2), fitted to all Violet variants, is a modified version of the
Green push bar. It includes the following features:
Spring shoes replaces the mounted blade for plate contact (note that these
are replaced every 12 months). The distance between springs depends on
the maximum size of plates used on the machine.
Clutch is not fitted.
The complete assembly easily removed and installed.
The bar is designed as an accurately aligned assembly biased to the drum sur-
face to ensure the plate is not skewed against the registration pins and is con-
formed to the drum for accurate registration. The bar moves around the drum
using a drive shaft with two pinions either end that locate on gear segment
rings. The strip contacts the trailing edge of the plate and drives it until the lead-
ing edge reaches the registration pins on the punch assembly.
Sensors: BS15 (fully-automatic) detects the forward limit of travel towards
the punch and BS6 indicates the bar Home position.
Motor: motor (BM2) and gearbox drives the assembly using adjustable gear
segments set into the drum.
Service checks need to be made on the push bar for:
A) Mechanical conformance: note that the plate can be poorly conformed
mechanically and still have adequate vacuum conformance.
B) Spring shoes: these may need to be replaced annually, depending on
production rate.
C) Pitch ring: these are checked during each visit for Delrin flakes, see Volume 3
Section 1.6.3.
NOTE: After completing any of the procedures below, make sure that the push bar and
drum are clean and free from obstructions.
Volume 2 Section 1.10.15 describes the Main Diagnostics commands for moving
the bar to step positions around the drum. Different size plates require a differ-
ent number of steps; as a general rule you can enter a higher number for the size
of plate and allow for the clutch to slip after the plate reaches the registration
Mechanical Conformance
For correct push bar operation, the support bar must be parallel to the pins, and
parallel to the axis of the drum. Push bar alignment is always carried out by
adjusting the gear segments ring around the drum.
Plate skew can cause poor vacuum conformance at one side of the leading edge.
As a quick check, lightly tap the leading edge of the plate at each end of the
punch and note if the sound is hollow or firm. A hollow sound indicates
there is a possible problem with conformance often caused by skew. Volume 3
Section 1.8.3.1 describes the main procedure for measuring if skew is within
specification.
Fully-Automatic Machines Only: plate skew is sometimes caused by poor align-
ment between the PTM and the Engine after the inter-module fixing screws
have loosened, see Volume 3 Section 1.8.2.1. Check that the external frame skins
are aligned correctly using the information in the Installation Manual.
Non-Punch machines Only: use the setup procedure to ensure that the plate is cor-
rectly conformed to the registration pins, see Volume 3 Section 1.8.3.
SPRING
WHEEL SHOE
ASSEMBLY
DRIVE
SHAFT
SPUR GEAR
BLANKING
PITCH RING BRACKET
ASSEMBLY
ROLLER
PLATE
NIP ROLLER
ROLLER
PLATE
MOTOR HOME SENSOR

END PLATE (ON DRUM)
SUPPORT
BAR
HUB SPUR
DRIVE GEAR
SHAFT
PITCH RING
V3 ASSEMBLY MOTOR
PITCH RING STUB SHAFT GEAR MOTOR
BEARING MOUNTING
BRACKET
Figure 3.59 Transport push bar (Mark 2) general view
Note that typical NVRAM parameters for the Mark 2 are different to the Mark 1:
A) PUSH_BAR_CENTER_DIST_LONG_MM = 11
B) PUSH_BAR_CONF_DIST_THIN__MM=6
C) CENTERER_RELEASE_DIST_MM=1.0.
3.4.2.6 Punch, Registration and Centerer (New Billows)

The complete punch, registration and centering assembly is fitted on the B1
platesetter as a Billows (New) version with minor changes on the centering
mechanism and registration pivot from the Old version:
The New version has the following sub-assemblies:
Registration: a pin mechanism to stop the leading edge of a plate in a refer-
ence position for imaging.
Centerer: a finger mechanism to centre the plate prior to punching.
Punch: a pin, die and guide mechanism with a plate punch configuration
suited to the customers production needs.
Sub-assemblies are replaced and adjusted by either removing the complete
assembly (see Volume 3 Section 2.4.7.1) from the machine or by accessing the
required part without removing the assembly.
REGISTRATION
BS14 PIN MOTOR
CENTERER (BM5)
MOTOR (BM3)
CENTERING A
ARM (LH)
PUNCH
BS3 LOCKNUT MOTOR
BS10 (BM4)
REG PIN
CAM
SPRING
PIVOT
UNDERNEATH
VIEW ON CRANK
ARROW A ARM
MOTOR
SUPPORT
BS11 BRACKET
ACTUATING
ROD
Figure 3.60 Centerer and registration assemblies (New Billows)

Using Punch Diagnostic Commands

From the diagnostic service menu you can operate the punch, centerer and reg-
istration motor/sensors using the following commands:
punch mechanism:
service/actuators> set bm4 <on/off/dis/no>
registration mechanism:
service/actuators> set bm5 <on/off/dis/no>
centerer mechanism:
service/st_motors> setmotors centerer
service/st_motors> move 2000 800
Punch Mechanism Assembly

ACTUATING ARM
VIEW ON SERVICE END OF
PUNCH ASSEMBLY
VANE EXTENSION
TAB
BS9
BS8
MOTOR
SUPPORT
PLATE
B
A
A = RETRACT PUNCH MOTOR

B = EXTEND
Figure 3.61 Punch sensors - location view
The punch sub-assembly comprises:

Punch pins, dies and guides.
Cam, lever arm and shoulder screw (with washers).
Actuating lever, punch shaft and linkages.
Motor (BM4) and gear head.
Punch motor limit sensors (BS8/9) and plate in punch sensor (BS3).
A punch assembly (with integral pins and dies) is supplied as one of the config-
urations described in Section 3.4.2.6.
Chad from the punch drops into a tray located at the base of the drum, see
Figure 3.49.
PUNCH ACTUATOR BAR
ACTUATING
LEVER
CAM
SHOULDER VIEW FROM

SCREW USER SIDE
MOTOR DIRECTION
DRUM FACE
Figure 3.62 Punch lever assemblies
Punch Mechanism Operation

Figure 3.62.
Attached to the assembly is a motor bracket that includes a cam for rotating the
pin actuator lever arm (via a shoulder screw) and punch shaft. Two limit sensors
indicate the following:
BS8: pins are extended (in punch).
BS9: pins are retracted (out of punch).
Sensor BS3 detects the leading edge of a plate to indicate that the media has
entered the punch successfully.
Registration Mechanism Assembly

See Figure 3.60.
The registration mechanism comprises:
Registration pin motor (BM5) and gear head.

Pin cam (eccentric) attached to the motor arm.
Actuating rod that mechanically drives the pin bar.
Sensors BS10/11 indicate to the system if the pins are extended or retracted.
Registration pins (6-off) attached to bar.
Registration Mechanism Operation

When driven by BM5, the pins have two possible positions:
1. Extended: the pins are in the plate path and the plate leading edge is stopped.
2. Retracted: the pins are out of the plate path and the plate can be pushed
towards the Buffer.
Centerer Mechanism Assembly

See Figure 3.60.
The plate centering mechanism comprises:
Two centerer arms (fingers) and rails driven by motor (BM3) via a rack and
pinion.
Centerer motor (BM3) and gear head
Centerer home sensor (BS14) allowing the arms to be set at 1174 mm apart.
Centering is achieved when there is electrical continuity between the two
side fingers and the plate.
Centerer Mechanism Operation

The plate is aligned for punching by the centerer after it is pushed into the
punch assembly. A centering operation occurs as follows:
1. Extended registration pins stops the plate leading edge in a datum position.
2. Centerer fingers in the Home position move inwards until both the left and
righhand side detect a plate, indicating the plate has been centered.
3. The fingers attempt to centre the plate and issue an error code if the plate has
not reached the punch or if step 2. above fails.
4. The fingers move back towards Home before the plate is conformed.
3.4.2.7 Punch Configurations

Customers can fit a range of configurations for a punch based on the configura-
tions described in Table 3.11 and illustrated in Figure 3.63.
HEIDELBERG+BACHER
780 mm
748 mm
A = BACHER
425 mm B = HEIDELBERG
C = HEIDELBERG
11 mm 393 mm
PUNCH A 6.35 mm x 9.525
PUNCH B 12.68 mm x 10
A A A A PUNCH C 12 mm x 14.68 mm
B B C C
8 mm
MAN ROLAND / MATSUMOTO / HEIDELBERG
780 mm
425 mm
11 mm
PUNCH A 12.68 mm x 10
PUNCH B 12 mm x 12 mm
A A B B
KOMORI
830 mm
550 mm
9 mm
PUNCH A 12 mm x 12 mm
PUNCH B 11.19 mm x 8
A A B B
DS400/700
700 mm
400 mm
6 - 9 mm
PUNCH A 6
PUNCH B 6 mm x 10
PUNCH B 6 mm x 8
A A B B
Figure 3.63 Plate punch configurations

Table 3.11 Plate punch configurations and part numbers

Punch Type Punch Assembly Part No
Dummy 7A03595
Heidelberg+Bacher 7A03596
Man Roland/Matsumoto/Heidelberg 7A03597
Komori 7A03598
Custom 7A03600
3.4.2.8 Punch, Registration and Centerer (Fuji)

This punch (referred to as Fuji) is an advanced design on the Billows punch. It uses
similar ID numbering for motors and sensors, and includes the registration, centerer and
punch modules that operate in a similar way to the Billows punch. New features for the
Violet punch include:
Fabricated in aluminium as a complete casting.
Uses Beryillium copper wiper strips to prevent chad collecting inside the die.
Accessible sensors and motors for improved servicing.
Facility to extend the service life of the punch crop pins.
CENTERING
S10 MOTOR
S14
(BM3)
REG PIN
CENTERING DC MOTOR CENTERING
ARM (LH) ARM (RH)
S13
BS3
PIN/DIE/ A
S12 CHAD WIPER
PUNCH
MOTOR
CENTERING (BM4)
MOTOR BS8/9
S11
REG PIN
CAM
NOTE: S12/S13 FITTED TO

CENTERING FINGERS
ON HIDDEN SIDE
REG PIN
REG PIN DC MOTOR
ACTUATING (BM5)
ARM
UNDERNEATH
VIEW ON CENTERING ACTUATING
ARROW A PINION SHAFT
Figure 3.64 Punch, registration and centerer (Fuji)

3.4.2.9 Registration Module

Fitted at the output end of the drum casting and accessible from the rear of the
Engine on all variants except for the fully-automatic (with punch).
The module operates two registration pins that stop the leading edge of a plate
before vacuuming and imaging. Electrical continuity between the two pins and
the plate indicates that the plate is not skewed.
Once factory fitted, the registration module is never removed from an on-site
machine.
SIDE
PLATE
PLATE
GUIDE
DRUM
CASTING
REGISTRATION
MODULE
BACK
STAY
Figure 3.65 Registration module (drum view)

VOLUME 2 (3-100) PLATE H ANDLING M ODULES
MOTOR SENSOR
BRACKET
ACTUATING
SHAFT
BEARING
BLOCK
SENSOR
GEARMOTOR
BASEPLATE
Figure 3.66 Registration module (detail view)
3.4.2.10 Swing Roller Module

See Figure 3.67.
This module is installed on all variants except for the fully-automatic (with
punch) system.
The swing roller module is fitted on the drum output and serves to:
4 conform the leading edge of the plate to the drum for imaging
4 guide the plate leading edge at the eject stage towards the output module.
The roller assembly consists of:
DC motor: 24 VDC with 60:1 gearbox with spur gear
Nip wheels: rubber wheels
Sensors: BS109 and BS110 to indicate if the nip wheels are in the Home posi-
tion (OUT) or IN
SENSOR SIDE PLATE SIDE PLATE

(BS110) BACK FRONT
BACK STAY
MOTOR
MOTOR
BRACKET SENSOR
(BS109)
PLATE
GUIDE
SHAFT
NIP WHEELS
Figure 3.67 Swing roller module (detail view)
3.4.2.11 Chad Tray (Punch Only)

A chad tray for the punch waste material is emptied by the operator at periods
determined by a software count. See the Luxel Platesetter Operator's Manual for
an illustration of the warning icon on the MMI. As a service procedure, make
sure that the chad exits correctly from all the punch pin channels.
A micro-switch (BS79), located at the far end of the tray, detects if the tray is in
the Home position. Access is from underneath the optics base after the rear
panel has been removed.
CHAD TRAY
PULL
Figure 3.68 Locating the chad tray
3.5 Buffer Plate Handling Modules

The Buffer consists of:
3.5.1 Buffer Control Assemblies

See Figure 3.69 showing the interconnection and locations of the control assem-
blies.
B1/B2 fully-automatic and semi-automatic platesetters: these are fitted with a
bridge conveyer to ensure a regulated flow of plates between the engine and
the processor.
B2 semi-automatic platesetters: these have a guide plate from the engine and a
box cover to bridge the two units.
3.5.1.1 Buffer Control Modules

See also Volume 2 Section 2.2.1.
Motor/gearbox
Sensors.1.
A band roller assembly on the Buffer moves the drive belts to synchronise
scanned plate outputs from the Engine with the transport rollers in the Proces-
sor. Plates are held in transit at the Buffer until the Processor sends a READY
request command for the next plate. Delays can be caused, for instance, when
the Processor chemical temperature needs adjusting for a different type of plate.
The Processor communication link is enabled or disabled from the TOOLS
menu on the MMI. If the link is disabled, the Processor still operates by sensing
the arrival of the plate at the input entry. However, the workflow output is likely
to be slower and more prone to jams.
BM7: Buffer Feed to Processor:
Type: stepper and dual-ratio gearbox.
Operation: drives the plate from the output module into the Buffer at
faster speed than BM6. Stepper reverses direction and gearbox slows
bands to match speed of Processor input.
IDLER GEAR
MOTOR AND GEAR

ASSEMBLIES
STEPPER
MOTOR
GUIDE
SENSOR (BS19)
GEAR
SENSOR
(BS20)
DOUBLE
SPUR GEAR
BAND
SERVICE SIDE ROLLER
SENSOR
BRACKET
SIDE PLATE
DRIVE BELT
PLATE RAMP
ADJUSTER RAIL BEARING/RETAINER CLIP
Figure 3.69 Buffer assemblies (old)

BS19: Buffer Entrance:

Type: Opto-reflective.
Operation: detects the presence of a plate at the Buffer entrance after the
output module.
BS20 Buffer Exit
Type: Opto-reflective.
Operation: detects the presence of a plate at the Buffer exit before the
Processor.
3.5.2 Buffer Assemblies (New)

The New Buffer operates as transport bridge between the Engine and the Proces-
sor using drive belts, gears and rollers. It is similar in operation to the old Buffer
except:
New Buffers are not fitted with a labyrinth or height adjuster.
New Buffers include a removable top cover to access motors and sensors.
IDLER GEAR
MOTOR AND GEAR

ASSEMBLIES
STEPPER
MOTOR
SENSOR
(BS20)
GUIDE
GEAR
SENSOR (BS19)
DOUBLE
SPUR GEAR
BAND
ROLLER
SERVICE SIDE SENSOR

BRACKET
SIDE PLATE
DRIVE BELT
PLATE RAMP
ADJUSTER RAIL BEARING/RETAINER CLIP
Figure 3.70 Buffer assemblies (new)

3.6 Inter-Module Connections and Control

3.6.0.1 Autofeeder-to-PTM Interconnections
Control and power interconnections from the Autofeeder are routed from the
PTM using the arrangement shown in Figure 3.71.
SCREW FIXING
VIEW FROM (SEE NOTE)
SERVICE SIDE
REMOVE SERVICE
SIDE COVER
ELV_IN ELV_LOCK RIB8
CONNECTOR
I/F PLATE PA
MAINS_ELV_IN
SCREW FIXING
(SEE NOTE)
NOTE: REPEAT SCREW FIXING POINTS AUTOFEEDER

ON USER SIDE INTERIOR FRAME
CONNECTIONS
Figure 3.71 Autofeeder-PTM control interconnection
NOTE: The Autofeeder must be mechanically coupled with the PTM so that there is no
risk of light `fogging' plates.
3.6.0.2 PTM-to-Engine Interconnections

Control and power from the Engine to the PTM use the connector interface
shown in Figure 3.72. Note that the PTM must be mechanically coupled with the
Engine and Autofeeder so that there is no risk of plate `fogging'.
REMOVE SERVICE SCREW FIXING CAN5_INT

SIDE COVER (SEE NOTE) (CAN A)
CAN3_INT
(CAN B)
CONNECTOR I/F
PLATE EP
FHMB3
PWR3_INT (8W) INT_EMERG (6W) FEED_INT (10W)
VACUUM INLET
INT_MAINS
RELAY
PTM INTERIOR
SCREW FIXING FRAME CONNECTIONS NOTE: SCREW FIXING POINTS
(SEE NOTE) ON EACH SIDE
Figure 3.72 PTM-Engine control interconnection
3.6.0.3 Buffer-to-Engine Interconnections

Control and power interconnections from the Engine are routed to the Buffer
using the drive arrangement shown in Figure 3.73. Note that the Buffer must be
mechanically coupled with the Engine so that there is no risk of light fogging
plates. A fume flap between the Buffer and Engine prevents chemical contami-
nation inside the Engine.
SERVICE SIDE
BUFF_S19/20
BUFF_M7
INTERLOCKS
BUFFER
ENTRY ON
ENGINE
CONNECTOR
I/F EB
Figure 3.73 Buffer-Engine interconnections (old)
SERVICE SIDE
CONNECTOR I/F EB
BUFFER ENTRY
ON ENGINE
INTERLOCKS BUFF_M7 BUFF_S19/20
Figure 3.74 Buffer-Engine interconnections (new)

Volume-Chapt er
TRAVERSE SCAN MODULES

This chapter describes the main traverse modules and how the scan system operates:
4
4
Introducing the Traverse Scan Modules .................................................................. 4-1
4
Media Scan System Description ............................................................................... 4-7
Edge Detect System Description ............................................................................ 4-18
4.1 Introducing the Traverse Scan Modules

See Volume 1 Section 2.3 introducing the traverse scan system and Volume 3
Section 3.1 describing how traverse scan FRUs are replaced.
The media scan system includes the modules shown in Figure 4.1. with their
physical location shown in Figure 4.2.
NOTE: All Luxel platesetter variants use the same traverse scan modules and method of
operation.
4.1.1 Beam Assemblies

A cast aluminium beam provides the main support for the traverse carriage and
includes the following sub-assemblies:
V-groove rail: provides a sliding surface for the ball cage.
Ball cage: a precision assembly of ball bearings that allow the carriage to slide
along the V-groove. Both carriage and cage need to be physically aligned
using the procedure in Volume 3 Section 1.7.2. A separate software utility
checks for `creep' (ie the two assemblies gradually become misaligned as the
system constantly traverses)
Drive rail: provides a drive rail for the traverse motor spindle and a base for
the linear scale.
Linear scale: runs along the drive rail to provide position coding for the read-
head encoder.
Actuators: All position measurements are offset from two actuators that indi-
cate the exact reference (Index) and coarse reference (Home).
2-4-2 T RAVERSE S CAN M ODULES
4.1.2 Traverse Carriage Assemblies

The carriage assembly is motor-driven to run along the beam drive rail from its
Home position on the Service side. Scanning is from the user to the service end.
A traverse motor, which moves the carriage, is controlled directly from the
Traverse PCB that operates as a CAN node. Position feedback is provided by a
readhead sensing micro positions on the linear scale; commands from the Sys-
tem PCB, via the Traverse PCB, control the position and direction of the car-
riage.
Traverse PCB: this PCB runs local software handling routines for operating
the traverse carriage mechanisms. See also Section 4.1.2.1.
Spinner: the spinner (Speedring type) includes an encoder that returns an
Index signal for each revolution and a rotating mirror for reflecting the laser
beams onto the plate. See Section 4.2.2.
Baffles: two baffles are fitted: removable and fixed. Baffles are fitted to help
conform film to the drum and prevent laser light scattering on the plate. See
Section 4.2.1.1.
Traverse Motor: a DC motor drives a spindle along the drive rail.
Readhead: an encoder with sensors that reads the micro positions on the lin-
ear rail to detect current position.
Umbilical: an umbilical ribbon cable from the Traverse PCB to FHMB4 con-
nects the CAN control/status signals and the power voltages. The cable is
positioned along a tray and flexes as the carriage traverses the drum.
Edge Detect PCB and Laser: detects the side edge of the plate for calculating a
horizontal start imaging position. See Section 4.3.
The carriage is removed from the engine using two extenders fitted to the beam.
Most service procedures are completed while the carriage is located on the
extenders.
BEAM
SCALE
READHEAD ACTUATORS
LSB
FROM
OPTICS
POSITION DRIVE RAIL BASE
FLYWHEEL/ DATA
MOTOR/
CAN SHAFT LASER
BEAM
+36V SPINNER
DC DRIVE INDEX
TRAVERSE
PCB ENCODER
FHMB (4) UMBILICAL
(CAN + POWER)
MIXER
FAN
EDGE DETECT (OUTSIDE
LASER/PCB BAFFLE END CAP)
Figure 4.1 Media scan system assemblies

(SERVICE END)
L UXEL P LATESETTER 2-4-3
PCB SUPPORT
BRACKET READHEAD
SUPPORT
READHEAD BRACKET
PCB BAFFLE
V-GROOVE SPINNER
RAIL
TRAVERSE
CARRIAGE WIPER
BAFFLE
BRACKET
(FRONT)
L6 LENS
ASSEMBLY
SPINNER
CLAMP
EDGE DETECT
PCB AND LASER
MOTOR
MOTOR
SUPPORT
FLYWHEEL
CLAMP
BAFFLE
BRACKET FLYWHEEL
(REAR)
Figure 4.2 Traverse assemblies - general view

REMOVABLE
TRAVERSE
BRACKET
PCB
BEARINGS
BEARING
PLATE
MOTOR
SHAFT
4.1.2.1 Traverse PCB

PL11 PL12
PROCESSOR
TP26
PL9
PL10
TP10
TP9
PL6 PL7
PL1 PL4 PL5
PL2
Figure 4.3 Traverse PCB layout
Location
Located on the PCB support bracket on the underside of the carriage, see
Figure 4.2.
LEDs and Links

Traverse PCB Connectors

A) PL1: Molex mini-fit 4-pin to Traverse motor.
B) PL2: Molex milligrid 16-pin header to Traverse Encoder (readhead).

C) PL3: Not used.
D) PL4: Molex mini-fit 8-pin to Spinner encoder.
E) PL5: Molex mini-fit 12-pin to Spinner motor.
F) PL6: Not used.
G) PL7: Not used.
H) PL8: Not used.
I) PL9: Not used.
J) PL10: 45-way connector for umbilical flexible cable (power, spinner signals
and CAN bus).
K) PL11: Not used.
L) PL12: Not used.

See Volume 2 Section 8.1.
Test Points
The most useful test points for field servicing are:
A) TP9: Sawtooth waveform. When compared with a `Demand' signal (see
TP11), produces a pulse-width modulated signal controlling spinner speed.
The sawtooth waveform is seen after the `Spinner Reset' command is
entered.
B) TP10: Demand signal. Produces a saturated voltage level on startup which
then reduces to a lower running level when the spinner is locked. If the
signal remains saturated, the Traverse PCB needs to be replaced.
C) TP26: DATA A signal (960 lines/rev).
4.1.2.2 Traverse PCB Functional Description

The Traverse PCB controls the spinner and traverse mechanisms, and also pro-
vides the drive currents for the spinner and traverse motors.
MPU Controller
The main functions of the MPU (Motorola 68376) are:
To control the Traverse PCB locally by receiving and interpreting high-level
commands sent from the System PCB over the CAN bus. These commands
typically include, for example, Spinner Start/Stop, Traverse Datum, Fans On/
Off.
Initialises the Precision Motion (PM) Controller that operates the closed-
loop position feedback system for the traverse control.
Pass control and position data to the PM controller.
Control the flow of diagnostic data to a local VDU.
4.2 Media Scan System Description

4.2.1 Scanning Overview
This section describes the function and operation of the scan system control
modules that operate around the Traverse PCB. The media scan control system
is broadly divided into two areas:
Spinner control: a high-speed air-bearing spinner driven by a brushless dc
motor. The spinner includes a mirror to reflect laser beams onto the plate
and an enclosed rotary encoder that supplies a SPIN INDEX signal to the
System PCB.
Traverse control: a spinner carriage mounted on beam that runs the length of
the drum. Position feedback is taken from a readhead and a linear scale
fixed to the drive rail. Spinner and traverse operations are managed locally
by a Traverse PCB attached to the carriage.
Carriage motion is from a friction drive shaft turned by a dc motor. Note
that the shaft has a precise diameter and any dirt or damage on or around
the shaft will give a mis-registration pattern.
The scanning system controls the traverse mechanisms and consists of the fol-
lowing features:
dedicated precision motion controller
traverse closed-loop servo compensation system
traverse motor amplifier
two sensors to detect positions from fixed actuators on the drive rail:
4 coarse Home position
4 exact Index position (reference)
linear encoder supplying position data.
Expose scanning to plate is from a spinner that has the following features:
discrete Traverse PCB circuitry that controls the drive current
spinner feedback encoder signals to regulate speed and avoid fluctuations
3-phase supply with transistor switching to energise the motor windings
braking from an System PCB command.
The traverse carriage is supported on a linear bearing and a plain drive rail, see
Figure 4.6. Both bearing and drive rail are parallel to a beam which runs the
length of the drum. The linear bearing consists of a long V-groove section fixed
to the beam, and a short section mounted on the carriage. An open ball cage
assembly separates the two sections. A traverse motor shaft, supports and
drives the carriage along a plain drive rail that holds the linear scale and the
traverse reference actuators.
The ball cage and traverse rail are aligned to ensure that the cage is always
under the rail for the entire travel of the carriage. Volume 3 Section 1.7.1
describes the alignment procedure.
4.2.1.1 Mixer Fan and Baffles

A mixer fan mixes (equalises) the drum air thermals around the spinner to pre-
vent error patterning. The fan is mounted on a hinged bracket that locates out-
side the drum end cap on the service side and is controlled from a relay fitted on
the engine underneath FHMB1.
Two baffle assemblies are fitted on the carriage to prevent light scattering from
the plate surface and exposing other areas of plate. The baffle (user side) is
removable for spinner mirror cleaning; the baffle (service side) is fixed.
4.2.1.2 Traverse PCB Imaging Control

When the system is ready to output an image, the Traverse PCB receives infor-
mation from the System PCB on:
1. horizontal start of image (right-hand edge when the machine is viewed from
the front)
2. vertical start of image (first part of image exposed after the Index pulse)
3. image resolution
4. number of laser beams (1 or 2)
5. traverse direction of imaging (user to service end).
The Traverse PCB then moves the carriage to the correct position. After image
data has finished downloading from the RIP, the System PCB instructs the
Traverse PCB to start scanning.
4.2.1.3 Scan Interlock Protection

The covers and doors on the platesetter are interlocked using the system fully
described in Volume 1 Section 3.3. If a cover is opened, and the interlocks not
overridden, voltage supply (+36V and +24 V) to the Traverse PCB is removed.
This halts spinner rotation.
4.2.1.4 Traverse Diagnostics

Traverse PCB on-board diagnostics check for cage creep if the engine traverse
level falls outside the specification. A set of utilities allow you, for instance, to
move the carriage to a set position, to datum the carriage or halt the traverse.
4.2.1.5 Umbilical Interface

Electrical and power connection to the scanning system is from a 45-way flexi-
ble ribbon cable. This conveys power and CAN command signals to the
Traverse PCB, and returns status signals to the System PCB. With the exception
of the CAN bus, all other differential signals are RS422 interface standard.
4.2.2 Spinner Control Subsystem

Spinner control is a closed-loop system with a common clock source to the spin-
ner control circuit and traverse controller. All the main spinner control functions
are located on the Traverse PCB. Commands for the spinner (for instance, Start/
Stop and Full/Idle Speed) are transmitted to the controller via the CAN bus from
the System PCB.
4.2.2.1 Spinner Encoder

The spinner is fitted with a rotary encoder that provides two differential signals:
DATA A with a resolution of 720 lines/rev. This signal is used locally for the
spinner closed-loop control, and is transmitted back to the System PCB
where it is multiplied for use by the pixel data clock. It is compared (on the
Traverse PCB) to a crystal-derived reference clock to give an error signal, via
a compensation circuit, that varies the current to the spinner motor wind-
ings.
SPIN INDEX occurs once per spinner revolution. This signal is transmitted
directly to the System PCB where it is used to synchronise the carriage and
spinner mirror positions.
4.2.2.2 Spinner Controller

This function operates from the Traverse PCB and is responsible for driving the
spinner motor based on feedback information derived from the encoder. The
controller regulates motor current by varying the duty cycle of the switching
waveforms applied to the power stage. At 40,000 rpm, the pulse width modula-
tion signal and the Hall effect signals are synchronised.
Also, the traverse and spinner speeds are synchronised from the same reference
clock signal to ensure correctly aligned raster imaging. See Section 4.2.4 below.
4.2.2.3 Spinner Diagnostics

A set of service diagnostics for the spinner is available to start and stop the
spinner, display index counts, set image offset position on the plate and run
spinner auto-tests..
4.2.2.4 Spinner Condition Sensing and Braking

Besides the servo loop, spinner control is also determined by a number of exter-
nal conditions and detector signals that are monitored for diagnostic use.
Current Limit
Maximum current to the spinner from the controller output is set not to exceed
15 A (for 1.5 secs) on spinner startup, with maximum current for each phase is
limited to 8 A thereafter.
Braking
When braking is switched on, the spinner comes to rest at approximately 20 secs
from full speed. Braking is applied by shorting out the three windings and using
regenerative braking to decelerate the spinner. It is active when:
A) the spinner controller initialises
B) power is removed from the Traverse PCB (for instance, an interlock is
opened)
C) on-demand signals via the software.
Braking also occurs for the following conditions listed below:
Stalled Rotor
If the rotor fails to move following a Start command.
Hall Effect Sensor Failure

The controller monitors the validity of the Hall effect sensor codes when the
spinner starts to turn. There are six valid (and two invalid) codes depending on
the initial rotor positions. On detection of an invalid code, power is removed
from the motor.
Overspeed/Underspeed Detection
Power is removed from the motor if the spinner is stalled or is rotating too
slowly. Speed is calculated from the spinner shaft encoder.
Over-temperature
Local ambient temperature around the spinner output terminals on the Traverse
PCB is monitored by an on-board detecting device. If the temperature exceeds
100C, the controller removes power to the motor.
4.2.3 Traverse Motor Control Subsystem

See Figure 4.4.
Direction of traverse travel can be both ways depending on system software
decisions, although normal scanning direction for imaging is from user to serv-
ice end. Datum is determined from two sensors in the readhead which are actu-
ated by two magnets:
4 Home (HOME) - coarse detection
4 Index (TRAV INDEX) - fine reference detection.

Units of measurement on the traverse system are in microns with the Index
actuator defined as position 0. The valid range of the beam (in microns) is
approximately 0 m to -1,220,000 m in steps of 1 m.
DRUM
1,220,000 m VE
+VE
SE
EN
CARRIAGE HOME INDEX
RAIL ACTUATOR
Figure 4.4 Traverse positioning
4.2.3.1 Linear Encoding

Position and servo control for the traverse is derived from signals fed to the Pre-
cision Motion controller by a readhead digital encoder system (Renishaw
RGH22).
Scanning speeds vary with resolution and the number of beams operating.
Traverse speed is directly proportional to the number of beams (for instance, a
dual-laser beam at 96 l/mm speed equals two times a single-laser beam at 96 l/
mm).
Linear Scale
The linear scale is a 6 mm wide, self-adhesive steel strip that is gold-plated and
lacquer coated. It is pressed with small corrugated pitches (facets) set at 20
microns. Gold plating on the scale assists optical reflection/diffraction from the
readhead, while lacquer coating protects the strip from minor surface damage.
It is attached to the drive rail and covers the length required for an end-to-end
carriage movement.
The design of the readhead and scale ensures it is tolerant of small amounts of
contamination or damage. It is cleaned by wiping with a cloth dipped in an
approved cleaning agent described in Volume 3 Section 1.5.2.If the scale is badly
damaged, it is possible to replace the complete strip in-situ; but this is not a
standard replacement procedure and requires advice from FFEI Customer Sup-
port.
Readhead
See Figure 4.5.
This is a position feedback transducer that supplies digital signals directly to the
PM controller. The current device is a Renishaw RGH22X that runs from a sup-
ply of 5 VDC, has a resolution of 1m, and operates an infra-red diode as a
source of illumination.
Infra-red light obliquely illuminates the scale facets which then reflect and scat-
ter light towards the readhead window. An index grating inside the device redi-
rects the light to form fringes identical to the scale pitches. Each fringe point is
the summation of light from 100 scale facets to give an averaging effect that
helps to overcome the problem of scale contamination. Photo-sensitive diodes
then generate phased currents from these fringes.
Interpolation hardware in the readhead sub-divide the composite signals to pro-
duce two quadrature square waves with a resolution of 1 m.
The readhead is a field replaceable unit that includes a plastic spacer to check
the recommended 0.8 mm distance between the head and the scale. Note that
there is a registration procedure to setup the readhead with the index actuator.
READHEAD
READHEAD
WINDOW
OBLIQUE LIGHT
FROM
INFRA-RED LED
CLEARANCE
0.8 mm
CONTAMINANTS
COATING SCALE SCATTERS
GOLD PLATED LIGHT > 100
SCALE FACETS ACTIVE FACETS
RAIL
PITCH 20 M
Figure 4.5 Readhead operation
To ensure accurate encoding, the gap between the scale and the readhead must
be set using the 0.8 mm spacer supplied with the head. When the head is
replaced, the setting should be checked over the entire length of the scale track
by observing the readhead LED as the carriage is pushed from one end to the
other.
Optical signal generated from the scale is read by a built-in monitoring circuit
that measures relative alignment and set-up conditions. Any indication of error
is shown by a bi-colour LED. As a servicing check, the diagnostic LED is visible
from the user end while the carriage travels along the complete scan distance.
LED colour indications are as follows:
Green: set-up conditions are acceptable.
Orange: conditions are acceptable but small adjustments are required for
obtaining an improvement. The manufacturer's Installation Guide explains
how to set-up the alignment.
Red: conditions are unacceptable. The manufacturer's Installation Guide
explains how to set-up the alignment.
NOTE: A correctly setup readhead is essential for accurate encoding.
Traverse Servo
A desired reference trajectory is generated on the PM controller as a sequence of
positions and this is compared to a register that holds data on the current car-
riage position received from the linear encoder (readhead). The resulting digital
error signal is processed as a new numerical value by the controller and sent as
an update to the DAC. Dynamic response (speed of response, etc) of this servo
loop is determined by an external compensation circuit to give an output that
drives the traverse motor from a linear power amplifier.
Traverse Amplifier
Analogue signals from the servo is converted to current by a linear push-pull
amplifier, with local feedback to ensure that current through the motor is pro-
portional to the input. Output current from the amplifier is fed back to an MPU
A-to-D channel for diagnostic measurement.
Traverse Motor Assemblies

This is fitted to the carriage casting as an assembly of:
Motor: a brush DC motor (with casting).
Motor shaft: a friction shaft that consists of a hardened silver steel with a cen-
tral crown that moves along the drive rail. Avoid damaging or knocking this
item. The diameter of the shaft is 9 mm.
Flywheel: used to smooth the speed of the carriage along the rail. Turn the
flywheel by hand to start the traverse along the rail.
Drive rail wiper: forms a housing over the motor shaft and includes an
arrangement of felt pads that keeps the motor shaft clean as the carriage
moves. Both the rail and shaft must be free of contaminants to avoid mis-
registration.
Traverse Actuators
Figure 4.6 shows the position of the two reference actuators and linear scale
detected by the readhead. The end stop is fitted as a mechanical stop.
BALL CAGE
(SEE FIGURE 9.19 FOR
CAGE ORIENTATION)
VIEW ON ARROW A
V-GUIDE
RAIL
CAGE
STOPPER
BEAM
UMBILICAL
TRAY
BUFFER
SIDE
DRIVE RAIL
HOME
ACTUATOR
(3-OFF)
ENDSTOP
AND BRACKET
INDEX
ACTUATOR
LINEAR
SCALE
Figure 4.6 Location of actuators and linear scale
Carriage Position Encoder

This consists of a linear scale fixed to the drive rail, and a readhead attached to
the carriage which passes over the scale as the carriage moves. Position data is
passed directly to the Traverse PCB for use by the servo control. Resolution for
position movement is set at 1 m.
The readhead also includes two sensing circuits (Index and Home) triggered by
passive actuators (magnets) fitted to the rail on the Buffer side of the beam.
Home Actuator
This sensor actuator generates a signal before the mechanical stop to define one
end of the beam, see Figure 4.7.
The Home signal is active for the final 20 mm of carriage movement until the
carriage reaches its mechanical end stop. It is used as a coarse position sensor,
determining which way to move the carriage at power up. It is also used as a
software warning flag to indicate that the Index sensor in close proximity. Note
that it is not possible to move the carriage beyond the active region of the Home
signal while it is traversing.
COARSE HOME POSITION SIGNAL
CARRIAGE TRAVEL CARRIAGE

ACCURATE INDEX SIGNAL STOP
RAIL
Figure 4.7 Home and Index signal relationship
Index Actuator (Reference Mark)

This sensor actuator is positioned opposite the Home actuator and provides a
precise reference point for linear movement. All absolute positions are meas-
ured from the point where the TRAV INDEX signal is asserted.
The index signal (TRAV INDEX) is active for the same distance as the main scale
(1 m). It is repeatable, short and accurate, and is asserted approximately 5 mm
'inside' the Home sensor region.
This sensor is always approached by the carriage from the same direction dur-
ing the datum operation to ensure the highest repeatability. The method is as
follows:
A) a valid Home signal is detected
B) carriage moves left slightly beyond the Index sensor
C) moves right and halts on the left-hand edge of the Index sensor.
Because the position of the reference mark pulse is set for very high precision
repeatability, some form of registration is necessary. Using the readhead LED
indicators, the optimum phasing of the reference mark trigger signal, relative to
the incremental signal from the scale, is determined. A screw fixing on the actu-
ator sets the correct registration.
If the readhead mounting is disturbed, or the readhead is replaced, the reference
mark will need to be re-registered using the procedure supplied by the manu-
facturer's Installation Guide. Make sure the retaining screws for the readhead are
not disturbed.
Overspeed and Braking

To prevent traverse control from driving the carriage too fast, the rate of encoder
pulses are measured and, if excessive, a signal is sent to brake the traverse
motor. Braking occurs if:
the readhead detects a poor setup/alignment along the linear encoder track,
see the Readhead section above.
the Traverse PCB detects that the encoder is missing or not connected. A
position error is generated if the carriage does not align with a reference
point.
a power failure is detected.
The normal maximum speed of the carriage is 100 mm/sec which is measured
from the carriage encoder signals. If the speed exceeds 110 mm/sec the brake is
operated. A braking status message is available to the System PCB.
Local ambient temperature around the Traverse PCB output devices is meas-
ured by an on-board sensor. If the temperature exceeds approximately 100 C,
power to the motor is removed and a signal is sent to the System PCB.
4.2.3.2 Optical/Traverse Synchronisation

See Figure 4.8.
The precision motion (PM) controller on the Traverse PCB requires a system
clock that is scaled by a phase lock loop (PLL) and derived from the same crystal
reference used for the spinner. This locks the spinner and traverse rates together,
giving the exact resolution required. For lower resolutions the traverse moves at
a correspondingly faster rate.
BEAMS X
Y
SCAN
SWATHE Q
A
P DRUM
SCAN
SWATHE
B
Figure 4.8 Traverse and optical differences
Synchronisation of this kind is important for a dual-laser system where beam

separation of the X and Y beams within a scan swathes (A and B) is determined
optically by the spinner, but swathe separation is determined by traverse veloc-
ity. Any differences between optical and traverse scanning affects expose den-
sity and may give a raster defect. Synchronising should ensure that the distance
at P matches the distance at Q. This principle of operation, when applied in prac-
tice, produces scan lines that are effectively at equidistance.
4.2.3.3 Traverse Diagnostics

Traverse diagnostics, controlled from the Traverse PCB, check that the motor,
power drive and linear encoder are connected and operating. There are also
diagnostic commands to move the traverse in small incremental steps.
Traverse encoding is constantly monitored by the board MPU while the motor is
enabled. To avoid the possibility of damage to the system, the traverse registers
in the PM controller are checked as a background task to ensure that:
the scanning speed is within a specified range
a new traverse position count has not deviated
the linear encoder is sending valid codes and is working within its specifica-
tions.
Other periodic and initialisation traverse checks are for:
Home and Index sensor operation
obstructions along the length of the track.
4.2.4 Traverse Initialisation Sequence

The board MPU runs a sequence of check routines to initialise the traverse sys-
tem, after a reset or power up, in the following way:
1. Checks that a linear encoder is connected to the Traverse PCB.
2. If connected, then runs the on-board diagnostics.
A) Checks for encoder alignment errors.
B) Checks for the type of digital encoder and initialises the controller device
accordingly.
3. Checks the status of the HOME signal to determine if the carriage is in the
Home region.
4. Sets up the PM controller to move in the appropriate direction.
5. Start the carriage movement in the direction set at step 4. above.
6. Stops carriage movement when a HOME signal is received; also, guards
against the signal being stuck at `0'.
7. Resets the traverse position counter to `0'.
8. Checks the INDEX signal is set to the correct value and guards against the
signal being stuck at `0'.
9. Loads the traverse position counter with an offset to complete the traverse
initialisation.
10. Starts the spinner.
11. Checks that the spinner is rotating correctly and starts plate handling.
4.3 Edge Detect System Description

CAUTION: The laser diode is a Class IIIB device. Follow the warning notices in Volume 1
Section 3.2.
4.3.1 Module Assemblies

See Figure 4.9.
The Edge Detect module consists of the following assemblies:
Edge Detect PCB: see Figure 4.10.
Rear Traverse Bracket: see Figure 4.9
Laser Diode: wavelength at 405 nm with a mounting that allows for focus
adjusting.
REAR
BRACKET LASER
FRONT LASER LED
BRACKET
BRACKET
PCB
PCB
BRACKET
TRAVERSE
BAFFLE
Figure 4.9 Edge Detect assemblies
4.3.1.1 Edge Detect PCB

See Figure 4.10.
Connectors
PL1: To STB fan power.
PL2: To STB
PL3: To laser diode.
See Volume 2 Section 9.5 for a description of the cable interconnections.
PL1 PL2 PL3 LED
TP2
LASER
TP4
(GND)
VR1
Figure 4.10 Edge Detect PCB
4.3.2 Operation
Plate edge detection is fitted on all Luxel variants other than the fully-automatic
punch machine. Effectively, it is an electronic method for determining the start
of imaging position from the plate edge inside the drum without the need to
mechanically center the plate. A plate is loaded and its edge detected by a laser
diode light pointing towards the drum. As the traverse moves towards the
plate, any change of reflected light is sensed by a phototransistor receiver which
detects the difference between the drum surface (scattered light) and the plate
surface (specular light). This method takes advantage of very precise traverse
measurement system for positioning the imaging beam along the slow scan axis.
An LED, viewed from the service end, indicates when the laser light is on the
plate (LED OFF) and on the drum (LED ON).
NOTE: Accurate detection is dependent on the correct set up and alignment of laser and
phototransistor. See Volume 3 Section 3.3.9.
The sequence for detection operates as follows (see Figure 4.11):

1. A plate is loaded and makes contact with the two registration pins where
continuity is checked to ensure the plate is not skewed.
2. The traverse starts moving from user to service end, and the laser is
switched ON.
3. When the plate edge is detected, the laser is switched off and the STB soft-
ware is informed.
4. The traverse moves a number of steps set by NVRAM parameter.
5. Imaging starts.
2
5
3 4
IMAGE
PLATE
DRUM
Figure 4.11 Edge detect operation

Volume-Chapt er
MEDIA EXPOSE MODULES

This chapter describes the optics system and the function of each main module.
4
4
Media Expose System ................................................................................................ 5-1
Media Expose Control and Operation ....................................................................5-29
5.1 Media Expose System

Media expose for all the Luxel CTP systems are based on a laser diode module
generating light in the violet spectrum at 405 nm. Beams from two diodes, or
pens, are combined using polarisation to provide a single emission. There is an
option of one of a single- or dual-laser systems with an upgrade path between
the two configurations.
The media expose system consists of three main modules:
Optics Base - includes laser modules, optics modules (EOD, etc) and the
EODHV - see Section 5.1.1.
Periscope and Spinner - see Section 5.1.3.
Violet Boxer Optics Motor Board (VBOMB) - see Section 5.1.6.
An outline introduction of how the Violet Luxel expose system, and its main
PCB modules, function is given in Volume 1 Section 2.4.
The Violet media expose system is able to operate under two lighting condi-
tions:
1. Yellow safelight for Manual and Semi-Automatic machines - the plates are
unpacked and exposed within a set time period.
2. Office lighting for Automatic machines - the plates are fed into a light-tight
cassette and machine.
5.1.1 Optics Base Modules

The base assembly, shown in Figure 5.2, is accurately mounted on the Engine
frame and drum casting to ensure that a collimated beam exits at a pre-deter-
mined position. It is not designed to be field replaceable - so it is important
not to remove or adjust the location of the base unit.
L6 SPINNER
M2
FOCUS
SM4 LASER SM2 ADJUST
POWER
S6 DETECTOR
S3 POD BEAM
L3 SPLITTER L9 M3
APERTURE POD
M1 L5 L4 L3 L2 S2 LASER
VOLUME 2 (5-2) M EDIA E XPOSE M ODULES
BEAM DUMP L1
S4 S5 CONVERTER
SM3
S1 SM1
APERTURE CONTROL
ND WEDGE
FILTER
EOD X
BEAM
BEAM COMBINER
SHIFTER
LASER MODULE (X)
EOD Y
Figure 5.1 Optics base - block view (2-beam)

M3
WAVEPLATE
LASER TEMP/HUMIDITY
LASER MODULE (Y)
SENSOR
POD
APERTURE GUIDE BEAM FOCUS BEAM
L5 CONTROL SLOT CONVERTER SM3 ADJUST SM2 SPLITTER L9 M3 L1
POD APERTURE
ND WEDGE
BEAM FILTER
SHIFTER
EOD (X)
BEAM
LASER COMBINER
MODULE
(X)
SM1
*
EOD (Y)
PHOTO DIODE
TEMP/HUMIDITY PCB
MODULE ELANTEC
PCB
Figure 5.2 Optics base - module locations

EODHV
FAN
PCB
LASER MODULE (Y) WAVEPLATE M3
VBOMB
* WAVEPLATE IS
OPTIONALLY FITTED
The base is divided into three separate working enclosures:

1. Laser Diodes and VBOMB: single or two laser diode modules, each with
Photo Diode (PD) and Laser Diode (LD) head boards. Image data, drive con-
trol, temperature and power control are provided by the VBOMB PCB
housed underneath.
2. Optics Modules: a set of beam processing devices between the laser diode
and the base exit lens, L5.
3. EODHV: supplies the deflected high voltage inputs to the two EODs.
Modules are mounted on a baseplate made from cast aluminium with pads and
dowel pin fixing points that precisely locate them for accurate beam alignment.
The base consists of three enclosures, each with its own removable cover. To pre-
vent dust contamination inside the base, it is important that these covers are not
removed unless a module replacement is required. When a cover is replaced,
make sure all foam rings and seals inside the base are not disturbed.
The following optics base modules are fitted as FRUs (Field Replaceable Units):
1. Laser Module
2. EOD
3. POD
4. ND Wedge Filter
5. Motors (SM1, SM2, SM3 and SM4)
6. Sensors (S1, S2, S3, S5 and S6)
Remaining assemblies (beam combiner, lenses, mirrors, etc) on the base are not
field replaceable.
Each optic module on the beam path is accurately aligned during manufacture.
If an optics module is replaced, it is usually necessary to run an optics_mmi
setup procedure from Diagnostics to ensure that the new working part is cor-
rectly integrated into the expose system. See Volume 3 Section 4.4.
After replacement, follow the recommended steps so that overall expose calibra-
tion is correct and within product specifications.
Software control routines for base modules are run during the main operating
stages for power on initialisation, expose setup, pre-scan and scanning.
Resolutions operated by the Violet expose system are listed in Table 5.1.
Table 5.1 Luxel CTP VIolet resolutions

Dots per Inch D/mm
1200 47.2
1219 48
1800 70.9
1828 72
2400 94.5
Table 5.1 Luxel CTP VIolet resolutions

Dots per Inch D/mm
2438 96
2540 100
3657 144
5.1.1.1 Laser Module

WARNING: Once the covers are removed on the Luxel platesetter, radiated laser beams
are classified as Class IIIB. With the covers in place, the laser operates as a Class1
source. Class IIIB lasers can only be serviced by engineers that have undergone a Laser
Eye Test. Read all product laser Safety Notices before servicing laser equipment.
Laser Module Assemblies

See Figure 5.3.
A Luxel system is configured as either:
A) Single beam: using laser diodes LD3 (Y) only; there are two versions:
upgradeable to dual-beam and non-upgradeable.
B) Dual beam: using laser diodes LD1 (X) and LD3 (Y).
The module is field replaceable.
The Violet laser module comprises:
Photo Diode (PD) PCB
Laser Diode (LD) PCB
Diode pen
Beam correction lenses.
The two laser modules (X and Y) are interchangeable. Each module is supplied
with the two PCBs, Photo Diode and Laser Diode, already fitted. Control of
laser output is from an Enable signal that is switched on when the system is
scanning, and off when not scanning.
The laser diode is directly modulated by image data from the VBOMB. Drive is
provided for bias and data switching via the Laser Diode PCB. Laser power is
measured from the LPD in order to achieve balance between the two beams.
Laser Input
The laser diode is driven by two current levels, bias and modulated drive data,
shown in Figure 5.4. The addition of bias and drive current gives an output of
approximately 25 mW. The power balance control from Phote Diode feedback
vary the current slightly from the 30 mW setting.
A separate Enable signal, set from the VBOMB control circuitry, serves as a laser
shutter to halt beam emission.
LASER VIEW ON
BLOCK ARROW A PELTIER
LASER DIODE
ELANTEC
PCB PCB
THERMISTOR
PHOTO DIODE
PCB PCB COVER
F60 LENS
ASSEMBLY A
CYL 22 LENS
ASSEMBLY
CYL 60 LENS
ASSEMBLY
LASER DIODE
PHOTO DIODE
DISTRIBUTION
PCB
PCB
MOUNTING
PLATE
LASER COVER
Figure 5.3 Laser module - general view

30 mW O/P POWER
DRIVE
CURRENT
(SWITCHED BY
IMAGE DATA)
BIAS
CURRENT
IMAGE DATA FLOW
A)
IMAGE
DATA FEEDBACK
BIAS
AND
DRIVE
CURRENT
ONE FULL SPINNER REVOLUTION

B)
Figure 5.4 Image and data input current
Laser Output
Beam divergence is corrected by two cylinder lenses: CYL22 for fast axis and
CYL60 for slow axis. Correction by these lenses are to compensate for ellipticity
and astigmatism. The initial beam from the diode is 3 mm x 1 mm which uses
the lens, LF60, to set a focus for the other two compensation lenses.
The final output from the module is a circular, collimated beam (1 mm x 1 mm)
at approximately 25 mW with a wavelength of 400-410 nm. The beam is also
modulated by image data sent from the VBOMB.
The laser module driver operates in constant power mode using feedback data
from the Photo Diode. As the diode ages over time, current is increased gradu-
ally to compensate for the loss of power.
Laser Setup and Diagnostics

The supplied module is set up and calibrated at the factory before shipment.
After a field replacement, the laser module must be set up again using the pro-
cedure in Volume 3 Section 4.4 onwards.
A set of diagnostic checks that apply to the laser module are described in
Table 5.2. See also Volume 2 Section 1.10.4.1.
Table 5.2 Laser diagnostic checks

Diagnostic Description
Power Balance Balancing of the two beams from the LPD using a defined ND value.
Check EODD OK Checks if the interlocks are closed for scanning.

X/Y Beam Enable/Disable Switches beams on and off
Le(enable) Enable X and Y lasers with parameters for bias and drive levels for each
resolution.
Ld(isable) Disable X and Y lasers

Laser Calibration Check Checks drive level and remaining life for X and Y lasers
LPD Power v ND Pos Characterises LPD power readings against ND position.
Laser Temperature Control

See Volume 1 Section B.2 for a description of laser condensation control.
Temperature control around the diode is set by:
Two thermistor sensors (laser base and block) send temperature data to the
VBOMB where it is used to modify Peltier temperature and provide a pro-
tection limit reading for the laser enable circuit.
A Peltier holds the internal diode temperature at 25 C.
Note that the fan is for cooling the VBOMB and not the laser modules.
5.1.1.2 Photo Diode (PD) PCB

See Figure 5.3.
This PCB is located on top of the laser module.
Connectors
PL1: 20-way header to VBOMB.
Links and Test Points
There are no links or test points.
Operation
See Figure 5.5.
A beam splitter on the output of the laser diode reflects a small percentage of the
laser light onto a photo detect diode. It is measured once per spinner revolution
and while the scanning beam is focused on the imaging area data is passed to
the VBOMB to regulate laser power for beam balancing.
Power supply to the PCB +15/-15 VDC.
The PD PCB is replaced as part of a new laser diode module.
CAUTION: Do not remove the PD PCB from the laser module.
5.1.1.3 Laser Diode (LD) PCB

See Figure 5.3.
This PCB (includes an Elantec VLD device) is located at the back of the laser
module.
Connectors
PL1: 20-way header to VBOMB
Operation
See Figure 5.5.
This PCB supplies the drive current for the laser bias and switched data levels
from the VBOMB. This drive is adjustable and is set by two separate VBOMB
signals.
Power supply to the PCB is +5 VDC and 7.5 VDC. These supplies are regulated
from the +15 V output on the VBOMB.
The LD PCB is replaced as part of a new laser diode module.
5.1.1.4 Laser Air Temperature and Humidity Control

A temperature and humidity module, located close to the laser module(s), mon-
itors surrounding air inside the enclosure to prevent condensation on the laser
block when the dew point level is raised.
Volume 1 Section B.2.1 describes the operation of the module and Volume 1 Sec-
tion 2.3 describes how it is replaced.
VOLUME 2 (5-10) M EDIA EXPOSE M ODULES
LASER POWER SENS
LASER
ASSEMBLY
PHOTO DIODE
PCB
PELTIER FAST SLOW APERTURE

AXIS AXIS (1.5 mm)
1 mm x 1 mm
DIODE BEAM LF60 CYL22 CYL60
THERMISTOR
SPLITTER
LASER DIODE PCB

ENABLE
TEMP
SENS
IMAGE
DATA IN
DATA DRIVE BIAS

LEVEL LEVEL
CURRENT CONTROL
CURRENT LIMIT
TEMP OVER
CONTROL TEMP LIMIT CURRENT/
PELTIER & THERMISTOR OVER &
NOW GO VIA UNDER
PHOTO DIODE PCB TEMP/
OVER
POWER POWER
CONTROL
PROTECTION
VBOMB
Figure 5.5 Laser diode - beam control
5.1.1.5 Beam Shifter

See Figure 5.2.
This module compensates for position errors as the two beams arrive at the
beam combiner. It consists of a plane parallel plate tilted at 10 and rotated as a
factory setting to change the beam position. The beam shifter is not always
required on all machines.
The beam shifter assembly is not field replaceable.
5.1.1.6 Waveplate
See Figure 5.2.
A waveplate, located in front of EOD Y, rotates the beam polarisation plane by
90. Some machines may optionally have a waveplate for EOD X.
The waveplate is not a field replaceable unit.
5.1.1.7 Electro-Optic Deflector (EOD)

See Figure 5.6.
Two EODs (X and Y) deflect the beams (X and Y) to compensate for spinner
rotation. Both modules use high voltage drive provided by the EODHV board:
EOD X: sine deflector.
EOD Y: cosine deflector.
EOD sine and cosine data are transmitted after addressing the deflector LUTs
for each spinner revolution. During an expose, the EOD deflecting voltage lev-
els are dynamically updated from the EODD.
CONNECTOR
WAVEPLATE
ALLEN CAPHEAD
BASEPLATE
Figure 5.6 EOD module - general view
Beam deflection is necessary for correctly aligning beam swathes on a plate and
for preventing beam cross-over caused by the circulating motion of the spinner
mirror.
WARNING: The cable connections from the EODHV driver to the EOD generate up to
2 Kvolts (pk-to-pk) and are potentially dangerous when the system is switched on with
the interlocks overridden.
The EOD module is field replaceable.
5.1.1.8 Beam Combiner

See Figure 5.2.
The main purpose of the beam combining prism is to merge deflected beams X
and Y onto the same optical axis. It consists of one polarising prism appropri-
ately positioned and angled so that the deflected beams are reflected onto the
correct axis. Special optical coatings on each plate ensure that the optical power
emerging from the module is nominally the same for each beam.
This module is specially adjusted at the factory and is not field replaceable.
5.1.1.9 Neutral Density (ND) Filter

See Figure 5-5.7.
A variable ND filter, attached to a wheel, filters the intensity (illumination) of
the light beams to ensure that the correct exposure setting can be obtained. The
positions of the wheel, in steps from a Home reference point, are derived during
the expose calibration.
NOTE: The ND wedge must be cleaned with IPA.
The ND filter assembly includes a sensor (S1), which detects the Home position,
and a stepper motor (SM1) that drives the wheel in `N' number of steps from the
home position. An increasing number of steps from home gives increasing
intensity in the light beams. Fine adjustment of laser power intensity is usually
controlled at the laser module.
The SM1 motor and sensor (S1) is a field replaceable unit. After replacing the
motor or sensor, run the `ND_char' utility to setup a characterisation table of the
LPD readings against the ND setting required for exposure calibration.
The ND filter assembly is field replaceable.
SENSOR (S1)
SENSOR
STAY BRACKET
MOTOR
BRACKET
ND FILTER
FILTER
WHEEL
MOTOR
(SM1)
Figure 5.7 ND filter assembly - general view
5.1.1.10 Position Detector (POD)

See Figure 5.2.
The main function of the POD board is to ensure that the two beams are co-inci-
dental (aligned) within a margin of tolerance. This is done by measuring the rel-
ative position of each beam and providing compensatory offsets (change of DC
bias voltages) using the EODs. Coincidence on the POD does not necessarily
give coincidence on the drum. So, during an expose, further X and Y offsets are
added to the LUT values for adjusting the two coincidence settings. Periodically,
beam coincidence checks and adjustment routines are made via the detector
when the system is in non-scan mode.
To ensure correct measurements, the detector is accurately mounted (in relation
to the beam axis) on a PCB and a mechanical holder. It is also pre-aligned at the
factory before it is fitted in the optics base.
A POD beam splitter of wedged glass reflects a small part of the combined beam
back to the POD via L9 lens used for focusing the reflection and an aperture to
prevent any secondary reflections.
The POD is a field replaceable unit.
5.1.1.11 Focus Adjust

See Figure 5.8.
A focus adjust lens moves backwards and forwards to give a fine focus adjust-
ment for correcting small tolerance errors on the drum and different plate thick-
nesses.
The lens is driven from a stepper motor (SM2) that moves in a number of steps
depending on the thickness of the plates.
SM2 drives a wheel that rotates 360 and also moves lens (L2) laterally along a
pivotal axis in a leadscrew-type movement. One sensor (S3) is activated when
the wheel approaches one end of the axis (Home), and another rotational sensor
(S2) activates for a period during each 360 rotation.
Note the focus difference between the green optics and the violet optics:
Green: 1 step at focus (for 96 resolution) represents 0.345 m on the plate.
Violet: 1 step at focus (for 96 resolution) represents 3.75 m on the plate.
The focus adjust is not a field replaceable unit but it can be removed from the
base plate provided it is accurately re-positioned against the dowels.
SENSOR
(S2)
L2 LENS
LENS BRACKET
SENSOR
(S3)
MOTOR BRACKET
BEARING
LEAD SCREW
HOOK FLANGE
BEARING
MOTOR
OPTICS
BASEPLATE
SPRING
POST CLAMPING
PLATE
SHAFT
FOCUS
BASEPLATE
Figure 5.8 Focus adjust - general view

5.1.1.12 Aperture Control (Spot Size)

See Figure 5.9.
An aperture control changes position according to the resolution (144, 100, 96,
72, 48 l/mm) selected and so changes the spot size on the plate. At the 96 l/mm
resolution, near to lens (L2), the beams provide the smallest spot size for the
drum; as the mechanism moves towards lens L5 (using a pulley mechanism),
the beam is clipped to provide 72 l/mm. The aperture is removed from the light
path for the 96 and 48 resolutions and travels into position for 72 l/mm using a
mechanical groove.
SLIDE
APERTURE APERTURE
ASSEMBLY
BRACKET
BEARING
BRACKET BEARING
CLAMPING
PLATE
L5 LENS ASSEMBLY
(SEE NOTE)
APERTURE
SLIDE
BEAM CONVERTER
TIMING BRACKET
PULLEY
BARREL
FIXING
BARREL
SCREW
SPRING
SENSOR
(S5) BARREL
ASSEMBL
BELT
GUIDE SHAFT
MOTOR (SM3)
PIVOT L3 V-BLOCK
SHAFT
Figure 5.9 Aperture control (and beam converter) - general view
At 48 l/mm, the aperture mechanism moves back to lens (past the 96 l/mm
position) and mechanically pushes a beam converter mechanism into position.
This mechanism, which is on a pivot, maintains beam power by locating lens
(L3-48). The three possible resolutions are shown in Table 5.3.
Table 5.3 Aperture control settings

Resolution Spot Size (Approx) Converter State
48 25.4 - 31.8 Barrel Lens IN, Aperture Out of Way

72 16.6 - 20.8 Barrel Lens OUT, Aperture Clips Beam
96 <14 Barrel lens OUT, Aperture Out of Way
Stepper motor (SM3) controls the position of the resolution changing aperture
and the operation of the beam converter. Sensor (S5) prevents the motor being
driven beyond a certain point.
The aperture control module is not a field replaceable unit and can be removed
from the base plate.
5.1.1.13 Optics Lenses

See Figure 5.2 showing the location of each lens.
Optics base lenses are not field replaceable and do not require cleaning as a
service procedure. They function as follows:
Lens (L1)
Laser beam single lens used for focusing and collimating.
Lens (L2)
A single lens used for focusing and collimating.
Lens (L3)
L3-48 fixed in a barrel sets the 48 resolution from the beam converter mecha-
nism.
Collimating Lens (L5)
A collimating lens mounted at the entrance of the periscope to ensure that the
light travelling through the periscope and along the drum axis does not diverge
or converge.
Focusing Lens (L6)
This lens is located on the traverse carriage and focuses the beams onto the
drum surface via the spinner mirror. Lens L6 is only cleaned by the service engi-
neer and not the customer. Once fitted on an installed machine it must not be
adjusted.
Lens (L9)
Focus lens for the reflected beam on the POD.
5.1.1.14 Optics Mirrors

See Figure 5.2 showing the location of each mirror.
Mirror (M3 - A to C)
Three mirrors (A, B and C) deflect laser beams through an arrangement of optics
sub-modules inside the base. The mirrors are aligned at manufacture to avoid
reflective errors, and are also fixed to ensure that the two beams are parallel and
at the same height to minimise errors. Any small angular error on a mirror will
cause a much larger output error from the optics base.
See Section 5.1.3 for locations of M1 and M2 mirrors on the periscope.
Optics mirrors are not field replaceable.
5.1.1.15 Motors and Sensors

The following motors and sensors are fitted:
ND Filter: SM1 and S2.
Focus Adjuster: SM2 and S2/S3.
Aperture Control: SM3 and S5.
Laser Power Detector: SM4 and S6.
All motors and sensors are field replaceable, but only some of the motors
require a setup procedure after being replaced.
5.1.1.16 EODHV Module

Figure 5.2 shows the location of the module inside the optics base.
The EODHV module provides the high voltage DC bias and AC drive for the
electro-optic deflectors. The module consists of:
PCB: see the EODHV PCB section below
Transformers: see the HV Transformer section below.
EODHV PCB
See Figure 5.10.
The assembly includes a high voltage DC-DC converter that supplies the fixed
HT bias voltage. Push-pull amplifiers to drive the transformers are fixed to the
X and Y heatsinks.
DC - DC
PL1 CONVERTER PL2
X-BLACK Y-BLACK
PL3 PL4
X-BROWN Y-BROWN
TP1
TP7
TP4
X Y
AMP PL5 PL6 AMP
TP8
X-VIOLET
Y-YELLOW
X-YELLOW Y-VIOLET
PL7 PL8
LK1 PL9
TP10
1 2 3
OFF ON
TP11
TP12
Figure 5.10 EODHV PCB - layout view
Connectors
PL1: Push connector (black ident). X-channel HT supply.
PL2: Push on connector (black ident). Y-channel HT supply.
PL3: Push on connector (brown ident). X-channel HT supply.
PL4: Push on connector (brown ident). Y-channel HT supply.
PL5: Push on connector (violet wire). AC Modulation for X-channel.
PL6: Push on connector (yellow wire). AC Modulation for Y-channel.

PL7: Push on connector (yellow wire). AC Modulation for X-channel.
PL8: Push on connector (violet wire). AC Modulation for Y-channel.
PL9: 10-W Molex Minifit. Connection to EODD.
See Section 8.1.4 for details of the connector and signal descriptions from the
EODD and the EODHV PCB.
Test Points
TP1: 12 VDC; TP4: X input (EODD); TP7: Y input (EODD); TP8: Y modulation; TP9:
24 VDC; TP10: X modulation; TP11:2 4 V GND; TP12: HV OK for both channels
(active low).
Links
See Figure 5.10 (the default setting is ON).
1-2: HT OFF
2-3: HT ON.
HV Transformer
See Figure 5.11.
Two toroidal step-up transformers, located below the EODHV PCB, supply the
high voltage AC component of the drive to the EODs. Each TX has a single pri-
mary input and two secondary outputs; resistance for the secondary windings
are approximately 140 ohms.
The push-on connectors are colour-coded so that the wire colour corresponds to
the silk-screened legend on the PCB.
WHITE
TO EOD
(X OR Y)
(BLUE TO RED SPOT)
BLACK SLEEVE
BLACK BROWN
(PUSH ON)
(HT) (HT)
TRANSFORMER
VIOLET/YELLOW (PRIMARY)
Figure 5.11 EODHV transformer assemblies

Transformer - Secondary Resistance Check

See Figure 5.11.
To check the two secondary windings on a transformer, use a DVM (on ohms
setting) and measure the following:
Black wire to Pin 1 of EOD connector (pin next to red spot): 140 ohms
(approximately) is the correct reading.
Brown wire to Pin 2 of EOD connector (away from red spot): 140 ohms
(approximately) is the correct reading.
5.1.2 Optics System Configurations

The optics system is fitted as two versions:
1. Two-beam: this system uses lasers (X and Y) and all the modules shown in Fig
Figure 5.2.
2. One-beam: this uses a single laser and has the following modules removed:
A) Laser diode (X)
B) EOD (X and Y)
C) Beam Combiner.
NOTE: Note that the setup procedures for the one-beam system are not the same for a
two-beam system.
A base that does not have a beam combiner fitted is non-upgradeable in the
field.
5.1.3 Periscope Assemblies and Operation

See Figure 5.12.
A periscope arrangement redirects beams from the optics base to the spinner. It
is not a single assembly but functions as three sub-assemblies:
M1: (optics base end) - see Section 5.1.3.1.
Laser Power Detector (LPD): see Section 5.1.3.2.
M2: (spinner end) - see Section 5.1.3.3.
A removable cover between the two mirrors protects the LPD sensor from dust
and prevents small changes of air temperature from affecting the beam.
LASER POWER
DETECTOR M1
M2 ASSEMBLY (SEE FIGURE 10.19) ASSEMBLY
OPTICAL
BEAM
Figure 5.12 Periscope assemblies - general view
5.1.3.1 Top Mirror (M1) Assembly

This mirror directs the beams through the periscope towards mirror (M2). It is
setup at the factory and is not field replaceable.
5.1.3.2 Laser Power Detector (LPD) Assembly

A laser power detector assembly, located between M1 and M2, rotates a concen-
trating lens to focus the beams onto a large area detector. It includes a motor
(SM4) and a sensor (S6). While the system is not scanning, the laser is switched
on and average beam power for X and Y beams are measured. The purpose of
these measurements are:
Beam balance: any power difference between the two beams is equalised by
adjusting the laser current drive for the stronger beam to match the weaker
beam.
Operation: each beam is checked for correct operation as a diagnostic proce-
dure.
The LPD also acts as a shutter when closed inline with the beam. It includes a
manual safety shutter allowing the engineer to investigate a problem inside the
drum while the optics system is active.
The limit sensor (S6) detects when the LPD mechanism has reached its Home
position. The motor has a 3:1 gear reduction to give finer control over the posi-
tion of the sensor.
NOTE: On current production machines, the LPD board is isolated from chassis ground
by a gasket mask in order to ensure accurate readings.
The LPD motor, PCB and sensors are field replaceable units.
SENSOR
(S6)
LENS AND
LENS FILTER MOUNT
SUPPORT
FILTER
CLIP
MANUAL
SHUTTER
DETECTOR
PCB
POWER
LENS
ND FILTER AND
'O' RING
PULLEY
MOTOR SHAFT
MOTOR
TIMING (SM4)
SUPPORT
PULLEY
Figure 5.13 Laser Power Detector assembly - general view
5.1.3.3 Bottom Mirror (M2) Assembly

This mirror assembly is set at the factory for coarse and fine optical alignments.
Coarse settings are not field-adjustable; fine settings may be adjusted to correct
for errors (after, for instance, replacing a spinner) if the registration checks indi-
cate a problem. See Section 4.7.2.1 for information about the registration (image
form) correction procedure.
M2 BRACKET
ADJUSTING
SCREW
M2
MIRROR
ADJUSTING HOUSING
SCREW
Figure 5.14 M2 Mirror assembly - general view
See Section 4.7.2.1 for a description on how to adjust M2 for correcting image
form errors.
5.1.4 Spinner Assembly and Operation

WARNING: If the interlocks are overridden when the end panels are removed, make sure
the spinner is not rotating during a service procedure.
The spinner currently specified comprises a mirror, shaft, body, motor, encoder
and cables.
NOTE: The spinner mirror is metal-based with a special reflection-enhancing coating.

Always use the cleaning procedure described in Volume 3 Section 1.5.1..
A single facet mirror, angled at approximately 47.5, rotates at the following

speeds to reflect light to the plate surface from the periscope:
10,000 rpm idle speed.
33,333 rpm (556 Hz) for 48 and 47.2 (1200 dpi):
4 Operates at a slower speed in order to get sufficient power to image.
4 Use diagnostics command: Spinner> start 33.

40,000 rpm (667 Hz) for all other resolutions.
Acceleration from rest to full speed is less than 20 seconds, and from idle speed
to full speed approximately 10 seconds. The carriage only traverses when the
spinner is stationary or at full speed.
CO
SIGNALS
MOTOR DRIVE
SIGNALS
MIRROR
SURFACE
LASER
BEAM
DEFLECTED
LASER
BEAM SPINNER ENCODER
MOTOR
Figure 5.15 Spinner assembly
The assembly consists of a shaft supported on air bearings and rotated by a

brushless DC motor. The bearing air supply is internally generated by the
motor. Spin speed is at all rates with drive current supplied from 36 VDC. Spin
direction is always anti-clockwise (looking from the mirror end).
At one end of the shaft an incremental encoder, operating from a 5 V supply,
generates the following signals for System Board image data control:
rotational frequency (SPIN INDEX) at one per revolution
angular position data (DATA A) with a resolution of 720 lines per revolu-
tion.
Three Hall effect sensors are located in the spinner. When the spinner acceler-
ates, these sensor signals (with 120 timing) indicate the rotor position; they are
decoded by the spinner controller to commutate the drive currents to the correct
switching sequence. In a steady state, commutation operates internally without
the need for sensor signals.
The spinner has two cable interface connections:
spinner motor signals (12-pin Molex)
spinner encoder signals (8-pin Molex).
This assembly is a field replaceable unit and includes a cleaning procedure for
the mirror.
A replaced spinner assembly must be returned to FFEI Customer Support (UK).
5.1.5 Fast Photo Detect (FPD)

See Figure 5.16.
An FPD sensor (BS21), located behind the drum (service end, input side), has
two functions:
1. Compares the power at the drum to the power at the LPD to determine the
extent of contamination.
2. Measures laser power during exposure calibration to set the requested level
at the drum.
Details of these two machine features are in the Luxel Operators Manual.
The sensor and the ND filter must be kept clean to give accurate readings.
See Volume 3 Section 4.2.9 for the full replacement and setup procedures to
ensure that the exposure calibration is accurate.
DRUM SERVICE END
INTERFACE
CONNECTOR
TO FHMB4
NEUTRAL
DENSITY
FILTER
PHOTO SENSOR
BOARD ASSEMBLY
FPD MOUNT
Figure 5.16 FPD - location view

5.1.6 Optical Motor Control PCB (VBOMB)

The VBOMB is a CAN node PCB that controls optics exposure on command
from the LSB. Volume 1 Section 2.4.3.1 describes how the VBOMB operates with
its main functions as:
channelling image data from the LSB to the laser module
controlling the optics base stepper motors
detecting the current status of the motors for Home and Limits
providing drive control circuitry for the laser module
providing laser diode temperature control
setting laser diode temperature stability.
NOTE: For early application software releases, the laser current limits must be manually
set at each service visit using the procedure in TIS 13887.
5.1.6.1 Optical Motor Control PCB Assembly

See Figure 5.17.
Location
Lower interior of the optics base, see Figure 5.2.
Connectors
PL1: 10-way. Not used.
PL3: 10-way. LPD sensor detector.
PL5: 14-way. POD sensor.
PL8: 5-way. Envir I/P from laser temperature/humidity PCB.
PL9: 40-way. Laser (X).
PL10: 40-way. laser (Y).
PL11: 10-way Molex minifit. +5V, +15V, +24V and -15V DC supplies from the PWR
FILTER PCB.
PL12: 3-way. Fan.
PL13: 24-way. Motor sensor inputs.
PL14: 6-way. ND Filter motor drive.
PL15: 6-way. LPD motor drive.
PL16: 6-way. Aperture control motor drive.
PL17: 6-way. Focus motor drive.
SK1: 8-way. Image data
SK2: 15-way. CAN1.

The cable connections to the VBOMB PCB are described in Figure 9-9.3, show-
ing the system interconnections, and Appendix A listing the pin signals.
PL8
PL5 PL3
PL9
(x)
PL12 PL10
TP6
(y) +15V
PL13
FRONT VIEW
SK1
PL11
FS1
PL14
LK1
PL15
PL1
PL16
TP1
+5V
PL17
PL18
PL2
SK2 LK2
PL7
Figure 5.17 Optics Motor Control PCB (VBOMB) layout
Fuses
FS1: 3A slow-blow (97280015).
Links
LK1: Link is removed.
LK2: Link is removed.
5.1.7 Optics Base Cabling

Figure 5.18 shows the cabling between the optics base modules and the
VBOMB. These cables are carefully routed and tied as looms and should not be
disturbed. If a cable replacement is required, make sure there is a minimum of
alteration to the loom routing.
LD PCB LASER (x) LD1
VBOMB_IHPEN
LD PCB PD
LASER (y) LD3
VBOMB_IHPEN
LD PCB PD
RFI BOX
LSB VBOMB_LPD
PL9 PL10 PL3

CAN1 VBOMB_LPDM HOME
SK2 PL15
S6
LPD
ND FILTER
LSB_DATA VBOMB_NDM HOME
SK1 PL14
S1
VBOMB
APERTURE
POWER VBOMB_PWR VBOMB_ADM HOME
FILTER PL11 PL16
S5
FOCUS S3
VBOMB_FOCM HOME
PL5 PL17
VBOMB_POD FOCUS
PL8 PL12 LIMIT
PL13 S2
VBOMB_
POD ENVIR_ VBOMB_SENSORS
MON
TEMP/ VBOMB_FAN FAN

HUMIDITY (VBOMB)
MODULE
Figure 5.18 VBOMB cable interconnections

5.2 Media Expose Control and Operation

5.2.1 Expose Sequence
The following operations are performed during an expose operation:
Load a plate into the drum.
Start up the spinner.
Close the LPD to prevent exposing the plate.
Switch on the lasers in bias mode.
Perform cage creep compensation if required.
Move the traverse to the start of scan position.
Adjust the ND position to set the power level depending on resolution.
Adjust the focus position depending on plate thickness.
Adjust the aperture to set the spot size depending on resolution.
If resolution has changed, then perform power balance.
Apply sinusoidal deflection to the beams.
Open the LPD shutter.
Start the traverse.
Modulate the lasers with image data.
At end of expose, stop the traverse.
Perform cage creep compensation if required.
After a timeout, stop the spinner.
5.2.2 System Calibration

The following operations are performed every 1.5 hours if an expose job is
requested:-
4 Check power balance and adjust if required
4 Check beam_co and adjust if required.
The following operation is performed every 24 hours if an expose job is
requested:
4 Check for laser aging and adjust the laser current limits if required.
The following operation is performed on demand by the user from the MMI:
4 Check and adjust the ND settings for all 8 resolutions to give the correct
exposure calibration.
5.2.3 Expose Control Functions

See Figure 5.19.
The following expose control functions are used:
EOD deflection.
Laser aging control.
Power balance.
Beam coincidence.
Drum coincidence.
Exposure Calibration.
5.2.3.1 EOD Deflection

With no EOD deflection, the 2 beams will be on top of each other all the way
around the drum. If a static deflection is applied, the beams separate in the slow
scan direction at one point on the drum. At 90 degrees spinner rotation, the
beams are separated in the fast scan direction instead. At 180 degrees spinner
rotation, the beams cross over and separate in the slow scan direction again. To
make the beams run parallel, a compensating sinewave deflection is added to
the EODs. The X-EOD has a sinewave deflection and the Y-EOD has a cosine
wave deflection.
Static deflection is used to get co-incidence of the beams on the drum after beam
coincidence is obtained on the POD. Sinewave deflection is used to separate the
beams in the slow scan direction to get even spacing of lines. The amplitude of
the sinewaves are adjusted to get the correct spacing at all resolutions. The abso-
lute phase of the sinewaves i.e. the phase relative to the spinner index is
adjusted to maximise the deflection in the slow scan direction.
The LSB generates the deflector sinewave LUTs. This digital data is passed
down the EODD bus to the EODD board and converted into low voltage sine
and cosine waveforms using DACs. This is then passed to the EODHV board
which generates the high voltage signals required for the EOD deflectors.
5.2.3.2 Laser Aging Control

The laser has an integral photodiode detector board. This is used in a negative
feedback loop to control the laser output power in APC (Automatic Power Con-
trol) mode. The current taken by the laser diode is adjusted automatically to
give the correct power.
As the laser ages, the current required increases to give the same power output.
The laser has a current limit which is set at 10% higher than the operating cur-
rent. As the operating current increases, the current limit has to be also
increased to prevent current limiting. The laser aging control loop is executed
once every 24 hours. This checks the operating current of each laser and changes
the current limit to give a 10% margin. The rate of change of current is checked.
If this exceeds 7% in 24 hours, then a serious warning is given on the MMI that a
laser change is required urgently. When the operating current reaches 50%
higher than the original operating current when the laser was new, then a less
serious warning is given on the MMI that a laser change is required within a few
weeks.
Each time the laser current increases by 10%, an entry is added to laser statistics
tables in diagnostics. The table is capable of holding 5 pairs of data values. By
inspecting this table, the rate of laser aging can be calculated and a prediction
made of when the 50% overcurrent will occur.
SPINNER
CAN TO LUXEL
M2 STB SYSTEM
BOARD
LPD TO DRUM SURFACE
VBOMB POSITION
APERTURE FOCUS DETECTOR
M1 (POD)
PERISCOPE ND WEDGE
FILTER
VBOMB VBOMB VBOMB
OPTICS
LASER EOD BEAM
BASE
(X) (X) COMBINER
LASER EOD
(Y) (Y)
TRANSFORMERS
X/Y
PD AND LD IMAGE
DATA & PD AND LD
PCB PCB
CONTROL EODHV
DRIVE/POWER CONTROL
APERTURE
FOCUS POD TEMPERATURE/

LPD ND HUMIDITY
SENSOR BOARD
VBOMB EODD
CAN IMAGE DATA
CAN LUXEL CONTROL

STB SYSTEM
BOARD
RFI BOX
IMAGE DATA SCSI

DIAGNOSTICS
(RS232)
RIP SERVER
Figure 5.19 Expose control - top level block view

5.2.3.3 Power Balance

The purpose of power balance is to get equal powers in both beams at the drum.
The actual powers are measured at the LPD since the transmission loss is the
same for both beams between LPD and the drum.
Power balance depends on resolution. If a job is requested and if there is a reso-
lution change or if a 1.5 hour timer has expired, then power balance is checked.
If the powers are within limits, then the job is exposed. If the powers are outside
tolerance limits, then the powers are adjusted.
Power balance is achieved as follows:
Set both laser drive powers to maximum (25 mW at the output of the laser
module).
Set the optics motors to the 96 resolution position.
Check the power levels on the LPD.
For the laser with the highest power, reduce the drive power until the pow-
ers are equal.
The powers are adjusted separately for 3 different optical models. The LOW res-
olution model is for 1200 and 48 resolutions which has the drop down lens in
the beam converter (aperture mechanism) to give the largest spot size at the
drum. The MID resolution model is for 1800 and 72 resolutions which has an
aperture in the beam to give a mid size spot at the drum. The HIGH resolution
model is for 2400, 96, 100 and 144 resolutions which has no aperture to give the
smallest spot size at the drum.
5.2.3.4 Beam Coincidence

The purpose of beam coincidence (beam_co) is to get the 2 beams to be coinci-
dent (on top of each other) at the POD. The X deflector can only deflect the beam
in the X direction i.e. horizontally when viewed on the POD (assuming the
optics base is in the machine). The Y deflector can only deflect the beam in the Y
direction i.e. vertically on the POD. The result is that at coincidence, the beams
will normally not be exactly centred on the POD. The beams will be within
100 m of the POD centre for a new machine but may be up to 200 m from the
centre after optics modules are replaced in the field.
Beam-co is achieved as follows:
Adjust the powers in the X and Y beams to be 200 W on the POD.
Measure the positions of the X and Y beams on the POD (X1 and Y1 in
Figure 5.20).
Deflect both beams by a small amount.
Measure the new positions of the X and Y beams (X2 and Y2 in Figure 5.20).
The coincidence point is where the lines on the graph cross.
Calculate the deflection required to make the beams coincident.
Adjust the deflection and check the accuracy of coincidence.
If outside tolerance limits, repeat beam_co until within limits.
Update NVRAM parameters EODD_LB_X_OFFSET_FULL_POWER and
EODD_LB_Y_OFFSET_FULL_POWER in NVRAM with the new deflector
drive values.
Y2
COINCIDENCE
POINT
X
X1 X2
Y1
POD DETECTOR
Figure 5.20 POD beam_co measurements
5.2.3.5 Drum Coincidence

When the beams have been made co-incident on the POD, there may still be a
small offset between the beams at the drum. This is corrected by adding small X
and Y static offsets to the deflector drive values calculated from beam_co. The
required offsets are measured by running the Co-incidence X and Y test patterns
from the Optics MMI and the results are stored in the Final Values table.
5.2.3.6 Exposure Calibration

The purpose of Exposure Calibration is to set a constant energy density level
measured in J/cm2 at the drum. At lower resolutions, for example, 48l/mm,
since the traverse is moving more quickly than at 96l/mm, more power is
required to achieve the same energy density. The power level is measured
directly at the drum using a Fast Photo Detector (FPD).
The FPD is mounted behind the drum at the service end and a hole in the drum
allows the beam from the spinner to pass through. As the spinner rotates past
the FPD, the pulse of power is converted to a photodiode current. This is passed
to FHMB4, converted to a DC voltage level and then read by an ADC.
Exposure calibration is affected by spinner contamination or optics aging, both
of which degrade over a long period. Exposure calibration is not affected by
temperature or humidity. Therefore, exposure calibration only needs to be run
once per week or if the spinner mirror has been cleaned. Exposure calibration is
run from the MMI.
Exposure calibration works as follows:
1. Start the spinner.
2. Move the traverse to the FPD position which is defined in
TRAV_HIGH_SPEED_POS
3. Set the optics motors to 48l/mm.
4. Measure the powers in the X-beam and the Y-beam.
5. Calculate the ND adjustment required to give the correct exposure at 48 res.
6. Calculate the ND offset to give the correct exposure for 1200 res.
10. Calculate the ND offset to give the correct exposure for 1800 res.
14. Calculate the ND offsets to give the correct exposures for 2400, 100 and 144
res.
15. Store all 8 ND values into NVRAM.
Volume-Chapt er
POWER AND CONTROL

MODULES
This chapter describes the main power and control assemblies and interconnections:
4
4
Introducing Power and Control Modules ................................................................. 6-1
4
System Power Distribution ........................................................................................6-2
4
Interlock Box Modules ...............................................................................................6-6
4
RFI Box Modules ...................................................................................................... 6-16
4
RFI Box - DC Power Modules ..................................................................................6-19
4
RFI Box - Image Processing Modules ....................................................................6-23
MMI and External Alert .............................................................................................6-30
6.1 Introducing Power and Control Modules

Power and control functions for the the plate handling, optics and vacuum sub-systems
are as follows:
System Power Distribution: shows how AC and DC voltages are distributed around
the Engine, PTM and Buffer.
Interlock Box Modules: explains how the interlock and emergency stop circuits
operate.
RFI Box PCBs: describes the main control PCB for the CAN network, the electro-
deflection control PCB and the filter PCB for the DC voltages and interlock signals.
Hard Disk Drive (HDD): describes the function image disk buffer and
Man-Machine Interface (MMI): the console control interface.
External Alert: a description of a customer option for setting up a laser external alert
in the platesetter room.
6.1.1 Accessing Engine Assemblies

Power and control sub-systems are housed on the Engine with access shown in
Figure 6.1. Note that these modules have a common location for all variants.
RFI box: located at the rear of the Engine on the service side. Remove the box cover
VOLUME 2 (6-2) P OWER AND C ONTROL M ODULES
(18-off posidrive screws) to access the RFI box assemblies. Interface connectors
between the RFI box and the rest of the system are on the service side of the Engine,
accessed after removing the side cover.
Mains filter box: located on the Engine service side. The unit is a field replaceable
unit (FRU) with a cover plate that can be removed for inspection (4-off posidrive
screws). Always remove the mains power lead first before servicing the mains
filter box.
Interlock box: located on the Engine service side. This box houses FRUs and is
accessed by opening a front cover plate (2-off posidrive screws) shown in
Figure 6.4.
INTERLOCK
BOX
ACCESS TO
RFI BOX
I/F CONNECTOR
MAINS
FILTER
BOX
USER SERVICE
SIDE SIDE
POSIDRIVE RFI BOX

SCREW
(18-OFF)
Figure 6.1 Accessing the power and control assemblies (fully-automatic)
6.2 System Power Distribution

AC supply is fed directly to a mains filter box before it is routed directly to:
PSU 1 in the RFI box for generating DC voltages
PTM and Autofeeder
Vacuum pump and compressors (after relay switching).
6.2.1 AC Mains Power Pre-Requirements

Voltage supply to the platesetter must conform to the site pre-requirements given in the
Luxel Platesetter Pre-Installation Manual. A summary of these requirements are:
1. A standard build platesetter operates with:
A) 230 VAC single-phase volts 177-264 at 47-63 Hz.
B) An external pump for drum vacuum is supplied with the equipment. Mains
supply and control is a direct 230 VAC connection from the platesetter.
C) Other platesetter equipment (PAT, processor, RIP PC and plate stacker) have
separate AC supply points.
2. The site must include safety isolators and equipment circuit breakers that conform to
local regulations.
A slow-acting dedicated circuit breaker (or fuse) should be fitted to the local distri-
bution supply for the platesetter. The type of fuse protection should be within local
regulations. Recommended rating for the fuses are:
V-9600 CTP Fully-Automatic: 16 A

Vx-9600 CTP Fully-Automatic: 16 A
V-9600 CTP Manual and Semi-Automatic: 10 A
Vx-9600 CTP Manual and Semi-Automatic: 10 A
V-6000 CTP Manual and Semi-Automatic: 10 A
Vx-6000 CTP Manual and Semi-Automatic: 10A
3. A safety isolating switch must be mounted within 4 m (158 in) of the mains input
connection on the Engine. The switch should be marked ÒN' and ÒFF'.
4. A low impedance and interference-free earthing system must be provided. Earthing
requirements are:
A) The platesetter requires a dedicated system earth via a common earth point.
B) Earth circuit resistance less than 0.5 Ohm from the platesetter to common earth.
5. All platesetter equipment must be connected to the same phase if the site has a 3-
phase supply. Do not use extension cords to supply AC mains to platesetter equip-
ment.
6.2.2 Mains Filter Box

See Figure 6.1.
This unit is located on the service side underneath the interlock box. Note the warning
below:
WARNING: Always remove the mains power lead first before servicing the mains filter
box.
A mains filter box, rated at 20 A (250 VAC), protects the system electronic modules
from external glitches before supply reaches the interlaock box.
The mains filter box is replaced as a single module in the event of failure.
6.2.3 System AC/DC Cable Distribution

See also Volume 2 Chapter 2-10 for views of the AC/DC cable interconnections and
Volume 2 Section 8.1 for a description of the cable pin voltages and signals.
A single mains supply to the two PSU (1 and 2) is controlled by an ON/OFF switch on
the Engine and two emergency stop buttons on the PTM. While the emergency stop cir-
cuits are not activated, AC supply is distributed to each module from interconnecting
cables.
The PTM and Autofeeder have separate panel AC connectors that can be disconnected
to isolate supply as:
Engine-to-PTM AC supply (INT_MAINS): see Volume 2 Figure 3.72.
PTM-to-Autofeeder AC supply (MAINS_ELV_IN): see Volume 2 Figure 3.71.
Engine-to-Buffer DC supply (ENG_M7): see Volume 2 Figure 3.73.
The Processor and Plate Stacker supply have separate AC connections described in the
Luxel Platesetter Pre-Installation Manual.
6.2.4 System DC Cable Distribution

See Figure 6.2 and Figure 6.3
This section describes the DC voltages and cabling to the modules and devices (sensors,
motor, etc) from the PSU in the RFI boxes. It also shows the PCBs that generate/convert
on-board DC voltages for local use.
Distribution PCBs are employed to optimise machine cabling.
Sensor Distribution PCBs are non-active and serve as +5 VDC supply to the stand-
ard plate opto-reflective sensors
24 V Distribution PCBs include active devices to attenuate sensor outputs and chan-
nels +24 V to sensor devices that require a +24 V supply.
+24V +36V +24V +36V TRAV MOTOR
(24V_ENG) (PWR2) +36V +24V +36V
I/LOCK BOX STB
TRAVERSE SPINNER
AC (UMB)
+5v
(MAINS_RFI_IN) READHEAD
RFI BOX
FHMB4
MAINS AC +24V
IN MOTORS
+24V
+5V MOTORS
+5V +5V
SENSORS
+24V
+15V BUFFER
-15V (ENG_FHMB PWR) +24V +5V SENSOR +5V
+12V DIST AND SENSORS
(EOD) 24V DIST +24V
+24V SENSORS
+5V SENSOR +5V

+24V SENSORS
FHMB1 DIST
EODHV VBOMB +5V
+24V
+5V MOTORS
(SEE BOX)
+12V
(EOD)
+5V
2kV FHMB3
+24V SENSOR +5V
SENSORS
+5V +24V/+5V DIST
LASER +24V
EOD 1/2 +24V
SENSORS
(PWR3) 24V
+5V
DIST SENSORS
Figure 6.2 DC distribution - Engine, PTM and Buffer

LASER +24V
MOTORS
FHMB2
POD +/-15V
LPD +/-15V TO AUTOFEEDER
+5V
OPTICS BASE PTM
+5V ELEVATOR +5V

FHMB2 DISTRIBUTION
(RIB8) (ELV_LOCK)
SENSORS
+24V
Z-DIRECTION
+24V
DOCKING
LIGHT
CASSETTE
FHMB2 DOOR LOCK
(INT_OUT)
+24V
ABS LMT CONTACTOR
CONTACTOR_24V
(ELV_LOCK)
ELEVATOR
MOTOR
MOTOR
CONTROL ELEVATOR
CONTROL
+24V
INVERTER
AC AC
PTM MAINS
AUTOFEEDER
Figure 6.3 DC distribution - Autofeeder
6.3 Interlock Box Modules

WARNING: Always remove the mains power lead first before servicing the mains filter
box.
6.3.1 Interlock Box Functions

WARNING: Ensure that the platesetter is powered off but still connected to the AC mains
source to maintain Earth/Ground continuity if PCB static protection is required. Note the
WARNING below.
A mains filter box, rated at 20 A (250 VAC), protects the system electronic modules from
external glitches before supply reaches the interlock box.
This unit is replaced as an FRU in the event of failure.
The interlock box houses devices and circuits described in the following sections:
External interconnections: see Section 6.3.2.
Mains power input and emergency stop control: see Section 6.3.3.
Interlocks control: see Section 6.3.5.
Drum vacuum control.
Interconnect wiring between the interlock assemblies is shown in Figure 6.7.
6.3.2 External I/O Interconnections

See Figure 6.5.
INTERLOCK
FUSEHOLDERS
AND 3-OFF FUSES
INTERLOCK
CONTACTOR
INTERLOCK PWR 1
COMPRESSOR
MONITORING
RELAY (BV31) INTERLOCKS
MODULE
DISTRIBUTION
TERMINAL
BLOCK SHUTTER
(LASER ON/OFF)
END STOP
SURGE
SUPPRESSOR
NL N L
RAIL
PWR 3
PWR 2
PSU
(30W +24V)
POWER IN
LINKS
PSU MAINS EMERGENCY
COVER
VAC
VAC OVERCURRENT
ON/OFF SWITCH CIRCUIT BREAKER
(CIRCUIT BREAKER (8A)
24V FUSE
& RELEASE COIL) (0.5A 250V)
VAC PUMP
RELAY (BV5)
LED
DIAGNOSTICS
PUMP (2)
(MAINS TO PTM) MAINS_RFI_IN
(MAINS TO RFI BOX) COMPRESSOR BOX
MAINS_DIST (MAINS TO COMP)
(FROM MAINS FILTER) PUMP (1)
(MAINS TO VAC PUMP)
Figure 6.4 Interlock box assemblies - location view

(LASER ON/OFF)
SHUTTER
INTERLOCKS
PWR 1
PWR 3
PWR IN
PWR 2
EMERGENCY
CIRCUIT BREAKER
RESET BUTTON
VAC PUMP
(0.5A 250V)
FUSE 24V
VAC PUMP
CONTROL
Figure 6.5 Interlock box - connector layout
See also Volume 2 Chapter 2-10 for views of the interlock box cable interconnections
and Volume 2 Section 8.1 for a description of the cable pin voltages and signals.
The interlock box has an external panel with I/O connections for:
1. VAC PUMP CONTROL: input from FHMB4 controls the vacuum relay to switch
mains supply to the drum vacuum pump while the system is scanning.
2. PWR IN: input from +36 and +24 VDC supply, via the Power Filter PCB and the
laser EODD interlock control signals.
3. INTERLOCKS: input from interlock panel sensor connections to the box interlock
controls.
4. EMERGENCY: emergency stop circuit to/from the PTM via ENG_FHMBPWR.
5. PWR 1: output cable for +24 VDC to FHMB(1) via ENG_FHMBPWR.
6. PWR 2: output cable for +24 and +36 VDC to FHMB(4).

7. PWR 3: output cable for +24 VDC to FHMB(2 and 3) via ENG_FHMBPWR.
AC Power inlet and distribution is via five cable glands on the interlock box shown in
Figure 6.4.
1. MAINS_DIST: AC voltage direct from the mains filter.
2. MAINS_RFI_IN: emergency-protected AC supply to the RFI box for generating sys-
tem DC voltages.
3. PUMP (1): AC power supply for the drum vacuum pump controlled from the vac-
uum drum relay inside the interlock box.
4. PUMP (2): AC power supply for the plate feeder and elevator motor.
5. COMP_MAINS: AC power is supplied, via a relay (BV31), to the drum blow com-
pressors in the compressor box.
6.3.3 Mains Input and Emergency Stop Control

Figure 6.6 shows the circuit wiring for the mains input and emergency stop system.
6.3.3.1 Mains Input Control Assemblies

Circuit Breaker and Undervolt Detector (15A)
This is an On/Off (2-pole) rocker switch/circuit breaker for the operator that includes
under-voltage release coil (for the emergency stop circuit) and short-circuit protection.
The main circuit breaker is tripped in the event of a loss of voltage. To reconnect the
load, the switch must be reset so as to avoid the automatic restart of the machine.
24 V PSU (Emergency)
A +24 V (30 W, 1.2 A) dedicated supply for the emergency stop circuit. It includes a
selectable transformer setting for 240/110 VAC at 47-63 HZ. The AC input is protected
by fusing; there is also overvoltage protection. Output regulation is <0.1 %.
Fusing
See Section 6.5.3.
Emergency Stop Control

See Figure 6.6.
This facility is for use by the engineer or operator to power off the machine during an
emergency. The switch is fitted to the PTM (fully-automatic) and on the Engine (manual
and semi-automatic).
WARNING: AC Mains supply is still live at the interlock box when the emergency stop has
been pressed. Make sure the AC supply is removed or switched off at the mains outlet
before accessing the box.
While the system is operating normally the mains supply from the mains input filter
generates a +24 V DC supply from the +24 V PSU (Emergency). This voltage is routed
through to the emergency safety contactor coil which switches the contactor.
6 WAY
CONNECTOR
2
5 +24V
EMERGENCY
1 STOP
99700424
99700243
TERMINAL
BLOCKS 99700447 NOTE: 0455 FEEDS INTO TOP OF
TERMINAL BLOCKS.
N L
1 2 0122 FEEDS INTO BOTTOM
OF TERMINAL BLOCKS
+24
CIRCUIT VDC
BREAKER +
UNDERVOLTAGE
COIL NEUTRAL LIVE 24V GND ENG 24V_GND
SIE A2
+24V ENG 24V SIE 21NC
C/B N L (OUT)
2 4
99700444
+24V
LINKS LINKS CONNECTOR
99700455 NEUTRAL
(NOTE) WIRES SOLDERED TO PSU
LIVE
99700444 CONNECTOR
4 +OUT
A 3 1
99700444 24V DC
BV31 COMP 99700310 09700310
1 4 SUPPLY
(FHMB4) 24V RELAY
SEE 'A' (BV31) -OUT
8
B 4 6 A
VAC PUMP
24V RELAY EARTH CONNECTED TO CASE
(BV5)
99700454 7 9 B
99700424 0.5A FUSE
99700444 8-WAY
99700122 (NOTE) CONNECTOR
VAC PIN 2
CIRCUIT
BREAKER 99700456 BV5
PIN 6
(5A) (FHMB4)
CHASSIS CHASSIS CHASSIS CHASSIS
CHASSIS PIN 1
'A' PIN 4
BV31
Figure 6.6 Interlock box - mains wiring, vacuum and emergency stop control
MAINS TO MAINS TO RFI BOX MAINS TO PTM MAINS TO PUMP LIVE & NEUTRAL FROM (FHMB4)
'A' PIN 8
COMPRESSORS 99700122 99700150 (ENGINE) MAINS FILTER
99700150 99700243
While closed, the contactor routes +24 V to the circuit breaker (On/Off switch). At the
same time the circuit breaker switchs AC voltage to the drum vacuum relay, the RFI
box, the PTM and the Autofeeder.
Pressing the emergency stop button causes a +24 V undervoltage to the circuit breaker
which trips the AC supply. The drop in voltage to the circuit breaker is sensed internally
by its integral undervolt detector and causes the circuit breaker to switch off.
Supply is not restarted until the steps below are completed in the following sequence:
1. The pressed emergency stop red button is turned in a clockwise direction to its reset
position.
2. The ON/OFF circuit breaker is switched on again.
This resumes the +24 VDC supply and re-energises the emergency stop contactor.
Emergency Stop Replacements

If any component of the emergency stop circuit is replaced or altered, the stop operation
must be fully verified before the system is restored to the customer.
6.3.4 Drum Vacuum Control

See also Volume 2 Figure 7.1.
Relay
A 25 A DPDT relay at 24 V. Control is from FHMB4 that switches the relay when vac-
uum is required to conform a plate to the drum prior to a scan.
Circuit Breaker (Thermal)
This is a two-pole, 8 A breaker used to protect the drum vacuum circuit. Push in to reset
circuit breaker.
6.3.5 Interlocks Control

This section applies to all variants.
This section provides further information for the engineer to service the interlock sys-
tem. Refer to Volume 1 Section 3.3 for interlock safety warnings and Volume 1 Section
3.16 the location of the cover sensors.
See Volume 2 Chapter 2-10 for views of the interlock cable interconnections and Vol-
ume 2 Section 8.1 for a description of the cable pin voltages and signals.
See also Volume 2 Section 3.2.1 for a description of the Autofeeder interlock control cir-
cuit.
Interlock Box Assemblies

The interlock sensor system operates as a feedback loop circuit with a keyswitch (Nor-
mally Open contact) to enable the circuit. Supply voltage to the circuit is +24 V. Inter-
lock sensors (and the external laser door switch) return a signal to the safety relay
located inside the interlock box.
The main interlock assemblies are:
Sensors: interlock sensors on the platesetter and an external sensor that controls the
DLA (Designated Laser Light) for the platesetter room.

Safety relay (Schmersal AES1235): this monitors the status of the interlock sensors
and operates two microprocessor-controlled relays switch on/off drives for the:
+24 VDC supply to the two interlock contactors on the Engine and the Autofeeder.
See below for a description of the AES 1235 operation.
Contactor (Siemens 3RT1016): when energised from the safety relay 24 V supply, it
closes the following contacts:
A) +24 V to the FHMB motor drives.
B) +36 V to the spinner.
C) laser interlock status control to the EODD.
and opens the following contact:
D) +24 V to the safety relay (contactor confirm).
Since the contactor forms an inductive load it requires a separate plug-in surge sup-
pressor.
A contactor of the same type also controls the AC supply to the elevator motor. See
Volume 2 Section 3.2.1 for the Autofeeder contactor.
Fuses (F1 to F3): protect the +24V input and the interlock feed circuit. Fuse rating
is: 1 A, 250 V.
Interlock Override Keyswitch: located on the Engine. While the key is inserted it is
not possible to shut the service side cover. Setting the switch bypasses the cover
interlock sensors and the external interlock. It opens an NC contact that alerts the
LSB to indicate (on the MMI) that the interlocks are in an overridden state.
Interlock Replacements
Use the information in Section 6.3.5 above to replace an interlock assembly.
Interlock Checks
The interlock operation for the safety relay is tested by opening and closing each cover
in turn to check if the safety relay automatically operates when a cover is shut. Any
functional failures disables the circuit until the fault is fixed. To check the contactor,
open a cover and determine if power has been removed from the MMI Error Handling
screen.
Interlock Operation
See also Volume 2 Chapter 2-10 for views of the interlock cable interconnections and
The safety relay monitors inputs from the interlock sensors (covers, external interlock
and override keyswitch). If the inputs indicate a suitable state (covers closed, override
not on), then the two safety relay contacts are closed.
Contact 2: routes +24 V from the Power Filter PCB to energise the two interlock contac-
tors, one in the interlock box and the other in the Autofeeder.
Interlock Box Contactor: when energised by the +24 V from the safety relay contact
routes:
A) +24 V to the safety relay to confirm it has operated

B) +24 V to the FHMB and STB
C) +36 V to the STB
Autofeeder Contactor: when energised by the +24 V from the safety relay contact,
routes the 3-phase mains from the inverter to the elevator motor. A contactor confirm
signal is routed to FHMB2.
When the safety relay detects an unsuitable condition (cover open or external interlock
problem AND interlocks NOT overridden), the two safety relay contacts are opened.
They put the machine in a safe condition as follows:
+24 V from the Power Filter PCB to the two interlock contactors is cut off:
A) Interlock box contactor drops out and:
safety relay detects that the contactor has dropped out
+24V is not supplied to the FHMBs and STB (operator accessible motors cannot
move)
+36 V is not supplied to the STB (the spinner cannot move).
B) Autofeeder contactor drops out and:
mains supply to/from invertor to elevator motor is cut off.
In addition to the action of the safety relay, signals are sent from the cover interlocks and
the interlock override switch to the LSB. If the LSB detects an unsuitable condition it
issues an error code on the MMI.
INTERLOCK I/LOCK
BOX SHUTTER
(LASER ON/OFF)
I/LOCKS
+36V
+24V
PWR1
A1+ 13 23 A2- 22NC 6T3 4T2 2T1 51C F1A F2A F3A
A2- Y1 X1
CONTACTOR
(SIE 3RT 1016-1BB42)
SAFETY RELAY
FUSE FUSE FUSE PWR2
(AES 1235) PLUG IN SURGE (1A) (1A) (1A)
SUPPRESSOR 3RT
1916-1BB00
S13 S21 S22
S14 14 24 A1+ 21NC 5L3 3L2 1L1 52C F1B F2B F3B
PWR3
Figure 6.7 Interlock wiring - schematic view

+36GND
+36V +24V +24GND
EODD LASER IL PWR_IN

ENG 24V 24V FROM PSU
EODD LASER ILR
ENG 24V GND

24V GND FROM PSU
Safety Relay Monitor Operation (AES 1235)

The AES 1235 operates as an interlock system monitor with two independent safety cir-
cuits, each consisting of a microprocessor and a relay. All inputs to the module are mon-
itored and controlled by the device. Its main features are:
two enabling paths, both having normally open (NO) contacts in series
operating voltage of 24 V (+15 %)
short-circuit protection (FS1).
All inputs to the relay are monitored by the processors; if one of the switch contacts
monitoring the interlock sensor changes state, while the interlock remains closed, then
both safety relay circuits are disabled.
When an interlock sensor is opened the safety relay outputs are disabled. Two micro-
processors check the state of the switch inputs to determine if:
failure of the interlock switch to change state
shorting or break across the switch cable circuit cabling
failure of the safety relay contacts to change state
failure of the internal module circuitry
failure of one of the processors.
If a fault is determined, the operation of the safety relay is blocked and the fault type is
shown on a diagnostic LED.
If all the tests are satisfactory, the safety relays are energised. While the relays are
closed, external sensors and module internal components are continuously monitored.
The safety relay also includes over-current protection for the two contacts.
The output (Y1) is High when the relay contacts are open and the outputs are disabled.
Safety Relay - Using the LED Diagnostics
The safety relay uses LEDs to indicate a variety of switching conditions (see Table 6.1)
and failures (see Table 6.2). The error indication is cleared once the cause of the fault
has been rectified and after all the interlocked covers have been tested (opened/closed)
by the safety relay.
Table 6.1 Safety relay LED switching states

Display Description
Green LED on Interlock is closed

Yellow LED flashing (0.5 Hz) Interlock is open
Yellow LED flashing (2 Hz) Interlock closed but incorrect operation
caused voltage drop or open feedback
control loop.
Table 6.2 Safety relay LED failure states

Display (Orange) Failure Possible Causes
One pulse Switch - Defective lead to switch

- Defective sensor switch
- Switch only partially activated
Table 6.2 Safety relay LED failure states (Continued)

Four pulses Malfunction at relay inputs - Possibly high capacitive/inductive
interference at sensor leads
Five pulses one or both relays not - Insufficient operating voltage
responding within monitoring
- Defective relays
range
Six pulses Relays do not operate when - possible defective contacts

cover is opened
Seven pulses Cross-monitoring failure - Failure in one channel
- Data transfer interruption
External Interlocks
See also Volume 2 Chapter 2-10 for views of the interlock cable interconnections and
An external laser interlock is fitted as an option by the customer to any suitable area
where personnel need protection from accidental laser risks. This facility is disabled/
enabled by the wiring connections to the external laser connector at the rear of Engine
external connector plate.
The lock needs to be a 2-way switch with one way normally closed and the other nor-
mally open. Switch toggling for each way should be at the same time, or else the safety
relay will indicate faulty wiring.
Operate machine without an external interlock: this is the normal setup and uses an
override plug on the connector.
Operate machine with an external interlock: this may be required if the Class IV
laser is seen as an unacceptable risk. The wiring arrangement on the external plug is
as follows:
Door is closed in the safe condition: pins 2 and 7 are shorted and pins 4 and 9 open.
Door is open in an unsafe condition: pins 2 and 7 are open and pins 4 and 9 shorted.
6.4 RFI Box Modules

This section describes the main RFI assemblies and their interface connections with the
platesetter system.
6.4.1 RFI Box Layout and Assemblies

See also Volume 2 Chapter 2-10 for views of the RFI box cable interconnections and
SENSOR DISTRIBUTION
PCB ASSEMBLY 24V DISTRIBUTION
PCB ASSEMBLY
MAINS INLET
DC CABLE
(10A 250V)
PSU POWER
FILTER
PCB
POWER
FILTER PCB
INTERFACE
DONGLE
(OLD PCB ONLY)
EODD PCB DISK DRIVE
EXTERNAL
ALERT
RELAY
DISK DRIVE
MOUNTING
BRACKET
SYSTEM (LSB)
PCB
INTERFACE
SYSTEM (LSB)
PCB
RFI BOX
LSB FAN
Figure 6.8 RFI Box assemblies - location view
The RFI Box consists of the following modules.

AC Mains (Input): see Section 6.3.3.
PSU 1: see Section 6.5.1.
Power Filter PCB: see Section 6.5.4.
LSB Fan: see Section 6.5.2.
Electro-Optic Deflector Driver (EODD) PCB: see Section 6.6.1.
System PCB (LSB): see Section 6.6.2.
Hard Disk Drive 1: see Section 6.6.3.
An alert control relay is housed at the service side of the box, see Section 6.7.2 for a
description of the circuit.
6.4.1.1 RFI Box External I/O Connections

See Figure 6.9.
External I/O connections from the RFI box are from a side panel accessed when the
Engine service side cover is removed.
24V DISTRIBUTION SENSOR DISTRIBUTION

PCB ASSEMBLY PCB ASSEMBLY
POWER
FHMB POWER
VBOMB
POWER
MAINS INLET
PSU CONTROL
(TO LSB)
24V
INTERLOCKS
EXTERNAL
ALERT
RELAY SIGNAL
RIP (SCSI)
MMI
CAN2 (FHMB1)
CAN1 (VBOMB)
PLATE
PROCESSOR
DIAGNOSTICS
(RS232)
PSU
CONTROL
IMAGE
EODD IMAGE (VBOMB)
(VBOMB)
RFI
BOX
Figure 6.9 RFI Box external signal/power connections

6.5 RFI Box - DC Power Modules

This section describes the main RFI box modules
4 PSU 1: see Section 6.5.1.
4 Fans: see Section 6.5.2.
4 Fusing: see Section 6.5.3.
4 Power Filter PCB: see Section 6.5.4.
6.5.1 PSU 1
See also Volume 2 Chapter 2-10 for views of the PSU cable interconnections and Vol-
This is a switch mode PSU rated at 800 W (max) with built-in power factor correction
and internal cooling fans. Once factory-fitted (or supplied as a spare) it does not need to
be adjusted in the field for the correct DC supply voltages. In the event of a failure, the
PSU is replaced as a unit.
PSU 1 +36V PL4

PWR
+5V +5V PL5 FILTER
0V
15V
+15V PL10
+24V FHMB
+15V/-15V PL11
+36V
PL13 LSB
+5V
+15V/-15V PL17
+24V PL3
EODD
+24V
FAN 1 (PIN 2)
Figure 6.10 Cable: PSU (9970-0421) DC connections

SLOT 1 SLOT 3 SLOT 4 SLOT 5 SLOT 6
-15V
SENSE
0V
0V
0V 0V 0V 0V
+36V
+5V +24V +24V +15V
WHITE/BROWN RED WHITE/ WHITE/ YELLOW (+15V)

ORANGE ORANGE VIOLET (-15V)
Figure 6.11 PSU 1 - voltage outlets
6.5.2 Fan Assemblies

6.5.2.1 Fan Assembly
See Figure 6.8.
Three fan assemblies, fitted on mounting brackets, provide a flow of cool air for the
main modules:
PSU fan: Extracts hot air away from the PSUs. Note that the two PSUs include
built-in fans.
LSB PCB fan: blows in cool air towards the LSB. Note that failure of the LSB fan is
detected by the software to give an error code.
Each fan has a detachable finger-guard which needs to be refitted on a replaced fan.
6.5.3 System Control Fusing

The main fuses fitted on the platesetter are:
FHMB PCB:
4 2 A antisurge (FS1-7 and FS9-15) - 97280005.
4 5A antisurge (FS8) - 97280004.

Interlock box:
4 1 A antisurge (FS1-3) 3-off
4 0.5 A (24 V PSU)

LSB PCB:
4 2 A antisurge (FS1) - 97280005
Emergency stop PSU:
4 0.5 A, 250 V antisurge 20 mm
EODD
4 2 A A/S (FS2 and 4) - 97280005.
4 5A A/S (FS1 and 3) - 97280004.
6.5.4 Power Filter PCB

6.5.4.1 Power Filter Assembly
This PCB forms part of the DC distribution system and includes inline inductors for fil-
tering DC power to:
FHMBs (1 to 4).
Interlocks (+24 V).
VBOMB power.
The Power Filter PCB does not include LEDs, links or fuses.
Location
Mounted inside the RFI box at the back of the upper shelf, see Figure 6.8.
Connectors
See Figure 6.12.
PL1: 8-way Molex to FHMB (via Interlock Box).
PL2: 10-way Molex to VBOMB_PWR.
PL3: 4-way Molex to interlocks.
PL4: 10-way Molex to PSU 1.
PL8: 14-way Molex to EODD.
SK1: 15-way D-type to LSB.
SK2: 26-way D-type to Interlock box.

See also Volume 2 Chapter 2-10 for views of the Power Filter cable interconnections and
PL1
PL4
PL2
PL5
PL6
TP1 SK1
TP4
PL7 TP3 TP2
PL8
PL3
SK2
Figure 6.12 Power Filter PCB - layout view
6.5.4.2 Power Filter PCB Operation

The function of the Power Filter PCB is to:
Route interlock status signals to the LSB via the EODD.
Provide inductive EMI filtering all the voltage lines.
Distribute DC voltages (+24, Engine_24, +36, +15 -15) to the VBOMB and FHMBs
(via the Interlock box).
6.6 RFI Box - Image Processing Modules

This section describes the following electronic modules housed in the RFI Box:.
EODD (MK2): see Section 6.6.1.
System PCB: see Section 6.6.2.
Hard Disk Drives: see Section 6.6.3.
6.6.1 Electro-Optical Deflector Driver (EODD) PCB

6.6.1.1 EODD PCB Assembly
See Figure 6.13 showing the PCB layout.
TP8
TP13
TP11
PL9 TP14 PL6 TP3
TP6
TP20 TP9
TP12
TP17 TP10 FS2 FS1
PL10
PL2
FS3
PL3
TP15
FS4
TP16 TP7
PL14 PL4
SK4
TP18
PL13
SK2
TP19 PL8 TP2 TP1
SK1 TP4
PL11
SK3 TP5
PL5
PL12
Figure 6.13 EODD (MK2) PCB - layout view

Location
Mounted inside the RFI box on the lefthand side, see Figure 6.8.
Connectors
PL1: Not Used.
PL2: Not Used.
PL3: 8-way Molex Minifit. PSU connection to PSU 1.
PL4: 14-way Molex. Interlock sensor status routing to LSB.
PL5: Not used.
PL6: 6-way Molex. EOD (X) and EOD (Y) signals.
PL8: Not used.
PL9: Not used.
PL10: Not used.
PL11: Not used.
PL12: Not used.
PL13: Not used.
PL14: Not used.
SK1: D-type 37-way. EODD_IF connection to LSB.
SK2: Not Used.
SK3: Not Used.
SK4: Not Used.

See also Volume 2 Chapter 2-10 for views of the EODD cable interconnections and Vol-
Fuses
FS1: 5 A anti-surge (97280004)
FS2: 5 A anti-surge (97280005)
FS3: 5 A anti-surge (97280004) - Spare
FS4: 5 A anti-surge (97280005) - Spare.
LEDs and Links

None
Test Points
TP1: OV
TP3: +24 V
TP5: 0V
TP6: +12 V
TP7: +5 V
TP8: Y-DEFL
TP9: X-DEFL
TP11: O V.
6.6.1.2 EODD PCB Operation

See Figure 6.14.
The EODD provides a number of expose control functions:
Generates the EOD DIFF sine/cosine waves used to deflect the beams.
Serves as a control interface between the LSB DAC target settings and the EODs.
Receives interlock status signals from each interlocked cover to control the laser and
re-directs status signals to the LSB for interpretation.
EOD X SINE WAVEFORM

CONTROL DAC TO EODHV
LSB PORT
I/FACE
EOD Y COSINE WAVEFORM
DAC TO EODHV
OK
LSB
PANEL
POWER I/LOCKS
FILTER 6 PANEL REGISTER
I/LOCKS
EODD
STATUS
+5V
+8V
+24V EODD
BUS
Figure 6.14 EODD functions - block view
Status signals are passed to the monitoring LSB which, if necessary, returns an Error
Code to the MMI.
An OK signal line is returned to the LSB if any one of the interlocked covers are opened.
This signal, and the interlock status signals from th interlock covers, allow the LSB to
generate the appropriate icon on the MMI showing which cover needs to be closed for
scanning to continue.
EOD DIFF Deflector

A 12-bit DAC and a DIFF driver provides a composite DC bias and AC modulation
voltage for each EOD. These are passed to the EODHV module that filters the two com-
ponents and provides the HT drive. The deflector wave outputs, at 500 Hz locked to the
spinner rotation, are:
EOD X is sine wave
EOD Y is cosine wave.
EOD sine and cosine data is derived from the deflector LUTs on the LSB which are
addressed (updated) at a rate scaled to the spinner revolutions. Up to 2048 updates per
spinner revolution are possible, depending on the resolution selected.
6.6.2 System Board (LSB) PCB

6.6.2.1 System PCB Assembly
See Figure 6.15 showing the PCB layout.
Location
Mounted in the RFI box at the rear of the Engine, see Figure 6.8.
Connectors
PL1: Not used.
PL2: 50-way male vertical header. Data to/from local SCSI disk drive 2.
PL3: 40-way male header. Used for dongle on old PCBs; not fitted on new PCBs.
PL4: Not Used.
PL5: Not Used.
PL6: 4-way male vertical header. +12V and +5VDC DC supplies to SCSI disk
drive1.
PL7: Not Used.
PL8: 4-way male vertical header. +12V and +5VDC supplies to SCSI disk drive2.
PL10: 6-way DIL male header. +15V DC supply from PSU to on-board regulators
supplying +12V to disk drive(s)
PL11: 12-way DIL male PCB header. -15V, +15V from the PSU.
PL12: Not Used.
PL13: 14-way DIL male PCB header. +5V from the PSU.
PL15: Not Used.
PL16: Not Used.
PL17: 10-way DIL male header. -15V, +15V from the PSU.
PL18: Not Used.
PL19: Not Used.
PL20: 9-way male D-type. RIP serial diagnostics.
PL21: 9-way male D-type. Processor serial connection to plate processor.
SK1: 37-way female D-type. Interface to EODD.

SK2: Not Used.
SK4: 26-way female D-type. Image VBOMB.
SK5: 15-way female D-type. PSU Control.
SK6: 15-way female D-type. CAN1 Bus to VBOMB.
SK7: 15-way female D-type. CAN2 Bus to FHMB (1).
SK8: 26-way female D-type. +5V and Data to/from MMI.
SK9: 68-way female connector. SCSI bus to RIP server.

See also Volume 2 Chapter 2-10 for views of the LSB cable interconnections and Vol-
Fuses
FS1: (5V, 2A) - Anti-surge. SCSI Power Termination.
ICs (Main Devices)

U31 NVRAM. Real-time clock.
U36: 512 k x 8 bit SRAM. SRAM temporary data store for main program.
U39: 512 k x 8 bit SRAM. SRAM temporary data store for main program.
U51: 512 k x 8 bit FLASH memory.
U69: Temperature Sensor. Monitors ambient temperature of System board.
U70: 512kx8 bit FLASH memory-plug-in. Contains program code for SRAM U76
and U113. Any change of code requires U70 to be exchanged.
U76: XC4020XL-2. Static RAM.
U113: XC4013XL-1. Static RAM.
U51-53 are FLASH memory which contain the System code (Boot, Diagnostics and
Application). Any change of code required is downloadable.
U65-67 are FLASH memory which contain the System code (Boot, Diagnostics and
Application). Any change of code required is downloadable.
RL1
PL11 PL13 PL17 PL18
U53 U67 SK2
SK1 U52 U66 SK9

TP13 D19
U51 U65
TP4
FS1
PL7 PL12 TP5
PL3 SK8
(DONGLE) TP15
TP3
TP12
SK7
TP14
SK6
PL2 LK6
LK7
U76
PL21
PL19
PL16 PL20
TP18
TP2 U70
PL1
U113
SK5
TP7 TP9
U69
PL6 PL8 LK2 TP6 TP8 TP16
SK4
TP10
PL5
PL10 LK1 LK3 LK4 LK5 PL15
PL4
Figure 6.15 System Board (LSB) layout
LEDs
D2: Red LED. Illuminated = System board in Reset.
D3: Green LED. For S/W purposes.
D4: Green LED. For S/W purposes.
Links
LK1: Not fitted.
LK2: Pins 1 and 2 connected (on-board program enabled).
LK3: Not fitted.

LK4: Not fitted.
LK5: Not fitted.
LK6: Not fitted.
LK7: RS232 Comms. interface to film processor. Link in if processor has no Flow
Control. MAKE SURE THE LINK IS OUT.
Test Points
TP5: Reset.
TP8: Not used.
TP9: Not used.
TP11: Digital Gnd
TP12: Digital Gnd.
TP13: Not used.
TP14: PLL_LOCKED
TP15: Not used.
TP18: TTL pixel clock (fast clock for image data output to VBOMB.
TP19: ECL Ground.
6.6.2.2 Dongle
A Dongle PCB is stacked on the LSB PL3 header (see Figure 6.15) to enable the soft-
ware for a dual-beam system.
6.6.3 Hard Disk Drives (HDD)

See Figure 6.8.
6.6.3.1 Disk Drive Assembly

A single SCSI disk drive has a data capacity of 18 Gbytes and is supported by a mount-
ing bracket at the side of the RFI box. Its main functions are:
Buffers single image compressed data before it is decompressed and sent to the
optics system for laser modulation.
Holds a copy of the NVRAM parameters used by the LSB.
Backup copies of the Configuration files and System Registry.
Local persistent images (PIs)
Error Log files.

Cassette and elevator databases.
Local statistics on the system current usage.
SCSI Standard
The HDD is Narrow (8-bit) Ultra SCSI.
Disk Drive Settings
The HDD should be correctly configured by the manufacturer. Details of the configura-
tion are labelled on the drive. The working SCSI ID can be any number from 0 to 6 (but
not 7), but it is usually set to 0.
DC Supplies
+12 V 5% (regulated from the LSB) and +5 V.
Operating Temperature
5C to 55C.
Terminators
The HDD has its own controller which requires terminating using passive an inline
cable terminator. You can leave the existing terminator in place when replacing the
drive.
Disk Drive Cable Connections
See also Volume 2 Figure 9.3 for views of the HDD cable interconnections and Volume
2 Section 8.1 for a description of the cable pin voltages and signals.
6.7 MMI and External Alert

6.7.1 Man Machine Interface (MMI)
The MMI is a display console that operates the platesetter user controls from an iconic
menu system. The console consists of an LCD, an analogue touchpanel, Invertor PCB
and MMI PCB. These devices are assembled as a single FRU fitted inside a plastic con-
sole and held by a support moulding to the engine. A clear window with the display and
touchpanel is presented to the user.
MMI PCB Assembly
See Figure 6.16.
SK1 SK2
U1
PL1
WD1
(BUZZER)
SK4
SK3
FS1
MMI PCB
Figure 6.16 MMI PCB layout
Location
Mounted inside the MMI Display console on the Engine.
MMI Connectors
PL1: 3-way. Supplies +5V, Ground and on/off control signal to Inverter board.
SK1: 4-way. Signals from touchpanel.
SK2: Not used.
SK3: 14-way. Routes drive signals to the LCD.
SK4: 26-way D-type. +22V, +5V and data lines from System board.
The console (including MMI board, LCD, Inverter and touchpanel) is supplied and fitted
as a complete FRU assembly.
See also Volume 2 Chapter 2-10 for views of the MMI cable interconnections and Vol-
Fuses
1A Fast-acting (97280008). Protects 5V DC supply to the LCD.
MMI Operation
See Figure 6.17.
The MMI PCB is located underneath the console and provides mechanical support for
the connectors from the System Board, a buzzer (beeper) for operator alerts, the LCD
and touchpanel. It is a non-serviceable unit replaced as part of a `sandwich' assembly
that includes the console, LCD, Inverter board and touchpanel.
The PCB includes buffers for the touchpanel data sent to the System Board, and receiv-
ers for the returned LCD control data. A cable link to the System board supplies voltages
and control signals for operating the touchpanel soft buttons and LCD display. An LCD
controller device, on the System Board, initialises the display and controls the output of
pixel bitmaps.
Voltages supplied to the MMI PCB include:
+5 V: converts +5 V to 300 V for the cold fluorescent lamps used by the LCD as a
backlight. The +5 V voltage is also used for the on-board electronic devices and the
LCD.
+22 V: a nominal voltage for the LCD contrast which is adjusted by the user and is
typically set at +17 V by the System Board.
TO LCD
SK1 SK2 WHITE
U1
PL1
INVERTER
PCB
WD1
(BUZZER) CAUTION
HIGH
VOLTAGE
SK4
SK3
FS1 CN1
MMI PCB
LCD AND TOUCHPANEL

TO PL1 (MMI PCB)
Figure 6.17 MMI console assemblies
The MMI includes:

LCD display: with monochrome (emulating grey levels) for the MMI buttons and
icons. The screen is specially adapted for daylight viewing, with a facility for the
user to adjust the contrast.
Inverter board: located next to the MMI board, powers a single fluorescent lamp for
the LCD backlight. The LCD backlight is also used as the machine power-on indica-
tor. CAUTION ON VOLTAGE: the inverter generates high voltage (300 VDC).
Touchpanel: allows the operator to select soft menus buttons. This panel may
require periodic calibration by the user.
MMI board: includes the I/O connectors to the System Board and an audible buzzer
to alert the user. Adjustments for frequency and loudness is possible from the panel.
Support moulding: engine support for the MMI assemblies.
A full description of how the platesetter operates from the MMI console is given in the
Luxel Platesetter Operator's Manual.

MMI control and drive voltages are managed from the System Board to include:
dedicated LCD display controller
display memory (128 K DRAM)
contrast control (negative voltage generator) for varying the LCD backlight
buffer for LCD data/control signals
+5V for the Inverter board and MMI PCB devices
touchpanel supply voltage (+5 V) to X and Y touch panel axes
A-to-D signals for X and Y positions
beeper ON signal.
A Diagnostics submenu runs a set of self-tests for the engineer and user.
6.7.2 External Alert Control

An external alert facility is fitted as a customer option using the circuit shown in
Figure 6.18. The customer is responsible for supplying and fitting the remote alert
device (light or buzzer) and an external DC PSU.
The alert is initiated by the application software when an error is indicated (for instance,
a plate jam or a lack of media for the next job). The control relay (BV8) is located on the
RFI box, see Figure 6.9.
ENGINE
EXTERNAL
PLATE
ENGINE
EXTERNAL
ALERT
RELAY
PIN 7 PIN 2
ALERT
CONTROL PIN 3
FROM FHMB1
PIN 4
REMOTE LIGHT
9-WAY OR
COIL A D-TYPE AUDIBLE ALARM
ALERT (FEMALE)
RELAY
(ON RFI UP TO 36V DC SUPPLY
BOX) (24V TYPICAL)
RATING LESS THAN 2A
COIL B
PIN 7
PIN 4
Figure 6.18 Connecting an external alert

Volume-Chapt er
VACUUM AND AIR CONTROL

This chapter describes drum vacuum/air blow system for plates in the drum, and the air
knife and purified air system for controlling contaminants:
4
4
Vacuum and Contamination Control ........................................................................ 7-1
4
Drum Vacuum and Drum Blow .................................................................................. 7-4
4
Air Knife..................................................................................................................... 7-18
Air Purifier (PAT) ....................................................................................................... 7-21
7.1 Vacuum and Contamination Control

Volume 2 Section 2.3 describes the sequence of steps for moving, de-skewing, conform-
ing and ejecting a plate inside the drum. Figure 7.1 shows the vacuum/blow sub-system
control for the drum and air knife/curtain.
7.1.1 Drum Vacuum and Drum Blow

This provides plate vacuum conformance and ejection inside the drum. The vacuum is
sourced by an external pump with AC power switched from FHMB4 control to relay
BV5; drum blow air is provided by internal compressors with AC power controlled by
FHMB4 to relay BV31. Two types of vacuum/blow configurations are fitted on Violet
machines:
A) Old Drum Vacuum and Blow: applies to machine configurations up to 117.
B) New Drum Vacuum and Blow: applies to machine configurations from 118.
7.1.2 Contamination Control

This is provided by two separate functions:
1. Air Knife: switches on air at the Engine input to blow surface contaminants from the
plate as it advances into the drum. Air generated from the compressor box is
switched by BV41. Air knife assemblies on early fully-automatic Violet machines
use a fan blower located on the PTM to generate air movement.
See Section 7.3.
LEAD EDGE
MANIFOLDS NOT SHOWN
VACUUM L CABLE: ENG_BLOW_AUTO_PUNCH NOTE: SEE FIGS. 3 TO 5

PUMP FOR EACH CAGE
CONFIGURATION
CCT BV40 MAIN VAC

BREAKER PL10
FHMB1
SHORT BLOW
VOLUME 2 (7-2) VACUUM AND A IR C ONTROL
BV30
BV5
L RELAY
MAINS PL1 PL10
INLET L
AIR KNIFE
PL8 PL16 BV41
LONG BLOW
FHMB4
VALVE CAGE
BV31
RELAY FUSE NOTE: SYSTEM SHOWN:
L B1 FULLY AUTO,
COMPRESSOR
INTERLOCK SEMI, MANUAL
BOX (NO PUNCH)
Figure 7.1 Vacuum/drum blow system control

L MANIFOLDS NOT SHOWN
COMPRESSOR
FUSE
COMPRESSOR BOX
FUSE: 6.3 x 32 250V 2A A/S
2. Air Purifier (PAT): distributes filtered air into the drum compartment and optics
base. This module, located outside the Engine, is not controlled by the platesetter
system. It operates by supplying a constant flow of high quality clean air which also
raises positive air pressure inside the Engine compartment.
See Section 7.4.
7.1.2.1 Contamination Managementl

The contamination management system uses an inline air knife/air curtain to remove
contaminants, such as:
4 aluminium shards from the plates (cut edges)
4 external dust
4 PVA debris
4 paper debris
4 scrapings from painted surfaces, rollers, etc.

The air knife/curtain assemblies are described in Volume 2 Section 3.4.2.2.
NOTE: To ensure contamination is reduced to the minimum, all scheduled service clean-
ing procedures, described in Section Volume 3 Section 1.5, must be followed.
The aim of contamination control is to:

1. Prevent debris settling on any flat surfaces inside the platesetter where there is a risk
of transfer to the drum caused by circulating fan air.
2. Ensure plates are clean before a drum load.
3. Isolate system cooling fans from the drum interior.
4. Form effective seals on machine covers to prevent entry of debris.
5. Ensure there are no contaminants on the emulsion side of the plate.
6. Provide positive air pressure inside the Engine.
7. Provide a clean environment inside the optics base.
7.2 Drum Vacuum and Drum Blow

Drum vacuum is required for conforming plates to the drum before exposure to ensure
quality imaging. Drum blow control is applied:
A) Before imaging to provide a bed a of air for the plate as it enters the drum
B) After imaging to release the plate quickly from drum vacuum and assist ejection
to the output transport.
Drum vacuum and drum blow is controlled by sequencing software during the plate
load, plate conform, plate expose and plate eject stages. The plate handling sequence for
each variant is described in Volume 2 Section 2.3.
7.2.1 Drum Configurations

7.2.1.1 Drum with Manifolds
See Figure 7.2.
This section describes the drum blow configurations used for machine IDs 118 and
onwards (New) and their differences with the pre-118 (Old) drum configurations:
Old - ID 1 to ID 64 - these operate with 11 activated blow holes
Old - ID 65 to ID 117 - these have 9 activated blow holes and a second manifold for
additional 7 blow holes which are plugged, but capable of being upgraded in the
field.
New - ID 118 onwards - these have 9 and 7 activated blow holes described below.
The new drum vacuum/blow system is designed to improve the throughput of large
plates (greater than 350 mm) and small plates (less than 350 mm).
Sets of drum holes, starting from the drum input end, are arranged around the outside of
the New drum as follows:
1. Long Blow (LB): a set of 9 holes used to release the plate. Note that the two end
holes are plugged.
2. Short Blow (SB): an additional set of 7 holes added to the new drum. It operates at
the same time as LB but provides extra lift to prevent plate scratching.
3. Main Vacuum (MV): a set of 23 holes provide the main conform vacuum after the
plate has been de-skewed. Drum blow is applied to release the vacuum and plate
after imaging.
4. Lead Edge (LE): a set of 23 holes that operate on non-punch machines (Web) to vac-
uum and secure the leading edge of the plate, and prevent it from skewing when
applying vacuum to the rest of the plate.
EXTERNAL VACUUM PUMP
LEAD EDGE
VALVE
CAGE
MAIN VAC
BRANCH ELBOW BRANCH ELBOW

MANIFOLD
SHORT BLOW
LONG BLOW
VIEW FROM BELOW
Figure 7.2 Drum holes and manifolds (new drum with manifolds)
7.2.1.2 Drum with Chambers

See Figure 7.3.
Later machines have a revised drum design with direct pipe connections between the
valve cage and the four drum inlets for the lead edge, main vac, short blow and long
blow. This design replaces the network of branching manifolds with a network of cham-
bers inside the drum. As part of the servicing routine, check the vacuum/air seals of the
drum pipe inlets located under the drum and at the output end between the optical base
and RFI box.
EXTERNAL VACUUM PUMP
DIRECT FROM PUMP

ON SOME CONFIGS
LEAD EDGE
VALVE CAGE
MAIN VAC
OPTICS BASE RFI BOX
SHORT BLOW
LONG BLOW
VIEW FROM BELOW
Figure 7.3 Drum holes and manifolds (new drum with chambers)
7.2.2 Drum Vacuum and Blow Assemblies

See Figure 7.2.
The main vacuum and blow assemblies are as follows:
1. External vacuum pump: a Becker VT 4.25 pump powered from the 230 VAC Engine
supply. The pump requires periodic servicing described in the OEM service manual.
2. Solenoids, manifolds, tubing and drum: vacuum tubing from a branch system of
manifolds and solenoids distribute vacuum/air to a drum with the new configura-
tions shown in Section 7.2.3. Control of vacuum and air to the drum is from sets of
solenoid switches that regulate the precise time and flow of vacuum and air to the
drum for improved registration and ejection.
During a routine service these assemblies are checked for correct operation.
3. Compressor box: uses two compressors (Nitto) to provide air for drum blow and the
air knife. This box is located on the user side above the periscope on the righthand
side. The compressors are switched on by BV31 located inside the interlock box.
7.2.3 Drum Vacuum and Blow System

Old and New configurations are available for the following platesetter machines:
1. B1 Fully-Automatic and Manual (without a punch): see Section 7.2.3.1.
A) Old 1: see Figure 7-7.4.
B) Old 2: see Figure 7-7.5 and Table 7.1.
C) New 1: see Figure 7-7.6 and Table 7.2.
2. B1 Fully-Automatic (with a punch): see Section 7.2.3.2.
A) Old 1: see Figure 7.7 and Table 7.3.
B) New 1: see Figure 7.8 and Table 7.4.
C) New 2: see Figure 7.9 and Table 7.5.
3. B2 Manual and Semi-Automatic (without a punch): see Section 7.2.3.3.
A) Old 1: see Figure 7.10 and Table 7.6.
B) New 1: see Figure 7.11 and Table 7.7.
7.2.3.1 B1 Fully-Auto and Manual (without a Punch)

BV40
INPUT
VAC PUMP P A
LE
BLOW
BV5 A
MANIFOLD
R
BV30 MAIN
VAC
COMPRESSORS
(x 2)
R
MANIFOLD
A P
BV31 BV41
AIR KNIFE
VALVE CAGE
(P = PRESSURE; R = RETURN)
P
A AIR KNIFE
COMPRESSOR
BLOW
R
NOTE: RETURN IS NEAREST
TO VALVE CAGE PLATE BV41
P
VAC PUMP A
LEAD EDGE
R
BV40
P
VAC PUMP A
MAIN VAC
COMPRESSOR
R
BV30
Figure 7.4 B1 Fully-Auto and Manual without punch - vacuum circuit (Old 1)
BV40
INPUT
VAC PUMP P A
LE
BLOW
BV5 R A
MANIFOLD
BV30 MAIN
VAC
COMPRESSORS
(x 2)
P
MANIFOLD
A R
BV31 BV41
AIR KNIFE
VALVE CAGE
P
A AIR KNIFE
COMPRESSOR
BLOW
R
P
VAC PUMP A
LEAD EDGE
R
BV40
P
VAC PUMP A
BLOW
R
BV30
Figure 7.5 B1 Fully-Auto and Manual without punch - vacuum circuit (Old 2)
INPUT
VAC PUMP
LE
LONG
BV5 R A
BLOW
BV40 MAIN
VAC
SHORT
BLOW
R A
MANIFOLD
BV30
COMPRESSORS
(x 2)
P
MANIFOLD
A R
BV31
BV41
AIR KNIFE
VALVE CAGE
P
A LONG BLOW
COMPRESSOR
AIR KNIFE
R
P
LE & VAC A
MAIN VAC
AND BV30 (P)
COMPRESSOR
R
BV40
P
MAIN VAC A
(BV40) SHORT BLOW
COMPRESSOR
R
BV30
Figure 7.6 B1 Fully-Auto & Manual without punch - vacuum circuit (New 1)
Table 7.1 Solenoid logic table for B1 fully-auto and manual - no punch (Old 2)
Eject Blow
Main Vac
Solenoid
Function
Air Knife
Neutral
LE Vac
Blow
BV5 Vac Pump 0 0 0 1 1 0
BV31 Compressor 0 1 1 0 0 1
BV40 LE Valve 0 0 0 1 1 0
BV30 Vac Divert Valve 0 1 0 0 1 0
BV41 Blow Divert Valve 0 1 1 0 1 0
Table 7.2 Solenoid logic table for B1 fully-auto and manual - no punch (New 1)
Short Blow
Long Blow
Eject Blow
Main Vac
Solenoid
Function
Air Knife
Neutral
LE Vac
BV5 Vac Pump 0 0 0 0 1 1 0

BV31 Compressor 0 1 1 1 0 0 1
BV40 LE Valve 0 1 1 0 0 1 0>>1
BV30 Vac Divert Valve 0 1 0 0 0 1 0
BV41 Blow Divert Valve 0 0 1 1 0 0 1
7.2.3.2 B1 Fully-Auto (with a Punch)

INPUT
VAC PUMP
P BLOW
MANIFOLD
MAIN
R VAC
BV30
BV5
AIR KNIFE
A P
COMPRESSORS
(x 2)
R
MANIFOLD
BV41
VALVE CAGE
BV31
P
A AIR KNIFE
COMPRESSOR
BLOW
R
BV41

TO VALVE CAGE PLATE
BV30
P
VAC PUMP A
MAIN VAC
COMPRESSOR
R
Figure 7.7 B1 Fully-Auto with punch - vacuum circuit (Old 1)

INPUT
VAC PUMP
LONG
MANIFOLD BLOW
MAIN
VAC
SHORT
BLOW
MANIFOLD
A R
AIR KNIFE
BV41
P
COMPRESSORS
(x 2)
R A
MANIFOLD
PLUG BV30
VALVE CAGE
BV31
P
A SHORT BLOW
COMPRESSOR
AIR KNIFE
R
BV41

TO VALVE CAGE PLATE
BV30
P
COMPRESSOR A
LONG BLOW
PLUG
R
Figure 7.8 B1 Fully-Auto with punch - vacuum circuit (New 1)

INPUT
VAC PUMP
LONG
MANIFOLD BLOW
MAIN
VAC
SHORT
BLOW
A
BV5 MANIFOLD
R
BV41 P
A R
AIR KNIFE
BV41
P
COMPRESSORS
(x 2)
R A
MANIFOLD
PLUG BV30
VALVE CAGE
BV31
P
A SHORT BLOW
COMPRESSOR
AIR KNIFE
R
BV41
R
SHORT BLOW A

TO VALVE CAGE PLATE P
BV40
P
COMPRESSOR A
LONG BLOW
PLUG
R
BV30
Figure 7.9 B1 Fully-Auto with punch - vacuum circuit (New 2)

Table 7.3 Solenoid logic table for B1 fully-auto - with punch (Old 1)
Eject Blow
Main Vac
Solenoid
Function
Air Knife
Neutral
Blow
BV5 Vac Pump 0 0 0 1 0
BV31 Compressor 0 1 1 0 1
BV30 Vac Divert Valve 0 1 1 1 0
BV41 Blow Divert Valve 0 1 0 1 0
Table 7.4 Solenoid logic table for B1 fully-auto - with punch (New 1)
Long Blow
Eject Blow
Main Vac
Solenoid
Function
Air Knife
Neutral

Table 7.5 Solenoid logic table for B1 fully-auto - with punch (New 2)
Long Blow
Eject Blow
Main Vac
Solenoid
Function
Air Knife
Neutral

BV40 Extra Vac Valve Activated with BV41
7.2.3.3 B2 Semi-Auto and Manual (without a Punch)

INPUT
LE
VAC PUMP
MANIFOLD
P
A
PLUG LONG
R MANIFOLD BLOW
BV30
BV5 MAIN
VAC
AIR KNIFE
COMPRESSORS
(x 2)
P
A
MANIFOLD
R
BV41
VALVE CAGE
BV31
P
A AIR KNIFE
COMPRESSOR
MAIN VAC
R
BV41

TO VALVE CAGE PLATE
BV30
P
VAC/LE A
MAIN VAC/SHORT BLOW
PLUG
R
Figure 7.10 B2 Semi-auto and Manual without punch - vacuum circuit (Old 1)
INPUT
LE
VAC PUMP
MANIFOLD
P
A
PLUG LONG
R MANIFOLD BLOW
BV30
MAIN
VAC
SHORT
BLOW
AIR KNIFE
COMPRESSORS
(x 2)
P
A
MANIFOLD
R
BV41
VALVE CAGE
BV31
P
A AIR KNIFE
COMPRESSOR
MAIN VAC/SHORT BLOW
R
BV41

TO VALVE CAGE PLATE
BV30
P
VAC/LE A
MAIN VAC/SHORT BLOW
PLUG
R
Figure 7.11 B2 Semi-auto and Manual without punch - vacuum circuit (New 1)
Table 7.6 Solenoid logic table B2 semi-auto and manual without punch (Old 1)
Eject Blow
Main Vac
Solenoid
Function
Air Knife
Neutral
Blow
Table 7.7 Solenoid logic table B2 semi-auto and manual without punch (New 1)
Long Blow
Eject Blow
Main Vac
Solenoid
Function
Air Knife
Neutral
LE Vac
BV5 Vac Pump 0 0 0 1 1 0
BV31 Compressor 0 1 1 0 0 1
BV30 Vac Divert Valve 0 1 0 0 1 0
BV41 Blow Divert Valve 0 1 0 0 1 0
7.3 Air Knife

7.3.1 Air Knife (Compressor)
NOTE: the compressor version is fitted on later production machines.
See Figure 7.12 and Volume 2 Figure 3.56.

The air knife, located before the input transport module, blows clean air across an
advancing plate before it reaches the drum. This removes surface debris from the plate
before there is a transfer of contaminants to the drum.
The air knife system consists of the following assemblies:
1. Air knife pipe: this pipe, located above the input module, directs small streams of air
down to the plate and towards the plate feed area.
2. BV41: this solenoid, located on the valve cage, controls the flow of compressed air
from the compressor box to the air knife as a plate passes underneath.
PLATE ADVANCING
FROM AUTOFEEDER
AIR KNIFE/CURTAIN PIPE
DUCTING
PIPE
BV41
VALVE CAGE AND PLATE
Figure 7.12 Air knife contamination control (compressor)
7.3.2 Air Knife (Fan Blower)

NOTE: the fan blower version is fitted on early production machiones.

The air knife, located before the input transport module, blows clean air across
an advancing plate before it reaches the drum. This removes surface debris from
the plate before there is a transfer of contaminants to the drum.
The air knife system consists of the following assemblies:
1. Fan blower: an AV-mounted fan blows air into the pipe duct as the plate
advances from the feed head.
2. 24 VDC relay: switches the +24 V supply on/off (from FHMB3 control) as the
plate advances.
3. Air knife pipe: this pipe, located above the input module, directs small
streams of air down to the plate and towards the Autofeeder.
AIR KNIFE
PIPE
PLATE
ADVANCING
FROM
AUTOFEEDER
DUCTING
PIPE AV MOUNTS
OUTLET
DUCT
CONTROL
RELAY
(BV23)
FAN BLOWER
AND HOUSING
PTM INTERIOR
(SERVICE SIDE)
Figure 7.13 Air knife contamination control (fan blower)
7.3.3 Servicing the Air Knife

7.3.3.1 Fan Blower
1. Detach the ducting pipe above the housing.
2. Disconnect the fan from the relay (inline connector).
3. Remove the fan housing from the frame (4-off M5 nuts).
4. Remove and replace the fan blower assembly from its housing.
5. Replace the assembly and reconnect.
6. Check that the fan operates correctly when the plate starts to move towards the
input module.
7.3.3.2 Control Relay (BV23)

1. Detach the relay from the frame.
2. Disconnect the relay wires shown in Figure 7.14.
3. Replace and reconnect the relay.
4. Check that the fan operates correctly when the plate starts to move towards the
input module.
FHMB3 (PL1)
9970-0198
+24V
PTM AIR KNIFE
CONNECTOR FAN
PANEL 9970-0156
0V 0V
+24V
A B
BV23 RELAY
FRONT
Figure 7.14 Air knife control circuit
7.4 Air Purifier (PAT)

The PAT-506id operates as a separate module supplying highly purified air to
the drum from a flexible ducting connection to a manifold on the Engine cover
(service side). Clean air from the Engine is also drawn into the optics base by a
laser cooling fan. Purified airflow reduces contamination and thereby improves per-
formance by reducing time spent cleaning the spinner mirror and checking for image
quality.
NOTE: The PAT module is always located at the side of the Engine and not be positioned
under the Buffer. Make sure the module is positioned away from any heat sources, such
as, the vacuum pump and processor.
Two types of Air Purifiers are available, depending on the local AC supply:
1. 110 VAC
2. 230 VAC.
7.4.1 Servicing the PAT

Clean air on the PAT is supplied via three (staged) filters which need to be replaced
when a warning beep/LED flashing occurs. Although this warning indicates that the fil-
ters are due for replacement, customers can still operate the machine for a recommended
short period. Servicing the PAT depends on the local arrangement between the customer
and the PAT distributor. FFEI (UK) are able to provide more information on local PAT
servicing and parts supply.
CAUTION: Failure to replace filters as recommended could result in lower optics effi-
ciency and increased service visits.
Instructions on using the Air Purifier are in a separate OEM Installation and
Operation Guide. On installation, the PAT unit needs to be registered, via the
Internet, with the manufacturers before it is able to start operating.
The PAT 506id has a tricolour LED display that indicates the status of each filter stage as
follows:
1. Green: the purifier is operating normally.
2. Yellow: specific filters have two weeks before their scheduled replacement
3. Red: filter replacement is overdue but the customer is allowed a two week period
before the PAT shuts down automatically.
NOTE: Note that on later Engines (serial no.100 onwards), automatic shutdown is disa-
bled. However, for these machines FFEI recommend the filters are replaced before the
two week period has finished. For earlier machines, automatic shutdown is disabled by
contacting PAT and replacing the control panel.
7.4.2 Service Filtering for the Optics Base

Before accessing the optics base interior, purified air from the PAT is diverted to the
base using the service manifold tool (Part No 7A04975). A flow of clean air from the
ducting prevents contamination while the optics modules are exposed.
1. Switch off the platesetter and the PAT.
2. Loosen the PAT filter hose from the Engine door manifold and move the PAT to the
optics base.
3. Remove the optics base cover panel and fix the service manifold as shown in
Figure 7.15. Attach the duct to the service tool and switch on the PAT.
SERVICE
OPTICS MANIFOLD
BASE
DUCTING
TO PAT
Figure 7.15 Fitting the service manifold

Volume-Chapt er
SYSTEM CABLING
DESCRIPTIONS
This chapter describes the system cables, their signal descriptions and pin numbers.
See the next chapter for diagrammatic views of how the cables are interlinked.
4 Cable Pin Descriptions .............................................................................................. 8-1
8.1 Cable Pin Descriptions

8.1.1 I/LOCKS_MAINS (9970-0119)
Label FUSE" BROWN

0.25" FASTON
0.25 FASTON Label REL 9"

200 mm
M4 FORKS M5 FORKS
70 mm
BLUE 270 mm 70 mm
Label 3R 5L3" BLUE
BROWN Label 3R 1L1" BROWN
Label C/B IN"
45 mm 45 mm BLADES
BLUE
150 mm Label NEUTRAL FEED" BLUE
BROWN Label LIVE FEED" BROWN
Label C/B OUT"
0.25" FASTONS
40 mm 40 mm BLADES
Label REL 4" BLUE
150 mm
Label NEUTRAL" BLUE
Label REL 6" BROWN Label LIVE" BROWN
0.25" FASTONS
Label LID" Label BOX"

140 mm
M5 RINGS M5 RINGS
GREEN/YELLOW
VOLUME 2 (8-2) S YSTEM C ABLING DESCRIPTIONS
8.1.2 MAINS_RFI_IN (9970-0122)

Tie wraps Label LIVE DIST"
30 mm Brown
110 mm
200 mm
Blue
Label NEUT DIST"
Label RFI BOX" 120 mm
Label Part No. GREEN/YELLOW Label CHASSIS"
8.1.3 DISK_PWR (9970-0129)

Table 8.1 Disk_PWR
AMP 1-480424-0 (4W) SIGNALS AMP 1-480424-0 (4W) WIRE COLOUR
SSB PL 8 PIN 1 +12V DISK LEFT PIN 1 ORANGE
SSB PL 8 PIN 2 GND DISK LEFT PIN 2 GREY
SSB PL 8 PIN 3 DGND DISK LEFT PIN 3 BLACK
SSB PL 8 PIN 4 +5V DISK LEFT PIN 4 RED
SSB PL 9 PIN 1 +12V DISK RIGHT PIN 1 ORANGE
SSB PL 9 PIN 2 GND DISK RIGHT PIN 2 GREY
SSB PL 9 PIN 3 DGND DISK RIGHT PIN 3 BLACK
SSB PL 9 PIN 4 +5V DISK RIGHT PIN 4 RED
80 mm 80 mm
Label DISK LEFT
Label SSB PL8
400 mm
Label SSB PL6 Label DISK RIGHT

Equates to pin 1
8.1.4 EOD (9970-0135)

Table 8.2 EOD
MOLEX MINIFIT JR SERIES SIGNALS MOLEX MINIFIT JR SERIES WIRE COLOUR COMMENTS
(10W) EODD PL6 (10W) EODHV BD PL9
PIN 1 NOT USED PIN 1
PIN 2 EODX_SIGNA PIN 7 TWIST WITH

L PL6 PIN 7
PIN 3 EODY_SIGNA PIN 8 TWIST WITH

L PL6 PIN 8
PIN 4 +12V PIN 4 ORANGE 18 AWG
PIN 5 +24V PIN 5 WHITE/ 18 AWG

ORANGE
PIN 6 HV_BD_OK~ PIN 6 YELLOW 26 AWG
PIN 7 EODX_RTN PIN 2 26 AWG

Table 8.2 EOD

PIN 8 EODY_RTN PIN 3 26 AWG
PIN 10 GND (+24V) PIN 10 BLACK 18 AWG
Label EODHV BD PL9 Label EODD PL6
Label Pin 1 Label Pin 1
600 mm
8.1.5 CAN2 (9970-0138)

Table 8.3 CAN2
15 D TYPE SIGNAL 15 D TYPE PLG COLOUR COMMENTS
PLG
PIN 1 CHASSIS GND PIN 1 CONNECT SCREEN
PIN2 CAN GND PIN2 BLACK / RED (TWISTED PAIR WITH PIN 3)
BLACK / WHITE
PIN 3 CAN +5V PIN 3 RED / BLACK

WHITE / BLACK
PIN 4 CAN - PIN 4 BLACK / GREEN (TWISTED PAIR WITH PIN 5)
PIN 5 CAN + PIN 5 GREEN / BLACK
PIN 6 RESET - PIN 6 BLACK / YELLOW (TWISTED PAIR WITH PIN 7)
PIN 7 RESET + PIN 7 YELLOW / BLACK
PIN 8 INDEX- PIN 8 BLACK / ORANGE (TWISTED PAIR WITH PIN 9)
PIN 9 INDEX + PIN 9 ORANGE / BLACK
PIN 10 NO CONNECTION PIN 10 (
PIN 11 E_CLK- PIN 11 BLACK / BLUE (TWISTED PAIR WITH PIN 12)
Label SSB CAN SOMB Label SOMB SK3
pin 1 pin 1
1550 mm
8.1.6 MMI (9970-0139)

Table 8.4 MMI
26 W PLG SIGNALS 26 W PLG I COMMENTS
PIN 1 SCREEN PIN 1
PIN 2 DATA_0 PIN 2 TWISTED PAIR WITH PIN 10
PIN 6 +5V PIN 6 TWISTED PAIR WITH PIN 15
PIN 7 XL PIN 7 TWISTED PAIR WITH PIN 8
PIN 8 XR PIN 8
PIN 9 CP+ PIN 9 TWISTED PAIR WITH PIN 18
PIN 10 GROUND PIN 10
PIN 14 LAMP_ON PIN 14 TWISTED PAIR WITH PIN 23
PIN 15 +5V PIN 15
PIN 16 YU PIN 16 TWISTED PAIR WITH PIN 17
PIN 17 YD PIN 17
PIN 18 CP- PIN 18
PIN 19 LOAD PIN 19 TWISTED PAIR WITH PIN 20
PIN 21 FRAME_STA RT PIN 21 TWISTED PAIR WITH PIN 22
PIN 22 DIS PLAY_ON PIN 22
PIN 23 BUZZER PIN 23
PIN 24 +5V PIN 24
PIN 25 VADJ PIN 25 TWISTED PAIR WITH PIN 26
PIN 26 VEE PIN 26
Label m m i Ferrites Label SSB M M I
pin 1 pin 1
50 m m approx 50m m approx

4.2 m etres
8.1.7 INT_S41/S42 (9970-0140)

Table 8.5 INT_S41/S42
AMP CT SIGNALS AMP EI
PL4 PIN 1 NOT USED
PL4 PIN 2 CASS FWD LIMIT SUPPLY S41 PIN 1
PL4 PIN 3 CASS FWD LIMIT GROUND S41 PIN 2
PL4 PIN 4 CASS FWD LIMIT SIGNAL S41 PIN 3 TWISTED PAIR WITH S41 PIN 2
PL2 PIN 1 NOT USED
PL2 PIN 2 CASS REV LIMIT SUPPLY S42 PIN 1
PL2 PIN 3 CASS REV LIMIT GROUND S42 PIN 2
PL2 PIN 4 CASS REV LIMIT SIGNAL S42 PIN 3 TWISTED PAIR WITH S41 PIN 2
Label CASS ID PL4
Label S41
900 mm
Label S42
30 mm 50 mm
Label CASS ID PL2
8.1.8 ENG_INT (9970-0142)

Label FUSE" BROWN
0.25" FASTON
0.25 FASTON Label REL 9"

200 mm
M4 FORKS M5 FORKS
70 mm
BLUE 270 mm 70 mm
Label 3R 5L3" BLUE
BROWN Label 3R 1L1" BROWN
Label C/B IN"
45 mm 45 mm BLADES
BLUE
150 mm Label NEUTRAL FEED" BLUE
BROWN Label LIVE FEED" BROWN
Label C/B OUT"
0.25" FASTONS
40 mm 40 mm BLADES
Label REL 4" BLUE
150 mm
Label NEUTRAL" BLUE
Label REL 6" BROWN Label LIVE" BROWN
0.25" FASTONS
Label LID" Label BOX"

140 mm
M5 RINGS M5 RINGS
GREEN/YELLOW
Table 8.6 Eng_Int connector destinations

CONNECTOR DESTINATION
A ENGINE O/P COVER INTERLOCK

SENSOR
B EXTERNAL INTERLOCK
C INTERLOCK OVERRIDE KEYS-

WITCH
D LOCKS
Table 8.6 Eng_Int connector destinations

E INT_SYSTEM
F ENGINE I/P COVER INTERLOCK

SENSOR
G ENGINE SERVICE COVER INTER-

LOCK SENSOR
H PTM COVER INTERLOCK SENSOR
I ENGINE USER DOOR INTERLOCK

COVER
J BUFFER COVER INTERLOCK SEN-

SOR
Table 8.7 ENG_INT

SIGNAL
J PIN 2 NO LOOP INTO I/LOCKS A PIN 2
A PIN 2 NO LOOP INTO I/LOCKS I PIN 2
I PIN 2 NO LOOP INTO I/LOCKS G PIN 2
G PIN 2 NO LOOP INTO I/LOCKS F PIN 2
F PIN 2 NO LOOP INTO I/LOCKS H PIN 2
H PIN 2 NO LOOP INTO I/LOCKS B PIN 4
B PIN 4 NO LOOP INTO I/LOCKS C TINNED END LABEL PIN 1
J PIN 6 NO LOOP OUT FROM I/LOCKS A PIN 6
A PIN 6 NO LOOP OUT FROM I/LOCKS I PIN 6
I PIN6 NO LOOP OUT FROM I/LOCKS G PIN 6
G PIN 6 NO LOOP OUT FROM I/LOCKS F PIN 6
F PIN 6 NO LOOP OUT FROM I/LOCKS H PIN 6
H PIN 6 NO LOOP OUT FROM I/LOCKS B PIN 9
B PIN 9 NO LOOP OUT FROM I/LOCKS D PIN 2
J PIN 4 S/W COMMON BRIDGE TO O/P COVER A PIN 4
A PIN 4 S/W COMMON O/P COVER TO CUST DOOR I PIN 4
I PIN4 S/W COMMON CUST DOOR TO SERV DOOR G PIN 4
G PIN 4 S/W COMMON SERV DOOR TO I/P COVER F PIN 4
F PIN 4 S/W COMMON I/P COVER TO PANEL H PIN 4
E PIN 8 S/W COMMON IL1R-F TO IL2R_F E PIN 9
H PIN 3 NC LOOP FUSED D PIN 6
J PIN 7 NC LOOP BRIDGE B PIN 2
B PIN 7 NC LOOP AES S22 D PIN 3

Table 8.7 ENG_INT (Continued)

D PIN 3 NC LOOP KEYSWITCH C PIN 4
J PIN 3 NC LOOP BRIDGE TO O/P COVER A PIN 7
A PIN 3 NC LOOPO/P COVER TO CUST DOOR I PIN 7
I PIN 3 NC LOOP CUST DOOR TO SERV DOOR G PIN 7
G PIN 3 NC LOOP SERV DOOR TO I/P COVER F PIN 7
F PIN 3 NC LOOP I/P COVER TO PANEL H PIN 7
D PIN 7 NO LOOP AES S14 C PIN 2
H PIN 9 CONTACTOR F D PIN 4
H PIN 10 CONTACTOR R D PIN 8
J PIN 8 S/W FEEDBACK 1L1_F E PIN 1
A PIN 8 S/W FEEDBACK 1L2_F E PIN 2
I PIN 8 S/W FEEDBACK 1L3_F E PIN 3
G PIN 8 S/W FEEDBACK 1L4_F E PIN 4
F PIN 8 S/W FEEDBACK 1L5_F E PIN 5
H PIN 8 S/W FEEDBACK 1L6_F E PIN 6
J PIN 4 S/W COMMON E PIN 8
H PIN 3 NC LOOP FUSED C PIN 3
8.1.9 INT_STAT (9970-0143)

Table 8.8 INT_STAT
PL 4 SIGNALS PL 8 COMMENTS
PIN 1 INTERLOCK _P1 PIN 1 TWIST WITH PIN 8
PIN 8 INT_RET_P1 PIN 8
CN6 PL 3
PIN 1 L_INTERLOCK PIN 1 TWIST WITH PIN 4
NOT USED PIN 2
NOT USED PIN 3

Table 8.8 INT_STAT

PIN 2 LASER5V PIN 4
8.1.10 CAN5_ENG (9970-0145)

Table 8.9 CAN5_ENG
15 D TYPE PLG SIGNAL 15 D TYPE COLOUR COMMENTS
PLG
BLACK / WHITE

WHITE / BLACK
PIN 6 RESET - PIN 6 BLACK / YEL- (TWISTED PAIR WITH PIN 7)

LOW
PIN 7 RESET + PIN 7 YELLOW /

BLACK
PIN 8 INDEX- PIN 8 BLACK / (TWISTED PAIR WITH PIN 9)

ORANGE
PIN 9 INDEX + PIN 9 ORANGE /

BLACK
PIN 10 NO CONNECTION PIN 10
PIN 12 E_CLK+ PIN 12 BLUE / BLACK
PIN 13 0V PIN 13 BLACK / BROWN (TWISTED PAIR WITH PIN 14)
PIN 14 CAN_SIG_RTN PIN 14 BROWN / BLACK
8.1.11 ENG_FHMBPWR (9970-0146)

Label FHMB 1 PL31
Label I/LOCK BOX PWR 1 pin 1

100 mm
pin 1 120 mm
1100 mm Label PTM PANEL PWR
Label I/LOCK BOX PWR 3 pin 1

230 mm
pin 1
250 mm
pin 1
Label I/LOCK BOX EMERG
pin 1 220 mm
Label PTM PANEL EMERG

Table 8.10 ENG_FHMBPWR

MOLEX (10W) I/ SIGNAL MOLEX (8W) WIRE COLOUR COMMENTS
LOCK BOX PWR 1 FHMB1 PL31
PIN 1 CHASSIS GND PL31 PIN 1 BLACK SCREEN
PIN 2 +24V PL31 PIN 2 WHITE/ORANGE TWIST FHMB PL31 PIN 6
PIN 7 24V GROUND PL31 PIN 6 BLACK

LOCK BOX PWR 3 PTM PANEL
PWR
PIN 1 CHASSIS GND PIN 1 BLACK SCREEN
PIN 2 +24V PIN 2 WHITE/ORANGE TWIST PTM PANEL PWR PIN 6
PIN 3 +24V PIN 3 WHITE/ORANGE TWIST PTM PANEL PWR PIN 7
PIN 4
PIN 5
PIN 6
PIN 7 24V GROUND PIN 6 BLACK
PIN 8 24V GROUND PIN 7 BLACK
PIN 9
PIN 10

MOLEX (6W) SIGNAL MOLEX (6W) WIRE COLOUR COMMENTS
I/LOCK BOX PTM PANEL
EMERG EMERG
PIN 1 CHASSIS GND PIN 1 BLACK SCREEN
PIN 2 +24V EMERG PIN 2 WHITE/ORANGE TWIST WITH PIN 5
PIN 3 PIN 3
PIN 4 PIN 4
PIN 5 24V GND EMERG PIN 5 BLACK
PIN 6 PIN 6

PINS 3 TO 6
PINS 8 TO 10

MOLEX (10W) I/LOCK SIGNAL MOLEX (8W) WIRE COLOUR COMMENTS
BOX PWR 1 FHMB1 PL31
PINS 3 TO 6
PINS 8 TO 10
8.1.12 CAN3_ENG (9970-0147)

Table 8.15 CAN3_ENG
5 D TYPE PLG SIGNAL 15 D TYPE SKT COLOUR COMENTS
BLACK / WHITE

WHITE / BLACK

LOW

BLACK

ORANGE

BLACK
PIN 10 NO CONNEC- PIN 10

TION
Label FHM B 1 SK3 Label PTM PANEL CAN B
pin 1 pin 1
900 mm
8.1.13 PUMP/PTM_PWR (9970-0150)

Label I/LOCK BOX PTM GREEN/YELLOW
Label CHASSIS
Label PANEL PTM
Label LIVE DIST 130 mm
BROWN
30 mm
30 mm
220 mm BROWN
BLUE
1550 mm
150 mm BLUE
300 mm
Label NEUT DIST
GREEN/YELLOW
Label FUSE 220 mm BROWN

220 mm
BROWN 100 mm
BLUE
80 mm 30 mm GREEN/YELLOW
Label I/LOCK BOX PTM
BLUE
100 mm
Label REL 7
Label CHASSIS GREEN/YELLOW Label PUMP OUTLET
8.1.14 FEED_INT (9970-0152)
600 mm
250 mm
Label: PTM NTERLOCK
400 mm
Label INT SYSTEM

Label: ENG PANEL ILOCK and Tie wraps
Part number on Heatshrink
Table 8.16 FEED_INT

MOLEX 10W SIGNAL MOLEX 8W MOLEX 6W
PIN 1 PIN 1
PIN 2 NO LOOP INTO I/ PIN 2

LOCKS
PIN 3 NC LOOP FUSED PIN 3
PIN 4 S/W COMMON PIN 4
PIN 5 PIN 5
PIN 6 NC LOOP FROM PIN 6

I/LOCK
PIN 7 NC LOOP PIN 7

RETURN
PIN 8 S/W FEEDBACK PIN 8

1L6_F
PIN 9 CONTACTOR F PIN 3
PIN 10 CONTACTOR R PIN 4

8.1.15 CAN5_INT (9970-0155)

Label FHMB3 SK3 Label ENG PANEL CAN A
pin 1 pin 1
PLG SKT
820 mm
Table 8.17 CAN5_INT

15 D TYPE PLG SIGNAL 15 D TYPE SKT COLOUR COMMENTS
BLACK / WHITE

WHITE / BLACK
PIN 8 INDEX- PIN 8 BLACK / ORANGE (TWISTED PAIR WITH PIN 9)
PIN 9 INDEX + PIN 9 ORANGE / BLACK

TION

TION
8.1.16 PWR3_INT (99700156)

Label ENG PANEL
PWR and Part number
pin 1
120 mm 200 mm
pin 1 Label FHMB3 PL31
pin 1
Approx 50 mm Cable tie
1700 mm Label FHMB2 PL31
Label REL 7
760 mm 25 m m
Label REL 9
Table 8.18 PWR3_INT

ENG PANEL SIGNAL FHMB2/FHMB3 WIRE COLOUR COMMENTS
PWR
Table 8.18 PWR3_INT (Continued)

PIN 1 CHASSIS GND FHMB 3 PL31 PIN 1 BLACK SCREEN
FHMB 2 PL31 PIN 1
PIN 2 +24V FHMB 2 PL31 PIN 2, WHITE/ORANGE TWIST WITH FHMB 2 PL31 PIN
REL 7 (FASTON) 6, TWIST WITH REL 9
PIN 3 +24V FHMB 3 PL31 PIN 2 WHITE/ORANGE TWIST WITH FHMB 3 PL31 PIN 6
PIN 4
PIN 5
PIN 6 24V GROUND FHMB 2 PL31 PIN 6 BLACK

REL 9 (FASTON)
PIN 7 24V GROUND FHMB 3 PL31 PIN 6 BLACK
PIN 8
8.1.17 CAN3_INT (9970-0157)

Label ENG Panel CAN B Cable 1
700 mm 290 mm
Cable 1 Label FHM B2 SK1
550 mm
Cable 2 220 mm Label FHM B2 SK3
320 mm Cable 2
Tie wraps every 100mm
Label FHM B3 SK1
Table 8.19 CAN3_INT

15 D TYPE PLG SIGNAL 15 D TYPE PLG COLOUR COMMENTS
BLACK / WHITE

WHITE / BLACK

LOW

BLACK

ORANGE

BLACK
PIN 10 NO CONNEC- PIN 10 (

TION

Table 8.19 CAN3_INT (Continued)

TION
8.1.18 ENG_M7 (9970-0159)
L a b e l F H M B 4 P L 3 0 L a b e l P R O C P A N E L
M 7
p in 1
9 5 0 m m
Table 8.20 ENG_M7

6 WAY JST SIGNALS 10 WAY MOLEX
PIN 1 OUT A PIN 2 TWIST PAIR WITH 6 WAY PIN 5
PIN 2 OUT C PIN 4 TWIST PAIR WITH 6 WAY PIN 6
PIN 3 +24V PIN 3 TWIST PAIR WITH 6 WAY PIN 4
PIN 4 +24V PIN 8
PIN 5 OUT B PIN 7
PIN 6 OUT D PIN 9
NOT USED PIN 1
NOT USED PIN 5
NOT USED PIN 6
NOT USED PIN 10

8.1.19 RIB/RIB2 (9970-0161)

View from non CABLE 1
connection sides
200 mm
pin 1
Label FHMB 4 PL18"

As close as possible to connector 570 mm
Label DIST BD PL5"

As close as possible to connector
350 mm
View from non CABLE 2

connection sides
190 mm
pin 1
Label FHMB 4 PL19"

As close as possible to connector 630 mm
Label 24V DIST PL11"

As close as possible to connector
pin 1
270 mm
8.1.20 BUFF_M7 (9970-0168)

Part number
Label PANEL Label M 7
pin 1
100 mm
Table 8.21 BUFF_M7

6 WAY JST SIGNALS 10 WAY MOLEX
PIN 6 OUT A PIN 2 TWIST PAIR WITH 6 WAY

PIN 2
PIN 5 OUT C PIN 4 TWIST PAIR WITH 6 WAY

PIN 1
PIN 4 +24V PIN 3 TWIST PAIR WITH 6 WAY

PIN 3
PIN 3 +24V PIN 8
PIN 2 OUT B PIN 7
PIN 1 OUT D PIN 9
NOT USED PIN 1
NOT USED PIN 5
NOT USED PIN 6
NOT USED PIN 10

8.1.21 INT_S62/S71 (9970-0177)
Label FHMB 2 PL9 Label S62
520 mm
Label S71
30 mm

PIN 1 NOT USED
PIN 2 X DIRECETION DOOR UP SUPPLY S62 PIN 1
PIN 3 X DIRECETION DOOR UP GROUND S62 PIN 2
PIN 4 X DIRECETION DOOR UP SIGNAL S62 PIN 3 TWISTED PAIR

WITH S62 PIN 2
PIN 5 NOT USED
PIN 6 X DIRECETION DOOR DOWN SUPPLY S71 PIN 1
PIN 7 X DIRECETION DOOR DOWN GROUND S71 PIN 2
PIN 8 X DIRECETION DOOR DOWN SIGNAL S71 PIN 3 TWISTED PAIR

WITH S71 PIN 2
8.1.22 INT_S56/57/65 (9970-0178)
Label DIST PL6" Label S56

30 mm Cable 1
Cable 1 960 mm
100 mm Label S57
Label DIST PL9" 40 mm
Label S65 - 1
Cable 2 Label S65 - 4
Label FHMB 2 390 mm Cable 2
PL23"
Table 8.23 INT_S56/57/65

PL 6 PIN 1 NOT USED
PL 6 PIN 2 RETARD UP SUPPLY S56 PIN 1
PL 6 PIN 3 RETARD UP GROUND S56 PIN 2
PL 6 PIN 4 RETARD UP SIGNAL S56 PIN 3 TWISTED PAIR WITH S56 PIN 2
PL 9 PIN 1 NOT USED
PL 9 PIN 2 RETARD DOWN SUPPLY S57 PIN 1
PL 9 PIN 3 RETARD DOWN GROUND S57 PIN 2
PL 9 PIN 4 RETARD DOWN SIGNAL S57 PIN 3 TWISTED PAIR WITH S57 PIN 2
PL 23 PIN 1 NOT USED

Table 8.23 INT_S56/57/65 (Continued)

PL 23 PIN 3 CASS AT NUDGER GND S65-1 FASTONTWISRED PAIR WITH OTHER FASTON
PL 23 PIN 4 CASS AT NUDGER SIGNAL S65-4 FASTON
8.1.23 ENG_S4 (9970-0183)

Label DIST O/P PL2
pin 1 pin 1
Label S4
730 mm
Table 8.24 ENG_S4

AMP CT SIGNALS AMP CT
PIN 1 PLATE IN OUTPUT PUL_GND S4 PIN 1 TWISTED PAIR WITH S4 PIN 2
PIN 2 PLATE IN OUTPUT SUPPLY S4 PIN 2
PIN 3 PLATE IN OUTPUT GROUND S4 PIN 3 TWISTED PAIR WITH S4 PIN 4
PIN 4 PLATE IN OUTPUT GND SIGNAL S4 PIN 4
8.1.24 INT_S49/S50 (9970-0186)

Label DIST PL8"
140 mm
90 mm Label S49
880 mm
120 mm
24V DIST PL7"
Label S50
Label
PL 8 PIN 1 RETARD MADE PUL_GND S49 PIN 1 TWISTED PAIR WITH S49 PIN 2
PL 8 PIN 2 RETARD MADE SUPPLY S49 PIN 2
PL 8 PIN 3 RETARD MADE GROUND S49 PIN 3 TWISTED PAIR WITH S49 PIN 4
PL 8 PIN 4 RETARD MADE SIGNAL S49 PIN 4
PL 7 PIN 1 NO CONNECTION
PL 7 PIN 2 PLATE AT PRE DIVERTER S50 BROWN WIRE
PL 7 PIN 3 PLATE AT PRE DIVERTER S50 BLACK WIRE
PL 7 PIN 4 PLATE AT PRE DIVERTER S50 BLUE WIRE

8.1.25 ENG_S5 (9970-0187)

Label DIST O/P PL8
Label S5
730 mm
Table 8.26 ENG_S5

PL8 PIN 1 PLATE LEFT OUTPUT S5 PIN 1 WISTED PAIR WITH S5 PIN 2
PUL_GND
PL8 PIN 2 PLATE LEFT OUTPUT SUPPLY S5 PIN 2
PL8 PIN 3 PLATE LEFT OUTPUT GROUND S5 PIN 3 TWISTED PAIR WITH S5 PIN 4
PL8 PIN 4 PLATE LEFT OUTPUT SIGNAL S5 PIN 4
8.1.26 INT_S52 (9970-0188)

Label DIST PL2
pin 1 pin 1
Label S52
1000 mm
Table 8.27 INT_S52

PIN 1 PARK POS PRE INPUT PUL_GND S52 PIN 1 TWISTED PAIR WITH S52 PIN 2
PIN 2 PARK POS PRE INPUT SUPPLY S52 PIN 2
PIN 3 PARK POS PRE INPUT GROUND S52 PIN 3 TWISTED PAIR WITH S52 PIN 4
PIN 4 PARK POS PRE INPUT SIGNAL S52 PIN 4
8.1.27 ENG_S10/11 (9970-0190)

30 mm

Label S10" 50 mm Label DIST O/ P PL6"
230 mm

Label DIST O/ P PL9"

Label S11"
50 mm 80 mm

Label DIST O/ P PL12"
Table 8.28 ENG_S10/11

PL6 PIN 1 NOT USED
PL6 PIN 2 REG MOTOR OUT POS SUPPLY S10 PIN 1
PL6 PIN 3 REG MOTOR OUT POS GROUND S10 PIN 2
PL6 PIN 4 REG MOTOR OUT POS SIGNAL S10 PIN 3 TWISTED PAIR WITH S10
PIN 2
Table 8.28 ENG_S10/11 (Continued)

PL9 PIN 1 NOT USED
PL9 PIN 2 REG MOTOR IN POS SUPPLY S11 PIN 1
PL9 PIN 3 REG MOTOR IN POS GROUND S11 PIN 2
PL9 PIN 4 REG MOTOR IN POS SIGNAL S11 PIN 3 TWISTED PAIR WITH S10
PIN 2
PL12 PIN 1
PL12 PIN 2 CAN ID LINK TO PL 12 PIN 3
PL12 PIN 3 GND
8.1.28 ENG_S14/12/3 (9970-0194)
580 mm 670 mm
Approx 344 mm
Approx 344 mm
800 mm
Label S13
Label S12
550 mm
310 mm 210 mm This end piece has the pins fo
130 mm
Label S14
100 mm Label DIST O/P PL7"
Label S3
50 mm Label 24V DIST PL2"
This end piece has the pins for the links Label DIST O/P PL11"
Label PL11"
Label DIST O/P PL10"
Label SK11"
Cable free to move within the chain 50 mm
Label PL10"
Label SK10"
28 mm radius
12 mm
Table 8.29 ENG_S14/12/3

PL7 PIN 1 NOT USED
PL7 PIN 2 CENTERING HOME SUPPLY S14 PIN 1
PL7 PIN 3 CENTERING HOME GROUND S14 PIN 2
PL7 PIN 4 CENTERING HOME SIGNAL S14 PIN 3 TWISTED PAIR WITH S14 PIN
2
PL2 PIN 1 DETECT LE PUNCH PUL GND S3 PIN 1 TWISTED PAIR WITH S3 PIN 2
PL2 PIN 2 DETECT LE PUNCH SUPPLY S3 PIN 2
PL2 PIN 3 DETECT LE PUNCH GROUND S3 PIN 3 TWISTED PAIR WITH S3 PIN 4
PL2 PIN 4 DETECT LE PUNCH SIGNAL S3 PIN 4
(DRAG CHAIN ASSY)
PL10 PIN 1 CENTERING RH DETECT GROUND S12 PIN1
PL10 PIN 2 CENTERING RH DETECT SIGNAL S12 PIN2
(DRAG CHAIN ASSY)

Table 8.29 ENG_S14/12/3 (Continued)

PL11 PIN 1 CENTERING LH DETECT GROUND S13 PIN1
PL11 PIN 2 CENTERING LH DETECT SIGNAL S13 PIN2
DIST O/P PL11 PIN 1 NOT USED
DIST O/P PL11 PIN 3 CENTERING LH DETECT GROUND SK11 PIN1
DIST O/P PL11 PIN 4 CENTERING LH DETECT SIGNAL SK11 PIN2
DIST O/P PL10 PIN 3 CENTERING RH DETECT GROUND SK10 PIN1
DIST O/P PL10 PIN 4 CENTERING RH DETECT SIGNAL SK10 PIN2
8.1.29 ENG_S8/S9 (9970-0195)
Label INPUT DIST PL6" 60 mm

Label
850 mm
Label INPUT DIST PL9"
Label
Label INPUT DIST PL12"

90 mm
80 mm
Table 8.30 ENG_S8/S9

(PL6) PIN 1 NOT USED
(PL6) PIN 2 PUNCH MOTOR ON SUPPLY S8 PIN 1
(PL6) PIN 3 PUNCH MOTOR ON GROUND S8 PIN 2
(PL6) PIN 4 PUNCH MOTOR ON SIGNAL S8 PIN 3 TWISTED PAIR WITH

S8 PIN 2
(PL9) PIN 1 NOT USED
(PL9) PIN 2 PUNCH MOTOR OFF SUPPLY S9 PIN 1
(PL9) PIN 3 PUNCH MOTOR OFF GROUND S9 PIN 2
(PL9) PIN 4 PUNCH MOTOR OFF SIGNAL S9 PIN 3 TWISTED PAIR WITH
S8 PIN 2
PL12 PIN 1
PL12 PIN 3 GND

8.1.30 INT_M22ASSY (9970-0198)
Label PUM P REL A Label 24V DIST PL8
Label PUM P REL B 190 mm

Label B M24
30 mm 850 mm 300 mm
Label FHM B 3 PL2
80 mm
Label BM
510 mm 570 mm
30 mm 40 mm 50 mm 20 mm
170 mm
Label BM 22
20 mm 30 mm Sleeve
70 mm 530 mm
Label FHM B 3 PL1

Label FHM B3 PL22
Label FHM B3 PL20 Label B V20
L b l FHM B 3 PL10
Table 8.31 INT_M22ASSY
AMP 3 WAY SIGNALS MOLEX WIRE COLOUR
PL15 PIN 1 NOT USED BM24 PIN 1
PL15 PIN 3 DC_MOT_A BM24 PIN 3 RED TWISTED PAIR WITH BM24 PIN 3
PL15 PIN 2 DC_MOT_B BM24 PIN 2 BLACK
(NOTE THIS MOTOR PIN OUT IS REVERSED)
PL10 PIN 1 NOT USED BV20 PIN 1
PL10 PIN 2 DC_MOT_A BV20 PIN 2 RED TWISTED PAIR WITH BV20 PIN 3
PL10 PIN 3 DC_MOT_B BV20 PIN 3 BLACK
8 W MOLEX
PL1 PIN 1 NOT USED
PL1 PIN 2 NOT USED
PL1 PIN 3 NOT USED
PL1 PIN 4 NOT USED
PL1 PIN 5 +24V PUMP REL A GREEN TWISTED PAIR WITH BV23 -
PL1 PIN 6 SOL 1 PUMP REL B BLACK
PL1 PIN 7 +24V (BV24) PL 8 PIN 2 YELLOW TWISTED PAIR WITH BV8 PIN 3
PL1 PIN 8 SOL 2 (BV24) PL 8 PIN 3 BLACK
2 W MOLEX
PL2 PIN 2 24 V GND PL8 PIN 1 BLACK
PL2 PIN 1 NOT USED

8.1.31 INT_S55/59 (9970-0210)
Label 24V DIST PL12
750 mm Label 24V DIST PL9

350 mm
Label S59 Label 24V DIST PL3

Tie wraps
Rubber Sleeve 100 mm

80 mm
Label S55
Table 8.32 INT_S55/59

PL9 PIN 1 PLATE PAST DIVERTER S59 PIN 1 TWISTED PAIR WITH S59 PIN 2
PUL_GND
PL9 PIN 2 PLATE PAST DIVERTER SUP- S59 PIN 2

PLY
PL9 PIN 3 PLATE PAST DIVERTER S59 PIN 3 TWISTED PAIR WITH S59 PIN 4
GROUND
PL9 PIN 4 PLATE PAST DIVERTER SIG- S59 PIN 4

NAL
AMP CT
PL3 PIN 1 NOT USED
PL3 PIN 2 PAPER POST DIVERTER S55

BROWN WIRE +24V
PL3 PIN 3 PAPER POST DIVERTER SIG- S55

BLACK WIRE NAL
PL3 PIN 4 BLUE PAPER POST DIVERTER S55

WIRE GROUND
PL12 PIN 1
PL12 PIN 3 GND
8.1.32 INT_S66/S53 (9970-0214)

Label 24V DIST PL6
Label S66
100 mm 60 mm
910 mm
2 PIN
Label S53
Label DIST PL11

PL6 PIN 1 INTERLEAF NIP CLEAR PUL_GND S66 PIN 1 TWISTED PAIR WITH S66 PIN 2
PL6 PIN 2 INTERLEAF NIP CLEAR SUPPLY S66 PIN 2


PL6 PIN 3 INTERLEAF NIP CLEAR GROUND S66 PIN 3 TWISTED PAIR WITH S66 PIN 4
PL6 PIN 4 INTERLEAF NIP CLEAR SIGNAL S66 PIN 4
AMP CT 2 W MOLEX
PL11 PIN 1 NOT USED
PL11 PIN 2 NUDGER DOWN LIMIT SUPPLY
PL11 PIN 3 NUDGER DOWN LIMIT GROUND S53 PIN 1
PL11 PIN 4 NUDGER DOWN LIMIT SIGNAL S53 PIN 2 TWISTED PAIR WITH S53 PIN 1
8.1.33 INT_OUT (9970-0216)

95 mm 30 mm 40 mm
30 mm
Cable ties every 100mm
Label FHMB2 PL14 Label FHMB2 PL24 Label FHMB2 PL26

Label ELV PANEL LOCK
Label INT-SYSTEM
350 mm
240 mm
10
Label FHMB2 PL1
70 mm 100 mm 15 mm 40 mm 15 mm 80 mm
110 mm 50 mm
40 mm
Label ELV PAN
Label FHMB2 PL8 Label FHMB2 PL15

Table 8.34 INT_OUT

26 WAY SIGNALS AWG TWISTED PAIRS
PIN 1 NOT USED
PIN 2 SOL 0 PL 1 PIN 3 24 TWIST PAIR 26W PIN 11
PIN 6 BS74 PL 24 PIN3 26 TWIST PAIR 26W PIN 15
PIN 7 BS75 PL 26 PIN 3 26 TWIST PAIR 26W PIN 16
PIN 8 NOT USED
PIN 9 NOT USED
PIN 10 NOT USED
PIN 11 SOL 0 RTN PL 1 PIN 4 24
PIN 15 BS74 RTN PL 24 PIN 4 26
PIN 17 NOT USED
PIN 18 NOT USED

Table 8.34 INT_OUT (Continued)

PIN 19 NOT USED
PIN 20 NOT USED
PIN 21 NOT USED
PIN 24 CONTACT_24VR 6W MOLEX 24

TN PIN 4
PIN 25 NOT USED
PIN 26 NOT USED
14W MOLEX
PIN 1 NOT USED
PIN 2 LOCK PL 8 PIN 2 24 TWIST PAIR 14W PIN 9
PIN 3 BM28 PL 16 PIN 3 24 TWIST PAIR 14W PIN 10
PIN 4 CONTACT_24V 6W MOLEX 24

PIN 3
PIN 5 SUPPLY FOR PL10 PIN 2 24 OR 26 TWIST WITH 14W PIN 12

BS78
PIN 6 NOT USED
PIN 8 NOT USED
PIN 9 LOCK RTN PL 8 PIN 3 24
PIN 10 BM28 RTN PL 16 PIN 2 24
PIN 11 NOT USED
PIN 12 DOCK LIGHT PL10 PIN 3 24 OR 26

RTN
PIN 13 NOT USED
8.1.34 RIB7 (9970-0219)

Label FHMB POS2 PL18"
Reverse side
View from non connection side
580 mm
Label ELV PANEL" 60 mm Part number on

reverse side
pin 1
st nd
1 Fold 2 Fold
Table 8.35 RIB7

26 WAY SIGNALS 37 WAY
PIN 1 ANODE PIN 1
PIN 2 CATHODE PIN 20
PIN 3 GND PIN 2
PIN 4 SEN 8 PIN 21
PIN 5 GND PIN 3
PIN 6 SEN 9 PIN 22
PIN 7 +5V PIN 4
PIN 8 SEN 10 PIN 23
PIN 9 GND PIN 5
PIN 10 SEN 11 PIN 24
PIN 11 +5V PIN 6
PIN 12 PULSE SEN 8 PIN 25
PIN 16 5V PIN 27
PIN 17 SEN 16 PIN 9
PIN 18 GND PIN 28
PIN 19 SEN 0 PIN 10
PIN 20 5V PIN 29
PIN 21 SEN 1 PIN 11
PIN 22 GND PIN 30
PIN 23 SEN 2 PIN 12
PIN 24 5V PIN 31
PIN 25 SEN 3 PIN 13
PIN 26 BRD _ID0 PIN 32
NOT USED PIN 14
NOT USED PIN 33
NOT USED PIN 15
NOT USED PIN 34
NOT USED PIN 16
NOT USED PIN 35
NOT USED PIN 17
NOT USED PIN 36
NOT USED PIN 18
NOT USED PIN 37
NOT USED PIN 19

8.1.35 ENG_DIAGS (9970-0221)
Label SSB DIAGS Label EXTPANEL DIAGS
pin 1 pin 1
750mm
Table 8.36 ENG_DIAGS

9 D TYPE PLG SIGNAL 9 D TYPE SKT COMMENTS
PIN2 TX PIN2 (TWISTED PAIR WITH PIN 3)
PIN 3 RX PIN 3
PIN 4 PIN 4
PIN 5 GROUND PIN 5
PIN 6 PIN 6
PIN 7 PIN 7
PIN 8 PIN 8
PIN 9 PIN 9
8.1.36 ALERT (9970-0223)

Cable tie at break point
Label EXT ALERT PANEL Label ALERT
REL PIN 7
pin 1
Label ALERT
270 mm REL PIN 4
50 mm
Table 8.37 ALERT
9 WAY D SKT SIGNALS
PIN 1 SPARE
PIN 2 ALERT IN REL PIN 7 FASTON TWISTED PAIR WITH OTHER FASTON
PIN 3 ALERT OUT REL PIN 4 FASTON
PIN 4 SPARE
PIN 5 SPARE
PIN 6 SPARE
PIN 7 SPARE
PIN 8 SPARE
8.1.37 INT_MAINS (9970-0226)

Label PTM PANEL
240 mm
Label PUMP REL 4
80 mm
25 mm 55 mm BLUE
BLUE
900 mm BROWN
BROWN
GN/YL Label PUMP REL 6

Sleeve
Label ELV MAINS 100 mm
M5
Label CHASSIS
GN/YL
8.1.38 RIB8 (9970-0229)

360 mm
500 mm 140 mm Label ELV DIST

120 mm PL5
Part number etc
View from non connection side

Label PTM PANEL
Table 8.38 RIB8

26 WAY SIGNALS 26 WAY
PIN 1 ANODE PIN 1
PIN 2 CATHODE PIN 20
PIN 3 GND PIN 2
PIN 4 SEN 8 PIN 21
PIN 5 GND PIN 3
PIN 6 SEN 9 PIN 22
PIN 7 +5V PIN 4
PIN 8 SEN 10 PIN 23
PIN 9 GND PIN 5
PIN 10 SEN 11 PIN 24
PIN 11 +5V PIN 6
PIN 16 5V PIN 27
PIN 17 SEN 16 PIN 9
PIN 18 GND PIN 28
PIN 19 SEN 0 PIN 10

Table 8.38 RIB8

PIN 20 5V PIN 29
PIN 21 SEN 1 PIN 11
PIN 22 GND PIN 30
PIN 23 SEN 2 PIN 12
PIN 24 5V PIN 31
PIN 25 SEN 3 PIN 13
PIN 26 BRD _ID0 PIN 32
NOT USED PIN 14
NOT USED PIN 33
NOT USED PIN 15
NOT USED PIN 34
NOT USED PIN 16
NOT USED PIN 35
NOT USED PIN 17
NOT USED PIN 36
NOT USED PIN 18
NOT USED PIN 37
NOT USED PIN 19
8.1.39 ELV_CTRL (9970-0230)

100 mm Label: INV AL0"
Label: INV AL2" Label: INV L"

Label: INV BEHIND LID" 100 mm Label: INV 6"
Label: INV 4"
Label: INV 3"
Label: INV UPPER BLK"
Label: INV 2
Label: ELEV BD PL1"
70 mm 100 mm Label: INV 1"
50 mm
1350 mm
Label: INV P24"
100 mm Label: INV LOWER BLK"
Label: INV P24"
100 mm All 80 mm
Label: ELEV BD PL4"
Label: INV CM2"

Label: SIE 21NC"
40 mm
Label: INV 12"
80 mm
40 mm Label: SIE A2-" Label: INV 11"

100 mm
Label: SIE 22NC"
All 6mm tinned ends
Tie wraps
Table 8.39 ELV_CTRL

MOLEX SIGNAL ENDS COLOUR LABEL & COMMENTS
PL4 PIN 1 P24V 6MM TINNED BLUE LABEL: INV-P24 TWISTED WITH PIN 8
PL4 PIN 2 FWD 6MM TINNED BROWN LABEL: INV-1 TWISTED WITH PIN 4
PL4 PIN 3 NOT USED
PL4 PIN 4 REV 6MM TINNED YELLOW LABEL: INV-2
PL4 PIN 5 NOT USED
PL4 PIN 6 FAST 6MM TINNED ORANGE LABEL: INV-3
PL4 PIN 7 NOT USED
PL4 PIN 8 RST 6MM TINNED RED LABEL: INV-6

Table 8.39 ELV_CTRL (Continued)

PL4 PIN 9 NOT USED
PL4 PIN 10 ALARM 6MM TINNED WHITE LABEL: INV-12 TWISTED WITH PIN 12
PL4 PIN 11 NOT USED
PL4 PIN 12 OVERLOAD 6MM TINNED BLACK LABEL: INV-11
PL1 PIN 1 NOT USED
PL1 PIN 2 BS73 BLADE WHITE LABEL: SIE-21NC TWISTED WITH PIN 3
PL1 PIN 3 BS73_RTN BLADE WHITE/ORANGE LABEL: SIE-22NC
PL1 PIN 4 CONT_24V_R BLADE BLACK LABEL: SIE-A2-
LABEL INV-L GND ALARM 6MM TINNED BLACK LABEL INV-CM2
LABEL INV AL2 ALARM INPUT 6MM TINNED WHITE/BLUE LABEL INV-4
LABEL INV AL0 ALARM INPUT 6MM TINNED BLUE LABEL INV-P24
8.1.40 MAINS_ELV_IN (9970-0231)

0.25" FASTON Label CHASSIS PANEL" M5
GREEN/YELLOW 100 mm
Label MAINS PTM 0.25" FASTON

Label FILTER" 50 mm BROWN
750 mm BLUE
0.25" FASTON
Label PANEL" GREEN/YELLOW Label FILTER"

150 mm
M5 0.25" FASTON
Label FRAME"
GREEN/YELLOW 100 mm M5
Label FRAME" GREEN/YELLOW Label LID"

M5 M5
450 mm
Label INV L1"

BROWN M4 INSULATED FORK
35 mm 40 mm
0.25" FASTON BROWN
50 mm
0.25" FASTON
55 mm BLUE
40 mm
BLUE M4 INSULATED FORK
Label FILTER"
Label INV N"
8.1.41 ELV_IN (9970-0236)
Label E LV C T RL SK 1 Label PT M PA N EL
pin 1 pin 1
500 mm
Table 8.40 ELV_IN

26 W PLG SIGNAL 26 W PLG COMMENTS
Table 8.40 ELV_IN (Continued)

PIN2 SOL 0 PIN2 (TWISTED PAIR WITH PIN 11)
PIN 3 SOL 1 PIN 3 (TWISTED PAIR WITH PIN 12)
PIN 6 BS 74 PIN 6 (TWISTED PAIR WITH PIN 15)
PIN 11 SOL 0 RTN PIN 11
PIN 15 BS74 RTN PIN 15
PIN 24 CONTACT 24 RTN PIN 24
8.1.42 ELV_LOCK (9970-0237)

Label PTM
PANEL LOCK Label BM28
70 mm
750 mm
270 mm Label S63
50 mm 50 mm
Label S70
Label TOP 1250 mm 230 mm Label BS78
60 mm
LIMIT 11
1600 mm Label DOCK
80 mm LIGHT 50 mm
Label ELV
DIST PL4
450 mm 70 mm
Label ELV Labe
700 mm 760 mm
DIST PL3
100 mm Label LOCK
Table 8.41 ELV_LOCK

14 W MOLEX
Table 8.41 ELV_LOCK (Continued)

PIN 1 NOT USED
PIN 2 LOCK 8W PIN 2 BLACK TWIST WITH PIN 9
PIN 3 DC_MOT_A PIN 2 RED TWIST PAIR WITH PIN

(BM28) 10
PIN 4 CONTACTOR_24V 8W PIN 4 GREEN
PIN 5 SUPPLY TO BS78 BS78 PIN 2 YELLOW
PIN 6 NOT USED
PIN 7 BS72 8W PIN 3 RED TWIST WITH PIN 14
PIN 8 NOT USED
PIN 9 LOCK_RTN 8W PIN 6 WHITE
PIN 10 DC_MOT_B PIN 3 BLACK

(BM28)
PIN 11 NOT USED
PIN 12 DOCK LIGHT RTN FASTON YELLOW
PIN 13 NOT USED
PIN 14 BS72_RTN 8W PIN 7 ORANGE
M4 LABEL TOP CONTACTOR_24V 8W PIN 8 RED

LIMIT 11
BS78 PIN 3 BS78 TO BS77 BS77 PIN 2 YELLOW
BS77 PIN 3 BS77 TO DOCK LIGHT FASTON YELLOW
AMP CT 4 WAY AMP EI 3

WAY
PL4 PIN 1 NOT USED
PL4 PIN 2 Z DIRECT DWN SUPP S70 PIN 1
PL4 PIN 3 Z DIRECT DWN GND S70 PIN 2
PL4 PIN 4 Z DIRECT DWN SIG S70 PIN 3 TWIS PAIR WITH S70 PIN 2
PL3 PIN 1 NOT USED
PL3 PIN 2 Z DIRECT UP SUPP S63 PIN 1
PL3 PIN 3 Z DIRECT UP GND S63 PIN 2
PL3 PIN 4 Z DIRECT UP SIG S63 PIN 3 TWIST PAIR WITH S63 PIN 2
8.1.43 ELV_CON_24V (9970-0238)

Label: Bottom limit 11" Part number here
orange wire M4
M4 red 1.65 m ring
130 mm
ring terminal
70 mm
M4 red 550 mm
ring terminal Tie wraps RED wire
Label: Bottom limit 12" Label: SIE A1+"

Place 80mm from this en
Table 8.42 ELV_CON_24V

WIRE NO. END 1 SIGNAL END 2 WIRE COLOUR
1 M4 RED RING TERMINAL ELEVATOR_ M4 RED RING TERMINAL ORANGE

LABEL BOTTOM LIMIT 11 ENABLE_2 LABEL TOP LIMIT 12
2 M4 RED RING TERMINAL ELEVATOR_ INSULATED BLADE RED

LABEL BOTTOM LIMIT 12 ENABLE_3 LABEL SIE A1+
8.1.44 ENG_PROC (9970-0239)

Label: Bottom limit 11 Part number here
orange wire M4 red
M4 red 1.65 m ring terminal
130 mm
ring terminal
70 mm
M4 red 550 mm
ring terminal Tie wraps
RED wire
Label: Bottom limit 12 Label: SIE A1+

Place 80mm from this end
Table 8.43 ENG_PROC

9 D TYPE PLG SIGNAL 9 D TYPE SKT COMMENTS
PIN2 TX PIN2 (TWISTED PAIR WITH PIN 3)
PIN 3 RX PIN 3
PIN 4 PIN 4
PIN 5 GROUND PIN 5
PIN 6 PIN 6
PIN 7 SIGNAL 1 PIN 7
PIN 9 PIN 9
8.1.45 MAINS_INT_PUMP (9970-0240)

Label PUMP RELAY
REL 7"
80 mm
40 mm BLUE
0.25" Faston
BLUE
M4 (x2)
M5
650 mm 110 mm
BROWN Green / Yellow
Label CHASSIS"
30 mm
Label PUMP MOTOR"

30 mm
55 mm Brown
Tie wraps
GREEN / 0.25" Faston x2
YELLOW 0.25" Faston
50 mm
Label CHASSIS"
Brown
M4 Label PUMP 55 mm
50 mm
RELAY REL 9
Label C/BREAKER"
8.1.46 MAINS_DIST (9970-0243)
FUSE HOLDER
Label PSU 3 PIN 25 mm
20 mm 260 mm
BROWN 1
4.8x0.5 FASTONS
2
3 70 mm
BLUE Tie wrap at branch points and
connector and every 100mm
30 mm
50 mm
BROWN BROWN Label 3R 2T1
Label FILTER
430 mm
BLUE BLUE
100 mm 30 mm
Label 3R 6T3
Part number here

100 mm
M5 100 mm
Label CHASSIS
GREEN/YELLOW
GREEN/YELLOW M5 Label CHASSIS
GREEN/YELLOW
Label CHASSIS Label FILTER
100 mm
M5 M4
8.1.47 INT_EMERG (9970-0246)
Label EMERG STOP

SWITCH MMI END 50 mm
Label PANEL EMERG
2300 mm
pin 1
310 mm
750 mm
Label EMERG 50 mm
STOP SWITCH
Table 8.44 INT_EMERG

10W MOLEX SIGNALS
PIN 1
PIN 2 +24V M4 EMERG STOP WHITE/ORANGE
PIN 3
PIN 4
PIN 5 GND M4 EMERG STOP MMI END WHITE/

ORANGE
PIN 6
M4 EMERG LINK M4 EMERG STOP MMI END GREEN

STOP
8.1.48 I/LOCK_DC (9970-0252)
100 mm
15 mm AES S14
30 mm 15 mm
70 mm
AES A1+ 30 mm
70 mm
40 mm AES S13
5 mm AES A2- 40 mm
30 mm AES 14 5 mm
70 mm AES 13 110 mm
40 mm
5 mm AES S21
30 mm AES 24 5 mm
70 mm 30 mm
AES 23
70 mm
40 mm
AES S22 AES X1 40 mm
10 mm
10 mm
40 mm 40 mm 40 mm 40 mm
SIE A1+ SIE A2-
20 mm SIE 21NC SIE 22NC 20 mm

40 mm 40 mm 40 mm 40 mm
SIE 5L3 SIE 6T3
20 mm SIE 3L2 SIE 4T2 20 mm

80 mm 80 mm
SIE 1L1 SIE 2T1
10 mm 50 mm 10 mm
F1B 50 mm
F1A
10 mm 50 mm 10 mm
F2B F2A 50 mm
10 mm 50 mm 50 mm 10 mm
F3B F3A
15 mm 15 mm
50 mm 50 mm
60 mm 60 mm
40 mm 40 mm 40 mm 40 mm
30 mm 30 mm
100 mm
PWR IN PWR 3 PWR 2 PWR 1 I/LOCKS SHUTTER
80mm
AUX CONTACT MODUAL

51 NC
52 NC
25mm
Table 8.45 I/LOCK _DC

PIN SIGNAL COLOUR
SHUTTER PIN 1 CHASSIS GND M5 BLACK
SHUTTER PIN 2 NOT USED
SHUTTER PIN 3 AES 13 RED
SHUTTER PIN 6 AES 14 BLUE


I/LOCK PIN 1 I_LOCK GROUND 51 NC BLACK
I/LOCK PIN 2 F1A YELLOW
I/LOCK PIN 3 AES S22 ORANGE
I/LOCK PIN 4 SIE A1+ VIOLET
I/LOCK PIN 5 I_LOCK_STATE2 52 NC RED
I/LOCK PIN 6 F2A WHITE / GREEN
I/LOCK PIN 7 AES S14 WHITE / RED
I/LOCK PIN 8 SIE A2- WHITE / BLUE
PWR1 PIN 1 CHASSIS GND M5 BLACK
PWR1 PIN 2 +24V SIE 2T1 WHITE / ORANGE
PWR1 PIN 3 +24V SIE 2T1 WHITE / ORANGE
PWR1 PIN 4 +36V SIE 4T2 WHITE / BROWN
PWR1 PIN 5 +36V SIE 4T2 WHITE / BROWN
PWR1 PIN 6 NOT USED
PWR1 PIN 7 24V GND PWRIN PIN 9 BLACK
PWR2 PIN 2 +24V PWR1 PIN 2 WHITE / ORANGE
PWR2 PIN 4 +36V PWR1 PIN 4 WHITE / BROWN
PWR2 PIN 6 NOT USED
PWR2 PIN 7 24V GND PWR1 PIN 7 BLACK
PWR3 PIN 6 NOT USED
PWRIN PIN1 CHASSIS GND M5 BLACK


PWRIN PIN2 +24V IN SIE 1L1 WHITE / ORANGE
PWRIN PIN3 +24V IN SIE 1L1 WHITE / ORANGE
PWRIN PIN4 +36V IN SIE 3L2 WHITE / BROWN
PWRIN PIN5 SIE 21NC RED / BLACK
PWRIN PIN6 AES A1+ RED / BLUE
PWRIN PIN7 SIE 5L3 RED / BROWN
PWRIN PIN10 NOT USED
PWRIN PIN12 SIE A2- WHITE / BLUE
PWRIN PIN13 AES A2- ORANGE / BLACK
PWRIN PIN14 SIE 6T3 ORANGE / RED
F3A SIE 21NC RED / BLACK
SIE 22NC AES X1 VIOLET / RED
AES 23 F3B PINK
AES S13 F1B GREY
AES S21 F2B GREY / BLUE
AES 24 SIE A1+ VIOLET
8.1.49 I/LOCK_EMERG (9970-0253)
40 mm 30 mm
Label 24V PSU Label EMERG
(4 way) (6 way)
220 mm
Tie wrap every 100 mm

100mm
M5 Label CHASSIS
30 mm
Label A1+ Label A2-

M4
Table 8.46 I/LOCK_EMERG

6 WAY
(EMERG)
PIN 1 CHASSIS M5 BLACK
PIN 2 24V M4 (A2-) WHITE/ORANGE
PIN 3
PIN 4
PIN 5 24V GND 4W PIN 4 (24V PSU) BLACK
PIN 6
M4 (A1+) 24V 4W PIN 2 (24V PSU) WHITE/ORANGE

8.1.50 INT_M20/M27 (9970-0255)

Label BM20
Label FHMB2 PL22 40 mm 680 mm
80 mm
Label FHMB2 PL20 Label BM27

30 mm
1150 mm
Table 8.47 INT_M20/M27

AMP 3 WAY SIGNALS MOLEX
PL22 PIN 1 RESERVED BM20 PIN 1
PL22 PIN 3 DC_MOT_A BM20 PIN 3
PL22 PIN 2 DC_MOT_B BM20 PIN 2
NOTE THIS MOTOR PIN OUT IS

REVERSED
PL20 PIN 1 RESERVED BM27 PIN 1
PL20 PIN 2 DC_MOT_A BM27 PIN 2
PL20 PIN 3 DC_MOT_B BM27 PIN 3
8.1.51 INT_M25/M21 (9970-0256)
Label BM 25
Label FHM B3 PL16 220 mm 420 mm
300 mm
Label FHM B3 PL29 50 mm

290 mm
Label BM 21
Table 8.48 INT_M25/M21

JST 6 WAY SIGNALS JST 6 WAY + ADAPTER
PIN 1 OUT A PIN 6 TWISTED PAIR WITH PIN JST 6WAY PIN 5
PIN 2 OUT C PIN 5 TWISTED PAIR WITH PIN JST 6WAY PIN 6
PIN 3 +24 V PIN 4 TWISTED PAIR WITH PIN JST 6WAY PIN 4
PIN 4 +24 V PIN 3
PIN 5 OUT B PIN 2
PIN 6 OUT D PIN 1
AMP CT (PL16) MOLEX (BM25)
PIN 1 RESERVED PIN 1
PIN 2 DC_MOT_A PIN 2
PIN 3 DC_MOT_B PIN 3

8.1.52 ENG_M1 (9970-0281)

Label FHM B1 PL15 Label M 1
pin 1
300 mm
Part number here
Tie wrap at each end
close to the connector
Table 8.49 ENG_M1

AMP CT 3WAY SIGNALS 3 WAY MOLEX MINIFIT
PIN 3 DC_MOT_A PIN 2
PIN 2 DC_MOT_B PIN 3
8.1.53 ENG_M2 (9970-0282)
Label FHM B4 PL29

300 mm Label M 2
pin 1
1150 mm
25 mm sleeve at each end
Table 8.50 ENG_M2

JST 6 WAY SIGNALS JST 6 WAY + ADAPTER
PIN 1 OUT A PIN 6 TWISTED PAIR WITH PIN JST 6WAY PIN 5
PIN 2 OUT C PIN 5 TWISTED PAIR WITH PIN JST 6WAY PIN 6
PIN 3 +24 V PIN 4 TWISTED PAIR WITH PIN JST 6WAY PIN 4
PIN 4 +24 V PIN 3
PIN 5 OUT B PIN 2
PIN 6 OUT D PIN 1
8.1.54 ENG_M4 (9970-0283)
Label FHM B1 PL16 Label M 4
pin 1
1100 mm
Part number here
Tie wrap at each end
close to the connector
Table 8.51 ENG_M4

AMP CT 3WAY SIGNALS 3 WAY MOLEX MINIFIT WIRE COLOUR
PIN 3 DC_MOT_A PIN 2 RED

Table 8.51 ENG_M4

PIN 2 DC_MOT_B PIN 3 BLACK
8.1.55 INT_S45ASSY (9970-0284)

Label 24V DIST PL10"
Sleeve Label S47
Label S48
Label DIST PL10" 100 mm 100 mm
170 mm 130 mm
70 mm
Label 24V DIST PL1" 60 mm Label S45

670 mm 220 mm 90 mm
60 mm
Label 24V DIST PL4" Label S46

80 mm 290 mm
Label DIST PL4" Label S43
Label DIST PL3" 90 mm

50 mm
Label S51
Table 8.52 INT_S45ASSY

PL3 PIN 1 NUDGER DETECT PUL_GND S48 PIN 1 TWISTED PAIR

WITH S48 PIN 2
PL3 PIN 2 NUDGER DETECT SUPPLY S48 PIN 2
PL3 PIN 3 NUDGER DETECT GROUND S48 PIN 3 TWISTED PAIR

WITH S48 PIN 4
PL3 PIN 4 NUDGER DETECT SIGNAL S48 PIN 4
PL4 PIN 1 CASS EMPTY PUL_GND S43 PIN 1 TWISTED PAIR

WITH S43PIN 2
PL4 PIN 2 CASS EMPTY SUPPLY S43 PIN 2
PL4 PIN 3 CASS EMPTY GROUND S43 PIN 3 TWISTED PAIR

WITH S43 PIN 4
PL4 PIN 4 CASS EMPTY SIGNAL S43 PIN 4
PL10 PIN 1 NOT USED
PL10 PIN 2 RETARD DOWN SUPPLY S47 PIN 1
PL10 PIN 3 RETARD DOWN GROUND S47 PIN 2
PL10 PIN 4 RETARD DOWN SIGNAL S47 PIN 3 TWISTED PAIR

WITH S47 PIN 2
24V PL4 PIN 1 NOT USED
24V PL4 PIN 2 NUDGER DOWN LIMIT SUPPLY S45 PIN 1
24V PL4 PIN 3 NUDGER DOWN LIMIT S45 PIN 2

GROUND
24V PL4 PIN 4 NUDGER DOWN LIMIT SIGNAL S45 PIN 3 TWISTED PAIR
WITH S45 PIN 2
24V PL1 PIN 2 NUDGER UP LIMIT SUPPLY S46 PIN 1
24V PL1 PIN 3 NUDGER UP LIMIT GROUND S46 PIN 2
24V PL1 PIN 4 NUDGER UP LIMIT SIGNAL S46 PIN 3 TWISTED PAIR
WITH S46 PIN 2

Table 8.52 INT_S45ASSY (Continued)

24V PL10 PIN 2 PAPER POST DIVERTER SUP- S51 BROWN WIRE
PLY
24V PL10 PIN 3 PAPER POST DIVERTER S51 BLACK WIRE

GROUND
24V PL10 PIN 4 PAPER POST DIVERTER SIG- S51 BLUE WIRE
NAL
8.1.56 INT_S76 (9970-0285)

Label CASS ID PL1 Label S76
3450 mm
Table 8.53 INT_S76

CASS ID PL1 SIGNALS S76
PIN 1 FRONT DOOR PUL_GND PIN 1 TWIST PAIR WITH PIN 2
PIN 2 FRONT DOOR SUPPLY PIN 2
PIN 3 FRONT DOOR GROUND PIN 3 TWIST PAIR WITH PIN 4
PIN 4 FRONT DOOR SIGNAL PIN 4
8.1.57 I/LOCK_PUMPCTRL (9970-0287)

Label PUMP CTRL Label REL A
10 mm 210 mm
Fastons
100 mm M5 40 mm Label REL B

Single tie wrap at
each end Label CHASSIS
Table 8.54 I/LOCK_PUMPCTRL

8 WAY MOLEX SIGNALS
PIN 1 CHASSIS M5
PIN 2 REL A FASTON TWIST WITH PIN 4
PIN 3
PIN 4
PIN 5
PIN 6 REL B FASTON
PIN 7
PIN 8
8.1.58 BUFF_S19/20 (9970-0288)
Label Part No 680 mm Label S19

Label PANEL
pin 1
150 mm Label S20

1150 mm
Table 8.55 BUFF_S19/20

14W MOLEX SIGNALS AMP CT
PIN 1 NOT USED
PIN 2 BUFFER ENTRANCE PUL_GND S19 PIN 1 TWISTED PAIR WITH S19 PIN 2
PIN 3 BUFFER ENTRANCE GROUND S19 PIN 3 TWISTED PAIR WITH S19 PIN 4
PIN 4 BUFFER EXIT PUL_GND S20 PIN 1 TWISTED PAIR WITH S20 PIN 2
PIN 5 BUFFER EXIT GROUND S20 PIN 3 TWISTED PAIR WITH S20 PIN 4
PIN 6 NOT USED
PIN 7 NOT USED
PIN 8 NOT USED
PIN 9 BUFFER ENTRANCE INPUT SUPPLY S19 PIN 2
PIN 10 BUFFER ENTRANCE SIGNAL S19 PIN 4
PIN 11 BUFFER EXIT INPUT SUPPLY S20 PIN 2
PIN 12 BUFFER EXIT SIGNAL S20 PIN 4
PIN 13 NOT USED
PIN 14 NOT USED
8.1.59 ENG_S19/20 (9970-0289)

Label Part No
50 mm Label DIST O/P PL4
Label PANEL
Tie wraps
pin 1
770 mm Label DIST O/P PL3

50 mm
Table 8.56 ENG_S19/20

14W MOLEX SIGNALS AMP CT
PIN 1 NOT USED
PIN 2 BUFFER ENTERANCE PUL_GND PL4 PIN 1 TWISTED PAIR WITH PL4 PIN 2
PIN 3 BUFFER ENTERENCE GROUND PL4 PIN 3 TWISTED PAIR WITH PL4 PIN 4
PIN 4 BUFFER EXIT PUL_GND PL3 PIN 1 TWISTED PAIR WITH PL3 PIN 2
PIN 5 BUFFER EXIT GROUND PL3 PIN 3 TWISTED PAIR WITH PL3 PIN 4
PIN 6 NOT USED

Table 8.56 ENG_S19/20 (Continued)

PIN 7 NOT USED
PIN 8 NOT USED
PIN 9 BUFFER ENTERANCE INPUT SUPPLY PL4 PIN 2
PIN 10 BUFFER ENTERANCE SIGNAL PL4 PIN 4
PIN 11 BUFFER EXIT INPUT SUPPLY PL3 PIN 2
PIN 12 BUFFER EXIT SIGNAL PL3 PIN 4
PIN 13 NOT USED
PIN 14 NOT USED
8.1.60 ENG_S21 (9970-0291)

Label PHOTO
Label FHMB4
DETECT
PL4
1350 mm
Table 8.57 ENG_S21

3 WAY AMP CT SIGNALS MOLEX 22-01-2045
PIN 1 CATHODE PIN 2 (TWISTED WITH MOLEX PIN 1)
PIN 2 ANODE PIN 1
PIN 3 NOT USED
8.1.61 ENG_S79 (9970-0292)
30 mm
Label S79 -4
800 mm
Label 24V
DIST PL6
Label S79 -1
Table 8.58 ENG_S79

AMP CT SIGNALS
PL 6 PIN 1 NOT USED
PL 6 PIN 2 NOT USED
PL 6 PIN 3 CHAD TRAY HOME S79 -4 FASTON TWISRED PAIR WITH OTHER FASTON
PL 6 PIN 4 CHAD TRAY HOME RTN S79 -1 FASTON

8.1.62 MIX_FAN (9970-0295)

Cable ties every 360 mm
Label FHMB1 PL2
700 mm

Label MIX FAN Part number at this end
Table 8.59 MIX_FAN

6W MOLEX SIGNALS
PIN 1
PIN 2 FAN +24V PL2 PIN 1 TWISTED PAIR WITH PL2 PIN 2
PIN 3 FAN DETECT PL23 PIN 3 TWISTED PAIR WITH PL23 PIN 4
PIN 4
PIN 5 FAN GND PL2 PIN 2
PIN 6 FAN DETECT RTN PL23 PIN 4
8.1.63 MFAN (9970-0296)
30 mm
Label FAN +
150 mm
Label MIX
FAN Label FAN -
Table 8.60 MFAN

6W MOLEX SIGNALS COLOUR
PIN 1
PIN 2 FAN +24V RED LABEL FAN+ TWIST WITH FAN-
PIN 3 FAN DETECT YELLOW LINK TO 6W MOLEX PIN 6
PIN 4
PIN 5 FAN GND BLACK LABEL FAN-
PIN 6 FAN DETECT

RTN
8.1.64 BUFF_LOCK (9970-0298)

Part number
Label PANEL Label I_LOCK
500 mm
Table 8.61 BUFF_LOCK

8WAY SIGNALS 8 WAY

Table 8.61 BUFF_LOCK (Continued)

PIN 2 N/O LOOP PIN 2
PIN 3 N/C LOOP PIN 3
PIN 4 S/W COMMON PIN 4
PIN 6 N/O LOOP PIN 6
PIN 7 N/C LOOP PIN 7
PIN 8 S/W FEEDBACK PIN 8
8.1.65 PROC_COMMS (9970-0306)

Processor
Engine
Ferrites
4.5 metres
Table 8.62 PROC_COMMS

9W D TYPE STR SKT SIGNAL 25W D TYPE STR PLUG
PIN 5 GND PIN 7
PIN 2 TX PIN 3 (TP WITH 25WAY PIN 2)
PIN 3 RX PIN 2
PIN 7 SIGNAL 1 PIN 4 (TP WITH 25WAY PIN 5)
8.1.66 PSU_I/LOCK (9970-0310)

C a b le 1
15 m m 40 m m
6 m m T in n ed en d La b e l T A G 1
L a b el PS U 3 PIN
6 m m T in n ed en d La b e l T A G 4
C a b le 2
100 m m
M 5 L a b el FR A M E M 4 La b e l P SU
C a b le 3
25 m m 35 m m
1 0 m m T in n e d e n d L a b el + O U T
30 m m
La b e l + 2 4 V
1 0 m m T in n e d e n d L a b el -O U T
Table 8.63 PSU_I/LOCK

CABLE 1
3 W PIN 1 BROWN TAG 1
3 W PIN 3 BLUE TAG 4
CABLE 3
4 W PIN 2 WH / OR +OUT
Table 8.63 PSU_I/LOCK (Continued)

4 W PIN 4 BLACK -OUT
8.1.67 ELV_TLOCKSOL (9970-0379)

Label LOCK Part number here half way
20mm
100 mm 80 mm
10 mm 10 mm 5 mm
Table 8.64 ELV_TLOCKSOL

8 WAY SIGNAL NAME LABLE TINNED WIRE COLOURS
MOLEX ENDS
8W PIN 2 LOCK A1 BLACK TWIST WITH 8 WAY PIN

6
8W PIN 4 CONTACTOR_24V 21 GREEN
8W PIN 3 BS72 11 RED TWIST WITH 8 WAY PIN 7
8W PIN 6 LOCK_RTN A2 WHITE
8W PIN 7 BS72_RTN 12 ORANGE
8W PIN 8 CONTACTOR_24V 22 RED
8.1.68 ENG_BLOW (9970-0380)

Label DRUM VAC Place as near
to the connector as possible
2.4m 50 mm
340 mm 500 mm
140 mm
30 mm
Label FHMB4 PL8 Place as near
to the connector as possible
Label DRUM BLOW Place as Label FHMB4 PL10 Place as
Part number label
near to the connector as possible near to the connector as possible
Table 8.65 ENG_BLOW

PIN SIGNAL PIN WIRE COMMENT
PL8 PIN 1 NOT USED
PL8 PIN 2 SOL BV31 DRUM BLOW PIN 2 RED TWIST WITH PL8 PIN 3
PL8 PIN 3 SOL BV31 RTN DRUM BLOW PIN 3 BLACK
PL10 PIN 1 NOT USED
PL10 PIN 2 SOL BV30 DRUM VAC PIN 2 GREEN TWIST WITH PL10 PIN3
PL10 PIN 3 SOL BV30 RTN DRUM VAC PIN 3 BLACK
8.1.69 ENG_S3/S12 (9970-0406)

Cover this section with cable wrap Cover this section with cable wrap
600 mm
625 mm
Approx 344 mm Approx 344 mm This end piece has the pins for the links
790 mm 60mm
Label S13
Label S12
540 mm Chain must be able to bend in
155 mm Label Punch Frame this direction.
325 mm Chain must be able to bend

in this direction.
210 mm 100 mm
Label S14
Label S3 Label DIST O/P PL7
This end piece has the pins for the links Part number here Label 24V DIST O/P PL2
40 mm
Label DIST O/P PL11

Label PL11
Wire with cable wrap free to move within the chain 60mm
Label SK11 Label DIST O/P PL10
Label PL10
Label SK10
28 mm radius 30mm Example 20mm
12 mm
Labels to be position as shown Use tie wraps every 100 mm where shown
above from their connector
8.1.70 ENG_S109/110 (9970-0390)
65 mm
Label S110 720 mm
Label FHMB4 PL9
Label S109 Tie wraps every

150 mm 100mm
Label Part No etc
Place 70mm from connector
Table 8.66 ENG_S109/110

SIGNALS
PL9 PIN 1 NOT USED

Table 8.66 ENG_S109/110

PL9 PIN 2 SWING ROLLER IN DRUM SUPPLY S110 PIN 1
PL9 PIN 3 SWING ROLLER IN DRUM GROUND S110 PIN 2
PL9 PIN 4 SWING ROLLER IN DRUM SIGNAL S110 PIN 3 TWISTED PAIR WITH S110 PIN 2
PL9 PIN 5 NOT USED
PL9 PIN 6 SWING ROLLER HOME SUPPLY S109 PIN 1
PL9 PIN 7 SWING ROLLER HOME GROUND S109 PIN 2
PL9 PIN 8 SWING ROLLER HOME SIGNAL S109 PIN 3 TWISTED PAIR WITH S109 PIN 2
8.1.71 ENG_S100/103 (9970-0392)
60 30
Label S100
Cable jacket only to cover this Label 24V DIST PL1
section with part no in centre
475
Label S103 position labels 25mm

60 from connectors.
Label 24V DIST PL4
30
S100
Table 8.67 ENG_S100/103

AMP CT (24V SIGNALS AMP EI
DIST)
PL4 PIN 1 NOT USED
PL4 PIN 2 REG PIN MTR HOME SUPPLY S100 PIN 1
PL4 PIN 3 REG PIN MTR HOME GROUND S100 PIN 2
PL4 PIN 4 REG PIN MTR HOME SIGNAL S100 PIN 3 TWISTED PAIR WITH S100 PIN 2
PL1 PIN 1 NOT USED
PL1 PIN 2 REG PIN MTR OUT SUPPLY S103 PIN 1
PL1 PIN 3 REG PIN MTR OUT GROUND S103 PIN 2
PL1 PIN 4 REG PIN MTR OUT SIGNAL S103 PIN 3 TWISTED PAIR WITH S103 PIN 2
8.1.72 MAINS_PSU (9970-0420)

700 mm
20mm 40 mm
Blue 35 mm Label PSU
Brown
Brown
Green/Yellow 50mm Blue
100 mm
Suppliers part
Label INLET
number etc Label CHASSIS
100 mm
Cable 1
M5
150 mm Green/Yellow
M5
Green/Yellow
Cable 2
Label CHASSIS RFI BOX (20mm from end) Suppliers part number etc in centre Label INLET (20mm from end)
100 mm
M5
Green/Yellow M5
Cable 3
Label CHASSIS PSU TRAY (20mm from end) Suppliers part number etc in centre Label CHASSIS RFI BOX (20mm from end)
8.1.73 PSU (9970-0421)

Label CHASSIS
pin 1
120 mm 100 mm
Label PWR FILT PL4
80 mm pin 1
40 mm
Label PWR FILT PL5
Label SL2 +36V
Place labels close to the
Label SL2 0V connector and then a cable tie
A 30 mm to stop the wires straining the
Label SL3 +5V (2 off) labels
70 mm Label SL3
Label SL3 0V (2 off)
25 mm
Label SL4 +24V (2 off)
Label SL4 0V (2 off) REFERENCE BREAKOUT

25 mm POINT A
Label SL5 +24V (2 off)
Label SL5 0V (2 off)
50 mm 25 mm
Label SL6 +15V(1)
40 mm
Label SL6 0V(1)
40 mm
Label SL6 +15V (2)
50 mm
Label SL6 0V(2)
Label next to
connector, then a Label SSB PL17
cable ties and then at
100mm spacing
Label Part No 100 mm
Next to PL11 branch point 2 cable ties at 50mm
Label EODD PL3 spacing along this
50 mm 200 mm 150mm section
pin 1 50 mm
70 mm 80 mm 80 mm
300 mm TO REFERENCE
POINT A
2 cable ties at 50/60
170 mm Label next to
mm spacing along this pin 1 pin 1 connector, then a
157mm section
Label LSB PL 11 Label LSB PL13 cable ties
Label FAN1 80 mm
200 mm
pin 1
130 mm
Label LSB PL 10
Table 8.68 PSU

FASTONS SIGNAL CONNECTORS WIRE COL- COMMENTS
OUR
M5 RING (SL2+36V) +36V PL4 PIN 10 WHITE/ TWIST WITH PL4 PIN4
BROWN
M5 RING (SL2 0V) +36V_GND PL4 PIN 4 BLACK

(REF 8)
USE ABOVE M5 36V TO CHASSIS M5 CHASSIS BLACK

GND LINK
SL3 +5V +5V PL5 PIN 3 RED TWIST WITH PL5 PIN 1
USE ABOVE FASTON +5V PL13 PIN 3 RED TWIST WITH PL13 PIN
10
SL3 +5V +5V PL13 PIN 4 RED TWIST WITH PL13 PIN
11
USE ABOVE FASTON +5V PL13 PIN 5 RED TWIST WITH PL13 PIN
12
PL13 PIN 5 LINK 5V PL13 PIN 6 RED
PL13 PIN 6 LINK 5V PL3 PIN 6 RED TWIST WITH PL3 PIN 2
SL3 PIN1 +5V SENSE PL13 PIN 2 RED/WHITE TWIST WITH PL13 PIN
9
SL3 0V +5V_GND PL 5 PIN 1 BLACK
USE ABOVE FASTON +5V_GND PL13 PIN 10 BLACK
SL3 0V (REF 7) +5V_GND PL13 PIN 12 BLACK
PL13 PIN 12 LINK 0V PL13 PIN 13 BLACK
SL3 PIN2 0V SENSE PL13 PIN 9 WHITE/

BLACK
Table 8.68 PSU

SL4 +24V +24V PL4 PIN 1 WHITE/ TWIST WITH PL4 PIN 5
ORANGE
USE ABOVE FASTON +24V PL4 PIN 6 WHITE/ TWIST WITH PL4 PIN 9
ORANGE
ORANGE
ORANGE
PL4 PIN 2 +24V PL4 PIN 7 WHITE/ TWIST WITH PL4 PIN 8
ORANGE
PL4 PIN 7 +24V F1 PIN 2 WHITE/ TWIST WITH F1 PIN 3

ORANGE
8.1.74 DISK DATA (9970-0423)

120 mm 680 mm
Label TERM Label DISK

85mm
Part Number etc (in centre)
Equates to pin 1
View from pin side Label LSB2 SK11
8.1.75 MAINS_DIST (9970-0424)

FUSE HOLDER
25 mm
20 mm 260 mm
BROWN 1 4.8x0.5 FASTONS
2
BLUE 3 70 mm
Tie wrap at branch points and
Label PSU 3 PIN connector and every 100mm
Label FILTER
100 mm
50 mm
BROWN BROWN Label CB IN_L next to
faston
20 mm 430 mm
BLUE BLUE Label CB IN_N next to
100 mm 30 mm faston
100 mm
100 mm
Part number here
100 mm
(Cable 1)
M5 20 mm Label CHASSIS
Label CHASSIS 20 mm GREEN/YELLOW
GREEN/YELLOW
Part number here M5
GREEN/YELLOW (Cable 2)
Label CHASSIS next to ring 50 mm Label FILTER next to fork
M5 100 mm M4
8.1.76 CAN1 (9970-0425)

Label LSB CAN SOMB Label VBOMB SK2
Part number
pin 1 20 mm pin 1
20 mm
100 mm
1800 mm
Table 8.69 CAN1

15 D TYPE PLG SIGNAL 15 D TYPE PLG COLOUR COMENTS

ORANGE

BLACK
PIN 10 SPARE PIN 10 BLACK / WHITE (TWISTED PAIR WITH PIN 15)
PIN 14 CAN_SIG_RT PIN 14 BROWN / BLACK

N
PIN 15 SPARE PIN 15 WHITE / BLACK
8.1.77 VBOMB_PWR (9970-0427)

Label RFI BOX
SOMB PWR Part Number Label VBOMB PL 11
pin 1 pin 1
20 mm 20 mm
100 mm
2500 mm
8.1.78 24V_ENG (9970-0428)

Label RFI BOX FHMB PWR
14 W Recepticle)
250 mm 300 mm 50 mm
(8 Way)
Label I/LOCK BOX
100 mm
PWR IN
Part Number here

100 mm
120 mm
(26 Way)
(14 Way Plug)
Label INT-SYSTEM Label RFI BOX I/LOCK
Table 8.70 24V_ENG

PIN SIGNAL COLOUR
8 W PIN 1 NOT USED
8 W PIN 2 +24V 14 W (RECEPTACLE) PIN 2 WH/OR
8 W PIN 3 24V GND 14 W (RECEPTACLE) PIN 8 BLACK
8 W PIN 4 +36V 14 W (RECEPTACLE) PIN 4 WH/BN
8 W PIN 5 NOT USED
8 W PIN 6 +24V 14 W (RECEPTACLE) PIN 3 WH/OR
26 W PIN1 NOT USED
26 W PIN2 NOT USED
26 W PIN3 NOT USED
26 W PIN4 24V ILOCK 14 W (RECEPTACLE) PIN 6 ORANGE
26 W PIN5 NOT USED
26 W PIN6 NOT USED
26 W PIN7 NOT USED
26 W PIN8 +24GND 14 W (RECEPTACLE) PIN 13 BLACK
26 W PIN9 NOT USED
8.1.79 EDGE_LASER (9970-0434)

Table 8.71 EDGE_LASER
JST PHR-3 SIGNALS JST PHR-2 COLOUR
EDGE BD PL3 LASER
PIN 1 NOT CONNECTED
PIN 2 LASER POWER PIN 1 RED
PIN 3 GROUND PIN 2 GREEN

8.1.80 VBOMB_SENSORS (99700435)

L a be l A P H O M E L a b e l F O C U S L IM IT
L a b el V B O M B P L 1 3
200mm
560m m 200m m
300 mm 500 mm
200mm Label N D H O M E
P a r t N o et c 600mm
L a be l F O C U S O P R
Label SE N S LPD
C o nn e c to r L a be ls 2 0 m m fr o m c o n n e ct o r. P a r t nu m b e r 7 0 m m
fro m V B O M B P L 1 3
P in 2 fro m c a b le
e n tr y sid e
V B O M B PL13
o rien ta tio n
P in 1 fro m c a ble
e nt ry sid e
Table 8.72 VBOMB_SENSORS

MOLEX 24W VBOMB SIGNALS
PL13
PIN 1 +5V
PIN 2 0V
PIN 3 SPARE
AMP 3W SENS LPD
PIN 4 +5V PIN 1
PIN 5 0V PIN 2
PIN 6 SENS LPD PIN 3
AMP 3W ND HOME
PIN 7 +5V PIN 1
PIN 8 0V PIN 2
PIN 9 ND HOME PIN 3
PIN 10 +5V
PIN 11 0V
PIN 12 SPARE
AMP 3W AP HOME
PIN 13 +5V PIN 1

Table 8.72 VBOMB_SENSORS

PIN 14 0V PIN 2
PIN 15 AP HOME PIN 3
AMP 3W FOCUS OPR
PIN 16 +5V PIN 1
PIN 17 0V PIN 2
PIN 18 FOCUS OPR PIN 3
AMP 3W FOCUS LIMIT
PIN 19 +5V PIN 1
PIN 20 0V PIN 2
PIN 21 FOCUS LIMIT PIN 3
PIN 22 NC
PIN 23 NC
PIN 24 NC
8.1.81 VBOMB_LPD (9970-0436)
Label LPD
100mm Part no etc 100 mm
pin 1 pin 1
25mm
1000 mm
Label VBOMB
PL3 Max deviation is 45 degrees
from the horizontal
Table 8.73 VBOMB_LPD

JST PHDR-10VS SIGNALS JST PHDR-10VS LPD
VBOMB PL3
PIN 1 0V PIN 1
PIN 2 POWERDET PIN 2
PIN 3 0V PIN 3
PIN 4 +15V PIN 4
PIN 5 0V PIN 5
PIN 6 -15V PIN 6

8.1.82 VBOMB_LPDM (9970-0437)
Lab el LP D M O T O R P L1 5 P a rt N o e tc Lab el LP D M O T
p in 1
p in 1
25 m m
100 mm
25 m m
2450 mm
Table 8.74 VBOMB_LPDM

JST HRP-06 LPD MOTOR PL15 SIGNALS DF11-6DS-2C LPD MOT
PIN 1 LPD MOTOR PHASE ORANGE PIN 1
PIN 2 LPD MOTOR PHASE RED PIN 2
PIN 3 +24V PIN 3
PIN 4 +24V PIN 4
PIN 5 LPD MOTOR PHASE BLUE PIN 5
PIN 6 LPD MOTOR PHASE YELLOW PIN 6
8.1.83 VBOMB_APM (9970-0438)
L a b e l A P E R T U R E M O T O R
P a rt N o e tc Lab el A P M O T
PL16
p in 1
p in 1
25m m
25m m
100 mm
1570 mm
Table 8.75 VBOMB_APM

JST HRP-6 APERTURE MOTOR SIGNALS DF11-6DS-2C AP MOT
PL16
PIN 1 AP MOTOR PHASE ORANGE PIN 1
PIN 2 AP MOTOR PHASE RED PIN 2
PIN 3 +24V PIN 3
PIN 4 +24V PIN 4
PIN 5 AP MOTOR PHASE BLUE PIN 5
PIN 6 AP MOTOR PHASE YELLOW PIN 6

8.1.84 VBOMB_NDM (9970-0439)

L a b e l N D M O T O R P L 1 4 P art N o etc Lab el N D M O T
p in 1 p in 1
25 mm
100 mm 25m m
780 mm
Table 8.76 VBOMB_NDM

JST HRP-06 ND MOTOR PL14 SIGNALS DF11-6DS-2C ND MOT
PIN 1 ND MOTOR PHASE ORANGE PIN 1
PIN 2 ND MOTOR PHASE RED PIN 2
PIN 3 +24V PIN 3
PIN 4 +24V PIN 4
PIN 5 ND MOTOR PHASE BLUE PIN 5
PIN 6 ND MOTOR PHASE YELLOW PIN 6
8.1.85 VBOMB_FOCM (9970-0440)
L a b e l F O C U S M O T O R P L 1 7 P art N o etc Lab el FO C M O T

p in 1
p in 1
25 mm
100 mm 25m m
1550 m m
Table 8.77 VBOMB_FOCM

JST HRP-06 FOCUS MOTOR PL17 SIGNALS DF11-6DS-2C FOC MOT
PIN 1 FOCUS MOTOR PHASE ORANGE PIN 1
PIN 2 FOCUS MOTOR PHASE RED PIN 2
PIN 3 +24V PIN 3
PIN 4 +24V PIN 4
PIN 5 FOCUS MOTOR PHASE BLUE PIN 5
PIN 6 FOCUS MOTOR PHASE YELLOW PIN 6

8.1.86 PSU_CTRL (9970-0442)

50 m m
P art n um b er L a b e l K E Y N /O P IN 3
200 m m 450 m m
L a b e l K E Y N /O P IN 4
p in 1 F e r r it e
p in 1
150m m
10 m m L a b e l I/L C O N T A C T O R
900 m m p in 1
300 m m
L ab el L S B P S U C T R L
L a b e l I/ L O C K S H U T T E R
Table 8.78 PSU_CTRL

LSB PSU CTRL SIGNAL ILOCK_SHUTTER COLOUR COMENTS
PIN 1 NOT USED
PIN 2 NOT USED
PIN 3 I_LOCK PIN 3 BLACK TP WITH PIN 6
PIN 4 NOT USED
PIN 5 GROUND I/L CONTACTOR PIN 1 BLACK TP WITH PIN 10

2 WAY MOLEX
PIN 6 NOT USED
PIN 7 NOT USED
PIN 8 NOT USED
PIN 9 NOT USED
PIN 10 I_LOCK_STATE2_IN I/L CONTACTOR PIN2 WHITE

2 WAY MOLEX
PIN 11 NOT USED
PIN 12 INT_SUPPLY PIN 6 YELLOW
PIN 13 INT_STAT_KEYSWITC M4 FORK (KEY N/O PIN BLUE TP WITH PIN 15

H 3)
PIN 14 NOT USED
PIN 15 GND M4 FORK (KEY N/O PIN BLACK

4)
8.1.87 VBOMB_POD (9970-0443)
Label VBOMB PL5 Pinout designation

Keep sleeving back by 75 mm
2 1
Label POD 4 3
75 mm
Part No etc
6 5
8 7
pin 1 pin 1
10 9
25 mm 12 11
100 mm 25 mm
14 13
1170 mm
Table 8.79 VBOMB_POD

JST PHDR-14VS VBOMB PL5 SIGNALS JST PHDR-14VS POD
PIN 1 0V POWER PIN 1
PIN 2 PDX1Y1 PIN 2
PIN 3 0V PIN 3
PIN 4 PDX2Y1 PIN 4
PIN 5 0V PIN 5
PIN 6 PDX2Y2 PIN 6
PIN 7 0V PIN 7
PIN 8 PDX1Y2 PIN 8
PIN 9 0V PIN 9
PIN 10 +15V PIN 10
PIN 12 -15V PIN 12
8.1.88 I/LOCK_MAIN (9970-0444)

60 mm
45 mm SOLDERED TAILS
150 mm Label NEUTRAL FEED
BLUE BLUE
BROWN Label LIVE FEED BROWN
Label C/B OUT
0.25 FASTONS Cable 2
Position labels at this end of the wires
55 mm
SOLDERED TAILS
40 mm
Label REL 4 150 mm
BLUE Label NEUTRAL BLUE
Label REL 6 BROWN Label LIVE BROWN
0.25 FASTONS Cable 3
Label LID Label BOX

140 mm
M5 RINGS M5 RINGS
GREEN/YELLOW Cable 4
8.1.89 ENG_S6/S15 (9970-0445)

(20mm from connector) (20mm from connector)
50 mm
Part number etc

(40mm from cable tie)
Cable tie 80 mm
Label S15 Label S6

(20mm from
(20mm from
connector)
connector)
1040 mm 600 mm
Table 8.80 ENG_S6/S15

PL 7 PIN 1 NOT USED
PL 7 PIN 2 PUSH BAR HOME SUPPLY S6 PIN 1
PL 7 PIN 3 PUSH BAR HOME GROUND S6 PIN 2
PL 7 PIN 4 PUSH BAR HOME SIGNAL S6 PIN 3 TWISTED PAIR WITH S6 PIN 2
PL 12 PIN 2 PUSH BAR FWD LIMIT SUPPLY S15 PIN 1
PL 12 PIN 3 PUSH BAR FWD LIMIT GROUND S15 PIN 2
PL 12 PIN 4 PUSH BAR FWD LIMIT SIGNAL S15 PIN 3 TWISTED PAIR WITH S15 PIN
2
8.1.90 ENG_BLOW (9970-0446)

Label FHMB4 PL10
Label BV30 230mm 770mm 70mm
2650mm (sleeved)
50 mm
100mm 60mm
20mm
Label BV31 Sol
Label BV40 Label BV31 Part number label

Label FHMB1 PL10
Table 8.81 ENG_BLOW

AMP CT SIGNAL NAME MOLEX MINIFIT JR COMMENT
FHMB4 PL10 BV30
PIN 1 NOT USED
PIN 2 MAIN VAC MANI- BV30 PIN2 TWIST WITH BV30 PIN 3
FOLD
Table 8.81 ENG_BLOW

PIN 3 MAIN VAC MANI- BV30 PIN 3
FOLD RTN
FHMB1 PL10 BV40
PIN 1 NOT USED
PIN 2 LEADING EDGE BV40 PIN 2 TWIST WITH BV40 PIN 3
PIN 3 LEADING EDGE RTN BV40 PIN 3
MOLEX MINIFIT
JR
BV31 SOL BV31
BV31 PIN 1
PIN 1 DRUM BLOW BV31 PIN 2 TWIST WITH BV31 PIN2
PIN 2 DRUM BLOW RTN BV31 PIN 3
8.1.91 I/LOCK_DC (9970-0447)

100 mm
RELEASE COIL 1
40 mm
15 mm
210 mm 30 mm AES S14 15 mm
70 mm
RELEASE COIL 2 AES A1+ 30 mm
70 mm
40 mm AES S13
AES A2- 40 mm
5 mm
30 mm 5 mm
AES 14
70 mm AES 13 110 mm
40 mm AES S21
5 mm
30 mm 5 mm
AES 24
70 mm 30 mm
AES 23
70 mm
40 mm AES S22
AES X1 40 mm
10 mm
10 mm
40 mm 40 mm 40 mm 40 mm
SIE A1+ SIE A2-
Label 24V PSU
SIE 21NC SIE 22NC 20 mm
20 mm
40 mm 40 mm SIE 6T3 40 mm 40 mm
SIE 5L3
20 mm SIE 3L2 SIE 4T2 20 mm

80 mm
SIE 1L1 SIE 2T1 80 mm
30 mm 10 mm 50 mm 10 mm
F1B F1A 50 mm
10 mm 50 mm 10 mm
F2B F2A 50 mm
10 mm 50 mm 10 mm
F3B F3A 50 mm
15 mm 15 mm
50 mm 50 mm
60 mm 60 mm 60 mm
40 mm 40 mm 40 mm 40 mm
40 mm
30 mm 30 mm 30 mm 52NC
100 mm 90 mm 51NC
EMERG PWR 3 PWR 2 PWR 1 I/LOCKS SHUTTER

PWR IN
Table 8.82 I/LOCK_DC

SIGNAL GUAGE COLOUR
SHUTTER PIN 1 (1) CHASSIS GND M5 (1) 18 BLACK
SHUTTER PIN 2 (1) NOT USED
SHUTTER PIN 3 (1) AES 13 (1) 24 RED
SHUTTER PIN 6 (1) AES 14 (1) 24 BLUE
I/LOCK PIN 1 (1) SW_FEEDBACK_1 51NC (1) 18 BLACK
I/LOCK PIN 2 (1) F1A (1) 24 YELLOW
I/LOCK PIN 3 (1) AES S22 (1) 24 ORANGE
I/LOCK PIN 4 (1) SIE A1+ (2) 24 VIOLET
I/LOCK PIN 5 (1) SW_FEEDBACK_2 52NC (1) 24 YELLOW
I/LOCK PIN 6 (1) F2A (1) 24 WHITE / GREEN
I/LOCK PIN 7 (1) AES S14 (1) 24 WHITE / RED
I/LOCK PIN 8 (2) ENG_24V_GND SIE A2- (2) 24 WHITE / BLUE
I/LOCK PIN 8 (2) ENG_24V_GND AES A2- (1) 24 ORANGE / BLACK
PWR1 PIN 1 (1) CHASSIS GND M5 (1) 18 BLACK
PWR1 PIN 2 (2) +24V_ILOCKED SIE 2T1 (2) 18 WHITE / ORANGE
PWR1 PIN 3 (2) +24V_ILOCKED SIE 2T1 (2) 18 WHITE / ORANGE
PWR1 PIN 4 (2) +36V_ILOCKED SIE 4T2 (2) 18 WHITE / BROWN
PWR1 PIN 5 (2) +36V_ILOCKED SIE 4T2 (2) 18 WHITE / BROWN
PWR1 PIN 6 NOT USED
PWR1 PIN 7 (2) 24V GND PWRIN PIN 13 (2) 18 BLACK
PWR2 PIN 2 (2) +24V_ILOCKED PWR1 PIN 2 (2) 18 WHITE / ORANGE
PWR2 PIN 4 (2) +36V_ILOCKED PWR1 PIN 4 (2) 18 WHITE / BROWN
PWR2 PIN 6 NOT USED
PWR2 PIN 7 (2) 24V GND PWR1 PIN 7 (2) 18 BLACK

Table 8.82 I/LOCK_DC

PWR3 PIN 6 NOT USED
PWRIN PIN1 (1) CHASSIS GND M5 (1) 18 BLACK
PWRIN PIN2 (1) +24V IN SIE 1L1 (2) 18 WHITE / ORANGE
PWRIN PIN3 (1) +24V IN SIE 1L1 (2) 18 WHITE / ORANGE
PWRIN PIN4 (1) +36V IN SIE 3L2 (1) 18 WHITE / BROWN
PWRIN PIN5 NOT USED 24 RED / BLACK
PWRIN PIN6 (1) +24V_ILOCKED PWR3 PIN 3 (2) 18 WHITE / ORANGE
PWRIN PIN7 (1) EODD_LASER_IL SIE 5L3 (1) 24 RED / BROWN
PWRIN PIN 8 (2) 24V GND PWRIN PIN 9 (2) 18 BLACK
PWRIN PIN10 NOT USED
PWRIN PIN13 (2) 24V GND PWRIN PIN9 (2) 18 BLACK
PWRIN PIN14 (1) EODD_LASER_ILR SIE 6T3 (1) 24 ORANGE / RED
F3A (2) ENG_24V SIE 21NC (2) 24 RED / BLACK
F3A (2) ENG_24V AES A1+ (1) 24 RED / BLACK
SIE 22NC (1) AES X1 (1) 24 VIOLET / RED
AES 23 (1) F3B (1) 24 PINK
AES S13 (1) F1B (1) 24 GREY
AES S21 (1) F2B (1) 24 GREY / BLUE
AES 24 (1) SIE A1+ (2) 24 VIOLET
24V PSU 4W PIN 2 (2) ENG_24V SIE 21NC (2) 24 RED / BLACK
24V PSU 4W PIN 4 (2) ENG_24V_GND SIE A2- (2) 24 WHITE / BLUE
EMERG 6W PIN 1 (1) CHASSIS GND M5 (1) 24 BLACK
EMERG 6W PIN 2 (1) ENG_24V RELEASE COIL 1(1) 24 WHITE/ORANGE
EMERG 6W PIN 3 NOT USED
EMERG 6W PIN 5 (1) ENG_24V_GND 24V PSU 4W PIN 4 (2) 24 BLACK
RELEASE COIL 2 (1) ENG_24V 24V PSU 4W PIN 2 (2) 24 RED / BLACK
8.1.92 EDGE_DETECT (9970-0448)

NOTE this view from
230mm the wire entry side
Label ED PL2
Pin 2
Label STB PL6 20 mm
20 mm Pin 1
20mm 20mm
Part number etc (in centre)
Label STB PL3 Label ED PL1
110mm 40mm 30mm
Table 8.83 EDGE_DETECT

AMP CT SIGNALS
ED PL1 STB PL3
PIN 1 +5V PIN 14
PIN 2 SIGNAL PIN 10
PIN 3
PIN 4 0V PIN 9
LINK 0V PIN 9 TO PIN 5
MOLEX STB PL6

ED PL2
PIN 1 24V PIN 1
PIN 2 SWITCHED 0V PIN 3
8.1.93 LSB_DATA_VBOMB (9970-0449)
L ab e l L S B IM A G E
( 2 0 m m fr o m c o n n e c t o r ) L abel V B O M B S K 1
P a r t n u m b e r e tc ( 2 0 m m fro m c o n n e c t o r)
p in 1
26 W ay
70m m
2100 m m
Table 8.84 LSB_DATA_VBOMB

26W HD PLUG (SSB) SIGNALS 8W RJ45 (VBOMB SK1)
PIN 1 CHASSIS GND CABLE SCREEN CONNECTOR SHELL
PIN 6 PWCON+ PIN 7 TWISTED PAIR WITH PIN 8 THIS

CONNECTOR
PIN 7 PWCON- PIN 8
PIN 9 BSCON- PIN 2 TWISTED PAIR WITH PIN 1 THIS

CONNECTOR
PIN 10 LD1- PIN 4 TWISTED PAIR WITH PIN 3 THIS

CONNECTOR
Table 8.84 LSB_DATA_VBOMB

PIN 18 BSCON+ PIN 1
PIN 19 LD1+ PIN 3
PIN 20 LD3- PIN 6 TWISTED PAIR WITH PIN 5 THIS

CONNECTOR
PIN 21 LD3+ PIN 5
8.1.94 VBOMB_IHPEN (9970-0450)

Pins down
Label VLD BRD

Label VBOMB
Label
PD BRD
315mm 120mm
150mm Pins up
Pull off loop
50mm Label Part No etc
Table 8.85 VBOMB_IHPEN

IDC SOCKET SIGNALS HEADER VLD BRD
PIN 1 LASER PRESENT PIN 1
PIN 2 POS PIN 2
PIN 3 +5V ANLG PIN 3
PIN 4 ANLG GND PIN 4
PIN 5 PIN 5
PIN 7 EDGE DETECT ENABLE BAR PIN 7
PIN 9 DRIVE LEVEL PIN 9
PIN 11 LOW LEVEL PIN 11
PIN 13 BIAS LEVEL PIN 13

8.1.95 REG_PIN (9970-0451)
Label
REGPIN
20mm RIGHT
Label REGPIN LEFT Label RPI PL3

50mm
100 mm pin 1
60 mm
20 mm
Part number
520 mm 1000 mm
Table 8.86 REG_PIN

AMP CT PL3 SIGNALS
PIN 1 NOT CONNECTED
PIN 2 NOT CONNECTED
PIN 3 REG PIN LEFT M4 RING TERMINAL
PIN 4 REG PIN RIGHT M4 RING TERMINAL
8.1.96 REG_FHMB (9970-0452)
Label FHMB4 PL25

Label RPI PL2
20 mm
pin 1
20 mm
75 mm Part number
400mm
Table 8.87 REG_FHMB

AMP CT SIGNALS MOLEX
FHMB4 PL25 RPI PL2
PIN 1 NOT CONNECTED
PIN 2 +5V PIN 1
PIN 3 0V PIN 2
PIN 4 REG PIN SIGNAL PIN 3

8.1.97 COMP_PANEL (9970-0453)

COMP 1
GREEN / YELLOW
RING TERM M4 RING TERM M5
110 mm Cable 1
COMP 2
GREEN / YELLOW
RING TERM M4 RING TERM M5
180 mm Cable 2
GREEN / YELLOW
FASTON RING TERM M5
420 mm Cable 3
FUSE 1
BROWN
PIGGY BACK FASTON
400 mm Cable 4
BROWN FUSE 2
FASTON
360 mm Cable 5
Place PART number / Cable 1, 2 3 etc label in the centre

of each cable
8.1.98 COMP_MAINS (9970-0454)

Label REL 9
30mm from end part number etc Label Compressors
Tie wrap 120mm

BROWN apart
200 mm
60 mm
240 mm
BLUE 4.3 m
Label REL 7
100 mm 30mm from end View from
GN/YL connection side
Label CHASSIS
8.1.99 ILOCK_COMP (99700-455)
Label REL 9
30mm from end part number etc Label Compressors
Tie wrap 120mm

BROWN apart
200 mm
60 mm
240 mm
BLUE 4.3 m
Label REL 7
100 mm 30mm from end View from
GN/YL connection side
Label CHASSIS
8.1.100 ILOCK_CTRL (9970-0456)

Label REL A
Label COMP
Fastons
40 mm Label REL B
300 mm
Label PUMP CTRL
10 mm 150 mm
Label REL A
50 mm
Fastons
Label REL B
40 mm
Label PUMP
100 mm
M5
tie wrap
Label CHASSIS
Table 8.88 ILOCK_CTRL

8 WAY MOLEX SIGNALS
PIN 1 CHASSIS M5
PIN 2 PUMP REL A FASTON TWIST WITH PIN 6
PIN 3
PIN 4 COMP REL A FASTON TWIST WITH PIN 8
PIN 5
PIN 6 PUMP REL B FASTON
PIN 7
PIN 8 COMP REL B FASTON
8.1.101 SOL_CTRL (9970-0457)
L a b el M IX R EL A 50 m m
L a b el M IX R EL 7
L a b el M IX R EL 4
La b e l M IX REL B
La b e l M IX REL 6 100 m m L a b el M IX FA N
La b e l M IX REL 9 600 m m
50 m m
430 m m L a b el FH M B 1 P L2 3
260 m m
La b e l FH M B 1 P L2
60 m m
L a b el A LE R T R E L
C O IL A
La b e l FH M B 1 P L1
1200 m m L a b el A LE R T R E L
C O IL B
50 m m
40 m m
P a rt N o etc
Table 8.89 SOL_CTRL

FHMB1 PL1 8 WAY SIGNALS
PIN 1 SPARE
PIN 2 SPARE
PIN 3 SPARE
PIN 4 SPARE
Table 8.89 SOL_CTRL

PIN 5 MIXER FAN FASTON MIX REL A T/PAIR WITH MIX REL B YELLOW
PIN 6 MIXER FAN RTN FASTON MIX REL B BLACK
PIN 7 ALERT COIL A FASTON ALERT REL COIL A T/PAIR WITH BLUE
ALERT REL COIL B
PIN 8 ALERT COIL B FASTON ALERT REL COIL B BLACK
FHMB1 PL2 2
WAY
PIN 1 +24V FASTON MIX REL 4 T/PAIR WITH MIX REL 6 WH/OR
PIN 2 RTN FASTON MIX REL 6 BLACK
MIXER FAN 6 WAY
PIN 1 SPARE
PIN 2 +24V FASTON MIX REL 7 T/PAIR WITH MIX REL 9 WH/OR
PIN 3 FAN DETECT PL23 PIN 3 T/PAIR WITH PL23 PIN 4 GREEN
PIN 4 SPARE
PIN 5 24V RTN FASTON MIX REL 9 BLACK
PIN 6 FAN DETECT PL23 PIN 4 WHITE

RTN
8.1.102 RIB3 (9970-0458)
4 20 m m
L abel FH M B P O S 1 P L 1 8
80 m m
L abel I N P U T D IS T P L 5 And p art nu mber
V iew fro m n o n co n n ectio n sid e
8.1.103 ENG_S1/2 (9970-0459)

Label S2
60 mm 300 mm 1000 mm
Label INPUT DIST PL3
60 mm Label S1
1020 mm
Part No etc Tie wrap every 100mm
Table 8.90 ENG_S1/2

PL4 PIN 1 LE PLATE IN INPUT NIP PUL_GND S1 PIN 1 TWISTED PAIR WITH S1 PIN 2
PL4 PIN 2 LE PLATE IN INPUT NIP SUPPLY S1 PIN 2
PL4 PIN 3 LE PLATE IN INPUT NIP GROUND S1 PIN 3 TWISTED PAIR WITH S1 PIN 4
Table 8.90 ENG_S1/2

PL4 PIN 4 LE PLATE IN INPUT NIP SIGNAL S1 PIN 4
PL3 PIN 1 TE PLATE PAST PUSH BAR PUL_GND S2 PIN 1 TWISTED PAIR WITH S1 PIN 2
PL3 PIN 2 TE PLATE PAST PUSH BAR SUPPLY S2 PIN 2
PL3 PIN 3 TE PLATE PAST PUSH BAR GROUND S2 PIN 3 TWISTED PAIR WITH S1 PIN 4
PL3 PIN 4 TE PLATE PAST PUSH BAR SIGNAL S2 PIN 4
8.1.104 VAC (9970-0460)
Lable BV31 Sol 25mm
100mm 1175 mm
Lable FHMB4 PL1
Label I/LOCK BOX

VAC PUMP
Label FHMB4 PL8
Part number and
160mm issue
Table 8.91 VAC

8 WAY MOLEX SIGNALS I/LOCK BOX VAC PUMP
PL1
PIN 1 SPARE
PIN 2 SPARE
PIN 3 PUMP RELAY 8 W MOLEX PIN 2 BLUE
PIN 4 PUMP RELAY RTN 8 W MOLEX PIN 6 BLACK ( TWIST PAIR PIN 2)
PIN 5 SPARE
PIN 6 SPARE
PIN 7 SPARE
FHMB4 PL8
PIN 1 NOT USED
PIN 2 COMP RELAY 8 W MOLEX PIN 4 ( 2 WIRES IN PIN 4) RED
PIN 3 COMP RELAY RTN 8 W MOLEX PIN 8 (2 WIRES IN PIN 8) BLACK ( TWIST PAIR PIN 4)
BV31 SOL
PIN 1 COMP RELAY 8 W MOLEX PIN 4 RED
PIN 2 COMP RELAY RTN 8 W MOLEX PIN 8 BLACK ( TWIST PAIR PIN 4)
8.1.105 ENG_M6 (9970-0461)

1160 mm
Label FHMB4 PL15
Label M6
100mm
Part No etc
AMP CT 3WAY SIGNALS 3 WAY MOLEX MINI- WIRE COLOUR

FIT
PL15 PIN 1 NOT USED M6 PIN 1
PL15 PIN 3 DC_MOT_A M6 PIN 2 RED TP WITH M6 PIN 3
PL15 PIN 2 DC_MOT_B M6 PIN 3 BLACK
8.1.106 ENG_M38 (9970-0462)

1600 mm
Label FHMB1 PL27
Label M38
100mm
Part No etc
JST 6WAY SIGNALS JST 6WAY + WIRE COLOUR

ADAPTER
PL27 PIN 1 OUT A M38 PIN 6 TWIST WITH M38 PIN 2
PL27 PIN 2 OUT C M38 PIN 5 TWIST WITH M38 PIN 1
PL27 PIN 3 +24V M38 PIN 4 TWIST WITH M38 PIN 3
PL27 PIN 4 +24V M38 PIN 3
PL27 PIN 5 OUT B M38 PIN 2
PL27 PIN 6 OUT D M38 PIN 1
8.1.107 ENG_S118 (9970-0463)
Label FHMB4 PL23

pin 1 Part No etc pin 1
100mm Label S118
1700 mm
Table 8.92 ENG_S118

PIN 1 PLATE ON PLATERN PUL_GND S118 PIN 1 TWISTED PAIR WITH PIN 2
PIN 2 PLATE ON PLATERN SUPPLY S118 PIN 2
PIN 3 PLATE ON PLATERN GROUND S118 PIN 3 TWISTED PAIR WITH PIN 4
PIN 4 PLATE ON PLATERN GND SIGNAL S118 PIN 4

8.1.108 ENG_M10 (9970-0464)
740 mm
Label FHMB1 PL28
Label M10
100mm
Part No etc
Table 8.93 ENG_M10

JST 6WAY SIGNALS JST 6WAY + ADAPTOR WIRE COLOUR
8.1.109 ENG_M11 (9970-0465)
2300 mm
Label FHMB1 PL30
Label M11
100mm
Part No etc
Table 8.94 ENG_M11

JST 6WAY SIGNALS JST 6WAY + ADAPTOR WIRE COLOUR
8.1.110 ENG_S114/116/113 (9970-0466)
L ab el FH M B 1 P L1 4
60 m m
150 m m
L ab el S 1 1 3 1080 m m
180 m m
L ab el FH M B 1 P L2 5
15 0mm 1 50 mm
Lab el S 1 1 6 6 30 mm 35 0m m
130 m m 590 m m
Lab el D IS T I/P P L1 0
Lab el S 1 1 4 L L ab el P art N o etc
P lace 7 0 m m from ju n ctio n
L ab el S 1 1 4 R
Table 8.95 ENG_S114/116/113

PL25 PIN 1 NOT USED
PL25 PIN 2 PLATE PUSHER HOME SUPPLY S116 PIN 1
PL25 PIN 3 PLATE PUSHER HOME GROUND S116 PIN 2
PL25 PIN 4 PLATE PUSHER HOME SIGNAL S116 PIN 3 TWISTED PAIR WITH S10 PIN 2
PL10 PIN 1 NOT USED
PL10 PIN 4 CENTERING HOME SIGNAL S113 PIN 3 TWISTED PAIR WITH S10 PIN 2
PL14 PIN 1
PL14 PIN 2
PL14 PIN 3 CENTERING CONTINUITY GROUND S114R TWISTED PAIR WITH S114L
PL14 PIN 4 CENTERING CONTINUITY SIGNAL S114L
PL14 PIN 5
PL14 PIN 6
PL14 PIN 7
PL14 PIN 8
8.1.111 ENG_M3/5 (9970-0467)
Label FHMB4 PL27

140 mm
Label M5 30 mm
900 mm
70 mm
Label M3
Tie wraps every
Part No etc 100mm
Table 8.96 ENG_M3/5

FIT
JST 6 WAY JST + ADAPTOR

8.1.112 ENG_M36/37 (9970-0468)
Label M37
40 mm
850 mm
880 mm 40 mm
Label M36
Label FHMB4 PL22
Tie wraps every
100mm Part No etc
Table 8.97 ENG_M36/37

FIT
8.1.113 INV_MOT (9970-0471)

M5 M5
M5 60 mm 120 mm
Label MOT_GND 100 mm
Label SCREEN (x2)
Label MOT_V1 M4 110 mm Cable Gland 40 mm Label SIE 1L1

530 mm
Label SIE 3L2
110 mm
Label MOT_U1 M4 Label SIE 5L3
Cable 1 and part number
in middle of cable
100 mm M5
Label MOT_W1 M4 120 mm Label GND
Table 8.98 INV_MOT

CONNEC- MOTOR SIGNAL CABLE COLOUR
TOR
MOT_V1 M4 SIE 1L1 BLADE BLUE
MOT_U1 M4 SIE 3L2 BLADE BROWN
MOT_W1 M4 SIE 5L3 BLADE WHITE
SCREEN M5 SCREEN M5 BLACK
MOT_GND M5 GND M5 GN/YL

M4 M5
145 mm 145 mm
Label INV GND M4 60 mm
Label SCREEN (x2)
Label INV U/T1 40 mm 40 mm Label SIE 2T1

110 mm Label SIE 4T2
40 mm
Label INV V/T2 Label SIE 6T3
Cable 2 and part number
40 mm in middle of cable
M5
Label INV W/T3 145 mm Label GND
Table 8.99 INV_MOT

CONNEC- MOTOR SIGNAL CABLE COLOUR
TOR
INV U/T1 M4 FORK SIE 2T1 BLADE BLUE
INV V/T2 M4 FORK SIE 4T2 BLADE BROWN
INV W/T3 M4 FORK SIE 6T3 BLADE WHITE
SCREEN M4 SCREEN M5 BLACK
INV GND M4 GND M5 GN/YL
8.1.114 VBOMB_FAN (9970-0472)
170 mm
Label FAN (near to Label Part Number etc Label VB OM B PL12

connector) (in the center) (near to connector)
Table 8.100 VBOMB_FAN

FAN SIGNALS VBOMB PL12 WIRE COLOUR
PIN 1 FAN FAIL PIN 2 YELLOW
PIN 2 FAN 24V PIN 1 RED
PIN 3 FAN 0V PIN 3 BLACK
8.1.115 CAN_FHMB1_4 (9970-0473)
Label FHMB4 SK1 Label FHMB 1 SK3

pin 1
30mm 30mm pin 1
100mm
Part No etc
1000 mm
Table 8.101 CAN_FHMB1_4

15 D TYPE PLG SIGNAL 15 D TYPE COLOUR COMENTS
PLG
BLACK / WHITE

WHITE / BLACK

ORANGE

BLACK
PIN 10 NO CONNECTION PIN 10 (
PIN 11 E_CLK- PIN 11 BLACK / BLUE (TWISTED PAIR WITH PIN

12)
PIN 13 0V PIN 13 BLACK / BROWN (TWISTED PAIR WITH PIN

14)
8.1.116 PUMP (9970-0479)
Label CB 220 mm 620 mm

BROWN
BROWN
BLUE
80 mm
BLUE GREEN/YELLOW
30 mm
Label REL 7 Label I/LOCK PUMP
100 mm
Label CHASSIS GREEN/YELLOW Suppliers part number etc in Label PUMP OUTLET
centre
8.1.117 ENG_FHMB_PWR (99700480)

Label FHMB1 PL31
Label I/LOCK BOX PWR 1
pin 1 100 mm pin 1
1230 mm
Part no. here

70mm
150mm
Label I/LOCK BOX EMERG

pin 1
70mm
Table 8.102 ENG_FHMB_PWR

PIN 1 CHASSIS PL31 PIN 1 BLACK SCREEN

GND
PIN 3
PIN 4
PIN 5
PIN 6
PIN 8
PIN 9
PIN 10
8.1.118 ILOCK_LINK (99700481)

Table 8.103 ILOCK_LINK
MOLEX (10W) PTM SIGNAL LOOPBACK
PANEL
PIN 1
PIN 2
PIN 3 INTERLOCK RELAY PIN 7
PIN 4 EODD INTERLOCK PIN 8

RETURN
PIN 5
PIN 6

RETURN
PIN 9
PIN 10
8.1.119 BUFF_LINK (9970-0482)

Table 8.104 BUFF_LINK
MOLEX (10W) PTM SIGNAL LOOPBACK
PANEL
PIN 1
PIN 2
PIN 4 EODD INTERLOCK RETURN PIN 8
PIN 5
PIN 6
PIN 7 INTERLOCK RELAY RETURN PIN 3
8.1.120 ENGB1_S118 (9970-0490)
Label FHMB4 PL23

pin 1 Part No etc pin 1
100mm Label S118
1960 mm
Table 8.105 ENGB1_S118

PIN 1 PLATE ON PLATERN PUL_GND S118 PIN 1 TWISTED PAIR WITH PIN 2
PIN 2 PLATE ON PLATERN SUPPLY S118 PIN 2
PIN 3 PLATE ON PLATERN GROUND S118 PIN 3 TWISTED PAIR WITH PIN 4
PIN 4 PLATE ON PLATERN GND SIGNAL S118 PIN 4
8.1.121 ENGB1_M10 (9970-0491)

800mm
Label FHMB1 PL28
Label M10
100mm
Part No etc
Table 8.106 ENGB1_M10

JST 6WAY SIGNALS JST 6WAY + ADAP- WIRE COLOUR
TOR


8.1.122 ENGB1_S1/S2 (9970-0492)
Label S2
60 mm 500 mm 900 mm
60 mm Label S1
1260 mm
Part No etc Tie wrap every 100mm
Table 8.107 ENGB1_S1/S2

PL4 PIN 1 LE PLATE IN INPUT NIP PUL_GND S1 PIN 1 TWISTED PAIR WITH S1 PIN 2
PL4 PIN 2 LE PLATE IN INPUT NIP SUPPLY S1 PIN 2
PL4 PIN 3 LE PLATE IN INPUT NIP GROUND S1 PIN 3 TWISTED PAIR WITH S1 PIN 4
PL4 PIN 4 LE PLATE IN INPUT NIP SIGNAL S1 PIN 4
PL3 PIN 1 TE PLATE PAST PUSH BAR PUL_GND S2 PIN 1 TWISTED PAIR WITH S1 PIN 2
PL3 PIN 2 TE PLATE PAST PUSH BAR SUPPLY S2 PIN 2
PL3 PIN 3 TE PLATE PAST PUSH BAR GROUND S2 PIN 3 TWISTED PAIR WITH S1 PIN 4
PL3 PIN 4 TE PLATE PAST PUSH BAR SIGNAL S2 PIN 4
8.1.123 ILOCK_LINK (9970-0493)
Table 8.108 ILOCK_LINK

MOLEX (10W) SIGNAL LOOPBACK
PTM PANEL
PIN 1
PIN 2
PIN 4 EODD INTERLOCK RETURN PIN 8
PIN 5
PIN 6
PIN 7 INTERLOCK RELAY RETURN PIN 3

8.1.124 ENGB1_M11 (9970-0494)

2800 mm
Label FHMB1 PL30
Label M11
100mm
600 mm
Part No etc

JST 6WAY SIGNALS JST 6WAY + ADAP- WIRE COLOUR
TOR
8.1.125 ENGB1_S114/116/113 (9970-0495)
L ab el F H M B 1 PL 1 4
1 30 m m
2 70 m m 2 40 m m L ab el FH M B 1 PL 25
L abel S1 13 8 00 m m
1 00 m m 40 0m m 50 m m
60 0 m m L ab el D IS T I/P PL 10
L abel S1 16 90 0m m 4 00 m m
13 0 m m 50 m m
L ab el Part N o etc 2 cab le ties
L abel S 11 4L Place 7 0m m fro m jun ction
L abel I/P D IS T PL 12
L ab el S 11 4R
Table 8.110 ENGB1_S114/116/113

PL25 PIN 1 NOT USED
PL25 PIN 2 PLATE PUSHER HOME SUPPLY S116 PIN 1
PL25 PIN 3 PLATE PUSHER HOME GROUND S116 PIN 2
PL25 PIN 4 PLATE PUSHER HOME SIGNAL S116 PIN 3 TWISTED PAIR WITH S10 PIN
2
PL10 PIN 1 NOT USED
2
PL14 PIN 1
Table 8.110 ENGB1_S114/116/113

PL14 PIN 2
PL14 PIN 3 CENTERING CONTINUITY GROUND S114R TWISTED PAIR WITH S114L
8.1.126 ENG_1BHP_S3/S10/S14 (9970-0497)

Label DIST O/P PL9 120mm Label DIST O/P PL10
Label DIST O/P PL7 Label DIST O/P PL11

Label DIST O/P PL12
Label DIST O/P PL6

Label 24V DIST O/P PL2
Label S10
Label S11 Cover this single wire with cable wrap
420mm
730 mm
Label S3 140mm
300 mm
80mm note 1 note 2 Part number here
120mm 267mm long
Label
Punch Label S13
Label S12 Frame 80 mm
Label S14
note 1 note 2
90 mm 300mm
240 mm 100 mm
267mm long
1170mm
400 mm
Wire with cable wrap free to move within the chain
Cover this single wire with cable wrap Chain must be able to bend in this direction.
700mm 30mm Rad 10mm.

note 1. This end piece has the holes for the links
S12 10mm pitch.
All others note 2. This end piece has the pins for the links
680mm
8mm
S13
Labels to be position as shown from their connector
Table 8.111 ENG_1BHP_S3/S10/S14

PL6 PIN 1 NOT USED
PL6 PIN 2 REG MOTOR OUT SUPPLY S10 PIN 1
PL6 PIN 3 REG MOTOR OUT GROUND S10 PIN 2
PL6 PIN 4 REG MOTOR OUT SIGNAL S10 PIN 3 TWISTED PAIR WITH S14 PIN
2
PL7 PIN 1 NOT USED
2
PL9 PIN 1 NOT USED
PL9 PIN 2 REG MOTOR IN SUPPLY S11 PIN 1
PL9 PIN 3 REG MOTOR IN GROUND S11 PIN 2
PL9 PIN 4 REG MOTOR IN SIGNAL S11 PIN 3 TWISTED PAIR WITH S14 PIN
2
PL10 PIN 1 NOT USED
PL10 PIN 2 NOT USED

Table 8.111 ENG_1BHP_S3/S10/S14

PL10 PIN 3 CENTERING RH DETECT GROUND PUNCH FRAME M4 RING TAG
PL10 PIN 4 CENTERING RH DETECT SIGNAL S12 (DRAG CHAIN ASSY)
PL11 PIN 1 NOT USED
PL11 PIN 2 NOT USED
PL11 PIN 3 CENTERING LH DETECT GROUND PUNCH FRAME M4 RING TAG
PL11 PIN 4 CENTERING LH DETECT SIGNAL S13 (DRAG CHAIN ASSY)
PL2 PIN 1 DETECT LE PUNCH PUL GND S3 PIN 1 TWISTED PAIR WITH S3 PIN 2
PL2 PIN 2 DETECT LE PUNCH SUPPLY S3 PIN 2
PL2 PIN 3 DETECT LE PUNCH GROUND S3 PIN 3 TWISTED PAIR WITH S3 PIN 4
PL2 PIN 4 DETECT LE PUNCH SIGNAL S3 PIN 4
PL12 PIN 1
PL12 PIN 3 GND
8.1.127 ENG_IHP_M3/5 (9970-0498)
Label FHMB4 PL27

Label M3 50 mm 140 mm
1150 mm

Label M5
600 mm Tie wraps every
50 mm 100mm
Part No etc
Table 8.112 ENG_IHP_M3/5

JST 6 WAY JST + ADAPTOR
PL27 PIN 1 OUT A M3 PIN 1
PL27 PIN 2 OUT C M3 PIN 2
PL27 PIN 5 OUT B M3 PIN 5 TWIST WITH M3 PIN 1
PL27 PIN 6 OUT D M3 PIN 6 TWIST WITH M3 PIN 2

8.1.128 ENG_FPD_S21 (9970-0499)
Label FHMB4 Label PHOTO

PL4 DETECT
1240 mm
200 mm Part Number
Table 8.113 ENG_FPD_S21

3 WAY AMP CT SIGNALS MOLEX 22-01-2045
PIN 1 CATHODE PIN 2 (TWISTED WITH MOLEX PIN 1)
PIN 2 ANODE PIN 1
PIN 3 SCREEN
8.1.129 MAN_STOP (9970-0500)
EMERG SWITCH
Label I/LOCK BOX EMERG Part no. here
pin 1
150mm 450mm
50mm
Table 8.114 MAN_STOP

MOLEX (6W) SIGNAL M4 FORK WIRE COLOUR COMMENTS
I/LOCK BOX EMERG
PIN 1
PIN 2 +24V EMERG M4 FORK WHITE/ORANGE TWISTED PAIR
PIN 3
PIN 4
PIN 5 24V GND EMERG M4 FORK WHITE/ORANGE
PIN 6
8.1.130 SEMI_S109/110 (9970-0501)
65 m m
L ab el S 1 1 0 720 m m
L ab el FH M B 4 P L9
Lab el S 1 0 9 T ie w rap s ev ery

150 m m 100m m
Lab el Part N o etc
Place 7 0 m m fro m co n n ector
Table 8.115 SEMI_S109/110

PL9 PIN 1 NOT USED
PL9 PIN 2 SWING ROLLER HOME SUPPLY S109 PIN 1
PL9 PIN 3 SWING ROLLER HOME GROUND S109 PIN 2
PL9 PIN 4 SWING ROLLER HOME SIGNAL S109 PIN 3 TWISTED PAIR WITH S109 PIN 2
PL9 PIN 5 NOT USED
PL9 PIN 6 SWING ROLLER IN DRUM SUPPLY S110 PIN 1
PL9 PIN 7 SWING ROLLER IN DRUM GROUND S110 PIN 2
PL9 PIN 8 SWING ROLLER IN DRUM SIGNAL S110 PIN 3 TWISTED PAIR WITH S110 PIN 2
8.1.131 SEMI_M36/37 (9970-0502)

L abel M 37
300 m m L abel F H M B 4 P L20
40 m m
850 m m
880 m m 40 m m
L abel M 36
L abel FH M B 4 PL 22
T ie w ra p s e v e ry
100m m P a rt N o e tc n e x t to th is
c a b le tie
Table 8.116 SEMI_M36/37

8.1.132 BV41PUNCH_LINK (9970-0503)
100MM
LABEL 24VDIST PL1
40MM
LABEL part no etc
LABEL 24VDIST PL4
C bl Ti h
Table 8.117 BV41PUNCH_LINK

AMP CT PL1 SIGNAL LOOPBACK
PIN 1
Table 8.117 BV41PUNCH_LINK

PIN 2
PIN 3 DIG GND CONNECT TO PL1 PIN 4
PIN 4 SENSOR INPUT
AMP CT PL4
PIN 1
PIN 2
PIN 4 SENSOR INPUT
8.1.133 BV41WEB_LINK (9970-0504)
LABEL DIST PL6
40MM
LABEL part no etc
LABEL DIST PL9
Cable Tie here
Table 8.118 BV41WEB_LINK

AMP CT PL6 SIGNAL LOOPBACK
PIN 1
PIN 2
PIN 4 SENSOR INPUT
AMP CT PL9
PIN 1
PIN 2
PIN 4 SENSOR INPUT
8.1.134 EXT_M11 (9970-0505)
Label
FHMB1 PL30
850 mm Label EXTEN M11
100mm
Part No etc
Table 8.119 EXT_M11

JST 6WAY SIGNALS MOLEX 6WAY WIRE COLOUR
FHMB1 PL30 PIN 1 OUT A EXTEN M11 PIN 1 TWIST WITH M11 PIN 5
FHMB1 PL30 PIN 2 OUT C EXTEN M11 PIN 2 TWIST WITH M11 PIN 6
FHMB1 PL30 PIN 3 +24V EXTEN M11 PIN 3 TWIST WITH M11 PIN 4
FHMB1 PL30 PIN 4 +24V EXTEN M11 PIN 4
FHMB1 PL30 PIN 5 OUT B EXTEN M11 PIN 5
FHMB1 PL30 PIN 6 OUT D EXTEN M11 PIN 6
8.1.135 FRONT_SENSOR_EXT (9970-0506)
Lab el FH M B 1 P L1 4
130 m m
240 m m Lab el FH M B 1 P L2 5
100 m m
Lab el Sen sor
E x ten sio n 50 m m
6 00 m m L ab el D IST I/P PL 1
L ab el P art N o etc 50 m m
2 cab le ties
P lace 7 0 m m from ju n ctio n 1000 m m
Lab el I/P D IST PL 1 2

L ab el FH M B 4 PL 2 3
Table 8.120 FRONT_SENSOR_EXT

AMP CT SIGNALS MOLEX
PL25 PIN 1 NOT USED
PL25 PIN 2 PLATE PUSHER HOME SUPPLY SENSOR EXT PIN 1
PL25 PIN 3 PLATE PUSHER HOME GROUND SENSOR EXT PIN 2 TP WITH PIN 3
PL25 PIN 4 PLATE PUSHER HOME SIGNAL SENSOR EXT PIN 3
PL10 PIN 1 NOT USED
PL10 PIN 2 CENTERING HOME SUPPLY SENSOR EXT PIN 4
PL10 PIN 3 CENTERING HOME GROUND SENSOR EXT PIN 5 TP WITH PIN 3
PL10 PIN 4 CENTERING HOME SIGNAL SENSOR EXT PIN 6
PL14 PIN 1
PL14 PIN 2
PL14 PIN 3 CENTERING CONTINUITY GROUND SENSOR EXT PIN 11 TP WITH TP 12
PL14 PIN 4 CENTERING CONTINUITY SIGNAL SENSOR EXT PIN 12
PL14 PIN 5
PL14 PIN 6
PL14 PIN 7
PL14 PIN 8
PL23 PIN 1 PLATE ON PLATERN PUL_GND SENSOR EXT PIN 7 TP WITH PIN 8
PL23 PIN 2 PLATE ON PLATERN SUPPLY SENSOR EXT PIN 8

Table 8.120 FRONT_SENSOR_EXT

PL23 PIN 3 PLATE ON PLATERNGROUND SENSOR EXT PIN 9 TP WITH PIN 10
PL23 PIN 4 PLATE ON PLATERN GND SUPPLY SENSOR EXT PIN 10
PL12 PIN 1
PL12 PIN 3 GND
8.1.136 B1_FRONTSENSOR (9970-0507)
Lab el S1 1 8
1 9 0m m
Lab el S1 1 3 900 m m
Lab el Sen sor
270 m m E x ten sio n
10 0m m 40 0m m
Lab el S1 1 6 90 0m m 4 00 mm
130 m m
Lab el S1 1 4 L Lab el P art N o etc

Place 7 0 m m from ju n ction
Lab el S1 1 4 R
Table 8.121 B1_FRONTSENSOR

MOLEX SIGNALS AMP
SENSOR EXT PIN 1 PLATE PUSHER HOME SUPPLY S116 PIN 1
SENSOR EXT PIN 2 PLATE PUSHER HOME GROUND S116 PIN 2
SENSOR EXT PIN 3 PLATE PUSHER HOME SIGNAL S116 PIN 3 TWISTED PAIR WITH S116 PIN 2
SENSOR EXT PIN 4 CENTERING HOME SUPPLY S113 PIN 1
SENSOR EXT PIN 5 CENTERING HOME GROUND S113 PIN 2
SENSOR EXT PIN 6 CENTERING HOME SIGNAL S113 PIN 3 TWISTED PAIR WITH S113 PIN 2
SENSOR EXT PIN 7 PLATE ON PLATERN PUL_GND S118 PIN 1 TWISTED PAIR WITH S118 PIN 2
SENSOR EXT PIN 8 PLATE ON PLATERN SUPPLY S118 PIN 2
SENSOR EXT PIN 9 PLATE ON PLATERN GROUND S118 PIN 3 TWISTED PAIR WITH S118 PIN 4
SENSOR EXT PIN 10 PLATE ON PLATERNGND SIGNAL S118 PIN 4
SENSOR EXT PIN 11 CENTERING CONTINUITY S114R TWISTED PAIR WITH S114L
GROUND
SENSOR EXT PIN 12 CENTERING CONTINUITY SIGNAL S114L

8.1.137 B2_FRONTSENSOR (9970-0508)
L ab el S 1 1 8 150m m
Lab el S1 1 3 900 m m
Lab el Sen sor
150 m m E x ten sio n
15 0m m 15 0m m
Lab el S1 1 6 63 0m m 3 50 mm
130 m m
Lab el S1 1 4 L Lab el P art N o etc

Place 7 0 m m from ju n ction
Lab el S1 1 4 R
Table 8.122 B2_FRONTSENSOR

MOLEX SIGNALS AMP
SENSOR EXT PIN 1 PLATE PUSHER HOME SUPPLY S116 PIN 1
SENSOR EXT PIN 2 PLATE PUSHER HOME GROUND S116 PIN 2
SENSOR EXT PIN 3 PLATE PUSHER HOME SIGNAL S116 PIN 3 TWISTED PAIR WITH S116 PIN 2
SENSOR EXT PIN 4 CENTERING HOME SUPPLY S113 PIN 1
SENSOR EXT PIN 5 CENTERING HOME GROUND S113 PIN 2
SENSOR EXT PIN 6 CENTERING HOME SIGNAL S113 PIN 3 TWISTED PAIR WITH S113 PIN 2
SENSOR EXT PIN 7 PLATE ON PLATERN PUL_GND S118 PIN 1 TWISTED PAIR WITH S118 PIN 2
SENSOR EXT PIN 8 PLATE ON PLATERN SUPPLY S118 PIN 2
SENSOR EXT PIN 9 PLATE ON PLATERN GROUND S118 PIN 3 TWISTED PAIR WITH S118 PIN 4
SENSOR EXT PIN 10 PLATE ON PLATERNGND SIGNAL S118 PIN 4
SENSOR EXT PIN 11 CENTERING CONTINUITY GROUND S114R TWISTED PAIR WITH S114L
SENSOR EXT PIN 12 CENTERING CONTINUITY SIGNAL S114L
8.1.138 B2_M11 (9970-0509)
1700 mm Label EXTEN M11

Label M11
100mm
Part No etc
Table 8.123 B2_M11

MOLEX 6WAY SIGNALS JST 6WAY + ADAP- WIRE COLOUR
TOR
EXTENM11 PIN 1 OUT A M11 PIN 6 TWIST WITH M11 PIN 2
EXTENM11 PIN 2 OUT C M11 PIN 5 TWIST WITH M11 PIN 1
EXTENM11 PIN 3 +24V M11 PIN 4 TWIST WITH M11 PIN 3
EXTENM11 PIN 4 +24V M11 PIN 3
EXTENM11 PIN 5 OUT B M11 PIN 2
EXTENM11 PIN 6 OUT D M11 PIN 1

8.1.139 B1_M11 (9970-0510)
2000 mm
Label EXTEN M11
Label M11
100mm
600 mm
Part No etc
No Tie wraps over this area

Table 8.124 B1_M11
MOLEX 6WAY SIGNALS JST 6WAY + ADAPTOR WIRE COLOUR
EXTEN M11 PIN 1 OUT A M11 PIN 6 TWIST WITH M11 PIN 2
EXTEN M11 PIN 2 OUT C M11 PIN 5 TWIST WITH M11 PIN 1
EXTEN M11 PIN 3 +24V M11 PIN 4 TWIST WITH M11 PIN 3
EXTEN M11 PIN 4 +24V M11 PIN 3
EXTEN M11 PIN 5 OUT B M11 PIN 2
EXTEN M11 PIN 6 OUT D M11 PIN 1
8.1.140 INT_STAT (9970-0511)

Label EODD PL4
Label PWR FILT PL8
580 mm
Table 8.125 INT_STAT

PL 4 SIGNALS PL 8 COMMENTS

8.1.141 ENG_BLOW_AUTO_WEB (9970-0512)
780mm 150mm
50mm Label FHMB4 PL16
2150mm (sleeved)
Label BV41
50 mm
Label BV30
Label FHMB4 PL10
125mm
Label BV40 Part number label 50 mm
Label FHMB1 PL10
Table 8.126 ENG_BLOW_AUTO_WEB

AMP CT SIGNAL NAME MOLEX MINIFIT JR COLOUR COMMENT
FHMB4 PL10 BV30
PIN 1 NOT USED
PIN 2 DIVERT VALVE BV30 PIN2 RED TWIST WITH BV30 PIN 3
PIN 3 DIVERT VALVE RTN BV30 PIN 3 BLACK
FHMB1 PL10 BV40
PIN 1 NOT USED
PIN 2 LEADING EDGE BV40 PIN 2 RED TWIST WITH BV40 PIN 3
PIN 3 LEADING EDGE RTN BV40 PIN 3 BLACK
FHMB4 PL16 BV41
PIN 1 NOT USED
PIN 2 AIR KNIFE BV41 PIN 2 RED TWIST WITH BV41 PIN3
PIN 3 AIR KNIFE RTN BV41 PIN 3 BLACK
8.1.142 ENG_BLOW_AUTO_PUNCH (9970-0516)

780mm 150mm
50mm Label FHMB4 PL22

2150mm (sleeved)
Label BV41
50 mm
Label BV30
Label FHMB4 PL10
125mm
Label BV40 Part number label 50 mm
Label FHMB1 PL10
Table 8.127 ENG_BLOW_AUTO_PUNCH

AMP CT SIGNAL NAME MOLEX MINIFIT JR COLOUR COMMENT
FHMB4 PL10 BV30
PIN 1 NOT USED
PIN 2 DIVERT VALVE BV30 PIN2 RED TWIST WITH BV30 PIN
3
PIN 3 DIVERT VALVE RTN BV30 PIN 3 BLACK

Table 8.127 ENG_BLOW_AUTO_PUNCH

FHMB1 PL10 BV40
PIN 1 NOT USED
PIN 2 LEADING EDGE BV40 PIN 2 RED TWIST WITH BV40 PIN
3
PIN 3 LEADING EDGE RTN BV40 PIN 3 BLACK
FHMB4 PL22 BV41
PIN 1 NOT USED
PIN 2 AIR KNIFE BV41 PIN 2 RED TWIST WITH BV41

PIN3
PIN 3 AIR KNIFE RTN BV41 PIN 3 BLACK
8.1.143 AIRKNIFE_VAC (9970-0517)
Lable BV31 Sol 25mm
100mm 1075 mm
Lable FHMB4 PL1
Label I/LOCK BOX

VAC PUMP
Label FHMB4 PL8
Part number and
160mm issue
Table 8.128 AIRKNIFE_VAC

8 WAY MOLEX SIGNALS I/LOCK BOX VAC PUMP
PL1
PIN 1 SPARE
PIN 2 SPARE
PIN 3 PUMP RELAY 8 W MOLEX PIN 2 BLUE
PIN 4 PUMP RELAY RTN 8 W MOLEX PIN 6 BLACK ( TWIST PAIR PIN 2)
PIN 5 SPARE
PIN 6 SPARE
PIN 7 SPARE
FHMB4 PL8
PIN 1 NOT USED
PIN 2 COMP RELAY 8 W MOLEX PIN 4 ( 2 WIRES IN PIN 4) RED
PIN 3 COMP RELAY RTN 8 W MOLEX PIN 8 (2 WIRES IN PIN 8) BLACK ( TWIST PAIR PIN 4)
BV31 SOL
PIN 1 COMP RELAY 8 W MOLEX PIN 4 RED
PIN 2 COMP RELAY RTN 8 W MOLEX PIN 8 BLACK ( TWIST PAIR PIN 4)
8.1.144 XBLW3_IPWR (9970-0518)
CHAS
10 mm tinned ends M5
Part No @ Issue 90mm

90mm
DIST L IN 100mm IECIN L
IECIN E
380mm 50mm IECIN N
DIST N IN
70mm
See Note 1
Cable 2
120mm brown
LDIST FUSE1
FASTON
Cable 3
120mm brown
LDIST FUSE2
M5 RING (unless otherwise stated)
Cable 4 M4 200mm G/Y M5
10 MM TINNED
COMP1E CHASSIS
Cable 5
M4 250mm G/Y M5
COMP2E CHASSIS
Cable 6
M5
500mm G/Y M5
LID CHASSIS
Table 8.129 XBLW3_IPWR

CABLE 1 SIGNALS COLOUR
IECIN L FASTON LIVE DIST L IN (TINED END) BROWN
IECIN N FASTON NEUTRAL DIST N IN (TINED END) BLUE
IECIN E FASTON EARTH CHAS M5 RING GREEN/YELLOW

Volume-Chapt er
SYSTEM CABLING VIEWS

This chapter shows the system functional modules and how they are interlinked by
cables described in the previous chapter.
4
4
System functional view (all variants)........................................................................ 9-2
4
System DC cabling view (fully-automatic) ............................................................... 9-3
4
Engine cabling view (System PCB - all variants) .................................................... 9-4
4
Engine cabling view (Interlock box - all variants) ...................................................9-5
4
Engine cabling view (FHMB - fully-automatic with punch).....................................9-6
4
Engine cabling view (FHMB - fully-automatic without punch) ............................... 9-7
4
Engine cabling view (FHMB - B1/B2 manual/semi-automatic without punch) ..... 9-8
4
PTM cabling view (fully-automatic with/without punch) ......................................... 9-9
4
Autofeeder cabling view (fully-automatic with/without punch) ...........................9-10
Interlocks system view (all variants) ...................................................................... 9-11
PLATE HANDLING, VACUUM CONTROL
ENCODER
SENSORS MOTORS SENSORS MOTORS SENSORS MOTORS SENSORS MOTORS VAC/

ALERT
DRUM BLOW
TRAVERSE
CAN3 CAN4 CAN5 CAN_UMBIL

FHMB(1) FHMB(2) FHMB(3) FHMB(4) TRAVERSE
(ENGINE) (PTM) (PTM) (ENGINE) (STB)
PTM
LCD SPINNER/
ENCODER
CAN2 MIXER FAN
VOLUME 2 (9-2) S YSTEM C ABLING VIEWS
AUTOFEEDER
ELEVATOR ELEVATOR
DISTRIBUTION CONTROL
CASSETTE
MMI DOOR
SCSI DATA EODD I/F

EOD X
POD LPD BEAMS
DIAGNOSTICS X&Y
HV
LSB EODD EODD
PROCESSOR EOD Y
I/L
REF CLK LD1

VBOMB
DISK
DRIVE (1) LD3
OPTICS ND FOCUS,
SENSORS APERTURE MOTORS OPTICS
RFI BOX BASE
Figure 9.1 System functional view (all variants)

+24
APERTURE
VBOMB_APM

+15
POD
VBOMB_POD
+15
LPD
VBOMB_LPD
+24
ND FILTER
VBOMB_NDM
PL16 PL5 PL15 PL14

+5, +24 +24
PL2 PL17 FOCUS
VBOMB_PWR FOCM
+5
VBOMB TRAVERSE ENCODER
I/L BOX
FHMB(4)
24V_ENG
PL4/5 TRAVERSE MOTOR
+24, +36 +24, +36 +36, +24
SK2 PL31 PL6
PWR2 CAB_UMBIL STB
PL6 PHASE +36
SPINNER MOTOR
POWER ENG_FHMBPWR RIB/RIB2
+36 PL18 +5
PSU +5 FILTER SPINNER ENCODER
+24 EODD RIB/RIB2
PL19 24V
+24 DIST +5 SENSOR
+24 +12, +24 HV
PL3 DIST
+5 EOD EODD +24 FHMB(1)
PSU1
PSU RIB3/RIB9 +5 SENSOR
PL18
SYSTEM BOARD DIST
BV8_CTRL MFAN +24 MIXER

+5 PL23
PL13 PL31 FAN
PSU
15
PL11
PSU
+15 INT_EMERG +24 EMERGENCY
PL10 +15V STOP
PSU FHMB(3)
+12, +5
REG
0V RIB4/RIB5 +5 SENSOR
PL18
DIST
+30 DISK_PWR +5 +24
RESISTOR PL31
INT_M22 ASSY +24 NEW

PL19 24V
PSU +24 MMI PWR3_INT
DIST
DISK
+24 AIR KNIFE AIR
DRIVES
RELAY KNIFE
RFI BOX
FHMB(2)
Figure 9.2 System DC cabling view (fully-automatic)

FANS
INT_OUT +5 RIB8 ELEV
DIST
NOTE: SEE CHAPTER 2.9 FOR CABLE PIN DESCRIPTIONS PL18

+24
PL31
RIB7 +5 ELV_IN ELEV
CONTROL
RIB6 +5 CASS
PL19
ID
RFI BOX 24V_ENG TO INTERLOCKS, ENGINE,
FHMB_PWR FEEDER AND
PWR CONTACTOR (4)
PSU1 INT_STAT FILTER BD
VBOMB_PWR
5V
MAINS_PSU 15V PSU TO FHMB1 (4)
-15V
24V(FHMB)
24V(FHMB) OPTICS BASE
30V
36V PART OF EOD
Tx EODX
EOD
HV BD
EODD
5V, 24V PART OF EOD EODY
Tx
(8V, 900V)
PCB FAN
(from 24V rail)
LASER BASE X
PD
PD BD
DISTRIBUTION
LASER BASE Y
PD
PD BD
EODD_IF DISTRIBUTION
CAN2
DISK_PWR PSU_CTRL
OPTICS V_VBOMB_SENSORS
DISK 1 SYSTEM BOARD
DISK_DATA LSB_DATA_VBOMB ENCLOSURE
IEC FAN
INLET CAN1
MAINS_RFI_IN LPD_HOME
SCSI MMI LCD VBOMB_FAN
MMI LCD
LPD
(B2 MAN) ENG_DIAGS VBOMB_LPD
APERTURE HOME
ND HOME
(B2 MAN) ENG_PROC

VBOMB_LPDM
APERTURE
FOCUS HOME & FOCUS LIMIT
MAINS_RFI_IN VBOMB_APM MOTOR

MAINS_IN TO INTERLOCK BOX (4) VBOMB
FILTER MAINS_DIST MAINS_DIST VBOMB_NDM
REAR FRAME (20A) TO INTERLOCK BOX (4)
ND MOTOR
PANEL WITH VBOMB_FOCM
CONNECTORS ENG_INT (EXT I/L) ENG_INT
AND CABLE TO ENG_INT (4) FOCUS
Figure 9.3 Engine cabling view (System PCB - all variants)

GLAND FOR MOTOR
THE MAINS ALERT ALERT
TO CONTROL RELAY (4)
VBOMB_POD V_VBOMB_ENVIRMON
PUMP PUMP PUMP
(ENGINE) TO INTERLOCK BOX (4)
TEMPERATURE
POD
& HUMIDITY
SENSOR BD
(IF FITTED)
TO PUMP PUMP
(3) (5, 6, 7)
PSU_CTRL OVERRIDE
(3) (5, 6, 7)
SWITCH
(5, 6, 7)
ENG_INT ENG_FHMBPWR
(3)
USER
SERVICE DOOR DOOR
INTERLOCK INTERLOCK
I/P COVER OUTPUT COVER

INTERLOCK INTERLOCK
(SEE NOTE 1)
24V_ENG
(3)
8A VAC PUMP
CIRCUIT BREAKER
PUMP I/LOCKCTRL
VAC (5, 6, 7)
RELAY AIRKNIFE_VAC
BV5
MAINS_RFI_IN DIST
(3)
ON/OFF (15A) I/LOCK_DC (EMG)

CABLE WITH UNDER
GLANDS VOLTAGE
RELEASE
MAINS_DIST I/LOCK_MAINS PWR2 (5, 6, 7)

(3)
2A FUSE
SCHMERSAL
PSU_I/LOCK AES 1235
24V PSU SIEMENS

CONTACTOR
3RT1016-1BB42
I/LOCK_COMP
COIL
COMP RELAY
BV31(1) FUSES
I/LOCK_DC
INTERLOCK BOX
FUSES
COMP_MAINS
COMP 1
NOTE 1: B1 MAN & SEMI-AUTO
HAVE I/LOCK LINK COMP_PANEL
COMP 1
NOTE 2: B2 MAN & SEMI-AUTO
WITHOUT COMP BOX COMPRESSOR BOX
(SEE NOTE 2) ENG_FHMBPWR
(5, 6, 7)
CAN2
(3) (5, 6, 7)
ALERT CONTROL SOL_CTRL

(3) RELAY (5, 6, 7)
(BV8)
Figure 9.4 Engine cabling view (Interlock box - all variants)

(4) PUMP
ENG_INT
FRAME
(4) EMERG WITH
PANEL
ENG_FHMBPWR CONNECTORS
(4) (TO PTM)
CAN3_ENG
TO (8)
CAN5_ENG
ENG_M6
BM6 FRICTION BAND OUTPUT MODULE
BM5 REGISTRATION PINS BUFFER
ENG_M3/5 INTERLOCK
BM3 CENTERING ARMS
ENG_M7 BUFF_M7
PWR2 BM7 BUFFER FEED
TO PROC
ENG_M2
BM2 PUSH BAR BS19 BUFFER ENTRANCE
CARRIAGE
PCB
ENG_S19/20 BUFF_S19/20
SENS PCB
FHMB ENG_FPD_S21
BS21 FPD DIST BD SET CAN ID 0 BS20 BUFFER EXIT
BOARD 4 BUFFER
ENG_S10/11 BS10 REG MOTOR OUT POSITION
BS11 REG MOTOR IN POSITION
(4) ENG_S4
PCB BS4 OUTPUT ENTRANCE
RIB1/RIB2 ENG_S5
PL18 PCB BS5 OUTPUT EXIT
(OUTPUT)
BV41 PUNCH_LINK BS13 CENTERING LH DETECT
(4) PL19
BS12 CENTERING RH DETECT
BS14 CENTERING HOME
NEW ENG_S14/12/3
24V PCB BS3 PLATE IN PUNCH
DIST BD ENG_S79
BS79 CHAD TRAY HOME
BS112 PUSH BAR FWD LIMIT TRAVERSE ENCODER (READ HEAD)
ENG_S6/S112
BS6 PUSH BAR HOME
TRAVERSE MOTOR
UMBILICAL
STB
SPINNER MOTOR
ENG_BLOW BV30
BV41 (2) SPINNER ENCODER
CONTROL
VAC/AIRKNIFE_VAC RELAY
(BV3)
ENG_BLOW_AUTO_PUNCH MIXER FAN (BV3)

MFAN
BS80
MIXER FAN
DETECT
PCB BS1 INPUT ENTRANCE

ENG S1/2
CAN3_ENG SENS
FHMB PCB BS2 INPUT EXIT
BOARD 1 DIST BD
ENG_FHMBPWR SET CAN ID 0
(4)
RIB3 ENG S8/9 BS8 PUNCH MOTOR ON POSITION
CAN2 PL18
(4) (INPUT)
BS9 PUNCH MOTOR OFF POSITION
SOL_CTRL
(4)
ENG_EARTH
ENG M1
BM1 FRICTION BAND INPUT MODULE
ENG M4
BM4 PUNCH
Figure 9.5 Engine cabling view (FHMB - fully-automatic with punch)

(4) PUMP
ENG_INT
FRAME
EMERG WITH
(4)
ENG_FHMBPWR PANEL
(4) CONNECTORS
(TO PTM)
CAN3_ENG
TO (10.8)
CAN5_ENG
ENG_M6
BM6 FRICTION BAND OUTPUT MOD
BM36 REGISTRATION PINS BUFF_LOCK BUFFER
ENG_M36/37 INTERLOCK
BM37 SWING ROLLER
ENG_M7 BUFF_M7
PWR2 BM7 BUFFER FEED
TO PROC
ENG_M2
BM2 PUSH BAR CARRIAGE
ENG_S21
BS21 FPD
BS109 SWING ROLLER HOME BUFFER TO PLATE PROCESSOR

FHMB
BOARD 4 ENG_S109/110
BS110 SWING ROLLER IN DRUM
BS19 BUFFER IN
(4) PCB
REG_FHMB REG ENG_S19/20 BUFF_S19/20
PIN BD SENS PCB
DIST BD BS20 BUFFER OUT
REG_PIN BUFFER
BS104 REG PIN CONTINUITY

ENG_S4
ENG_S5
PCB BS5 OUTPUT EXIT
RIB1/RIB2 (OUTPUT) BV41 WEB_LINK

PL18
(4)
PL19 BS100 REG PIN MTR HOME

NEW ENG_S100/103
24V BS103 REG PIN MTR IN
DIST BD
ENG_S6/S15
BS6 PUSH BAR HOME
TRAVERSE MOTOR
UMBILICAL
STB
SPINNER MOTOR
ENG_BLOW_AUTO_WEB BV30
BV40 SPINNER ENCODER
BV31 (2)
EDGE
DETECT EDGE
CONTROL LASER
DETECT BD
VAC/AIRKNIFE_VAC RELAY
(BV3)
ENG_BLOW
MIXER FAN (BV3)
MFAN
BS80
MIXER FAN
DETECT
PCB BS1 INPUT ENTRANCE

ENG S1/2
CAN3_ENG SENS
FHMB PCB BS2 INPUT EXIT
BOARD 1 DIST BD
ENG_FHMBPWR
(4) RIB3
CAN2 PL18
(4) (INPUT)
(4) SOL_CTRL
ENG_EARTH
ENG M1
Figure 9.6 Engine cabling view (FHMB - fully-automatic without punch)

ENG_INT
(4) ILOCK_LINK
MAN_STOP
ENG_CAN_FHMB1_4 BUFF_LINK (MANUAL ONLY)
BUFFER TO PLATE PROCESSOR
BM36 REGISTRATION PINS BUFF_LOCK BUFFER

ENG_M36/37 (B2) INTERLOCK
BM37 SWING ROLLER
SEMI_M36/37 (B1) NOTE 1
PWR2
ENG_M7 BUFF_M7
BM7 BUFFER FEED
TO PROC
ENG_M2
BM2 PUSH BAR CARRIAGE
ENG_S21
BS21 FPD
BS109 SWING ROLLER HOME

FHMB
(4) BOARD 4 ENG_S109/110
BS110 SWING ROLLER IN DRUM
BS19 BUFFER IN
(4) PCB
REG_FHMB REG ENG_S19/20 BUFF_S19/20 NOTE 2
PIN BD SENS PCB
DIST BD BS20 BUFFER OUT
REG_PIN BUFFER
BS104 REG PIN CONTINUITY

ENG_S4
ENG_S5
PCB BS5 OUTPUT EXIT
RIB1/RIB2 (OUTPUT) BV41 WEB_LINK
PL18
(4)
PL19 BS100 REG PIN MTR HOME

NEW ENG_S100/103
24V BS103 REG PIN MTR IN
DIST BD
ENG_S6/S112
BS6 PUSH BAR HOME
TRAVERSE MOTOR
UMBILICAL
STB
SPINNER MOTOR
ENG_BLOW_AUTO_WEB BV30
BV41 SPINNER ENCODER
CONTROL EDGE_DETECT EDGE EDGE_LASER LASER

AIRKNIFE_VAC
RELAY DETECT BD
(BV3)
MIXER FAN (BV3)
SOL_CTRL MFAN
BS80
MIXER FAN DETECT
ENG_M38
BM38 OUTPUT MOTOR
RIB3 PCB BS1 INPUT ENTRANCE

PL18 ENG_S1/2
SENS (ENG B1)
DIST BD PCB BS2 INPUT EXIT
(B2) CAN ID0
FHMB4
FHMB (PL23) (INPUT)
ENG_FHMB_PWR BOARD 1 BS114 CENTERING CON 1
(4) B2_FRONTSENSOR
CAN2 BS113 CENTERING HOME
(4) FRONT_SENSOR_EXT BS116 PLATE PUSHER HOME
ENG B1_S114 PCB BS118 PLATE ON PLATEN
SOL_CTRL ENGB1_M10
(4) BM10 PLATE CENTERING
EXT_M11 B2_M11 ENG_EARTH
BM11 PLATE PUSHER
ENG_M1
NOTE 1: B1 SEMI-AUTOMATIC HAS

BUFFER INTERLOCK
NOTE 2: B1 AND B2 MANUAL DO NOT
HAVE A BUFFER
Figure 9.7 Engine cabling view (FHMB - B1/B2 manual/semi-automatic without

punch)
24V 36V
INT_M21/25 BM21 STACK HEIGHT
INT_S56/57/65 BS65 CASS AT NUDGER
BM25 RETARD DROP BS56 RETARD UP
LIMIT SENSOR BS57 RETARD DOWN
CAN5_INT PLUG PL9 DIST INT_S52
BOARD PCB BS52 PARK POSITION (PRE-INPUT)
INT_S44/61 BS61 STACK HEIGHT TOP
EMERGENCY BS47 STACK HEIGHT POSITION
STOP SWITCHES
BS44 STACK HEIGHT HOME PCB BS43 CASS EMPTY
RIB4/RIB5
PL18 PCB BS48 NUDGER DETECT
PL19 INT_S49/50
PCB BS49 RETARD MADE
BS50 PLATE AT PRE DIVERTER
BM22 NUDGER & INT_S66/53
FHMB TAKEAWAY BS53 PAPER TENSIONER
BOARD 3
BM23 NUDGER LIFT PCB BS66 INTERLEAF NIP CLEAR
BV20 DIVERTER
BM24 INTERLEAVE DRIVE
INT_M22ASSY INT_S45ASSY
BS51 PAPER POST DIVERTER
NEW BS45 NUDGER DOWN LIMIT
24V BS46 NUDGER UP LIMIT
CAN4
24V 36V DIST
ENGINE BM20 CASSETTE FWD BOARD SET CAN ID 1
INT_M20/27
BS55 PAPER POST DIVERTER
INT_EMERG BM27 X DIRECTION DOOR INT_S55/59
TO EMERG PCB BS59 PLATE PAST DIVERTER
BM62 X DIRECTION
DOOR UP
INT_S62/71 BS71 X DIRECTION
TO CAN5_ENG
DOOR DOWN RIB6 BS41 CASS FWD LIMIT
PL19 CASS ID BOARD INT_S41/42
TO PWR3_INT BS42 CASS REV LIMIT
BV22 CASS DOOR LOCK BS36 CASS ID1
ENG_FHMBPWR INT_S76
BS72 CASSETTE DOOR CLOSED BS37 CASS ID2 PCB BS76 FRONT DOOR OPEN
BS38 CASS ID3
CAN3_INT FHMB BV25 DOCKING LIGHT
TO CAN3_ENG BS39 CASS ID4
BOARD 2 BM28 Z DIRECTION CONTROL BS40 CASS ID5
FROM BM26 ELEVATOR STOP
(5, 6, 7)
BM26 ELEVATOR STOP
FEED_INT BS74 VECTOR DRIVE ALARM
TO ENG_INT
BS75 VECTOR DRIVE OVERLOAD INT_OUT
TO ELEVATOR DIST BD
RIB7
FRAME WITH PL18 TO ELEVATOR CTRL BD
PANEL
CONNECTORS
(ENGINE) PTM INT_OUT
I/LOCK TO (9)
(EARLY MACHINES ONLY)
24V BV23 AIR KNIFE
PTM AIR KNIFE
AIR KNIFE FAN

INT_MAINS INT_MAINS
TO PUMP_PTM MAINS TO ELEVATOR SECTION
Figure 9.8 PTM cabling view (fully-automatic with/without punch)

INT_EARTH
NOTE 1: KNIFE MOVED TO ENGINE FRAME WITH PANEL
ON LATER MACHINES CONNECTORS
BS30 ELEVATOR (TOP)
BS31 ELEVATOR (BOTTOM)
RIB8
BS32 ELEVATOR SHELF 1
ELEVATOR DISTRIBUTION BD
BS78 DOCKING RH BS77 DOCKING LH
DOCKING INDICATOR
BS63 Z DIRECTION UP
BS70 Z DIRECTION DOWN
BM28 Z DIRECTION CONTROL

PTM
CASSETTE DOOR LOCK
ELV_LOCK ELV_LOCKS SCHMERSAL

SOLENOID LOCK
(BV22)
FROM CONTACTS (BS72)

(10.8)
BM26 ELV_IN ELEVATOR
CONTROL BD
RED
TOP LIMIT
FRAME WITH PANEL ORANGE
CONNECTORS
ELV_CTRL ELV_CON_24V BOTTOM LIMIT
(PTM)
RED
SIEMENS
MAINS_ELV_IN HITACHI RFI PART OF FILTER INV_MOTOR INV_MOTOR ELEVATOR
INVERTER CONTACTOR
FILTER CABLE 2 3RT1016- CABLE 1 MOTOR ELEV_EARTH
1BB42
inc BS74 and BS75
Contacts for BS73
Figure 9.9 Autofeeder cabling view (fully-automatic with/without punch)

AES 1235 CABLE 'ENG_INT'
I/LOCK PIN3 EXTERNAL DLA

S22 CONNECTIONS OVERRIDE KEY
I/LOCK PIN7 ENG USER ENG O/P BUFFER B SWITCH OFF
S14 PTM TOP ENG I/P ENG SERV
H (6) F (5) G (4) I (3) A (2) J (1) PIN 9 C
I/LOCK PIN2
S13 F1B 1A F1A 2 6 2 6 2 6 2 6 2 6 2 6 1 2
PIN 4
I/LOCK PIN5 3 7 3 7 3 7 3 7 3 7 3 7 3 4
S21 F2B 1A F2A
4 8 4 8 4 8 4 8 4 8 4 8 PIN 2
PIN 7
CABLE 'ENG_INT' 1-6 SWITCH POSITION WITH PANELS CLOSED AND NOT OVERRIDDEN
+- 15V FROM PSU LSB

13 PIN2 SEE NOTE
ON ROUTE S/W STATUS (PSU - CTR)
14
RELAY
ON LSB STAT 1 NOTE:
STAT 2 'ENG_INT' TO
STAT 3 (PL4) PWR FILTER TO
+15V TO STAT 4 'INT_STAT' TO
VBOMB STAT 5 EODD
STAT 6
CONFIRMS CONTACTOR SWITCHING EODD

X1
FROM INTERLOCK
BOX +24V 52 51
SSB SSB
FROM FHMB SENSORS AVAILABLE IN DIAGNOSTICS
POWER ILOCK SENSORS READ_PSU_STATUS OK MEANS COVER IN POSITION
+24V GND +24V 1L1 2T1 TO FHMBs ILOCK_RELAY GIVES INCORRECT READING
A2- +24V POWER ILOCK OVERRIDE KEY READ_SENSOR ILOCK_OVERRIDE OFF MEANS INTERLOCKS NOT OVERRIDDEN
+24V +36V 3L2 4T2 TO FHMBs ILOCK CONTACTOR (ENGINE) READ_SENSOR ILOCK_RELAY OFF MEANS INTERLOCKS OK,
A1+ OK TO FEED POWER TO FHMB'S & LASER
+36V POWER
5L3 6T3 ILOCK CONTACTOR (AUTOFEEDER) READ_SENSOR BS73 OFF MEANS INTERLOCKS OK,
OK TO FEED AC TO ELEVATOR MOTOR
S23 +24V +24V 21NC 22NC +24V
F3B 1A F3A CASSETTE DOOR LOCK READ_SENSOR BS72 ON MEANS DOOR CLOSED,
OK TO FEED AC TO ELEVATOR MOTOR
S24 A1+ A2- +24V GND
FUSED +24V
I/LOCK CONTACTOR
(I/L BOX)
I/LOCK PIN4 AUTOFEEDER
CONTACTOR
INVERTER (ELEVATOR) ELEVATOR
FILTER MOTOR
E 4T2 3L2
MAINS V/T2 V
Figure 9.10 Interlocks system view (all variants)

INPUT L 2T1 1L1
FROM L1 U/T1 U BM26
PTM N 6T3 5L3
SOL LOCK N/L3 W/T3 W
BS72 11 12 BS72RTN BS73RTN 22NC 21NC BS73 FHMB(2)
FHMB(2)
FUSED +24V 21 22 FUSED +24V A1+ A2- +24V GND
BV22 A1 A2 BV22RTN ABS LIMIT ABS LIMIT

TOP BOTTOM
INTERLOCK BOX DOOR DRIVE FHMB(2) +24V

Volume-Chapt er
ROUTINE MAINTENANCE
This chapter describes the required service tools, the service schedule and the main
service procedures for a site visit.
4
4
Field Service Tools ..................................................................................................... 1-1
4
Overriding the Interlocks ...........................................................................................1-2
4
Opening Service Covers ............................................................................................ 1-3
4
Maintenance Schedule ...............................................................................................1-4
4
Cleaning Procedures.................................................................................................. 1-5
4
Maintenance Procedures ...........................................................................................1-9
4
Checking the Traverse .............................................................................................1-14
Checking the Platesetter Output............................................................................. 1-16
1.1 Field Service Tools

Useful tools for a service visit include:
Metric Allen key set (1.5 mm to 10 mm). Keys required are 3, 4, 5, 6 and 8
mm; sizes 1.5, 2, 2.5 and 10 mm will also be useful as spares.
Metric socket set and open-ended spanner set, including 24 mm socket plus
27 mm and 28 mm open-ended spanner.
Digital voltmeter (DVM).
Laptop PC - minimum specification: Pentium 32 Mbyte RAM, 800x600 (Min)
screen resolution with Windows NT4, Lotus Notes (V4.6) and modem. This
tool is optional.
Pliers (medium and small).
Side-cutters.
Soldering iron (transportable, gas type) and solder.
Flat-blade screwdriver (medium and small).
Philips screwdriver (medium and small) - magnetic.
Dummy pozidrive screwdriver.
Steel ruler (6 in/150 mm).
VOLUME 3 (1-2) R OUTINE MAINTENANCE
Microscope (x100).
Spirit level, approximately 610 mm (24 in) long.
Antistatic mat.
Torch.
Interlock override key.
Vernier gauge to 25 m.
Glass ruler to 450 mm (with magnifiers).
Vernier ruler.
Film comparison ruler.
Edge detect laser setup tool (if supplied).
Cassette door lock (Schmersal) manual release key.
Small hand-held vacuum cleaner with plastic attachments.
10 mm spacer for setting up BS51 and BS55.
1.2 Overriding the Interlocks

See Figure 1.1.
Cover interlocks are temporarily overridden by a two-position keyswitch fitted
on all engine variants. Remove the service side engine cover to access the switch
(fully-automatic) or open the service side cover (manual and semi-automatic).
KEYSWITCH
(IN OVERRIDE
POSITION)
KEYSWITCH IN
INTERLOCKS
ENABLED
POSITION
ENGINE - SERVICE SIDE

(COVER REMOVED FOR CLARITY)
Figure 1.1 Interlock override - keyswitch location (fully-automatic)

In the interlock override state, the MMI display shows a background pattern of
laser warning symbols.
After completing the service work, return the interlocks to their enabled state by
removing the key and replacing the engine side cover. Note that you cannot
install the cover if the key is still in the lock.
1.3 Opening Service Covers

1.3.1 Manual and Semi-Automatic
The service side door on Manual and Semi-Automatic machines are locked by
screw fixings shown in Figure 1.2. Note that earlier machines may have doors
without the screw fixings. Access to the optics base and RFI box is the same as
the Fully-Automatic machine.
1.3.2 Fully-Automatic
All service covers are locked by screw fixings that are only removed by an
approved engineer. The location and number of the fixings is shown in
Figure 1.2 below.
SERVICE SIDE
RFI BOX
(LID ONLY)
AUTOFEEDER PTM ENGINE
OPTICS
BASE
LOWER COVER
USER SIDE
NOTE: CASSETTE DOOR LOCK BOTTOM SCREW LOCK
IS S/W CONTROLLED
TOP SCREW LOCK
NOT LOCKED
Figure 1.2 Removing locked covers (fully-automatic)

Removing Covers:
1. Unlock the cover using a pozi-screwdriver to remove the M4 Panhead screw
fixings at the top and bottom.
2. Remove the cover by lifting it up and then away from the frame.
3. Avoid damaging the screw lock tabs on the bottom of the cover when it is set
aside.
Replacing Covers:
4. After completing a service visit, make sure that the removed covers are replaced
and securely locked again. This is to ensure the safety of the operator.
NOTE: The engine doors can be lifted off their frame hinges to allow better access to the
machine.
1.4 Maintenance Schedule

Recommended servicing visits for the platesetter are every six months where
the engineer needs to perform checks and procedures based on the schedule
below. Before a service visit, make sure the operator has completed all the rou-
tine maintenance tasks described in the Operator's Manual.
Routine service procedures are constantly added and revised to ensure product
reliability over the long term. Make sure that you have consulted the latest
releases of the Technical Information Sheets (TIS) provided by FFEI (UK).
NOTE: The cleaning procedures in the Operators Manual are carried out weekly, or more
often if the machine scans more than 200 plates a day. For high volume production,
inspection of the platesetter should determine if daily cleaning is required.
Complete the following scheduled tasks:

Six-Month Visit:
1. Discuss any problems the customer has had with the machine since the last
service visit.
2. Check that all operator maintenance tasks have been completed.
3. Output a full-size image to check for correct machine operation.
4. Output and check four full-size images for any indications of quality faults.
5. Check error statistics and the error log (elog) file: see Volume 2 Section 1.5.3.
6. Complete the required cleaning procedures: see Section 1.5.
7. Check and adjust the punch if 35,000 punch operations have occurred since the
last maintenance visit: see Section 1.6.2.
8. Check for push bar pitch ring flake containment: see Section 1.6.3.
9. Check that the drum blow system is operational: see Section 1.6.4.
10. Check the extinction levels of the lasers: see Section 1.6.5.
11. Check the absolute limit switches on the elevator: see Section 1.6.7.
12. Check the trolley and cassette for damage: see Section 1.6.7.1.
13. Check the paper detect sensors: see Section 1.6.8.

14. Check and re-align the traverse ball cage and carriage: see Section 1.7.1.
15. Check plate output: see Section 1.8.
16. Run the levelling utility to check for ball cage creep: see Section 1.7.1.
17. Check the optics system for Focus: see Volume 3 Section 4.4.
18. Check the optics system for image form on the plate: see Section 4.7.
19. Carry out the vacuum maintenance procedures listed in the OEM manual.
20. Check the PAT unit for correct operation, change of filters and note if the door
gasket is intact.
21. Complete the pre-cautionary diagnostics tasks: see Section 1.6.6.
22. Output and check a full-size image for correct machine operation before
returning it to the customer.
Twelve-Month Visit:
1. Replace the push bar spring shoes, see Volume 3 Section 2.4.5.
1.5 Cleaning Procedures

Customers need to be aware of the importance of a clean environment in and
around the platesetter.
1.5.1 Cleaning the Spinner Mirror and L6 Lens

CAUTION: Avoid touching or marking the lens (L6) in front of the spinner mirror.
Only use tissues/wipes soaked with IPA.

1. Access the spinner mirror.
CAUTION: Only use light pressure when applying a wet wipe. Never rub a coated mirror
surface with a dry wipe. Only use wet tissues or wipes.
2. Soak a lens tissue with IPA.

3. Draw the lens tissue across the spinner mirror without applying direct pressure.
4. Repeat step 2. and 3. until the mirror is clean.
The tissue must be kept damp and changed frequently throughout this
procedure. Check for solvent streaking when the cleaning is complete.
1.5.1.1 Focusing Lens (L6)

The lens is held by an assembly of two metal plates, adjusted by screw fixings
and two springs. These are accurately set at the factory and are not field
adjustable.
1. Use a cotton bud, wrapped with a lens tissue soaked in IPA, and gently clean
the lens on both sides, see Figure 1.3. Check that there are no fibres remaining
on the lens.
2. Carry out the setups in Table 4.1 on page 3-4-3.
TRAVERSE
CARRIAGE
L6 LENS
BAFFLE
ASSEMBLY
CLEAN
REAR
CLEAN
FRONT
Figure 1.3 Cleaning focusing lens (L6)
1.5.2 Cleaning the Traverse Assemblies

Cleaning the linear scale, rail and readhead is only carried out as necessary to
maintain reliable operation. Cleaning periods vary depending on the amount of
contamination collecting on the scale or readhead. Make sure all the unused
beam holes are blanked out with black felt or self-adhesive tape.
1.5.2.1 Linear Scale and Drive Rail

A lacquer coating is applied to protect the scale and render it easy to clean. Use
the following procedure:
1. Clean the rail and scale with a clean dry cloth after removing any abrasive
particles.
2. Gently wipe along the scale with a lint-free cloth to remove dust.
Avoid solvents for cleaning the scale. Do not use solvents, such as, Acetone,
Benzine, Methylated Spirits, chlorinated solvents or any lubricants - since these
are likely to damage the lacquer.
If the scale needs to be de-greased as a result of handling or replacement, use N-
Heptane.
1.5.2.2 Readhead
This procedure can be completed when the traverse carriage has been removed
from the platesetter, or when the carriage is moved to the service side.
1. Remove the readhead from the carriage using the procedure in Volume 3
Section 3.3.8.
2. Clean the readhead window with a cotton bud soaked in IPA.
3. Replace the readhead.
1.5.2.3 Drive Rail Wiper

This procedure is completed when the traverse carriage has been moved to
extenders and detached from the rail.
1. Remove the drive rail wiper, see Volume 3 Section 3.3.4.
2. Clean the wiper by brushing any dust particles from the felt pad. If the pad is
too dirty or damaged, then remove and replace the wiper assembly.
3. Refit or replace the wiper.
1.5.3 Cleaning the PTM Assemblies

NOTE: TAK cloths used for the removal of very fine particles can be ordered from FFEI.
Feed Head
Clean the nudger and takeaway rollers with a damp lint-less cloth rinsed in
warm water.
Retard Pad
Clean with a TAK cloth or a damp lint-less cloth soaked in warm water. Clean in
the direction of the loading plate.
Guides and Surfaces

Plate and paper dust must be removed from the guides to prevent plate scratch-
ing.
Air Knife
This module does not require maintenance but check for any accumulated con-
taminants inside the system.
1.5.4 Cleaning the Engine Assemblies

Drum
1. Use a small hand-held vacuum cleaner to remove dust from the inside of the
drum and around the traverse rail and beam.
2. Vacuum clean the left and right-hand side contamination traps near the push
bar tracks. Generally, dust is pushed to the side of the drum as plates are loaded.
3. Polish the drum with TAK cloths, making sure the vacuum holes are clear of
any dust and debris.
Input and Output Modules

Clean the rubber rollers and belts with a damp lint-free cloth soaked in warm
water.
Punch
Clean the punch surfaces with a soft brush and a TAK cloth.
Push Bar (Cleaning)

1. Yearly: remove the push bar and replace the two push bar shoes.
2. Clean and replace the push bar then record the change in the machine Log Book.
3. Check for mechanical/vacuum conformance and for plate skew.
LPD
1. The LPD lens and the box assembly interior surfaces are cleaned with Ethyl-
alcohol.
MMI Touchpanel
The panel is cleaned by gently wiping with a soft cloth, tissue or absorbent cot-
ton in order to remove surface dust. Use a proprietary glass cleaner if further
cleaning is required. Make sure the surface is not rubbed with any hard mate-
rial.
FPD Filter Lens

1. From its hole inside the drum, clean the FPD filter lens with an air duster (if
available).
PAT Air Filter

1. Follow the filter maintenance procedures in the supplied in the PAT Installation
and Operation Guide.
2. Check the door gasket.
3. Clean the air inlet grille at the base of the unit.
1.5.5 Cleaning the Module Interior

Use a small hand-held vacuum cleaner (with a soft nozzle) to remove dust from
the following areas:
base plate floors
doors, lids and covers
all recesses inside the machine
clean the inlet filter on the drum vacuum pump.
Check that the contamination control system is operating properly where:
4 contaminants are picked up from the nudger/takeaway rollers
4 contaminants are brushed from the plate, belts and rollers, and collected
by vacuum bars.
1.5.6 Cleaning the Cassette

The cassette should be cleaned and inspected at each plate load using a TAK
cloth or a damp cloth rinsed in warm water. Clean the following:
Platen side guides.
Cassette lids.
Cassette ball transfers.
1.5.7 Cleaning the Elevator

Inspect and clean the elevator shelves and motor control compartment. Chain
links are internally self-lubricating and only need to be visually checked for
signs of corrosion on the side plates if the machine is operating in a humid envi-
ronment. Where there are signs of external corrosion, the apply a coating of thin
oil to the affected area. The recommended lubricant is Kluber oil (4UH1-68) or, if
this is unobtainable, any low viscosity (10-40) oil.
1.6 Maintenance Procedures

1.6.1 Interlock Checks
1. Open and close a cover and then check the MMI for the appropriate Error
Handling screen. Check that all the plate handling motors, the laser module and
spinner motor are switched off.
2. Check that elevator motor switches off when the cassette door is opened.
3. Repeat the same procedure for each cover in turn.
1.6.2 Punch Checks

1. Check and adjust the punch if 35,000 punch operations have occurred since the
last service visit.
diagnostics/log_utils> disp_stats
2. Use the information in Volume 2 Section 3.4.2.6 to service the punch.

3. Record punch numbers and all service procedures in the machine Log Book.
1.6.3 Push Bar Flake Containment Checks

NOTE: This procedure should be completed at every scheduled and unscheduled visit to
a customers site.
The pitch ring on the push bar includes a material called delrin that tends to
break into small flakes during normal use. This can sometimes result in drive
errors while the push bar is moving in the drum.
1. Remove the plastic flakes with a sharp instrument from the pitch ring -
especially from the corners of the pitch ring profile.
2. Vacuum clean the inside of the drum with a soft brush attachment.
3. Apply small amounts of Vaseline (see TIS 13886-01) in the pitch ring grooves,
opposite the eight gear track joins.
4. Move the push bar by hand to distribute the Vaseline along the grooves.
5. Check that the Vaseline is evenly distributed around the grooves and is not on
the casting.
1.6.4 Drum Blow Checks

1. Turn on drum blow as follows:
set bv31 on
set bv30 off
set bv41 off
2. Check for air flow through the blow and main areas of the drum. If an air knife
is fitted:
set bv41 on
3. Check for air flow through the air knife and turn off drum blow:
set bv31 off
set bv41 off
1.6.5 Laser Extinction Level Checks

The aim of this check is to set the required extinction ratio between the laser
drive power and the laser bias power for a required laser.
1. Measure laser extinction values for both lasers as follows:

2. The extinction ratios should be between 180 and 220 for both lasers (if fitted). If
they are not then adjust them as follows:
4 to increase the extinction ratio of a laser you need to decrease the bias cur-
rent
4 to decrease the exctinction ratio of a laser you need to increase the bias cur-
rent.
3. Adjust the bias current of the required laser(s) as follows:
diagnostics/service/optics/laser>set_bias_level change
Changing values


dec hex

Updating Values
numerical keys:
rent
4 to decrease the exctinction ratio of a laser you need to increase the bias cur-
rent.
time.
laser.
This will update all the working laser bias values in NVRAM.
1.6.6 Pre-Cautionary Checks

1. Check if ND filter adjustment is running out during calibration.
2. Check the laser end of life statistics using diagnostic commands:
>laser_x_stat
>laser_y_stat
A 40% change in laser current since installation indicates the laser has aged
significantly. It does not indicate the end of life; in fact, the laser could last for
several more months. You should advise the service manager and prepare for
the possibility of a laser failure.
3. Update NVRAM parameters to HDD and keep a copy on the system:
save_nvram
cp general/sysnvram.bin general/nvram****.rmv
where **** is the year and month of the visit - for example, 0210 is October 2002
and .rmv indicates routine maintenance visit.
4. Note and reset the error counts. Set Capture Text on the diagnostics terminal
and enter:
display_errors
reset_error_stats
Print out the captured text and store it in the Machine Logbook.
1.6.7 Absolute Limit Sensor Check

1. Visually check that the two absolute limit sensors on the Autofeeder are reset
(button pulled out).
2. Enter the following command to move the elevator (where a = top shelf and e =
bottom shelf):
main> diagnostics/service/medtran> move elevator <e>
WARNING: Understand the dangers of moving parts on the Autofeeder.
3. While the elevator is moving, trip one of the limit sensors by hand.
4. Check if MMI error 1351 appears and the inverter displays error 01.
5. Reset the inverter (press Reset), reboot the platesetter and reset the limit sensor.
6. Repeat steps 2) to 5) for the other limit sensor.
1.6.7.1 Trolley and Cassette Checks

Trolley
As a maintenance procedure, check the following:
corner buffer blocks are not damaged
the magnetic docking sensor operates correctly
the retainer spring and castor brakes operate correctly.
Cassette
Service engineers need to check periodically for the following problems:
1. Light-tight seals are effective. Normally, a full cassette should not be left in
daylight conditions for too long since this is likely to cause fogging on the top
plate. All loaded cassettes need to be housed inside the Autofeeder. If there is a
problem with plate fogging, load a single plate into the cassette and put the
cassette under a strong light for more than an hour and process to check for
light-tightness.
2. Check the outer buffers for signs of damage.
3. Check that the ID label is in place.
4. Check that the top lid fits properly.
5. Make sure that the interior is dust-free.

Refer to FFEI Customer Services (UK) for information on how to replace cassette
fittings, such as the latch, buffer corner, clamp and magnetic catch.
If an error is reported that points to failed ID readings, first check that the cas-
sette ID label is in place and is correctly aligned with the sensors.
1.6.8 Paper Detect Sensor Check

This procedure is used to check if the PTM paper detect sensors (BS51 and BS55)
are operational:
1. Reboot the platesetter and, during the boot sequence, press ctrl-c at the second
request to stop the machine.
2. Open Main diagnostics and run the sensor check utility:
main>diagnostics/service/sensors/read_con ip
3. Using an interleaf sheet, check that the two sensors switch for all possible
positions between the sensors.
Move the sheet up, down and across to check that both sensors switch for the
full range of paper positions.
4. Refer to Volume 3 Section 2.3.2.1 for more information if either sensor needs to
be set up.
1.6.9 Light-Tight Checks

These checks only need to be completed if the customer complains of plate fog-
ging.
1.6.9.1 Modules
Check that all the covers, cover linings and doors close properly, and all the
external cable entry points are light-tight. Modules should be coupled with their
interconnected frames aligned without gaps. Adjust the module interconnect
screw fixings to ensure the frames are parallel.
1.6.9.2 Cassette
If there has been a report of media fogging and the cassette is suspected, use the
following procedure:
1. Place a single plate in the cassette and lock the top lid.
2. Shine a strong lamp light around the cassette for several minutes.
3. Develop the plate and check for signs of `fog'.
On a Manual and Semi-Automatic machine, fogging may be caused by leaving
the plates on the input platen or in the machine output. The diagnostic com-
mand, fog_time, will allow you to change the fog warning settings.
1.7 Checking the Traverse

1.7.1 Aligning the Carriage and Ball Cage
Both the traverse carriage and ball cage are setup manually so that they always
move back and forward as aligned assemblies. The procedure below can be
done at either end of the Engine.
1. Hold the ball cage and push the carriage back until a length of the cage is
exposed.
2. Pull the carriage forward, without holding the ball cage until the two assemblies
are inline with the screw fixing as shown in Figure 1.4.
3. You may have to repeat steps 1. and 2. several times to align the ball cage and
carriage accurately.
4. Complete the engine traverse level check below.
CARRIAGE
RAIL
BALL
CAGE
SERVICE
END
VIEW
ALIGN BALL CAGE AND

CARRIAGE RAIL HERE
Figure 1.4 Carriage rail and ball cage alignment
1.7.2 Engine Traverse Level Check

Use this procedure to run a service utility that checks if the engine is level from
the traverse end-to-end. The aim is to minimise the amount of ball cage creep as
the carriage continually moves backwards and forwards along the rail. If there
is a risk of the Engine settling into a soft floor surface, then repeat the check after
24 hours.
1. Make sure the ball cage and traverse carriage are correctly aligned using the
method in Section 1.7.1.
2. Check that the spinner and traverse are disabled. (They are enabled if the
application has been running). Select the following from Main Diagnostics:
diagnostics/service/spinner> stop
diagnostics/service/traverse> halt
3. Align the ball cage and carriage rail, see Figure 1.5.
4. Measure the distance between the end of the carriage rail/ball cage and the end
of the V-groove, see Figure 1.5.
MEASURE AND CORRECT

3 FOR CAGE CREEP
2 RUN TRAV. TEST
CARRIAGE
RAIL
ALIGN AND
1 MEASURE
BALL CAGE
V-GROOVE
Figure 1.5 Check traverse level
5. Run one of the following tests that moves the carriage 20 times up and down the
beam length:
diagnostics/test/traverse/trav_test
if the carriage and ball cage were aligned at the service end, or enter:
diagnostics/test/traverse/trav_test R
if the carriage and ball cage were aligned at the user end.
6. Release the traverse servo-drive by entering:
diagnostics/service/traverse/halt
7. Align and measure as in steps 2. and 3. above.
8. If the distance between the measurements is greater than 0.5 mm, then an engine
level adjustment is required. For instance, the ball cage extends beyond the
carriage towards the service end, so the service end needs to be adjusted
upwards.
Loosen the PTM-Engine fixing bolts (4-off, M5).
Adjust the feet to minimise creep and obtain an improved level. A small
adjustment of 1/4 to 1/2 (0.25-0.5 mm) turn on the adjust nut is usually
sufficient. See the table below.
Creep Towards Service End Creep Towards User End

(Adjust Up) (Adjust Down)
1 mm 1 1 mm 1
/2 TURN /2 TURN
2 mm 1 TURN 2 mm 1 TURN
3 mm 11/2 TURN 3 mm 11/2 TURN
9. Repeat steps 2. to 8. until creep is within the specification.

10. Adjust the PTM and Autofeeder to match any Engine adjustment. Tighten the
PTM-Engine fixing bolts (4-off, M5) and the PTM-Autofeeder bolts (4-off, M5).
1.8 Checking the Platesetter Output

1.8.1 All Platesetter Variants
1.8.1.1 Check Image Form Adjustment
A full description of the image form check and correction on for a B1 plate only
is given in Volume 3 Section 4.7.
1.8.1.2 Check Expose Tint Quality

1. Expose PI `tint' (1028 mm x 770 mm) 50% tint from the Run Test menu on the
MMI and process the plate.
2. Using a densitometer, check at the nine plate points shown in Figure 1.6:
Background points (reference) are at 0 %.
Saturated points (reference) are at 100 %.
Tint points conforms to 50 %. ( 1 %.) prediction errors.
BACKGROUND SATURATED
(0%) (100%)
IMAGE
TINT
(50%)
Figure 1.6 Tint predict check
3. Failure to predict 50% (+1%) could be caused by:

dirty spinner and/or optics
incorrect focus adjustment

poor mechanical/vacuum conformance
poor Processor conditions for:
4 pre-heat
4 process time
4 developer scrub pressure

4 developer pH reading should be 12.0 0.2.
Consult FFEI (UK) Customer Support to resolve a 50% predictive fault.
1.8.1.3 Check Image Quality

1. Expose the S&T pages (PI images) at a fixed PI resolution of 96 and test the
image quality against the supplied reference plates for:
screen quality
raster quality
vignette quality
dot prediction accuracy 1% (max).
highlight dot quality.
Use S&T image plates shipped with the machine as the test reference plates.
2. If the issue cannot be resolved then contact the FFEI Support Centre (UK).
1.8.2 Platesetters Fitted With a Punch

After checking a customer output image you may need to complete some of the
following procedures to ensure image/plate quality and accuracy:
Image form adjustment: see Section 1.8.1.1.
Tint quality: see Section 1.8.1.2.
Plate Load in Drum: see Section 1.8.2.1
Image position and skew: see Section 1.8.2.2.
Punch crop accuracy: see Section 1.8.2.3
Punch centering: see Section 1.8.2.4.
Image traverse centre position: see Section 1.8.2.5.
Image base offset: see Section 1.8.2.6.
Image quality: see Section 1.8.1.3.
1.8.2.1 Check Plate Load in Drum

Use this procedure on a fully-automatic machine if there is inaccurate plate
centering and poor plate transit from the PTM to the drum.
When loading large plates it is important that the plate is advanced to the centre
of the drum on machines where the punch mouth is 1175 mm wide. If the plate
is not loaded in the centre, then large plates (1160 mm wide) could be offset to
one side and cause a centering arm error (code 1750). For a 1160 mm plate, the
feed margin at the punch is 7.5 mm on each side of the plate.
1. Using the largest plate available, mark a centre line from the plate lead edge to
the trailing edge.
2. Load the plate into a cassette (widest side as leading edge).
3. Make sure the engine top covers are removed.
4. Advance the plate from the cassette to the drum.
5. Observe the plate loading into the engine and measure the distance the plate has
offset from the centre of the drum. Plate centre alignment should be within 0.5
mm of the drum centre.
FIXING
BOLT
(4-OFF)
Figure 1.7 Aligning the PTM, Engine and plate
6. If there is a misalignment then check the following:

The PTM to Engine connecting bolts are tight and the two units are parallel.
The plates are centred in the cassette and the plate guides are correctly
adjusted.
Check that the Engine interface guide plate and the transport rollers are par-
allel. If they are not, then adjust the PTM position by loosening the 4-off M5
caphead bolts securing the PTM main frame to the PTM cross members, see
Figure 1.7, and move the PTM main frame so that it is aligned with the
Engine.
1.8.2.2 Check Image Position and Skew

See Figure 1.8. This procedure does not apply to variants without a punch.
1. Full Punch: Expose four identical plates and determine the range of skew
between A and B using a glass ruler and magnifier.
Measure between the leading plate edge and the start of the image area.
2. Add the four values for A skew and divide by four to obtain the average value.
3. Repeat the same calculation for B skew.
4. Subtract A average value from B average value.
The difference should be less than 50 microns.
5. Dummy Punch: Check the squareness and position of the image in relation to the
leading edge of the plate where A - B is less than or equal to 200 microns.
A B
IMAGE
PLATE
Figure 1.8 Dummy punch position and image skew check
1.8.2.3 Check for Punch Crop Accuracy

See Figure 1.9. This procedure only applies to variants with a punch fitted.
Use a glass or steel ruler and a x10 eyeglass to check the punch crop depth from
the bottom of the depth to the top of the plate where A - B is less than 200
microns.
A B
PLATE
Figure 1.9 Full punch crop accuracy
1.8.2.4 Check Punch Centering

See Figure 1.10.
1. Full Punch Only: check that the crop positions are centered on the plate.
The centering mechanism is adjustable.
2. Check that the punch protocol matches the examples shown in Volume 2
Figure 3.63.
A B
PLATE
Figure 1.10 Full punch centering
3. For a Heidelberg punch format with 1030 wide plates, the dimension:
A = 119 mm (1 mm).
This is calculated as (A - B/2) - C where:
A = plate width.
B = centre distance between punch crops, depending on the punch proto-
cols.
C = half width of the punch crop; for instance, for a Heidelberg square crop
the half width is 6 mm, or 5 mm for a round crop.

4. Centre accuracy should be 1 mm, so A dimension for the centre is 119 mm and
B is 120 mm.
5. Check that the punch crops are the correct depth (standard depth = 12 mm but
custom punches can be 11 mm).
6. Check that the holes are cleanly cut, without debris in the hole corners or burrs.
1.8.2.5 Set Image Traverse Centre Position

A horizontal offset check is required to accurately position an image on the
plate. You can adjust the horizontal positions by entering new base offset values
in NVRAM.
NOTE: This procedure is not required on machines with Edge Detect.
See Figure 1.11.

1. From Main Diagnostics obtain the NVRAM menu:
diagnostics/log_utils/disp_nvram
2. Expose a PI `tint' on a 1028 mm x 770 mm plate.
3. Check that the image is centred on the plate with equal distances from the left
and right plate edges.
PLATE
0 m CENTRE 1220000
LEFT RIGHT
(PERISCO
END)
IMAGE
PLATE
TRAV_CENTRE_POSITION = -610000 m
Figure 1.11 Centering the image (dummy punch)
4. Adjust the TRAV_CENTRE_POSITION parameter to move the image towards the

centre using the diagnostics:
rd_centre_posn
wr_centre_posn
For instance, to move the image 10 mm (10,000 m) to the right of the plate, use
the example formula:
-6100000 + (- 10000) = -620000
or to move the image 10 mm (10,000 m) to the left of the plate, use the formula:
-6100000 - (- 10000) = -600000
5. If the machine has a punch fitted then make sure the image is centered at equal
distance from the outer crop marks, as shown in Figure 1.12. Use the method is
step 5. above to move the image.
PUNCH
CENTRE
A B
IMAGE
PLATE
Figure 1.12 Centering the image (full punch)
1.8.2.6 Set Image Base Offset

A vertical offset check is required to accurately position an image on the plate.
You can adjust the vertical positions by entering new base offset values in
NVRAM.
See Figure 1.13.
This procedure adjusts the non-imaged area at the top of the plate (punch end).
It is normally set at a default of 25 mm (25,000 m).
1. Expose a PI `tint' on a 1028 mm x 770mm plate.
2. Check for the default area, see Figure 1.13.
3. Modify the IMAGE_BASE_OFFSET parameter (in microns) using the diagnostic
commands:
rd_image_offset
wr_image_offset
A) To move the image nearer the punch, add the error value to 680000.
B) To move the image away from the punch, subtract the error value from
680000.
+ ERROR
VALUE
PUNCH END
IMAGE_ 25000 m
BASE_
OFFSET =
680000 m
ERROR
VALUE
IMAGE START
SCAN
POINT
PLATE
Figure 1.13 Setting the image base offset
1.8.3 Platesetters Fitted Without a Punch

These procedures apply to a platesetter without a punch and check for:
Image form adjustment: see Section 1.8.1.1.
Tint quality: see Section 1.8.1.2.
Image skew accuracy: see Section 1.8.3.1.
Edge detect function: see Section 1.8.3.2
Image start and edge accuracy: see Section 1.8.3.3
Image base offset: see Section 1.8.3.4.
Image edge sensor offset: see Section 1.8.3.5.
1.8.3.1 Check Image Skew Accuracy

Use 470 mm registration pin centre points for these skew measurements as plate
edge quality varies across the plate.
2. Measure reference lines A and B with a glass or steel ruler and a x50 eyeglass,
see Figure 1.14.
305 mm FOR B2
470 mm FOR B1 LEAD EDGE OF
REGISTRATION PINS
A B
IMAGE
PLATE
Figure 1.14 image skew check
3. Check that the difference between the two lines is less than or equal to 50
microns ( 25 microns).
4. Expose and measure 4 plates and check that repeatability is less than or equal to
30 microns.
5. A possible cause of error could be poor push bar alignment.
1.8.3.2 Check Edge Detect Function

Check the plate edge detect function as follows:
1. Reboot the Engine if the optics_mmi test patterns have been used beforehand.
2. Enter the command:
main> diagnostics/service/traverse> halt
traverse>medirq
Check that the Edge Detect PCB laser beam is ON.
3. Load a plate into the drum and move the traverse by hand so that the edge
detect beam moves across the plate edge.
4. Check that the LED on the Edge Detect PCB is OFF when the beam is on the
plate and ON when the beam is on the drum.
5. Press Ctrl-c to exit medirq.
1.8.3.3 Check Image Start and Edge Accuracy

2. Check that the distance between the image start positions and plate edge is as
shown in Figure 1.15. Measure from the registration pins for the image top
offset, and 67 mm down from the plate top edge for the image side offset
position.
A 305 mm FOR B2 B
470 mm FOR B1
2 mm ( +- 25 m)
67 mm
1 mm
(+- 25 m)
IMAGE
PLATE
Figure 1.15 Edge detect and image accuracy
1.8.3.4 Set Image Base Offset

This procedure adjusts the non-imaged area at the top of the plate.
2. Check for the default imaging area shown in Figure 1.16.
3. Modify the IMAGE_BASE_OFFSET parameter (in microns) using the diagnostic
commands:
rd_image_offset
wr_image_offset
A) To move the image nearer the registration pins, add the error value to the
default value.
B) To move the image away from the pins, subtract the error value from the
error value.
+ERROR
VALUE
IMAGE_BASE_
OFFSET = 2 mm
( +- 25 m)
- ERROR
VALUE
IMAGE START
SCAN
POINT
PLATE
Figure 1.16 Setting the image base offset
1.8.3.5 Set Image Edge Sensor Offset

1. Open the optics_mmi setup screen from:
main>diagnostics/service/optics/optics_mmi
2. Run a test pattern with the Scan Start position as 0 mm.
3. Eject and process the image and check that it is exactly 1 mm from the righthand
edge of the plate.
4. If it is not then find the current parameter EDGE_SENSOR_OFFSET value (in
microns) as follows:
diagnostics/log_utils/nvram> rd_edge_sensor_offset
5. If the image is more than 1 mm then decrease the parameter value; if it is less
than 1 mm then increase the parameter value. Use the following command:
diagnostics/log_utils/nvram> wr_edge_sensor_offset <required offset in microns>
Repeat this command until the offset is correct.
Volume-Chapt er
PLATE HANDLING SERVICE

PROCEDURES
This chapter describes how to remove and replace plate handling modules and devices.
4
4
Starting the Service Procedures ............................................................................... 2-1
4
Autofeeder Servicing ................................................................................................. 2-4
4
Plate Transport Module Servicing .......................................................................... 2-15
4
Engine Servicing ...................................................................................................... 2-27
Buffer Servicing ........................................................................................................2-57
2.1 Starting the Service Procedures

Plate handling assemblies are designed for easy removal and replacement. This
chapter describes how to service the following field replaceable units (FRUs)
used to convey and control plates:
General Plate Handling Replacements: a general method for replacing sensors
and FHMBs.
Autofeeder: replacements and checks for a fully-automatic system.
PTM: replacements and checks for a fully-automatic system.
Engine: replacements and checks on an engine for all variants.
2.1.1 General Plate HandlingReplacements

2.1.1.1 Sensor (Reflective-Opto PCB) Removal
VOLUME 3 (2-2) P LATE H ANDLING S ERVICE P ROCEDURES
BUTTON RIVET
CONNECTOR
PCB
INSERT
SENSOR MOUNTING
Figure 2.1 Removing a button snap rivet
SNAP RIVET
CONNECTOR
PCB
INSERT
PUSH OUT
SCREWDRIVER SENSOR MOUNTING
Figure 2.2 Removing a snap rivet
In some locations, the reflective-opto sensor is mounted using button or snap

rivets that are removed as follows:
1. Release the PCB from its mounting plate by pulling out the button rivet stud
from its insert (see Figure 2.1) or pushing out the rivet insert (Figure 2.2) with
the flat end of a screwdriver.
2. Carefully disconnect the cable lead to the header connector (you may need to
use a small screwdriver).
3. Reconnect the lead to the new PCB.
4. Replace the new PCB by refitting the insert into the PCB, locating the PCB on its
mounting position and gently pushing in the stud. The insert splays to secure
the PCB to its mounting.
2.1.1.2 Sensor (Opto-Slotted) Removal

See Figure 2.3.
These sensors are positioned on a mounting bracket by a locating pin.
1. Pull off the lead connector.
2. Release the sensor by removing the 1-off, M4 fixing screw.
3. Reconnect the lead and fit the new sensor in the same location.
4. Check that the metal tab moves freely in the sensor slots.
5. Use diagnostics to confirm that the new sensor operates correctly.
SENSOR
MOUNTING
BRACKET
LOCATING
DIMPLE
SCREW METAL
FIXING TAB
(M4)
CONNECTOR
Figure 2.3 Removing a typical opto-slotted sensor
2.1.1.3 FHMB Replacement

FHMB (1 to 4) are common assemblies that can be removed and replaced using
the same procedure. For more information on variant PCB connections see:
PTM: Volume 2 Section 3.3.1
Engine: Volume 2 Section 3.4.1
1. Disconnect cable ties, where appropriate.
2. Disconnect top cables (power minifit, etc).
3. Remove the 3-off Philips cover screws and remove the cover.
4. Disconnect all other cable connectors.
5. Remove the 6-off screws securing the PCB to the stand-offs.
6. Fitting the new board is the reverse of the above procedure. Make sure the
hidden cable connectors in Step 4. are fitted before fixing the cover.
7. Load the correct level of firmware on the newly-installed FHMB. All PCBs must
have the same level of firmware - if they do not match the system will not
function correctly.
8. FHMB4: if you are replacing FHMB4 you must update NVRAM parameter,
FHMB_GAIN, to ensure accurate exposure calibration. Enter the folowing:
development/nvram> snv FHMB_GAIN <factory value>
where <factory value> is the value written on the replacement FHMB.
Check the Configuration data from the Registry, see Volume 2 Section 1.11, and
change the firmware level from the supplied Luxel Firmware CD. Use the
procedure explained in Volume 2 Section 1.12.
2.2 Autofeeder Servicing

This section shows how to remove, replace and check the main FRUs on an
autofeeder:
2.2.1 Accessing Autofeeder Assemblies

Figure 2.4 shows which covers are removed for accessing the main replaceable
assemblies on the Autofeeder, and any screws that need removing.
Avoid damaging the screw tabs at the base of the covers when moving them to a
temporary location.
ELEVATOR MOTOR/GEAR
ELEVATOR DIST/CONTROL PCB's
INVERTER
I/L CONTACTOR
ABSOLUTE LIMIT SENSORS
SERVICE SIDE I/F CONNECTORS
CHAIN SPRINGS/
TENSIONERS CHAINS
DRIVE SHAFT OUTPUT SIDE
CHAIN SPRINGS/
TENSIONERS
CASSETTE DOOR: S/W

LOCKED FROM MMI
USER SIDE Z-DIRECTION ARM
BOTTOM SCREW LOCK CASSETTE DOOR LOCK
DOCKING MECHANISMS
TOP SCREW LOCK CHAINS
Figure 2.4 Accessing Autofeeder modules
2.2.1.1 RFI Filter Replacement

CAUTION: Do not touch the cooling fins while the elevator motor is operating.
See Figure 2.5.

1. Disconnect the mains supply from the PTM.
2. Remove the Elevator Control box cover, see Volume 2 Figure 3.1.
3. Remove the inverter assembly, see Section 2.2.1.2.
4. Remove the MAINS_ELV_IN cable and mark each wire.
5. Remove the RFI filter assembly.
6. Fit the replacement filter, inverter and reconnect the cables.
7. Make sure all earth bonding and cable shielding connections are correctly
refitted.
8. Reconnect the power cable to the PTM.
9. Switch on power.
10. Test elevator control by using the MMI Media Tools option to advance a cassette
from each shelf in turn.
2.2.1.2 Inverter Replacements

Inverter Fault-finding
The inverter includes a number of protective functions that will trip if the condi-
tions in Table 2.1 are detected. This causes the motor AC input to shut down and
remain in that state until it is reset. An LCD display shows the appropriate error
code, see Figure 2.5.
Table 2.1 Inverter error code conditions

Error Type Displayed Error Comment
Code
Over Current 01 to 04 Output of inverter is shorted, motor is locked or
the load is too heavy. Motor stops.
Overload E 05 Motor overload is detected. Motor stops.
Braking Overload E 06 Overvoltage is detected and motor stops.
Overload E 07 Motor overload is detected and mo tor stops
EEPROM Error E 08 Memory has problems due to noise or tempera-
ture. Motor stops.
Undervoltage E 09 Decrease in DC voltage to a certain cut off point.
Motor stops.
CT Error E 10 Large noise source too close to the inverter.
Motor stops.
CPU Error E 11 CPU malfunctions. Motor stops.
External Trip E 12 Abnormal signal from external source cuts off
motor.
USP Error E 13 Power is turned on while the inverter is running.
Ground Fault E 14 Ground fault detected between inverter and out-
put and motor.
Table 2.1 Inverter error code conditions (Continued)

Input Overvoltage E 15 Input voltage is above a certain limit. Motor
stops.
Thermal E 16 Temperature of inverter is too high.
PTC Error E 17 External thermistor is faulty. Motor stops.
ON/OFF LAMP
INVERTER
POWER
RUNNING
LAMP DIGITAL DISPLAY
RUN Hz
FREQUENCY OR
CURRENT DISPLAY
SETTING PRG A LAMP
PARAMETER
LAMP
STOP
RUN RESET
SETS FREQUENCY
RUN KEY DO NOT TOUCH
TO START MIN MAX
STOP/RESET
KEY
FUNCTION CONTRO
DO NOT TOUCH
Figure 2.5 Inverter digital display
Inverter Replacement
See Volume 2 Figure 3.2.
NOTE: The inverter is supplied with its cables and the software already loaded.
CAUTION: Do not touch the cooling fins while the elevator motor is operating.
1. Disconnect the mains supply from the PTM.

2. Disconnect the filter wires, the 3-phase INV_MOTOR cable and the ELV_CRTL
cable from the inverter box, see Volume 2 Figure 3.4. Make sure each wire is
marked.
3. Refit the replacement inverter box and reconnect the cables.
4. Make sure all earth bonding and cable shielding connections are correctly
refitted.
5. Reconnect the power cable to the PTM.
6. Switch on power.
7. Test the elevator control by using the MMI Media Tools option to advance
cassettes from each shelf in turn.
2.2.1.3 Contactor Replacement

1. Disconnect the cable connections to the contactor and mark each wire.
2. Remove the rail end-stop.
3. Slide out the contactor assembly.
4. Replace the contactor and refit the cables.
5. Switch on power and check that the elevator motor operates:
medtran> move_elevator <shelf letter> (where a = 0 or top; b = 1; c = 2; d = 3; e = 4)
6. Open an interlocked cover to check that the motor switches off.
2.2.1.4 Elevator Control PCB Replacement

1. Disconnect the three connectors from the PCB.
2. Remove the PCB from its mounting (4-off pozidrive screws).
3. Fit the replacement PCB and the connectors.
4. Use the following diagnostics commands to check the operation of the
Autofeeder:
medtran> init
to initiate a media transport. Ensure the cassette is reversed from the feed head
and the X-door is down.
medtran> move_elevator <shelf letter> (where a = 0 or top; b = 1; c = 2; d = 3; e = 4)
2.2.1.5 Elevator Distribution PCB Replacement

See Volume 2 Figure 3.1 and Volume 2 Figure 3.9.
1. Disconnect the three connectors from the PCB.
2. Scribe a line on the frame in line with the bracket to indicate the exact vertical
position of the PCB.
3. Remove the bracket and PCB (2-off Allen screws).
4. Remove the PCB from the bracket (4-off posidrives).
5. Fit the replacement PCB and reconnect the cables.
Autofeeder:
medtran> init
to initiate a media transport.
Ensure the cassette is reversed from the feed head and the X-door is down.
move_elevator <shelf letter> (where a = 0 or top; b = 1; c = 2; d = 3; e = 4)
7. Check and align the elevator shelves, see Section 2.2.1.6.
2.2.1.6 Setting Up the Elevator Shelf/Rail Alignments

Use the following procedure to check the mechanical alignment between the
Autofeeder cassette shelves and the PTM cassette guide rails if one or both of
the modules has been moved.
1. From Main Diagnostics enter the following command to drive the elevator to
shelf 3 (or a middle shelf):
service/medtran> move_elevator c
where shelf a = 0 (top); b = 1; c = 2; d = 3; e = 4.
Adjust the PTM rail, shown in Figure 2.6, so that the distance apart is initially
5 mm. This is to avoid damaging the rails if the two modules are misaligned and
the elevator is moving under motor control.
Table 2.2 Elevator-PTM rail measurements

Shelf Level (mm) Distance (mm)
User Service User Service
A (top)
B
C
D
E
2. Measure the difference in height between the Autofeeder shelf and the PTM rail,
and enter it in the table above.
3. Measure the distance between the Autofeeder shelf and the PTM rail, and enter it
in the table above.
4. Repeat steps 2) and 3) for each shelf.
5. From this table you will be able to make adjustments to ensure errors are within
the specification of:
Level: 1 mm vertical range between rails.
Distance Apart: +2 mm (maximum)/+1 mm (minimum) horizontal range
between rails.
Table 2.3 Level/distance measurements - example values

Shelf Level (mm) Distance (mm)
User Service User Service
A (top) +0.8 0 5.5 6.0
B +0.5 +0.5 6.0 7.0
C 0 -0.2 6.0 6.5
D -0.5 -1.0 6.5 7.0
E -0.2 -0.4 5.3 7.5
AUTOFEEDER
DISTANCE APART = +2 mm SHELF RAIL X-DOOR
(max) FLAP
LEVEL = 1 mm
ADJUST DISTANCE
PLATE
TRANSPORT
CASSETTE
GUIDE RAIL
Figure 2.6 Checking cassette-PTM guide rail alignment
6. Decide on the adjustments to achieve the Level specification; for instance, the
values in Table 2.3:
A) Shelf A: user side, change +0.8 mm to +0.4 mm; then service side will
change 0 to -0.4 mm.
B) Shelf B: does not require adjustment.
C) Shelf C: does not require adjustment.
D) Shelf D: user side, change -0.5 mm to +0.25 mm; then service side will
change -1.0 mm to -0.25 mm.
E) Shelf E: does not require adjustment but could be possibly set to +01 mm
and -0.1 mm.
Level adjustment is from the sensor vanes. Each vane is adjustable in the vertical
direction by loosening its top and bottom screws. The correct vane for each shelf
is the one where the lower vane edge is just entering into its PCB sensor. Adjust
as follows:
4 Elevator shelf too low then move the vane up.

4 Elevator shelf too high then move the vane down.
Adjust so that the minimum shelf level changes on either side are within
specification first of all, and then adjust the other shelves in turn. Check each
shelf after the adjustment.
If ALL the shelves need adjusting by the same amount, then the Elevator
Distribution PCB can be adjusted vertically. Its mounting bracket is fitted on
slotted holes.
For some levels you may have to move the elevator up a shelf to access the
lower screws hidden by the PCB. Slacken the hidden screw, move back to the
original shelf and adjust using only one of the vane screws. Tighten the other
screw when it appears.
NOTE: When aligning the shelf to the PTM rail on an uneven floor surface outside the
FFEI pre-install specification, always adjust the autofeeder feet to offset tilt differences.
Even if the cosmetic fit between module frames is slightly altered, a large clearance hole
for the interconnecting bolts allows for poor matching. The main priority is to ensure that
the cassette always runs freely between the two modules for each shelf and any tilt
between the shelf and runners is avoided.
7. Decide on the adjustments to achieve the distance specification. For instance,

with the measurements shown above:
User Side: Shelf E has the smallest gap, so set the Shelf E gap to 1 mm.
Service Side: Shelf A has the smallest gap, so set the Shelf A gap to 1 mm.
If the specification cannot be achieved, then adjust the top or bottom cam
follower brackets to move the elevator frame. The distance between the frame
edge and the PTM skins are factory-set at 130 mm, but an on-site adjustment at
the top or bottom brackets (2-off Allen screws) on either side is possible, see
Figure 2.7.
8. After adjusting a bracket, ensure that all the elevator vanes clearly pass through
sensors BS30 to BS34. On completing the adjustments, move the elevator to all
shelf positions and check that they are not obstructed.
9. Recheck that all the shelves conform to the level specification in Step 6.
10. Ensure that all the screws are tightened.
PTM
SKIN
FRAME
EDGE
NOTE: PTM SKIN TO

FRAME EDGE
= 130mm
CAM FOLLOWER
BRACKETS
Figure 2.7 PTM to elevator frame edge distance
2.2.1.7 Cassette Door Lock Replacement

Remove and replace the lock as follows:
1. Remove the 2-off pozidrive screws holding the lock assembly to a bracket.
2. Disconnect the 4-off wires to the lock and refit them to the new lock, see Volume
2 Figure 3.11.
3. Replacement is the reverse of the removal.
4. Check that the lock unlatches from MMI control.
If the door is jammed shut and unable to open under MMI control, a special tri-
angular key is available from Schmersal for manually releasing the lock. The
procedure to manually release the lock is:
A) Move the elevator down to its lowest position:
move_elevator a
B) Remove the cover underneath the cassette door.
C) Reach up inside (with the right hand), locate the tool in the lock and rotate
anticlockwise until the door opens.
D) Once the door is open, relocate the key into the lock and turn clockwise to
reset the lock.
2.2.1.8 Docking Lamp Replacement

The docking lamp (type: 28 V, 40 mA) is removed and replaced as follows:
1. Open the cassette loading door from the MMI menu option for installing the
cassette.
2. Remove the lamp holder front filter lens with a small sharp knife.
3. Remove and replace the bulb (you may require a lamp extraction tool).
2.2.1.9 Docking Sensor Replacement

Sensors (BS77/78) are removed and replaced as follows:
1. Open the cassette door.
2. Remove the docking buffer block (3-off M4 Allen screws)
3. Disconnect the sensor inline connector.
4. Unscrew the sensor from the block.
5. Replace the sensor making sure that it is flush with the buffer surface.
6. Re-assemble the sensor and block, and refit it to the platesetter.
7. Check that the sensor and lamp operate correctly.
2.2.1.10 Z-Direction Control Removal

1. Open the cassette door from the MMI Cassette Change procedure.
2. Switch off the platesetter.
3. Remove the cover bracket on the user side of the Autofeeder.
4. Remove the buffer block on the door frame (3-off M4 Allen screws).
5. Remove the Z-direction arm cover bracket.
6. Disconnect the motor (BM28).
7. Disconnect the sensors BS63 and BS70.
8. Remove the 2-off M4 caphead screws holding the assembly to the chassis.
9. Lift out the assembly.
2.2.1.11 Z-Direction Control Replacement

1. Replacement of the assembly is the reverse of the removal. Note: connect the
sensors before refitting the assembly.
2. Check the operation of the arm using the commands:
actuators> set bm28 on
sensors> read_con ip
actuators> set bm28 off
sensors> read_con ip
Check that the sensors switch.
2.2.1.12 Absolute Limit Safety Switch Replacement

1. With the platesetter powered off, remove the cover on the service side of the
autofeeder to access the two switches.
2. Remove the 2-off M3 retaining caphead screws on the switch.
3. Disconnect the two cable connections (ELV_CON_24V) inside the switch.

4. Fit the replacement switch, connect the two cables and the switch cover. Ensure
the switch is reset (yellow button in its outer position).
5. Switch on the platesetter.
WARNING: Testing absolute limit switches exposes you to danger from moving elevator
parts. Always plan ahead to avoid danger. Before starting this procedure, ensure you
know which parts will move, and how you access the switches while they move.
6. Check the operation of the switch as follows:

A) Visually check that the two absolute limit sensors on the Autofeeder are
reset (button pulled out)..
B) Enter the following command to move the elevator (where a = top shelf and
e = bottom shelf):
service/medtran> move elevator <e>
WARNING: Understand the dangers of moving parts on the Autofeeder.
C) While the elevator is moving, trip one of the limit sensors by hand.
D) Check if MMI error 1351 appears and the inverter displays error 01.
E) Reset the inverter (press Reset), reboot the platesetter and reset the limit
sensor.
F) Repeat steps 2) to 5) for the other limit sensor.
2.2.1.13 Elevator Motor (BM26) Replacement

1. Disconnect the mains supply from the Autofeeder to the PTM.
2. Disconnect the cable, INV_MOTOR, from the contactor.
3. Remove the 4-off M23 motor bolts from the gearbox coupling.
4. Lift out the motor and the cable assembly.
5. Fit the replacement motor using the same bolts.
6. Reconnect the cable to the contactor and reconnect the power.
7. Check the elevator operation by selecting different cassettes from the MMI.
2.2.1.14 Chain Tensioner Spring Replacement

1. Remove the two covers on the service and user sides.
2. From Main Diagnostics, select the top shelf to move the elevator to its lowest
position:
medtran> move_elevator b
3. Disconnect power to the Autofeeder by removing the power connector lead to
the PTM.
4. Insert wood safety blocks (approximately 13 cm high) under the four corners of
the elevator frame, see Figure 2.8.
5. Lower the elevator onto the blocks until the chains are slack by rotating the
motor cooling fan in the anti-clockwise direction using an Allen key through the
hole in the top of the motor cover.
CAUTION: Do not use the MOVE_ELEVATOR command for this operation.
6. The chain attached to the spring should be loose enough for you to detach from
the plate. As an extra security measure, use a G-clamp to clamp the link to the
sprocket.
SPRING
TENSIONERS
BLOCK
SUPPORTS
(4-OFF, 13cm HIGH)
Figure 2.8 Inserting safety blocks
7. Replace each spring, one at a time, using the following method:

A) Remove the split pins, remove the link plate and pull out the pin link
between the two bushes.
B) Remove the spring from the bush.
C) Fit the new spring into the free bush.
D) Replace the link and split pin.
8. Raise the elevator by turning the motor cooling fan clockwise until it is clear of
the blocks, and then remove the blocks.
9. Reconnect power to the Autofeeder.
Autofeeder:
medtran> init
To initiate a media transport. Ensure the cassette is reversed from the feed head
and the X-door is down.
move_elevator <shelf letter> (where a = 0 or top; b = 1; c = 2; d = 3; e = 4)
2.3 Plate Transport Module Servicing

PTM assemblies on and around the feed head are very precisely adjusted to
ensure continuous removal of plates and paper without the risk of media jams.
During a parts replacement, make sure the procedures in this chapter are fol-
lowed carefully so that PTM is setup for correct operation.
2.3.1 Accessing PTM Assemblies

The main PTM assemblies are accessed from the covers shown in Figure 2.9.
AIR KNIFE
FHMB 2 & 3
DISTRIBUTION PCB's
CASSETTE ID
I/F CONNECTORS
SERVICE SIDE
DIVERTER
PLATE GUIDES
CASSETTE FWD
FEED HEAD
INTERLEAF DRIVE ROLLER
X-DIRECTION DOOR
SENSORS/MOTORS
USER SIDE
BS76
DIVERTER
STACK INCREMENT
RETARD PAD
RELEASE SCREW X-DIRECTION DOOR
AT USER END SENSORS/MOTORS
AND SLIDE OUT
UNDER TRAY TO
ACCESS ASSEMBLIES
BOTTOM SCREW LOCK

INTERLEAF
NOT LOCKED DOOR OPEN
Figure 2.9 Accessing PTM assemblies

2.3.2 PTM Sensor Replacements and Setups

Section 2.1.1.1 and Section 2.1.1.2 describes the general replacement method for
opto-reflective and opto-slotted sensors.
2.3.2.1 BS55 Sensor Setup

This procedure is used to set up the paper detect sensor (BS55) after it has been
replaced.
This sensor is mounted below the post-diverter guide plate, see Volume 2
Figure 3.39. It detects paper stuck to the underside of the plate that has not been
removed from the feed head. It has a 3/4 turn adjustment potentiometer that is
rotated between 11 oclock (minimum sensitivity) and 4 oclock (maximum sen-
sitivity) positions.
Under normal operation, the plate or paper passes within 20 mm of the guide
plate. Since the adjusting pot is inaccessible from the top you will need to lift the
guide plate to carry out the procedure below.
Items required: small strip of plate and interleaf paper.
CAUTION: Lifting the guide plate with the machine powered on could damage the sen-
sors by shorting them to the frame.
1. While the machine is powered down, remove the 2-off M4 posidrive screws
holding the post-diverter guide plate in place.
2. Without removing any connections, position the plate so that you can access the
potentiometer. Locate a strip of plate where it can be detected by the sensor.
3. Power up the machine but prevent the main application from loading by
pressing Ctrl-c at the second prompt. This will stop the machine from generating
errors.
4. Power up the sensor using the command:
diagnostics/service/sensors> read_con ip
This utility polls the sensor to indicate its change of status. Check power is
applied to the sensor, indicated by an illuminated green LED.
5. Turn the pot fully anti-clockwise to the 11 o'clock.
6. Position a plate (with paper fixed to the underside of the plate) over sensor BS55
so that it covers the sensing aperture.
7. Raise the plate 20 mm above the guide plate, keeping the printing plate parallel
to the guide.
8. Adjust the sensor pot clockwise until the orange sensing LED is permanently
ON (not flickering).
9. Lift the plate until it is 35 mm above the guide plate.
10. Check that the sensor can still detect paper in this position, giving a 15 mm
operating margin.
The orange LED may flicker indicating that the sensor is still detecting paper.
11. If paper has not been detected, increase sensitivity (clockwise) until the orange
indicator starts flickering. Repeat this test several times to ensure adjustment
repeatability.
12. Remove the interleaf paper from underneath the plate.
13. Check that BS55 does not detect the underside of the plate (orange LED OFF).
Move the plate up and down parallel to the sensor and ensure that it does not
detect the plate in any position up to 35 mm from the sensor.
14. Power down the machine, replace the guide, and power up the machine again.
15. Confirm correct operation with both plates and paper.
2.3.2.2 BS51 Sensor Setup

This procedure is used to set up the paper detect sensor (BS51) after it has been
replaced.
This sensor is mounted above the post-diverter guide plate on the PTM frame
crossbar, see Figure 2.10. It detects paper stuck to the top of the plate that has
not been removed by the feed head.
It has a 3/4 turn adjustment pot that can be rotated from approximately
11 oclock (minimum sensitivity) to 7 o'clock (maximum sensitivity).
Items required: small strip of plate, small spacer of magnetic metal 10 mm x 9
mm, and interleaf paper.
NOTE: This spacer is used to increase the detection range of the sensor to approximately
54 mm and increase the operating sensitivity margin.
1. Power up the machine but prevent the main application from loading by
pressing Ctrl-c at the second prompt for bypass mode.
2. Power up the sensor using the command:
diagnostics/service/sensors> read_con ip
This utility polls the sensor to indicate its change of status. Check power is
applied to the sensor, indicated by an illuminated green LED.
3. Position a sample of paper on top of a plate (emulsion side up) on the plate tray.
Ensure they are parallel to the sensor.
4. Place a spacer under the sensor bracket, as shown in Figure 2.10.This will
increase the sensors range and sensitivity margin.
5. Turn the sensor potentiometer fully anti-clockwise to the 11 oclock.
6. Adjust the sensor clockwise until the orange indicator is fully on (not flickering).
7. Remove the paper and the spacer.
8. Keep the plate in position and check that the sensor does not detect the presence
of a plate (orange LED OFF).
9. Move the plate up to the sensor and further away as possible, keeping the plate
parallel to the sensor at all times. Check that the sensor is not activated at any
point.
10. Recheck the sensor with paper. Move the paper up to the sensor and further
away as possible, keeping the paper parallel to the sensor at all times. Check
that the sensor is always activated. Repeat this check several times.
11. The sensor is now set up.
.
PTM FRAME
CROSSBAR
SENSOR
BS51
FEED HEAD
ASSEMBLY
SENSOR 10mm SPACER

BRACKET
Figure 2.10 BS51 setup - positioning the spacer
2.3.3 X-Direction Door

2.3.3.1 X-Direction Door Replacement
1. Access the X-direction door assembly.
2. Move the bottom shelf on the elevator to line up with the feed assembly using
the command below or the MMI menu:
service/medtran>move-elevator e
3. Make sure the X-door is horizontal using the command:
service/actuators> set bm27 off
4. Switch off power to the Engine.
5. From the user side, disconnect the motor (BM27) cable and unbolt the motor
(BM27) bracket.
6. Holding the flap, tip the door 45 to avoid damage to the sensors and pull it
towards the user end with care.
7. Lift out the assembly (the bearing will slip out of the sensor end bracket). Take
care with the sensor vane.
8. Complete the reverse of the removal procedure above.
9. Actuate the flap using the command:
service/actuators> set bm27 on

10. You may need to adjust the horizontal position by moving the sensor bracket,
and the vertical position by moving the sensor vane.
Vertical Position:
The flap should be vertical or slightly away from the elevator.
Horizontal Position:
The flap should be horizontal or slightly above the cassette forward top plate,
see Volume 2 Figure 3.33. Ensure it is below the cassette forward arms.
2.3.3.2 Motor (BM27) Removal

1. Remove the assembly, as explained above.
2. Remove the circlip from the end of the shaft.
3. Slide the motor/gearbox from the shaft.
2.3.4 Cassette Forward

2.3.4.1 Cassette Forward Removal

4. While power is on, lift the X-direction door to the vertical position using the
command:
5. Ensure the elevator has an empty shelf at the feed level. Use the command:
service/medtran> move_elevator <shelf letter>
1. Access the cassette forward assembly, see Figure 2-2.9.
2. Release the belt tension by loosening the M6 caphead screw at the service side.
3. Mark the position of the assembly in the frame.
4. Disconnect cables to the following devices:
A) BM20 (cassette forward motor)
B) BS41 (cassette forward limit sensor)
C) BS42 (cassette reverse limit sensor).
5. Remove the 8-off M5 top plate screws holding the assembly to the mounting
frame.
2.3.4.2 Cassette Forward Replacement

7. Line up the assembly with the frame marks made in step 5 above.
8. Secure the assembly to the frame.
9. Put a screwdriver behind the eccentric as an aid for re-tensioning.
10. Tension the belt until it is difficult to twist more than 180 degrees. You can
access the belt through the top plate holes.
11. Ensure that the arms are synchronised and pointing towards each other by
adjusting the torque screw on the bearing at the user side. To align arms, the
sensor vane at the service side can be set to operate the sensors correctly.
Close the X-direction door using the command:
12. Check the cassette forward operation without the cassette using the command:
service/actuators> set bm20 on/off
13. Check the cassette forward operation with the cassette using the command:
service/medtran> load_cassette
service/medtran> unload_cassette

1. Remove the cassette forward assembly, as explained above.
2. Remove the 4-off M4 caphead screws securing the motor/gearbox.
3. Remove the drive wheel from the gearbox shaft by releasing the M19 screw.
2.3.4.4 Drive Belt Removal

1. Remove the circlip.
2. Loosen the M19 torque nut and withdraw the cassette arm and shaft from the
drive wheel.
3. Loosen the torque nut on the motor shaft.
4. Remove the 4-off 4 mm caphead screws holding the motor to the plate and
remove the motor.
5. Remove the belt by passing it over the idler wheel.
6. Fit the replacement belt over the drive wheel.
7. Insert the drive wheel into the housing, re-tighten the torque nut and re-fit the
circlip.
8. Re-fit the pulley housing assembly to the plate.
9. Fit the replacement belt.
2.3.5 Stack Increment

2.3.5.1 Stack Increment Removal

1. Switch off Engine power.
2. Access the stack increment assembly.
A) BM21 (stack height)
B) BS47 (stack height position)
C) BS61 (stack height top limit).
NOTE: Before removing the assembly, raise the stack increment to the top position by
manually moving the drive belt.
4. Remove the 8-off M4 caphead screws securing the stack increment to the cross-
bar.
5. Tip the assembly away from the cassette centering locators.
2.3.5.2 Stack Increment Replacement

1. Complete the reverse of the removal procedure.
2. Ensure that the lift bar leadscrew bearings are fully seated (that is, not restrained
vertically).
3. Manually lower the stack by moving the drive belt to ensure that the sensor
vane is between sensors BS47 and BS61
4. Switch power on.
5. Pull the cassette forward using the command:
service/medtran> load_cassette
6. Run the stack height routine using the command:
service/medtran> prepstack
7. Check that the cassette plinth is horizontal (+ 0.2 mm).
8. Check the stack set height.

1. Remove the M16 retaining nut on the motor shaft and withdraw the wheel from
the shaft.
2. Remove the 4-off M3 caphead screws retaining the motor/gearbox to the
support bracket and replace.
3. Adjust the slide motor fixings to tension the 410 belt.
2.3.5.4 Drive Belts Removal

1. Remove the stack increment assembly, as shown above.
2. Drive the stack increment up to set 4 mm spacing at both ends.
3. Loosen the 4-off M3 caphead screws retaining the motor to the mounting plate.
4. Detach the small and large belts and replace.
5. Check for parallel operation at each end. If there are signs of misalignment,
loosen the torque nut and adjust.
2.3.6 Feed Head

2.3.6.1 Feed Head Removal

1. Ensure that the nudger is up using the Main command:

1. Switch off the platesetter.
2. Access the feed head assembly.
A) BS43 (cassette empty) and p-clip
B) BS45 (nudger down)
C) BS46 (nudger up)
D) BS47 (stack height position)
E) BS48 (nudger detect)
F) BM22 (nudger and takeaway)
G) BM23 (nudger lift).
4. Pull all connector cables through the central hole.
NOTE: Do not remove the feed head interface plate from the cross-bar assembly. This is
factory-set.
5. Remove the 4-off M5 x 8 mm long caphead screws securing the feed head
assembly to the support backplate, see Volume 2 Figure 3.35. Avoid dropping
the screws into the machine.
6. Hold the assembly by the two motors and lift away from its two locating dowel
pins.
7. Place the assembly on a clean surface, ensuring that it is not resting on the
nudger detect bracket.
2.3.6.2 Feed Head Replacement

8. Place the assembly on locating pins, ensure the cables are clear and bolt to the
support backplate.
1. Ensure all the cables pass through the central hole of the PTM and feed head
assembly.
2. Replace all connectors.
3. Make sure the mylar strips are towards the Engine to allow the plates to feed.
4. Make sure BS46 (nudger up limit) is at the 12 o'clock position.
5. Switch on power.
service/medtran> init
and:
service/medtran> load_cassette (with a 1030 x 800 plate).
7. Check the BS48 (nudger detect) setting by entering:
service/sensors> read_con ip
The sensor should detect plates resting on the cassette edge.
Stack Height Position Check

Use this procedure to check if the top plate surface on a cassette stack is level
with the lead edge guide on the retard assembly. Once an offset has been
entered for one plate thickness, NVRAM parameters for all the other plate and
paper thickness are automatically adjusted.
1. Remove the lid from a selected cassette.
2. From the MMI, advance a cassette to the feed head with any plate height or size.
3. From Main Diagnostics, display the current offset by entering:
diagnostics/service/medtran> set_stack_height
4. Enter stack height as:
diagnostics/service/medtran> set_stack_height 0
This sets the current reference height to 0 and raises the plate stack to the lead
edge guide and lifts the nudge roller clear of the top plate.
WARNING: If using the set_stack_height command, wait for the nudge roller to lift clear
of the stack before reaching into the PTM.
5. Reach into the PTM and feel if the top plate is higher than the top of the lead edge
guide, see Figure 2.11.
You can also shine a torch light along the direct line of the two edges to check
levels by removing the feed head viewing plate behind the interleaf bin door.
TOP PLATE LEAD EDGE
PLATE STACK
STACK
INCREMENT
RETARD ASSEMBLY
Figure 2.11 Checking the stack height
6. If the stack is lower, adjust the stack height sensor bracket towards the Engine
and re-enter the command:
diagnostics/service/medtran> set_stack_height 0
7. Repeat steps 3) to 5) until the stack is higher than the lead edge guide.
8. Adjust the stack height offset by entering a value, for instance, set_stack_height -
0.5 (in mm). Each time you enter a value it updates the NVRAM parameters for
each plate size and thickness. The minimum increment is 0.1 mm.
9. Continue the adjustment until the top plate is level with the lead edge guide.
10. Push the top plate forward by applying downward pressure to the centre of the
plate and check if it butts against the lead edge. If the plate feeds across then
continue the adjustments.

1. Remove the feed head assembly, as described above.
2. Remove the 4-off M3 caphead screws holding the motor/gearbox to the
mounting end plate.
3. The nudger lift cam is retained on the motor shaft by a pin. Replace the cam on
the new motor.

1. Remove the feed head assembly, as described above.
2. Make a note of the chain tension.
3. Remove the 4-off M3 caphead screws holding the motor/gearbox to the
mounting end plate.
4. Remove the gear from the motor shaft by loosening the grubscrew with a 1.5mm
Allen key. Replace the gear on the new motor and tighten fully to avoid
slippage.
5. Re-tension the chain from the slotted holes in the mounting end plate.
2.3.7 Retard Pad

2.3.7.1 Retard Pad Removal

1. Access the retard pad assembly.
2. Move the retard pad to the up position using the command:
3. Switch off power.
4. Remove the feed head, see Section 2.3.6.
5. Remove the pre-diverter guides, see Section 2.3.8.
6. Disconnect cables from the following devices:
A) BM25 (retard drop motor)
B) BS56 (retard up)
C) BS57 (retard down)
D) BS65 (cassette at nudger).
NOTE: Do not remove the retard interface plate from the cross-bar assembly. This is fac-
tory-set.
7. Remove the 2-off M4 screws to remove the retard pad only.

8. Remove the 4-off M4 caphead screws on the outside of the mounting plate.
9. Lift the assembly straight up from the machine.
2.3.7.2 Retard Pad Replacement

2. Check that the retard pad is free to move up and down using the command:
3. Check that the pre-diverter guides are correctly located.
4. Check that the pre-diverter guides are flush with one another and below the
leading edge guide.
2.3.8 Interleaf Diverter and Drive Roller

2.3.8.1 Interleaf Diverter Removal

1. Access the diverter assembly.
2. Release the bearing retainer at the user end and lock the retainer clear of the
bearing.
3. Remove the M3 screw holding the counterbalance weight and remove the
weight.
4. Slide the assembly towards you until the bearing drops out. Slide the bearing off
the shaft.
5. Lift up the hinged sensor (BS51) so that its clear.
6. Slide the shaft to uncouple it from the solenoid. Leave the solenoid in position, if
possible.
7. Slide the shaft off the motor drive and lift out.
2.3.8.2 Interleaf Diverter Replacement

1. Slide the bearing (user side) end through the end plate hole first and slide back
to couple to the solenoid.
2. Slide the bearing onto the shaft and lock the retainer.
3. Replace the counterweight.
4. If the solenoid was replaced or moved, secure the bracket.
5. Actuate the solenoid to check its operation using the command:
service/actuators> set bv20 on
2.3.8.3 Interleaf Drive Rollers Removal

1. Access the drive roller assembly.
2. Remove the diverter and post-diverter guides.
3. Remove the drive roller assembly from the service side:
A) Loosen the 4-off M3 slot screws retaining the motor on the service side.
B) Remove the drive belt.
C) Remove the pulley from the drive roller and release the interleaf steady
bracket.
4. Remove the bearing retainer end plate at the user end (2-off M3 cap heads).
5. Loosen the lower guide plate (below rollers).
6. From inside the interleaf bin, pull out the drive roller assembly from the PTM
feed frame.
2.3.8.4 Interleaf Drive Roller Replacement

2. Check that all the plate guides do not touch the roller segments.
3. Bias the nip roller with the steady bracket. Ensure that there are no gaps
between the segments.
2.3.9 Transport Plate Guides

2.3.9.1 Pre-Diverter Plate Guide Removal

This guide is made up of two separate plates, lefthand (LH) and righthand
(RH), held by fixing brackets.
1. Remove the 3-off M4 caphead screws on the outside of each guide.
1. Loosen the 2-off wing nuts and M6 screws holding the guides to their fixing
brackets.
2. Lift out the LH and RH plates from the PTM.
3. Check that the plate guides do not have an aluminium build-up. If necessary,
polish with a metal polish or Autsol.
4. When replacing the two plates, make sure they are even at the centre to ensure a
smooth surface for the plate.
5. Advance a plate to the feed head and check if BS50 and BS49 operate correctly.
6. Check that the guide is subflush with the diverter (when down), see Figure 2.12.
You may need to insert washers under the corner fixings of the guide plates to
adjust the height slightly.
DIVERTER SUBFLUSH AND IN

PRE-DIVERTER GUIDE RECESS
DIVERTER
PRE-DIVERTER
GUIDE
Figure 2.12 Diverter subflush with guide plate
7. Check the operation of the diverter while feeding plates and paper.
2.3.9.2 Post-Diverter Plate Guide Removal

1. Switch off power to the machine.
2. Remove the 2-off M4 pozidrive screws holding the plate to the frame and lift out
the plate.
3. Disconnect the sensors (BS55 and BS59).
4. Replacement is the reverse of removal.
2.3.9.3 Engine Interface (Output) Plate Guide Removal

1. Remove the 2-off pozidrive screws.
2. Lift out the guide assembly with its sensor (BS52).
3. Disconnect the sensor cable.
2.4 Engine Servicing

2.4.1 Accessing Engine Assemblies
Figure 2.13 shows which covers are removed for accessing the main replaceable
assemblies on the Engine. See Volume 3 Section 3.1 for details on how to replace
the traverse FRUs (Edge Detect PCB, etc).
REG PIN OPTO ISOLATION

I/F CONNECTORS
FILTER BOX
FHMB 1
AIR KNIFE
SERVICE SIDE SWING ROLLER MOTOR
LOADING PLATFORM MECHANISMS INTERLOCK BOX
PUSH BAR MECHANISMS
DISTRIBUTION PCB'S
TRAVERSE PCB
TRAVERSE CARRIAGE MECHANISMS
MIXER FAN
EDGE DETECT
FAST PHOTO DETECT
INPUT SIDE OUTPUT SIDE
FHMB 4
FHMB 4
OUTPUT MODULE
INPUT MODULE
SWING ROLLER MODULE
UMBILICAL CABLE
REGISTRATION MODULE
USER SIDE
VACUUM SOLENOIDS
COMPRESSOR BOX
SCREW LOCKED PERISCOPE MECHANISMS
NOT LOCKED PUSH BAR
PUNCH
Figure 2.13 Accessing Engine assemblies
2.4.1.1 Removing the Drum End Caps

Figure 2.14 shows how the drum end cap is removed from the drum casting on
the user side.
Removing the user side end cap allows access to the traverse carriage and the
spinner mirror.
Figure 2.14 Removing the drum end cap (user side)
2.4.2 Loading Platform

The loading platform for the B1 and B2 variants are similar for removal and
replacement.
2.4.2.1 Loading Platform Removal (Manual)

This is a two-man procedure.
See Figure 2.15.
Removing the B2 Top Input Cover:
1. Remove top covers and the interlock switch (2-off pozi-screws).
2. Remove the 4-off pozi-screws holding the cover to the frame at each side.
3. Remove the two front cover trims by pushing down on the recessed clips with a
small screwdriver to release the trim.
4. Remove the cover by lifting up and tilting back to unclip it from the frame.
Removing the B1 Top Pod Cover:
1. Remove the two side doors.
2. Remove the 6-off pozi-screws holding the pod to the Engine.
3. Push the pod upwards from the back and remove horizontally so as not to
damage the input rollers.
COVERS REMOVED
3
4
B2 - REMOVE TOP INPUT COVER
2
3
COVER
REMOVED
B1 - REMOVE TOP POD COVER
Figure 2.15 Removing the top input covers
Removing the Platen:

1. Remove the 4-off pozi-screws holding the platen to the frame at each side.
2. Lift out the platen to access motors and sensors. If you are careful, you will be
able to lift out the platen without disconnecting any cables. Rest the platen on
wooden blocks to avoid straining cables.
3. Remove the cable ties at the user end.
5. Check the operation of the module by loading a plate and observing its
transport into the drum.
NOTE: If you are replacing the photo sensor (BS118), make sure the MMI indicates an
error if interleaf paper is loaded with the plate, and the plate is placed polymer side down.
2.4.3 Input Module

2.4.3.1 Input Module Removal (All Variants)
See Volume 2 Section 3.4.2.2.
The input module is removed as a complete assembly. This is a two-man opera-
tion.
1. Open the top cover on the Engine (PTM side).
2. Manual and Semi-Automatic only: remove the front hood above the platen (2-off
screw).
3. Manually move the push bar down into the drum.
4. Manual and Semi-Automatic: remove the top input cover by disconnecting the
interlock switch and removing the 4-off side pozi-screws.
5. Remove the cover by lifting up and tilting back to unclip it from the frame.
6. Disconnect the following cables:
A) BS1 (input entrance) - PL4, Sensor Distribution PCB.
B) BS2 (input exit) - PL3, Sensor Distribution PCB.
C) BM1 motor cable from FHMB(1), PL15, or from the inline connector at the
motor.
7. Remove the 4-off M5 Allen screws on each side holding the module mounting
bracket to the drum casting.
8. Lift out the module.
9. Replacement is the reverse to removal. Fit the assembly so that the bracket is
inline with the drum.
2.4.3.2 Roller and Drive Belt Removal

NOTE: Rollers and belts on the input and output modules can be replaced in-situ without
removing the module.
CAUTION: Always make sure you release a roller from BOTH ends before replacing a
drive belt. Do NOT attempt to replace the belt from one end only as you will strain the
bearing at the other end.
1. Unclip the roller bearing circlip at both ends of the roller and pull out the
bearing by hand.
NOTE: If the roller has a pulley or gear wheel, remove the wheel making sure the pin
inside is not mislaid.
2. Lift out the roller.

3. Input Only: remove the 2-off M3 Allen screws retaining the cross member at the
bottom of the input rollers.
4. Input Only: Disconnect the drive belt from the manual winding handle (inside
the drum) by loosening the 4 mm shoulder bolt. Note the two washers under the
head of the bolt.
5. Remove the belt.
6. Refit the new belt and ensure that all the belts are running on rollers with the
rough side as the outer side.
2.4.4 Output Module

2.4.4.1 Output Module Removal
CAUTION: The output module is easily twisted once it is outside the frame. Handle the
module with care.
Fully-Automatic:
The output module is removed as a complete assembly to access the punch, reg-
istration and centering mechanisms:
1. Put the Buffer into its service position, see Section 2.5.1.
2. Mark the position of the module on its support bracket slot.
3. Using a 5 mm Allen key, remove the 2-off screws at the module brackets on each
side, see Figure 2.16.
A) BS4 (output entrance)
B) BS5 (output exit)
C) BM6 or BM38 (friction and band output motor).
5. Remove the output guide, see Section 2.4.4.2. Do NOT touch any height
adjusting nuts between the mounting bracket and the support bracket.
7. Replacement is the reverse of removal. Check that the rollers inside the drum
are correctly located and run a plate to the output.
Make sure the plates are not scratched and not skewed by the output rollers.
OUTPUT TOP VIEW

MOUNTING (SERVICE SIDE)
BRACKET
OUTPUT SUPPORT BRACKET

(PART OF ENGINE FRAME)
OUTPUT SIDE PLATE

(PART OF OUTPUT MODULE)
FIXING SCREW
HEIGHT (MANUAL/SEMI SET UP POSITIONS)
ADJUSTER
Figure 2.16 Output module - fixing points
Semi-Automatic and Manual:

It should not be necessary to remove these output modules for field servicing
unless access to the swing roller or registration module is required.
1. Complete steps 1 to 5 for the Fully-Automatic machine above.
2. Replace the module but do not tighten the top 4-off fixing screws.
3. Check that the rollers at the drum end are not skewed.
4. Tighten the top fixing screws. There is no height adjustment for these variants.
2.4.4.2 Output Guide Removal

The output module includes a plate output guide that can be removed sepa-
rately to access the punch assemblies and RFI box Distribution PCBs.
1. Remove the 2-off M5 Allen screws attaching the guide to the output module.
2. Detach the BS5 sensor and lift out the guide.
2.4.5 Transport Push Bar (Mark 2)

2.4.5.1 Removing the Push bar
See Figure 2.17.
1. Switch off power and open the two covers at each side of the Engine.
2. Detach the cable connector to the push bar motor assembly.
3. Allow the bar to move to the bottom of the drum.

Insert a protective plate under the push bar to prevent damage.
4. Remove the roller plates from both ends (2-off M6 pozi-screws).
5. Lift/slide out the complete assembly from the drum to carry out any servicing,
as required.
SPRING
WHEEL SHOE
ASSEMBLY
DRIVE
SHAFT
SPUR GEAR
BLANKING
PITCH RING BRACKET
ASSEMBLY
ROLLER
PLATE
NIP ROLLER
ROLLER
PLATE
MOTOR HOME SENSOR

END PLATE (ON DRUM)
SUPPORT
BAR
HUB SPUR
DRIVE GEAR
SHAFT
PITCH RING
V3 ASSEMBLY MOTOR
PITCH RING STUB SHAFT GEAR MOTOR
BEARING MOUNTING
BRACKET
Figure 2.17 Transport push bar (Mark 2)
Replace the Spring Shoes

NOTE: Spring shoes should be replaced during a scheduled 12 month service visit.
See Figure 2.17.

1. Remove the push bar.
2. Loosen the 2-off M3 socket screws holding the shoes to the support bar.
3. Remove and replace the shoes and secure. Note that the distance between the
shoes depends on the maximum size of the plate (B1 or B2).
4. Replace the push bar and check for alignment using a plate.
2.4.5.2 Replacing the Push Bar

See Figure 2.17.
1. Make sure the rings on both sides are clean
2. Locate the push bar so that the trailing edge of the support bar is inline with the
centre scribed lines at each end of the drum.
3. Ensure that the pitch ring bearing is inserted inside the drum groove.
4. Refit the roller plates at the motor end. Grip the roller plate so that it fits tightly
against the drum before securing.
NOTE: Only one of the plate wheels will be in contact with the drum as the bar moves
around the drum.
5. Attach the motor umbilical cable.
Aligning the Push Bar

See Figure 2.18.
6. Visually position the back of the push bar as near as possible to the scribed line.
7. If there is a small conformance error (less than one tooth) then adjust the track at
the service side to line up the push bar to the scribed line. Loosen the M4
retaining screw at the end of the track direction that needs to be moved, see
Figure 2.18.
8. Carefully tap the gear segments to move them in the required direction and
tighten the retaining screw to ensure that there is no lateral movement.
9. Tap all the segments around the drum with a light hammer to ensure they are
securely in place.
10. Check the user end for a conformance error and adjust the track.
11. Tighten the segment retaining screw to ensure there is no movement.
2.4.5.3 Setting up the Push Bar

1. Obtain an 0.15 mm thick plate and measure its width and height, for example,
510 mm (width or lead edge) and 400 mm (height).
Use the smallest size and thinnest plate available. This ensures all plates will be
loaded without damage.
2. Load the plate manually into the drum and not from the cassette or plate loader.
3. Disconnect the mains cable supplying the compressors from the users side, see
Volume 2 Figure 9.4.
4. Run the medtran utility using a registration pin/push bar offset of -5:
service/medtran> setup_push_bar 400 0.15 -5
5. Check if the plate has reached the registration pins.

6. Keep increasing the offset until the plate conforms to the drum surface without
any deformation at the pins or the push bar spring shoes.
7. If conformance is different at each side of the plate, align the push bar (see
Section Aligning the Push Bar above).
8. Reconnect the mains cable to the compressors.
2.4.6 Drum Gear Segments

This procedure applies to gear segments used by both types of push bars.
2.4.6.1 Gear Segment Replacement

See Figure 2.18.
Gear segments with nylon spur teeth are fitted around the drum edges for the
push bar gear drive. There are 10 segments each side of the drum and each seg-
ment has 23 teeth.
1. Remove the M4 Allen screw from the nearest retainer and lift out the retainer.
Make sure the metal insert between the screw and the gear segment is not lost.
ADJUSTMENT
SCREW
RETAINER
SCREW
METAL INSERT
(BETWEEN SCREW
AND SEGMENT)
GEAR
SEGMENT
Figure 2.18 Push bar gear segment and retainer - detail view
2. Remove each segment in turn from their drum grooves to access the faulty
segment.
3. Replace the segments and secure by adding the metal insert.
The retainer screw is used to adjust the segment rings towards or away from the
punch.
4. Carry out the push bar setup procedure.
2.4.7 Punch, Registration and Centerer (Billows)

2.4.7.1 Accessing Punch Assemblies
You can optionally access punch assemblies for servicing, without having to
remove the complete punch from the machine:
centerer, punch and registration motors
centerer home sensor (BS14).
Remove the complete assembly (punch, centerer and registration) from the
machine if you have to:
replace punch pins, dies and guides (this is not recommended as a field
replacement - refer to FFEI (UK) Customer Support)
replace the centering side detect sensors (BS12/13)
replace the plate in punch (BS3) sensor
fit a new punch option.
Accessing punch assemblies for complete removal or servicing on the machine
will require you to initially complete the following procedures:
1. Lower the Buffer to its service position, see Section 2.5.1.
2. Remove the rear stretcher panel on the Engine.
3. Remove the output module, see Section 2.4.4.1.
2.4.7.2 Complete Punch Removal

CAUTION: Removing the punch from the drum is a two-man operation using the supplied
lifting handles. Always make sure the drum surface is protected before starting a punch
service procedure.
Accessing the Assembly

See Figure 2.19 showing how the punch is removed.
The complete assembly sits on two dowels fitted to the drum casting which
allow the assembly to be accurately located.
Remove the complete assembly as follows:
1. While the machine is switched on:
Make sure the punch pins are retracted (disengaged) using the command:
service/actuators set bm4 off
Move the traverse to the user end.
3. Protect the inside of the drum with any heavy-duty material that can take the
dropped weight of the punch.
4. Move the traverse carriage to the user end.
5. Remove the stretcher panel on the Buffer side of the Engine by removing the 2-
off screws at the top of the optics base cover and the 4-off M5 Allen bolts
holding the panel in place, and the cables at the service end.
6. Remove the output module, see Section 2.4.4.1 .
M6 BOLTS M6 BOLTS M6 BOLTS M6 BOLTS LOWER

BEAM
SUPPORT
DRUM
CASTING
DOWEL DOWEL
LOWER
BEAM
SUPPORT
SERVICE
SIDE
PLAN VIEW OF DRUM CASTING
PLAN VIEW OF PUNCH
LOWER
LOWER
BEAM
BEAM
SUPPORT LOCATION FOR SUPPORT
LIFTING HANDLE
LOCATION FOR
LIFTING HANDLE
LIFTING
HANDLE
PUNCH
(USER END)
Figure 2.19 Removing the punch assembly

Removing the Assembly

See Figure 2.19.
7. Disconnect the following sensor and motor cables to the punch:
A) punch motor and 2-off sensors (service side)
B) registration motor and 2-off sensors (rear of Engine)
C) centering motor and 3-off sensors (rear of Engine and both ends)
D) Plate in punch sensor.
8. Remove the punch assembly from the drum as follows:
A) Screw the two lifting tools (part no. 7A03809) into the assembly lifting points
shown in Figure 2.19 and lock into position.
B) Remove the 8-off M6 bolts set in pairs.
C) Using one person at each end, lift out the assembly. Once free of the locating
dowel pins, lift the user end out first.
D) Check that the two dowels are still in position in the drum.
9. The complete assembly can be serviced by laying it between the two cutouts on
the wooden transit fittings used for the Autofeeder.
2.4.7.3 Complete Punch Replacement

1. If you are fitting a new punch option or complete assembly, check that it has not
been damaged during transit.
2. Position the new punch on the dowels (they should fit through the guide holes).
The punch motor will be part of the assembly which makes this operation more
awkward. Avoid knocking the carriage flywheel.
3. Screw in (but do not tighten) the 8-off M6 bolts from the middle of the punch
outwards.
4. Check that the setback distance is 1 mm (+0.2/-0.0 mm), see Figure 2.20.
SET BACK DISTANCE

(1 mm)
LOWER BEAM
UPPER BEAM
LATERAL
FEET
DIRECTION
PLATE
DIRECTION
DRUM FACE
Figure 2.20 Punch setback distance
If the setback distance is incorrect then:

A) measure the incorrect distance
B) remove the punch from the drum
C) mark the lateral position of the feet before loosening.
D) adjust the position of the two outer punch feet (fastened by 2-off M4
panhead screws) to achieve the correct distance.
E) replace the punch, partially tighten the M6 bolts and recheck the distance.
5. Once the setback distance is correct, finally tighten the M6 bolts from the centre
outwards. Do not overtighten the bolts - the aluminium fixing hole threads in
the drum are easily damaged.
6. Reconnect all cabling on the service side and the registration/centerer motors.
7. Remove the lifting tools.
8. Switch power on and halt the reset at the second Control-C message on the
MMI.
9. Check that the punch motors and sensors operate.
10. Re-assemble the machine.
2.4.7.4 Punch Adjustments and Checks

Visual plate checks are recommended after approximately 35,000 punch opera-
tions have been completed. Check the NVRAM parameter for the current
number of operations.
They are also carried out after the complete punch assembly has been removed
and replaced.
Figure 2.21 shows a typical view of the pins, guide and die for a full punch
mechanism.
Visual Plate Punch Check

1. Discuss with the customer any issues or problems that have appeared since the
last service visit.
2. Load a large plate (1030 x 800 mm, minimum) and expose with a 50% tint image.
3. Punch the plate manually using the command:
set bm4 on
Make sure the pins are retracted before ejecting the plate:
set bm4 off
4. Place the exposed plate on a flat surface and check the following:
A) Punch crops are centred, see Volume 3 Figure 1.8.2.3.
B) Punch crops are the correct depth:
4 standard punch depth at 12 mm, custom at 11 mm
4 crops are equal depth when measured between left and right (specifica-
tion is 50 microns)
4 crops are cleanly cut without debris in corners or burrs.
4 plate lead edge to the image start position is inside the specification, see
Volume 3 Section 1.8.3.3.
4 image is centred on the plate.
5. Adjust the punch pins (see Section 2.4.7.5) if there is a problem with the pins.
Punch Mechanism Check

This procedure is carried out after the complete assembly has been replaced.
1. Lower the Buffer and remove the output module to access the drum side of the
punch motor.
2. Remove the shoulder screw (M5) and note the washer configuration.
3. Manually move the actuating arm and check if the mechanism is tight to move.
(Do not force the lever arm or the pins will drop out too far from the guides.
The limit of movement is set by the tab flag in the opto-slotted sensor. The lever
should be free moving.
4. Replace the shoulder screw.
5. Power up the machine.
6. Use Main Diagnostics to check the punch operation:
service/actuators> set bm4 on (to punch) and off (to retract)
7. Retract the registration pins and punch an 0.3 mm plate to obtain holes. Look for
non-uniform burring around the punched hole edges which indicates non-
concentric pins/dies.
Registration Mechanism Check

1. Operate the registration pins:
service/actuators> set bm5 on and off
2. Check that the spring on the actuating push/pull rod is not deflecting,
indicating that it is not binding. Use diagnsotics to repeatedly retract/extend the
pins.
Centering Mechanism Check

1. Check for a small amount of free movement of the two centering rails
underneath the centering motor.
2. Re-fit the output module and Buffer.
3. Run plates through to the Buffer and check the following:.
A) Push bar alignment and plate skew.
B) Plate conformance, see Section 2.4.5.3.
C) Traverse image centre position.
D) The plate is not damaged by the punch or centering mechanisms (plate edge
damage).
E) Punch chad is passing into the tray correctly and is not jamming or falling
into the drum.
Repack the removed punch assembly in the replacement crate, making sure it is
secure and does not move during transit.
2.4.7.5 Punch Pin Checks

NOTE: Use this procedure to check the pins for mechanical operation. Refer to Fujifilm
Customer Support for more information on removing pins, dies and guides if there is a
problem in setting up the mechanism.
Adjust Punch Pins

See Figure 2.21.
1. Switch off power to the platesetter.
2. Remove the operating arm to the motor shaft shoulder bolt by first loosening the
bolt grub screw.
BALLSCREW ACTUATING
SHAFT
PUNCH
KEYHOLE PUNCH
M6 SCREW
PUNCH GUIDE
PUNCH STRIPPER
LOWER BEAM
PUNCH DIE
Figure 2.21 Punch pins, guides and dies
3. Operate the punch actuating lever by hand to ensure that the punch pins are
free to move - a smooth movement should be possible with reasonable force. If
the pins are hard to move it could be due to:
A) Damaged pins that need replacing.
B) Pins are coated with aluminium oxide.
4. Remove each pin in turn and check the condition of the pin sponge accelerator
and replace as required.
5. Refit the punch arm shoulder bolt, power up the platesetter and check punch
operation using the diagnostic commands:
set bm4 on
set bm4 off
Punch Checks
After replacing a punch sub-assembly run the following checks:
Punch centering, see Volume 3 Section 1.8.2.4.
Image position and skew, see Volume 3 Section 1.8.3.1.
Image traverse center position, see Volume 3 Section 1.8.2.5.
2.4.7.6 Registration Mechanism Replacements

Motor (BM5)
This procedure is completed without removing the punch assembly.
1. Access the motor assembly, see Section 2.4.7.1.
2. Remove the motor and gear head (4-off posidrive screws).
3. Replace the motor and check that the pins retract/extend.
service/actuators> set reg_pins on/off
Sensors (BS10/11)
1. Remove and replace the sensor (opto-slotted).
2. Check the extend/retract positions of the pins.
2.4.7.7 Registration Mechanism Checks

1. Check the mechanical condition of the sensor vanes, cam, push-rod and spring
assemblies.
2. Remove the cam, apply a very small amount of light engineering grease to the
operating surface, and refit the cam.
1. Open Main> Diagnostics and repeatedly check for the smooth operation of the
registration mechanism:
actuators> set bm5 on
actuators> set bm5 off
2. Measure the following parameters with the Engine switched off:
extension of registration pins is 3 to 4 mm
retraction of pins is 0.5 to 1.0 mm sub-flush of guides.
Adjust, if necessary, to achieve these values by adjust the locknut position on
the actuating rod to set the amount pins extend and retract.
2.4.7.8 Centerer Mechanism Replacements

Motor (BM3) and Gear Head
1. Access the motor assembly.
2. Remove the motor/gear head bracket (4-off M5 screws)
3. Replace the motor and gear head (with the pinion already fitted on the gear
head shaft).
4. Complete the adjustment check in Section 2.4.7.9.
Sensors (BS14)
After replacing this opto-slotted sensor, check that the arm tab slides into the
slot correctly.
2.4.7.9 Checking the Centerer Mechanism

See Volume 2 Section 3.4.2.6
2. Access the rear of the punch.
3. Operate the centering arms by hand to ensure that the arms move fully open
(Home position) to fully closed.
4. Check for play between the motor gear and the centering arms. The engagement
of the arm to the gear wheel should allow free movement with the minimum of
vertical movement.
5. With the centering arms in the fully closed position, re-apply power and
confirm that the arms home with a smooth mechanical movement.
Adjusting the Centerer Mechanism

After replacing the motor or side detect sensors, complete the following:
1. Make sure the scribed lines on each of the arm rails is aligned with the motor/
gear head bracket edges.
2. Make sure there is a vertical clearance of between 0.2 and 0.5 mm between the
arm rail and the motor pinion.
2.4.7.10 Punch Mechanism Replacements

Motor (BM4)
This procedure is completed from the service side without removing the punch
assembly.
1. Remove the M5 shoulder screw.
2. Remove the 2-off M5 punch bracket screws and remove the bracket (located on
brackets) with the motor, gear head and sensors.
3. Lift out the motor assembly.
4. Refitting is the reverse of removal. Note the orientation of the black/white wires
and check that the motor turns in the correct direction.
5. carry out the punch checks in Section 2.4.7.4.
Sensors (BS8/9)
These are opto-slotted sensors. Make sure the tabs do not move beyond the A
and B points shown in Volume 2 Figure 3.61.
Sensor (BS3)
This procedure is completed after removing the punch assembly, see Section
2.4.7.2. Consult FFEI Customer Services (UK) for further advice on how to
replace this sensor.
Punch Pins, Dies and Guides

Replacing Billows pins, dies and guides on a Billows field machine is not recom-
mended without further consultation with FFEI Customer Services (UK).
Punch Crop Depth Adjustment

Refer to FFEI Customer Services (UK).
Drag Chain and Wiring Loom Removal

See Figure 2.22.
After removing the punch assembly from the machine you can detach the drag
chain and wiring loom from the assembly by:
1. Unscrew the drag chain bracket from the beam assembly (2-off posi-screws).
2. Unscrew the drag chain from the centering arm (2-off M3 cap heads).
3. Detach the ground and sensor (continuity) wires.
4. Release the wiring loom P-clips.
DRAG CHAIN
M3 CAPHEADS
POSI-SCREWS
(BRACKET)
SENSOR AND
GROUND
Figure 2.22 Removing the punch drag chain (new Billows)
2.4.7.11 Registration Mechanism Replacements

Motor (BM5)
2. Remove the complete motor bracket (centerer and registration motors) as
follows:
A) Remove the registration cam tab (1-off M4).
B) Loosen the centerer rail guides screws (2-off posidrives, top and bottom).
C) Remove the bracket (1-off posidrive) from the casting.
3. Remove the motor and gear head (4-off posidrive screws).
4. Replace the motor and check that the pins retract/extend using the command:
service/actuators> set reg_pins on/off
Sensors (BS10/11)
1. Remove and replace the sensor (opto-slotted).
2. Check the extend/retract positions of the pins.
2.4.7.12 Registration Mechanism Checks

1. Manually check the registration pin mechanism by pushing/pulling the
actuating rod. It should be free moving.
2. Run the following script:
>records test
>set bm5 on
>set bm5 off
>ctrl-x (to stop the script)
Alternatively, use the set command to switch the BM5 motor on and off.
3. Check the mechanical condition of the sensor vanes, cam and push-rod
assemblies.
4. Apply a very small amount of light engineering grease to the cam operating
surface.
2.4.7.13 Centerer Mechanism Replacements

Motor (BM3) and Gear Head

2. Loosen the top centerer rail guide to make it easier to insert the motor pinion.
3. Remove the motor/gear head bracket (4-off M5 screws)
4. Replace the motor and gear head (with the pinion already fitted on the gear
head shaft) and secure the top rail guide.
Sensors (BS12/13)
1. Remove the sensor (micro-switch) device from the centering arm.
2. Adjust switching on the centering finger by checking that the range of
movement furthest from the pivot end is 1 mm, with the switching point mid-
way.
Sensors (BS14)
After removing this is an opto-slotted sensor, check that the arm tab slides into
the slot correctly.
2.4.7.14 Checking the Centerer Mechanism

2. Access the rear of the punch.
3. Operate the centering arms by hand to ensure that the arms move fully open
(Home position) to fully closed.
4. Check for play between the motor gear and the centering arms. The engagement
of the arm to the gear wheel should allow free movement with the minimum of
vertical movement.
5. With the centering arms in the fully closed position, re-apply power and
confirm that the arms home with a smooth mechanical movement.
2.4.8 Punch, Registration and Centerer (Fuji)

2.4.8.1 Accessing the Assembly
A complete punch assembly (including motors, cables and drag chain) is supplied if the
old punch needs to be replaced.
The assembly sits on two dowels fitted to the drum casting to allow for accurate
location. You do not need to remove the punch motor beforehand.
1. Move the traverse to the user end.
holding the panel in place.
5. Remove the output module, see Section 2.4.4.1.
2.4.8.2 Removing the Assembly

CAUTION: If you are replacing a Billows on a Green machine with a Fuji punch, then the
output exit guide needs to be replaced and the output raised to avoid fouling the center-
ing arms.
CENTERING
S10 MOTOR
S14
(BM3)
REG PIN
ARM (LH) ARM (RH)
S13
BS3
PIN/DIE/ A
S12 CHAD WIPER
PUNCH
MOTOR
CENTERING (BM4)
MOTOR BS8/9
S11
REG PIN
CAM

CENTERING FINGERS
ON HIDDEN SIDE
REG PIN
REG PIN DC MOTOR
ACTUATING (BM5)
ARM
UNDERNEATH
Figure 2.23 Punch, registration and centerer assemblies
6. Remove the punch motor (optional), see Section 2.4.7.10.

A) punch motor and sensors (service side)
B) registration motor and sensors (rear of Engine)
C) centering motor and sensors (rear of Engine and both ends)
A) Remove the 8-off M6 bolts set in pairs.
B) Using one person at each end, lift out the assembly. Lift by first raising the
user end slightly. Avoid lifting from the drag chain.
C) Check that the two dowels are still in position in the drum.
9. The complete assembly is serviced by laying it between the two cutouts on the
wooden transit fittings used for the Autofeeder.
M6 BOLTS M6 BOLTS
LOWER
BEAM
SUPPORT
DRUM
CASTING
DOWEL LOWER
BEAM
SUPPORT
SERVICE
SIDE
Figure 2.24 Removing the punch assembly
2.4.8.3 Complete Punch Replacement

2. Make sure the drum surface is fully protected by heavy cardboard.
4. Screw in (but do not tighten) the 8-off M6 bolts from the outside towards the
middle of the punch.
5. Manually check that a large plate can enter and exit the punch correctly without
scratching. Check that the leading edge is picked up by the first output module
roller.
6. Tighten the M6 bolts from the centre outwards. Do not overtighten the bolts -
the aluminium fixing hole threads in the drum are easily damaged.
2.4.8.4 Punch Adjustments and Checks

tions have been completed. Use the command to check the NVRAM parameter:
diagnostics/log_utils> dis_stats
Note that the punch pins can be removed and replaced with the opposite end
operating as the punch surface. `Replacing the Punch Pins' on page 2-52.
Figure 2.21 shows a typical view of the pins, guide and die for a full punch
mechanism.
Visual Plate Punch Check

last service visit.
2. Run a punch job from the RIP.
tion is 50 microns)
4 crops are cleanly cut without debris in corners or burrs ( Replacing the
Punch Pins on page 2-52.
4. Check for correct chad removal, making sure the chad is `flicked' off each pin by
the strips.
NOTE: Refer to Fujifilm Customer Support for more information on removing pins, dies
and guides if there is a problem in setting up the punch mechanism.
CAUTION: Do not operate BM4 and BM5 manually. This could damage the wipers and
cause chad to drop into the drum.
Punch Checks
Replacing the Punch Pins

See Figure 2.25
The Fuji punch pins are able to cut at both ends by removing, turning and replacing them
during a service visit after checking if there are signs of burring around the punch holes.
Use the following procedure to obtain a clean cutting edge:
1. Remove the punch support plate and motor using the procedure in `Removing the Punch
Motor ' on page 2-53.
2. Gradually move the actuating lever until the stud appears at the stud clearance hole
(top).
3. Using an 8 mm Allen key (T-bar or right-angled key) remove the stud from the hole.
NOTE: The stud is secured by Loctite and requires extra force to break the seal.
4. Extract the pin from the pin clearance hole directly behind, turn the pin around and
replace.
5. Refit the stud (with Loctite) and screw down until it stops, then wind back back one half
screw turn.
6. Replace the punch motor support plate.
7. Check that the punch pins actuate correctly by manually moving the actuating lever.
CAUTION: Do not use the BM4 and BM5 motor commands. This could cause damage to
the wipers and eventually chad dropping into the drum.
ACTUATING
LEVER
ACTUATING
SHAFT
REMOVE
STUD
REMOVE
PIN
Figure 2.25 Servicing the punch pins
Removing the Punch Motor

This procedure is completed from the service side without removing the com-
plete punch assembly.
See Figure 2.26.

1. Disconnect the inline cables to the motor and sensors (BS8 and BS9).
2. Remove the punch motor support plate assembly with its motor and gear (4-off M5
bolts). You do not need to retract the pins beforehand.
3. When replacing the motor and plate assembly, add a small amount of light engineering
grease to the cam/lever slot hole. Make sure the DC wires are correctly orientated.
4. Check that the punch pins actuate correctly by manually moving the actuating lever.
CAUTION: Do not use the BM4 and BM5 motor commands. This could cause damage to
the wipers and eventually chad dropping into the drum.
PUNCH MOTOR
BS8
SUPPORT PLATE
(ON)
MOTOR/GEAR BS9
(BM4) (OFF)
Figure 2.26 Punch bracket and motor
Replacing the Chad Wipers

See Figure 2.27.
Chad wipers, made of Beryllium copper, are replaced every six months to avoid the
build-up of chad at the punch exit. Use the following procedure:
1. Remove the punch deflector shield.
2. Remove the wiper with its snap rivet.
If the punch is a a DS type then trim the wiper for the round punch holes, as
shown in Figure 2.27.
3. Refit the wiper and rivet making sure it is seated on top of the bracket.
Refit the shield.
4. Run a plate job from the RIP and check that the chad does not drop into the
drum.
CHAD
WIPER
SNAP
RIVET
PUNCH DIE
6 mm
CHAD
CUT CUT WIPER
WIPER
MOUNTING
BRACKET
DS (ROUND) CHAD DEFLECTOR
WIPER TRIM SHIELD
Figure 2.27 Removing the chad wiper
2.4.9 Swing Roller Module (SRM)

NOTE: Removal is a two-man operation. You do not need to remove the complete module
to service the motor and sensors.
2.4.9.1 Swing Roller Module Replacements

The swing roller module (SRM) is located on the drum casting.
1. Move the traverse carriage to its extenders.
3. From the service end, detach the two sensor connectors and motor.
4. Lower the Buffer to its service position, see Section 2.5.1
6. Remove the output module and guide plate, see Section 2.4.4.1.
7. Remove the 4-off M5 Allen screws holding the SRM side plates to the drum
casting.
SIDE
PLATE
PLATE
GUIDE
DRUM
CASTING
REGISTRATION
MODULE
BACK
STAY
Figure 2.28 Removing the swing roller module

9. Carry out a plate check described below.
2.4.9.2 Swing Roller Module Checks

Correct operation of the module depends on the height of the media, see Vol-
ume 2 Section 2.3.1.4 (large plates) and Volume 2 Section 2.3.1.5 (small plates).
1. Load a plate into the drum as an expose job and check that the spring rollers
push the plate into the drum at the correct sequence for large and small plates.
2. Make sure the critical timing sequence operates where the spring rollers contact
a small plate as the plate contacts the registration pins.
2.4.10 Registration Module

2.4.10.1 Registration Module Replacement
NOTE: This module is never removed from an installed system. It is factory-fitted to an
exact specification and should not need to be serviced in the field unless the motor or
sensors require replacing.
To access the module:

3. Remove the output module and guide plate, see Section 2.4.4.1.
2.4.11 MMI
2.4.11.1 MMI ReplacementM
The console (including MMI board, LCD, Inverter and touchpanel) is supplied
and fitted as a complete FRU assembly. The internal assemblies are similar for
all variants.
1. Switch off the machine.
2. Remove the 4-off M4 screws at the back of the MMI.
3. Lift off the front panel.
4. Disconnect the cable to SK4.
5. Replace the new console and check that it shows the correct display when the
system is switched on.
2.5 Buffer Servicing

The Buffer is fitted on all B1 variants except for the B1 Manual machine. Note
that the removal and replacement procedure are similar for the fully- and semi-
automatic systems. Later Buffer modules are without a sliding labyrinth but
have a removable upper cover, allowing improved access to assemblies.
2.5.1 Lowering the Buffer

See Figure 2.29.
Lowering the Buffer to its service position (in a vertical position attached to the
Processor) allows access to the Buffer assemblies and rear Engine assemblies.
1. Remove the Buffer interlocked top cover and disconnect the three cable
connections to the Engine, see Figure 3.73.
NOTE: new Buffers do not have a labyrinth.
PROCESSOR ENTRY
SHOULDER LOWER
SCREW
FIXING
BUFFER
a) LOWER BUFFER FROM ENGINE
SERVICE SIDE
TOP VIEW OF BUFFER WITHOUT SKINS
ENGINE
ENTRY
SLIDE
LABYRINTH *
SLIDE ADJUSTER
BUFFER FIXING FIXING HEIGHT
ADJUSTER RAIL SCREW (1) SCREW (2) ADJUSTER
SERVICE SIDE
b) DISCONNECT BUFFER FROM ENGINE LABYRINTH
* LABYRINTH
NOT FITTED ON
LATER MACHINES
Figure 2.29 Lowering the Buffer (old)

PROCESSOR ENTRY
SHOULDER RAISE
SCREW
FIXING
BUFFER
a) CONNECT BUFFER TO PROCESSOR
SERVICE SIDE
TOP VIEW OF BUFFER WITHOUT SKINS
ENGINE
ENTRY
STRETCHER
BAR
SLIDE ADJUSTER
BUFFER FIXING FIXING
ADJUSTER SCREW (1) SCREW (2) SERVICE SIDE
b) RAISE BUFFER TO ENGINE

c) SLIDE ADJUSTER ACROSS TO ENGINE
Figure 2.30 Lowering the Buffer (New)
2. Old Buffer: loosen the 2-off M6 screws holding the slide adjuster rail inside the
Buffer, slide the rail back and tighten.
3. Old Buffer: push back the labyrinth from the Engine interface.
4. New Buffer: remove the upper cover, see Section 2.5.2.1, and slide the adjuster
rail towards the Buffer.
5. While supporting the Buffer, repeat step 2 on the other side.
6. Lower the Buffer.
7. The Buffer is now supported by two M5 shoulder screw fixings on the Processor
allowing access to Buffer assemblies.
2.5.2 Accessing the Buffer Assemblies

See Figure 2.31.
DRIVE BELTS/ROLLE
I/F CONNECTORS SENSORS
MOTOR
SERVICE SIDE
USER SIDE
Figure 2.31 Accessing Buffer assemblies
Figure 2.31 above shows how to access the Buffer when replacing an FRU
assembly.
If you need to move the Buffer to its service position (detached from the
Engine), use the information in Section 2.5.1.
2.5.2.1 Removing the Upper Cover (Skin)

See Figure 2.32.
Removing the upper cover (New Buffers only) gives better access to the motor
and gear mechanisms.
1. Remove the top interlocked cover.
2. Detach the three cable connectors from the Engine interface, see Volume 2
Figure 3.73.
3. Remove the 4-off screws holding the upper cover to the frame and lift off the
cover (two-man lift).
SERVICE SIDE
CONNECTOR I/F EB
BUFFER ENTRY
ON ENGINE
Figure 2.32 Buffer-to-Engine interconnections (new)
2.5.3 Motor, Gear and Sensors

See Volume 2 Section 3.1.5 on plate handling.
2.5.3.1 Motor Replacement

1. Open the Buffer cover.
2. Disconnect the three interface cables to the Engine, see Volume 2 Figure 3.73.
3. Remove the 4-off M3 screws holding the motor/gearbox to the chassis, see
Volume 2 Figure 3.69.
4. Unclip the cable back to the BUFF_M7 connector.
5. Remove the motor and drive gear as a single assembly.
6. Fit the replacement motor and drive gear as a single assembly. Ensure that the
grubscrews (2-off M1.5) securing the drive gear to the motor spindle are at a
torque greater than 14 kg/cm to avoid slippage.
7. Restore the Buffer assembly to its operating position and reconnect the cables.
8. Check the motor operation by feeding a plate to the Processor.
2.5.3.2 Gear Replacement

3. Loosen the roller bearing retaining clips.
4. Roller gears are removed by extracting their circlips.
5. Drive gears are removed by taking out the M3 cap head screws.
6. Replace the defective gear wheel and refit the M3 cap head screw or circlip, as
necessary.
7. Check the operation of the drive by feeding a plate into the Buffer.
2.5.4 Drive Belts and Rollers

2.5.4.1 Drive Belt Replacement
3. Remove the broken belt and move the working belts to the service side to leave
space where the new belt will be fitted.
4. Loosen the two bearing retainer clips on each roller on the user side.
5. Lift out each roller and fit the replacement belt.
6. Refit the rollers back into their bearing slots.
7. Remove the 2-off M4 screws holding the plate ramp to the side plate and fit the
replacement belt.
8. Adjust the belts to their correct positions on the rollers.
9. Refit the bearing retainer clips.
10. Check that the rollers operate by feeding a plate through the Buffer.
2.5.4.2 Roller Replacement

NOTE: Replacement rollers have their bearings already fitted.

2. If necessary, lower the Buffer to its service position, see Section 2.5.1.
3. Release the bearing retainer clips (M3 Allen) at each end of the roller.
4. Slide out the roller from the drive belts.
5. Fit the replacement roller by sliding it through the belts and into its chassis
mounts.
6. Refit the retainer clips and secure.
7. Re-position the drive belt to the drive wheels.
8. Check the operation of the assembly by feeding a plate into the Processor.
2.5.5 Buffer Alignment Check

After returning the Buffer assembly to its vertical position, check that the height
of the first Buffer roller is aligned correctly to the Engine output module guide
plate.
Volume-Chapt er
TRAVERSE SCAN SERVICE

PROCEDURES
This chapter describes how to replace and set up assemblies on the traverse carriage.
4
4
Starting Scan System Replacements ....................................................................... 3-1
4
Accessing Traverse Scan Modules .......................................................................... 3-1
Replacing Traverse Assemblies ............................................................................... 3-4
3.1 Starting Scan System Replacements

NOTE: Ensure that the platesetter is powered off at the mains outlet but is still connected
to maintain Earth/Ground continuity if there is a risk of static damage to the Traverse
PCB.
All screw fixings must be replaced with their captive washers (spring and flat), if they are
initially fitted.
Make sure all cables are properly clamped and tie-wrapped with adequate slack for
removing connectors. Check that they are not trapped or mechanically pinched.
3.2 Accessing Traverse Scan Modules

The traverse carriage assemblies are accessed from the service end as follows:
1. Shutdown the machine and remove mains input power from the mains
distribution outlet.
2. Open and lift off the service side cover on the Engine.
3. Release the posidrive screw holding the mixer fan bracket, swing the bracket to
one side and remove the drum end cap.
4. The carriage is positioned at the service (home) end ready for a service
procedure, see Figure 3.1.
VOLUME 3 (3-2) TRAVERSE SCAN S ERVICE P ROCEDURES
TRAVERSE MOTOR
TRAVERSE BEAM
FLYWHEEL
TRAVERSE
READHEAD CARRIAGE
DRIVE RAIL
TRAVERSE PCB
EDGE
DETECT
(LASER/PCB)
SPINNER
BAFFLE
(FIXED)
SERVICE SIDE NOTE: END CAP REMOVED
Figure 3.1 Accessing traverse assemblies - service end view
The traverse mechanisms are manufactured and assembled to a high level of

precision to ensure correct exposure registration over the long term. While
replacing a traverse part there is always a risk of contamination or damage to
important mechanisms. Service engineers need to handle traverse assemblies
carefully and gently, while making sure that the carriage and rails are kept clean.
CAUTION: Failure to follow the correct replacement procedures can cause exposure
errors.
As a final task, at the end of each one of these procedures, return the carriage to
the rail and make sure that the ball cage and carriage are aligned correctly, see
Volume 3 Section 1.7.2.
3.2.1 Traverse Carriage Access

See Figure 3.2.
Depending on the assembly to be serviced, you can either:
1. Move the carriage to the end of the extenders to replace the following items
while the carriage is located on the extenders:
A) Fixed (PCB) Baffle: see Section 3.3.1.
B) Traverse PCB: see Section 3.3.2.
C) Drive Rail Wiper: see Section 3.3.4.
D) Umbilical Cable: see Section 3.3.5.
E) Spinner: see Section 3.3.6.
F) Ball Cage: see Section 3.3.7.

G) Readhead: see Section 3.3.8.
H) Edge Detect PCB and laser: see Section 3.3.9.
2. Remove the complete carriage from the service extenders and position it on a
suitable work surface to replace the Traverse Motor, see Section 3.3.3.
BEAM
UMBILICAL
TRAY
SERVICE
EXTENSION
(V-GROOVE)
END STOP
DRIVE
RAIL
SERVICE
EXTENSION
(FLAT)
Figure 3.2 End of rail and extenders
Moving the Carriage to the Service Extenders

Use the following method to move the carriage onto service extenders:
1. Secure the push bar in its Home position.
2. Follow the steps in Section 3.2 to access the carriage.
3. Pull the carriage by hand along the rail towards the service end.
4. Release the push bar motor cable attached to the end stop (P-clip) and secure it
out of the way.
5. Remove the 2-off M6 Allen caphead screws holding the end stop underneath the
beam and remove the stop bracket.
6. Fit the two extenders (V-groove and flat) to the end of the rail. (The extenders
are normally stored inside the Engine). Use the screw fixings shown in
Figure 3.2.
7. Hold the carriage by its casting and pull it very carefully on to the extenders.
The ball cage will stop at the end of the V-groove rail.
At this point, you can start to remove the carriage assemblies listed above.
Removing the Carriage from the Platesetter
1. To replace the motor, you will need to remove the entire carriage assembly from
the extenders.
2. Release the umbilical cable from the Traverse PCB and its support bracket, see
Section 3.3.5.
CAUTION: Do not hold the traverse carriage by its flywheel, spinner, L6 lens or readhead.
Make sure the motor drive shaft and beam actuators are not knocked or damaged while
removing the carriage.
3. Grip the carriage by its casting or the baffle and lift away.
4. Place the carriage on a nearby work surface with thick cardboard or a cloth
underneath. The baffle can be positioned to hangover the side of the surface
holding the traverse casting.
At this point, you can start to remove the motor.
Replacing the Carriage in the Platesetter
1. Put the carriage back on the extenders.
2. Make sure all the connectors are fitted after the service procedure.
3. Replace the umbilical cable.
4. Move the carriage from the service extenders onto the V-groove rail. Carefully
slide the carriage back into the drum until the ball cage appears in the V-groove
underneath the carriage.
5. Replace the end stop and push bar motor cables.
6. Remove and store the service extensions.
7. Complete the ball cage and carriage alignment procedure in Volume 3 Section
1.7.1 and then the cage creep check.
3.3 Replacing Traverse Assemblies

3.3.1 Baffle Assemblies
See Figure 3.3.
This procedure is completed from the user end and while the carriage is on the
extenders.
1. Push the carriage to the user side to access the removable baffle.
a) REMOVEABLE BAFFLE
REMOVEABLE
BAFFLE
FINGER-TIGHT SCREW
(2-OFF)
USER SIDE
b) FIXED BAFFLE
SERVICE SIDE
FIXED
BAFFLE
M5 SCREW
(4-OFF)
Figure 3.3 Removing the baffles (removable and fixed)

2. Remove the baffle using the two finger-tight screw fixings.

3. Push the carriage back to the service end and move it onto the extenders, see
Section 3.2.1.
4. Remove the Traverse PCB, see Section 3.3.2.
5. Remove the PCB support bracket by removing its 6-off M4 caphead screws.
Reposition the bracket to one side.
6. Remove the 4-off M5 screws holding the fixed baffle to the near and front
brackets.
7. Replacement is the reverse of the removal procedure.
3.3.2 Traverse PCB

CAUTION: When touching or handling the PCB, make sure all antistatic precautions are
followed.
The Traverse PCB, located on spacers on the support bracket and baffle, is
removed from its mounting while the carriage is on extenders.
1. Disconnect the umbilical cable (PL10), see Section 3.3.5.
2. Disconnect all other board cable connectors.
3. Remove the 4-off M3 caphead screws holding the PCB to the baffle and support
bracket.
4. Slide the PCB out of the support bracket.
6. Download the firmware level on the newly-installed Traverse PCB to match the
levels on the other PCBs. If they do not match, the system will not function
correctly. See Volume 2 Section 1.12.
7. Update the machine system registry file:
test/registry> update_registry system
8. Expose and test a plate to confirm correct operation.
3.3.3 Traverse Motor

See Figure 3.4.
For this procedure you need to remove the carriage from its extenders, see Sec-
tion 3.2.1, and place it on a work surface.
CAUTION: Make sure the motor shaft is not damaged.
1. Disconnect the motor cable (PL1) from the Traverse PCB.

2. Release the P-clip holding the readhead and motor cables.
3. Detach the flywheel from the motor assembly by removing the 2-off M2.5
caphead screws from the clamp inside and pulling away the wheel.
4. Remove the motor and support casting as a single field replaceable unit (FRU)
by removing the 3-off screws holding the assembly to the casting.
5. Replacement is the reverse of the removal procedure. Make sure the traverse
initialises correctly on power up and then expose a test plate.
MOTOR
BEARINGS FLYWHEEL
SHAFT
BEARING
PLATE
FLYWHEEL
NOTE: THE TRAVERSE MOTOR/SUPPORT CASTING CLAMP
IS REPLACED AS A COMPLETE FRU
Figure 3.4 Flywheel and motor - exploded view
3.3.4 Drive Rail Wiper

See Figure 3.5.
The wiper forms a housing over the motor shaft and is detached from the motor
support casting while the carriage is on the extenders.
1. Move the carriage onto the extenders, see Section 3.2.1.
2. The wiper is fixed by 2-off M4 caphead screws. Loosen (but do not remove) the
screws and lift out the wiper assembly.
3. Clean the wiper felt. Replace the wiper if the felt is worn or damaged.
4. Replacement is the reverse of the removal procedure:
A) clip the wiper to the Allen screws
B) while pushing on the wiper with a finger, tighten the two screws.
FLYWHEEL
SHAFT
WIPER
MOTOR
SUPPORT
CASTING
Figure 3.5 Accessing the drive rail wiper
3.3.5 Umbilical Cable

See Figure 3.6.
This cable can be replaced while the carriage is located on extenders.
1. Disconnect the cable end from SK2 on FHMB (4) by pressing down on the
connector clip with the thumb and pulling out the cable.
2. Remove the cable clamp (M4 screws) holding the cable to the tray.
3. Working from the top, gently remove the cable from the bracket by loosening it
from the button clips.
4. Disconnect the cable end from PL10 on Traverse PCB.
5. Replacement is the reverse of the removal procedure. replace the cable by
working back from the PCB and fastening under the button clips. Make sure the
cable is squarely located under the two clamps.
6. Check that the carriage moves up and down the drum correctly and the cable
runs squarely in the tray. Make sure the traverse initialises correctly on power
up.
BUTTON
CLIP
TO
FHMB (4)
PCB SUPPORT
BRACKET
UMBILICAL
CABLE
TRAVERSE
PCB
Figure 3.6 Fitting the umbilical cable
3.3.6 Spinner
CAUTION: Read the spinner disposal notices in Volume 1 Section 3.2.18 before starting
this procedure.
See Figure 3.7.

This assembly can be removed while the carriage is located on service extend-
ers. To obtain the exact location of the replaced spinner on the casting, follow
this replacement procedure carefully. Not completing the procedure correctly
could result in scan misalignment.
1. Detach the two connectors (PL4 and PL5) from the Traverse PCB to the spinner.
2. Detach the umbilical cable from the PCB and the first clip on the bracket, and
move to one side.
VOLUME 3 (3-10) TRAVERSE S CAN S ERVICE P ROCEDURES
CARRIAGE DOWELS
CASTING
PADS
(4-OFF)
1 LOCATE ON THE
FOUR PADS 2 ROTATE TO
ENGAGE LUG
VIEW ON ARROW A
LUG
LUG
SPINNER
3 SCREW SPINNER CLAMPS

INTO POSITION
SPINNER
CLAMP
A
CLAMP DOWEL SPINNER
Figure 3.7 Re-fitting the spinner
3. Loosen the 4-off M4 screws holding the spinner spring clamps to the casting.
4. Extract the spinner by rotating it anticlockwise and drawing it back.
5. Replace the new spinner as follows (see Figure 3.7):
A) Insert the spinner between the clamps so that the lug is top left of centre (1).
B) Rotate the spinner clockwise to engage the lug behind and left of the dowel
pins on the casting (2).
C) Hold the spinner in position with one thumb, grip the casting with the other
four fingers so that it does not move, and tighten the spring clamp screws
(3).
6. After replacing the new spinner, make sure that it is aligned exactly as the old
spinner. It should fit accurately onto the four pads, as the spring clamps are
closed, and then secured without the need for further checks. Push the spinner
very gently against the four pads and check that there is no movement.
7. Reconnect the cable connectors to the Traverse PCB.
8. Run the following optical checks for:
A) Focus and Beam Deflection Absolute Phase (see Volume 3 Section 4.4).
B) Image Form Adjustment (see Volume 3 Section 1.8.1.1).
C) Image base offset (see Volume 3 Section 1.8) for the type of machine.
D) Traverse centre position (see Volume 3 Section 1.8.2.5) or check edge detect
sensor offset for the type of machine.
3.3.7 Ball Cage Assembly

CAUTION: This assembly is very accurately assembled. Always make sure that it is sup-
ported at each end and is not flexed.
9. Place the carriage on the extenders.
CARRIAGE
RAIL
BALL CAGE
TRAVERSE
RAIL
Figure 3.8 Replacing the ball cage
10. Push the ball cage to the user end.

11. Lift out the ball cage strip and replace, making sure that the cage is fitted as
shown in Figure 3.8 with the vertical strip uppermost.
12. Setup the ball cage and carriage alignment, see Volume 3 Section 1.7.2.
3.3.8 Readhead
CAUTION: When touching or handling the readhead, make sure all antistatic precautions
are followed.
See Figure 3.9.

The following item is required:
Plastic feeler (Renishaw part no. M-9517-0122) supplied with the readhead part
or as a service tool. Do not use any other type of feeler.

Follow the procedure below:
1. Place the carriage on the extenders, see Section 3.2.1.
2. Release the P-clip holding the readhead and motor cables and disconnect the
cable from the Traverse PCB (PL2).
3. Remove the 2-off M4 screws holding the readhead bracket to the motor support
casting and remove the readhead from the bracket.
4. Replace the new readhead onto the bracket and refit the bracket. Make sure that
the bracket is fitted to the casting in its uppermost slot position to give
maximum clearance between the head and the scale.
5. Do not tighten the two screws.
6. Return the carriage to the drive rail and move it to the user end.
7. Insert the feeler between the scale and the readhead, then gently press the head
down to give a sliding fit.
8. Tighten each screw in turn, a little at a time, to avoid moving the readhead.
Check again for a sliding fit with the feeler.
9. Refit the cable in the P-clip and reconnect the readhead cable to the Traverse
PCB. Ensure the readhead cable is not bent at an acute angle.
11. Check that the readhead LED is green over the full length of travel. (The LED
should be visible along the drum from the user end).
If not, repeat Steps 7.to 10. until this condition is reached.
NOTE: When the carriage arrives at the Index actuator, the LED blinks red or orange and
off. These indications are correct and show that the head has `recognised' the actuator.
READHEAD TRAVERSE MOTOR

SUPPORT SUPPORT FLYWHEEL
BRACKET
READHEAD
DRIVE RAIL MOTOR
INSERT
FEELER
LINEAR
SCALE
Figure 3.9 Fitting the readhead
3.3.9 Edge Detect PCB and Laser Diode

3.3.9.1 Check Edge Detect Function
Check that the plate edge detect is able to operate as follows:
1. Reboot the Engine.
main> diagnostics/service/traverse> halt
traverse>medirq
Check that the Edge Detect PCB laser beam is ON.
3. Load a plate into the drum and move the traverse by hand so that the edge
detect beam moves across the plate edge.
4. Check that the LED on the Edge Detect PCB is OFF when the beam is on the
plate and ON when the beam is on the drum.
5. Press Ctrl-c to exit medirq.
3.3.9.2 Replacing the Edge Detect PCB

See Figure 3.10.
1. Move the traverse onto the service extenders.
2. Disconnect the PCB connectors.
3. From the service end, remove the PCB bracket.
4. Remove and replace the PCB.
5. Align the PCB so that its mounting screw is central in the PCB bracket slot.
6. Switch on the machine and reset the reset the voltage gain using the procedure
in Section 3.3.9.4 (steps 7 to 19).
7. Carry out the edge detect check in Section 3.3.9.1.
REAR
BRACKET LASER
FRONT LASER LENS
BRACKET
BRACKET
PCB
PCB
BRACKET
TRAVERSE
BAFFLE
Figure 3.10 Edge Detect PCB and laser assemblies
8. Check that the image is 1 mm 25 microns from the plate edge using the
procedure below. A typical value is 3,500 microns. Increase the value to push the
image further onto the plate.
A) Open the optics_mmi setup screen from:
main>diagnostics/service/optics/optics_mmi
B) Run a test pattern with the Scan Start position as 0 mm.
C) Eject and process the image and check that it is exactly 1 mm from the edge
of the plate.
D) If it is not then find the current parameter EDGE_SENSOR_OFFSET value
(in microns) as follows:
diagnostics/log_utils> disp_nvram <EDGE_SENSOR_OFFSET>
E) If the image is more than 1 mm then decrease the parameter value; if it is less
than 1 mm then increase the parameter value. Use the following command:
diagnostics/log_utils/nvram> wr_edge_sensor_offset <required offset in microns>
Repeat this command until the offset is correct.
3.3.9.3 Replacing the Laser Diode

See Figure 3.10.
1. Detach the removeable baffle at the MMI end and move the traverse to the
service end.
2. Slide the traverse onto its service extenders.
3. Disconnect the cable from the back of the laser, detach the laser bracket and
remove the old laser.
4. Fit the new laser to the bracket as follows:
A) Screw the laser (without the lens) to the bracket so that the connector is at
the top right-hand corner (looking from the back).
B) Insert the spring washer.
C) Screw the lens to the laser until it is securely held by the spring washer, and
then slowly turn it back to its fixed position shown in Figure 3.11:
LENS
LASER
BRACKET
WASHER
Figure 3.11 Laser lens fixing position

NOTE: If the lens window has been handled or looks marked then clean with cotton buds
and IPA.
5. Refit the bracket and laser.

6. Follow the setup procedure in Section 3.3.9.4.
3.3.9.4 Edge Detect Setup Procedure

See Figure 3.10.
NOTE: Supplied lasers are pre-focused at the factory to obtain the required laser spot
size.
1. Reboot the machine if you have been running optics_mmi test patterns.
2. Move the traverse to a set position at the service end:
traverse/datum
traverse/goto pos=-1200000
3. Switch on the laser and release the traverse:
traverse> medirq
traverse/halt
4. Set the vertical position of the laser on the drum. Slacken the 2-off screws
holding the laser bracket and rotate the laser until the beam is in the centre of
the gap between the leading and trailing edges vacuum grooves, see Figure 3.12.
Retighten the bracket screws.
LASER
BEAM
LE VAC
GROOVES
GAP
DRUM TE VAC
GROOVES
Figure 3.12 Positioning the laser beam

ALIGNMENT TOOL
BETWEEN GROOVES
TURN
LENS
(A) (B)
BEAM IN OFFSET BEAM IN VERTICAL
POSITION POSITION
Figure 3.13 Aligning the laser beam
NOTE: Make sure the line formed by the lens is exactly aligned with the vacuum grooves.
An error of 2.5 degrees will affect edge detect performance.
5. With alignment tool: Insert the alignment tool into a groove and check that the
beam is vertically aligned with the tool markings, see Figure 3.13:
Loosen the lens until the line formed by the lens is aligned with the lines on the
tool. The angle of the line on the face of the tool must be within 1 mm at points
10 mm either side of the centre of the tool.
6. Without alignment tool: Adjust the lens until it is vertical. It should align exactly
to the vacuum grooves above and below the edge detect gap. Stray light should
disappear into the grooves above and below the gap. You can check this by
gently moving the carriage. An error of 2.5 degrees will affect the repeatability
of the edge detect function.
7. Move the traverse to the datum point on the other side of the machine:
traverse/datum
8. Switch the multimeter to DC and connect to the test connectors to TP 2 and TP 4
(GND) on the Edge detect PCB, see Volume 2 Figure 4.10.
9. Turn the PCB potentiometer fully clockwise.
10. Load a small plate into the machine from the MMI.
11. Select traverse/halt to allow the machine to be moved by hand.
12. Select traverse/medirq to turn on the laser, if it is off.
13. Move the carriage until the spot is on the plate.
14. Adjust the potentiometer until the voltage reading is 1. 7 V.
15. Move the carriage until the spot is on the drum.

16. Make sure the DVM reading does not change by more than 0.1 V when working
in darkened conditions. Consult FFEI Customer Support if there is still a
problem.
17. Check that the voltage is greater than 2.6 V. If not, then tilt the PCB up a little so
that the right-hand screw is slightly higher than the centre position of the
adjustment slot.
18. Move the carriage back and forward over the plate edge. The LED should be
OFF when the laser spot is on the plate, and ON when the spot is on the drum.
19. Remove the plate. Set the following commands:
>verbose on
>medirq
20. Move the carriage the full length of the drum making sure the LED stays lit
without flickering.
Check that diagnostics error messages show that the laser has not tripped (that
is, changed state from drum to plate) during the entire travel to the other end.
The number of detect trips are shown as:
edge detect IRQ count: <trip numbers>
21. Complete the check in Section 3.3.9.2 (Step 8). The image should be 1 mm
25 microns from the plate edge. Adjust the NVRAM parameter,
EDGE_SENSOR_OFFSET, to start the image correctly. A typical value is 3,500
microns. Increase the value to push the image further onto the plate.
Volume-Chapt er
OPTICS SERVICE
PROCEDURES
This chapter describes how to replace optics field replaceable units (FRUs), how to
setup FRUs, run optics test strips and adjust image forms.
4
4
Starting Optics Module Replacements ........................................................... Page 4-1
4
Optics Replacement Setups ............................................................................ Page 4-3
4
Optics Base Replacements ........................................................................... Page 4-15
4
Exposing Test Strips ...................................................................................... Page 4-31
4
Check Raster Quality ..................................................................................... Page 4-50
4
Calibrate Exposure Level............................................................................... Page 4-51
B1 and B2 Image Form Adjustments ............................................................ Page 4-54
4.1 Starting Optics Module Replacements

CAUTION: Fixings in the optics base are marked with red paint are NOT disturbed to
avoid critical optical components becoming misaligned.
NOTE: Do not touch any optical surfaces such as mirrors and lenses. If a modules is
fixed to the baseplate with a shoulder bolt that has a spring and a washer, make sure that
its washer is replaced.
This chapter describes how to replace Field Replaceable Units (FRUs), how to
set them up and test them for correct operation:
Optics sensors - Section 4.3.1.
Optics motors - Section 4.3.2.
Laser Module - see Section 4.3.3.
EOD Module - see Section 4.3.4.
POD Module - see Section 4.3.5.
Optics base FRUs are accurately aligned with other optical mechanisms on the
engine at manufacture and should only be removed or adjusted using the rec-
ommended service procedures.
VOLUME 3 (4-2) O PTICS SERVICE PROCEDURES
After replacing an optics base module you will need to run the setup and diag-
nostic procedures shown in Table 4.1.
4.1.1 Accessing Expose Modules

CAUTION: On opening the optics modules enclosure, shown in Figure 4.1, fit the service
manifold tool (Part No 7A04975) to ensure that clean air from the PAT is distributed inside
the optics base.
Access the optics modules as follows:

Optics base: remove the appropriate enclosure cover to access a laser diode,
VBOMB, an optics module or the EODHV devices, see Figure 4.1.
Spinner: to access the traverse carriage assemblies, open the engine service
door and remove the drum end cap. The carriage can be removed after fit-
ting extension rails.
Periscope: to access the periscope assemblies (M1, M2 and LPD), open the
engine user door.
USER SERVICE
SIDE SIDE
VBOMB LASER MODULES OPTICS MODULES EODHV

(M4, 6-OFF) (M4, 8-OFF) (M4, 2-OFF)
AUTOMATIC SHOWN
Figure 4.1 Accessing the optics modules enclosure
After cleaning any of the optics base modules make sure the setup procedures in
Table 4.1 are carried out.
4.2 Optics Replacement Setups

After replacing an optics module you will need to carry out one of the setup/
test procedure(s) listed in Table 4.1 and the sections below.
NOTE: Note that this table shows the order of testing from top to bottom.
NOTE: If you are replacing the Focus, ND and LPD motors or sensors, run the setup
shown for the main module assembly shown in Table 4.1.
Table 4.1 Optics replacement setups chart

Modules:
Cleaning FPD, LPD,L6)
Aperture Assys
Laser (1-Laser)
Laser (2-Laser)
EODHV TX X/Y
Focus Assys
EODD PCB
LPD Assys
ND Assys
EOD X/Y
VBOMB
Spinner
EODHV
POD
FPD
Setups and Tests:
Find LPD position
(Section 4.2.1)
a
Update laser parame-
ters (Section 4.2.2)
aa
Clear laser aging stats
(Section 4.2.3)
aa
Set up laser current
limit (Section 4.2.4)
aa a
Check power balance
(Section 4.2.5)
a aa a a a
Set laser extinction
(Section 4.2.6)
aa a
Reset beam
coincidence
aa aaaa a
(Section 4.2.7)
Run Beam_co
(Section 4.2.8)
aaa aaaa a
Setup and locate FPD
(Section 4.2.9)
a
Setup ND characterisa-
tion (Section 4.2.10)
aa
Reset the spinner con-
tamination check
aa a
(Section 4.2.11)
Table 4.1 Optics replacement setups chart (Continued)

Modules:
Cleaning FPD, LPD,L6)
Aperture Assys
Laser (1-Laser)
Laser (2-Laser)
EODHV TX X/Y
Focus Assys
EODD PCB
LPD Assys
ND Assys
EOD X/Y
VBOMB
Spinner
EODHV
POD
FPD
Setups and Tests:
Exposure calibration
(Section 4.2.12)
aaaaaaaaaaaaaaa
Auto focus
(Section 4.2.13)
aaa a a
Auto ND wedge
(Section 4.2.14)
a a
Auto threshold wedge
(Section 4.2.15)
a a
Auto coincidence Y & X
(Section 4.2.16)
aa aaa a
Auto deflection abso-
lute phase for confi-
aaa
dence (Section 4.2.17)
Auto deflection abso-
lute phase setup
a
(Section 4.2.17)
Auto deflection ampli-
tude Y/X
aa aaa a
(Section 4.2.18)
Image form adjust-
ment (Section 4.2.19)
aa a
Expose calibration
(Section 4.2.20)
aaa aaaa a aa
Image base offset
(Section 4.2.21)
a
Edge sensor offset/trav
centre position
a
(Section 4.2.22)
Image check
(Section 4.2.23)
aa aaaaaaaaaaaa
4.2.1 Find LPD Position

Purpose of Setup:
To find the optimum position for reading power from the LPD.
Procedure and Typical Output:
1. Ensure the platesetter is fully booted and the MMI shows the system is in RUN
mode then enter:
edbg 24
diagnostics/service/utils> find_lpd_posn
to obtain:
no input - default lpd end = -294

****Laser scan params
****Laser scan params
laser drive = 1000 , bias = 539 , current limit = 394
Laser Enable server complete.
laser 1 shutdown state = FALSE
laser drive = 1000 , bias = 584 , current limit = 465
Laser Enable server complete.
laser 3 shutdown state = FALSE
lpd pos = -270, x beam power = 790.250000, y beam power = 732.250000

max pos = -278
ddbg 24
NOTE: The software utility above turns on all available lasers, tries various LPD stepper
motor positions and finds the best position for maximum power in both beams.
When fault-finding, run this utility to check if both lasers are able to turn on successfully
and laser light arrives at the LPD.
4.2.2 Update Laser Parameters

Purpose of Setup:
Inform machine software of the factory-set original operating conditions for the
new laser.
1. Run the command and edit values using the <backspace> key.
diagnostics/service/optics/laser> lcpd_params change

to obtain:
Original drive dac x val (dec) 1000

Enter the
Original bias dac x val (dec) 532 correct
parameters
Original current limit dac x val (dec) 384 here (using
Laser X Wavelength (dec) 405 <backspace> to
remove the
Original drive dac y val (dec) 1000 existing values).
Original bias dac y val (dec) 570
Original current limit dac y val (dec) 431
Laser Y Wavelength (dec) 405
CAUTION: Entering incorrect values can cause damage.
Original drive dac x val (dec) 1000 3e8

Original bias dac x val (dec) 539 21b
Original current limit dac x val (dec) 394 18a
Laser X Wavelength (dec) 405
Original drive dac y val (dec) 1000 3e8
Original bias dac y val (dec) 584 248
Original current limit dac y val (dec) 465 1d1
Laser Y Wavelength (dec) 405
4.2.3 Clear Laser Aging Statistics

Purpose of Setup:
To reset the historical laser aging data originally set for the replaced laser.
1. If you have changed X-beam laser then run:
diagnostics/log_utils>clear_laser_x_stat
diagnostics/log_utils>laser_x_stat
Date Laser current.

Oct 28 16:04:17 2002 1174
Jan 1 12:00:00 1998 0
Jan 1 12:00:00 1998 0
Jan 1 12:00:00 1998 0
Jan 1 12:00:00 1998 0
Jan 1 12:00:00 1998 0
2. If you have changed Y-beam laser then run:

diagnostics/log_utils/nvram>clear_laser_y_stat
diagnostics/log_utils/nvram>laser_y_stat
Date Laser current.

Oct 28 16:04:17 2002 1254
Jan 1 12:00:00 1998 0
Jan 1 12:00:00 1998 0
Jan 1 12:00:00 1998 0
Jan 1 12:00:00 1998 0
Jan 1 12:00:00 1998 0
NOTE: These should only show invalid dates and laser power values.
3. Reboot and allow the machine to fully reboot.
4.2.4 Set up Laser Current Limit and Start Aging Log

Purpose of Setup and Typical Output:
The laser current limit protects the laser in the event of external problems. The
Aging Log enables the engineer to check how quickly the laser is aging and
gives some guidance as to when it may fail.
Procedure:
1. Run the following command:
edbg 40
diagnostics/service/optics/laser>laser_aging
Original x current = 1212 read x current = 1260 end of life percentage = 50

Original y current = 1157 read y current = 1174 end of life percentage = 50
max rate of change = 7
about to do the x actual_rate calc.
last x current = 1259 read x current = 1260 actual +ve rate of change 0
about to do the y actual_rate calc.
last y current = 1175 read y current = 1174 actual +ve rate of change 0
previous x current limit = 415 new_current_limit x = 415
previous y current limit = 387 new_current_limit y = 387
ddbg 40
See also Volume 2 Section 1.10.4.1 for a description on how to use this com-
mand.
4.2.5 Check Power Balance (2-Beam Only)

Purpose of Setup:
To ensure that the 2-beams are at the same power level when they expose a
plate. Measured from the LPD, the power reading is equivalent to the power on
the plate.
Procedure:
1. Run the following command:
edbg 24
diagnostics/service/optics/laser> power_balance 48
2. Check that the power balance utility passes without error messages.
3. Check that the power balance utility passes without error messages.
4. Check that the power balance utility passes without error messages and enter:
ddbg 24
4.2.6 Set Laser Extinction

Purpose of Setup:
To set the required extinction ratio between the laser drive power and the laser
bias power for a required laser.
1. Measure laser extinction values for both lasers as follows:

2. The extinction ratios should be between 180 and 220 for both lasers (if fitted). If
they are not then adjust them as follows:
rent
4 to decrease the extinction ratio of a laser you need to increase the bias cur-
rent.
3. Adjust the bias current of the required laser(s) as follows:
numerical keys:
time.
laser.
This will update all the working laser bias values in NVRAM. Enter the
following:
diagnostics/service/optics/laser> set_bias_level change
VOLUME 3 (4-10) O PTICS SERVICE P ROCEDURES
Changing values


dec hex

Updating Values
4.2.7 Reset Beam Coincidence (2-Beam Only)

Purpose of Setup:
To carry out essential recalibrations of the optics.
1. Run the following command (development password is boxer.dev):
development/nvram> snv ORIGINAL_ND_P_POD 0
to obtain:
ORIGINAL_ND_P_POD updated...
Parameter | current | default |

min |
ORIGINAL_ND_P_POD 0/$00000000 0/$00000000
0/$0000
4.2.8 Run Beam Coincidence (2-Beam Only)

Purpose of Setup:
To cancel out misalignments within the optics up to the POD. This is added to
the Auto Coincidence Y and X set up to provide DC bias on the deflectors when
exposing.
Procedure:
1. Run the following:
edbg 19
diagnostics/test/optics> beam_co
2. Check that the beam coincidence utility passes without error messages and
enter:
ddbg 19
4.2.9 Set up and Locate FPD

Purpose of Setup:
To inform the machine of the characteristics of the new FPD to ensure accurate
exposure calibration.
1. Boot the platesetter and wait until the MMI indicates RUN mode.
2. Enter the following command (development password is boxer.dev):
development/nvram> snv FPD_GAIN <factory value>
to obtain:
FPD_GAIN updated...
Parameter | current | default | min |

FPD_GAIN <Factory value> 10.000000 1/$0001
where the <factory value> is a value of about 10.0 determined at the factory and
written on the FPD PCB.
3. Enter:
edbg 23
and run the following:
diagnostics/service/utils> setup_fpd_offset
diagnostics/test/spinner> locate_FPD
to obtain:
6: High speed detector value = 911 at position 10000

ETC

8: Start of Detector found at 1000 microns
ETC
14:Fast Photo Locator - Fast Photo Diode centered at -3750 microns

14:Fast Photo Locator - Fast Photo Diode centered at -3750 microns
14: Fast Photo Locator - NV_TRAV_HIGH_SPEED_POS set to -3750 microns
14:Fast Photo Locator - NV_TRAV_HIGH_SPEED_POS set to -3750 microns
4. Enter:
ddbg 23
4.2.10 Set up ND Characterisation

Purpose of Setup:
To inform the machine how power, measured on the LPD, varies with the ND
filter position and thereby ensure accurate exposure calibration.
Procedure:
This procedure is now described in Section 4.8 on page 4-63
4.2.11 Reset Spinner Contamination Checks

Purpose of Setup:
Spinner contamination checks tell the operator when to clean the spinner. This
routine sets the level of light after the spinner has been cleaned.
Procedure:
1. Clean the spinner.
2. Run the command:
diagnostics/log_utils/nvram> reset_spin_clean_level
4.2.12 Run Exposure Calibration

Purpose of Setup:
To set up the ND filter position for correct power on the plate before setting up
the optics.
Procedure:
Follow the procedure in Section 4.6 on page 4-51 below.
4.2.13 Set up Auto Focus

Purpose of Setup:
To set up the correct focus of the laser beam(s) on the plate for best image qual-
ity and dot sharpness.
Procedure:
Follow the procedure in Section on page 4-38.
4.2.14 Set up Auto ND Wedge (2-Beam Only)

Purpose of Setup:
To set up the correct level of laser power for exposing the deflection coincidence
and absolute phase test plates.
Procedure:
4.2.15 Set up Auto Threshold Wedge (2-Beam Only)

Purpose of Setup:
To set up the correct level of laser power for exposing the deflection amplitude
test plates (at the plate threshold).
Procedure:
4.2.16 Set up Auto Coincidence Y & X (2-Beam Only)

Purpose of Setup:
To set up the correct value of DC deflection to cancel out misalignments
between the POD and the plate. This is added to the beam_co values to provide
DC bias on the deflectors when exposing.
Procedure:
Follow the procedures in Section on page 4-42 and Section on page 4-44.
4.2.17 Run Auto Deflection Abs Phase (2-Beam Only)

Purpose of Setup:
To minimise AC deflection in the fast scan direction and to maximise it in the
slow direction.
Procedure:
Follow the procedure in `6: Auto Absolute Phase ' on page 4-45.
4.2.18 Run Auto Deflection Amp Y&X (2-Beam Only)

Purpose of Setup:
To set up the AC component of deflection which cancels out the undesirable
deflections caused by the spinner.
Procedure:
Follow the procedures in Section on page 4-47 and Section on page 4-49.
4.2.19 Adjust Image Form

Purpose of Setup:
To ensure that the image on the plate is square.
Procedure:
Follow the procedure in Section 4.7 on page 4-54 (for B1 and B2 plates).
4.2.20 Run Expose Calibration

Purpose of Setup:
To set up the ND filter position for correct power on the plate before image qual-
ity checks and returning the machine to the customer. Note that the setups car-
ried out since the previous calibration may have altered calibrated ND values.
Procedure:
Follow the procedure in Section 4.6 on page 4-51.
4.2.21 Image Base Offset

Purpose of Setup:
To adjust the horizontal position of the image on a plate.
Procedure:
Follow the procedure in Section 1.8.2.6 on page 1-22 and Section 1.8.3.4 on
page 1-25.
4.2.22 Edge Sensor Offset/Traverse Centre Position

Purpose of Setup:
To adjust the lateral position of the image on a plate.
Procedure:
Follow the procedure in Section 1.8.3.5 on page 1-26 and Section 1.8.2.5 on
page 1-21
4.2.23 Check Image Quality

Purpose of Setup:
To check that the quality of the platesetter output is satisfactory before returning
the machine to the customer.
Procedure:
1. Expose a standard Fujifilm Screen and Tint page from the RIP using a Fujifilm
Quality Screen. This page is supplied from the RIP CD during the machine
installation.
2. Assess the resulting plates for image quality using the guidelines included in
the image.
Refer to Section 4.5 on page 4-50.
4.3 Optics Base Replacements

the optics base.
The optics base replaceable assemblies consist of:

Sensors - 5 sensors (S1-S5) - see Section 4.3.1.
Motors - 4 motors (SM1-SM4) - see Section 4.3.2.
Optics modules - laser, EOD and POD.
After replacing an optics module inside the optics base or RFI box, check for the
appropriate setup and diagnostic procedures shown in Table 4.1. Check for the
MODULE name in the lefthand column and run the SETUP ticked for each row.
4.3.1 Optics Base Sensors

The four FRU sensors fitted inside the optics base are:
S1: Neutral Density Filter.
S2: Focus Limit.
S3: Focus Home.
S5: Aperture Home.
The Laser Power Detector Home (S6) is fitted as part of the LPD.
4.3.1.1 Replace Optics Base Sensors

All sensors in the optics base are opto-slotted and have identical mountings.
1. Disconnect the 3-wire connector to the sensor.
2. Using a 3 mm Allen key, unscrew and remove the Allen screw securing the
sensor to its mounting point.
NOTE: The Allen screw for sensor, S3, is difficult to access and requires a right-angled
Allen key.
3. Fitting the new sensor is the reverse of the above.
4.3.1.2 Setup Optics Base Sensors

S2/S3 (Focus)
1. Carry out the setups for the Focus Assys in Table 4.1.
2. Output a typical customer job and check for quality.
S5 (Aperture)
Setups are not required.
S1 (ND Filter)
1. Carry out the setups for the ND Assys in Table 4.1.
2. Output a typical customer job and check for quality.
4.3.2 Optics Base Motors

This section describes how to remove the following optics motors:
SM1: ND Filter (The motor is replaced as part of the ND Filter assembly).
SM2: Focus Adjust.
SM3: Aperture Control.
SM4: Laser Power Detector.
the optics base.
4.3.2.1 ND Filter Assembly (Including SM1)

NOTE: As the motor gear mesh and filter are set up at the factory, the complete assembly
is replaced if the motor fails.
Replace ND Filter Assembly

1. Shutdown the platesetter.
2. Access the optics modules enclosure (fit the PAT and optics service manifold).
3. Disconnect the inline connectors from the motor and sensor.
4. Remove the 3-off M3 screws holding the module to the base, see Figure 4.2.
5. Inspect the new ND filter assembly for dust and clean with a puffer, if
necessary.
6. Fit the new ND filter assembly to the dowel pin and secure using the M3 screws.
7. Reconnect the motor and sensor.
8. Replace the optics module enclosure cover.
9. Switch on the platesetter and setup the filter.
Setup ND Filter Assembly

1. Carry out the setups for the ND Assys shown in Table 4.1.
2. Output a customer job and check for quality.
SENSOR (S1)
SENSOR
STAY BRACKET
MOTOR
BRACKET
ND FILTER
FILTER
WHEEL
MOTOR
(SM1)
OLD BASE
FIXING
NEW BASE
LOCATING FIXING
DOWEL
Figure 4.2 Replacing the ND filter
4.3.2.2 SM2 (Focus Adjust)

Replace SM2
See Figure 4.3.
2. Access the optics base interior.
3. Disconnect the inline connector from the motor and sensor. Note the orientation
of the motor connections.
4. Remove the focus adjust cover (3-off screws) secured to the adjust mounting.
5. Remove the 2-off 3 mm caphead screws (3 mm Allen key) holding the motor
bracket to its mounting point.
6. Unclip the spring.
7. The motor shaft is fixed to a gear wheel. Remove the bracket and attached
motor, taking care to allow the gear wheel to pass through the metalwork hole.
8. Remove the 4-off crosshead screws securing the motor to the bracket.
9. Remove the gear from the motor shaft.

10. Replacement is the reverse of removal. Make sure the gear is replaced with
grubscrew fixed on the flat surface of the motor shaft.
SPRING
MOTOR
SCREWS
MOTOR
BRACKET
SM2 MOTOR
BRACKET
SCREWS
Figure 4.3 Replacing the SM2 motor (Focus Adjust)
Setup SM2
1. Run the setups for the Focus Assys shown in Table 4.1.
4.3.2.3 SM3 (Aperture Control)

Replace SM3
See Figure 4.4.
3. Remove the aperture control module cover.
4. Disconnect the inline connector from SM3 motor.
SPRING
BELT
MOTOR
S6 SENSOR
BASEPLATE SCREW
(4-OFF)
Figure 4.4 Replacing the SM3 motor (Aperture Control)
5. Disconnect the cable to the S6 and S2 sensors.

6. Remove the 4-off M4 Allen caphead screws holding the aperture control module
to the baseplate and remove the module.
7. Note the approximate tension on the drive belt.
8. Remove the single screw (shown at arrow A) holding the drive-belt bracket
located at the opposite end of the motor.
9. Slacken and remove the drive belt from the pulley.
10. Remove the spring from the motor bracket.
11. Remove the 4-off screws securing the bottom of the motor bracket and lift out
the motor.
12. Remove the pulley from the motor.
13. Replacement is the reverse of the removal. Make sure the pulley grubscrew is
against the flat surface of the motor shaft. Tension the drive belt to its previous
level.
Setup SM3
1. Run the setups for the Aperture Assys shown in Table 4.1.
4.3.3 Laser Diode

WARNING: ALWAYS follow the laser warning notices in Volume 1 Section 3.2.
CAUTION: Always follow the antistatic precautions when unpacking, handling and
replacing the laser diode module.
NOTE: After a laser module has been removed make sure it is returned to FFEI (UK) for
disposal.
4.3.3.1 Replace the Laser Diode

See Figure 4.5.
1. The diode is delivered with factory-set parameters (written on the module base
plate) that need to be entered from the lcpd-parameters menu, see Volume 2
Section 1.8.3. Note that the NVRAM parameter, ORIGINAL_ND_P_POD, is
automatically set back to 0.
CAUTION: Make sure the new data values are entered BEFORE the replaced diode is
switched on.

3. Access the optics base interior (laser modules).
4. Detach the VBOMB connection.
5. Hold the module in place and remove the 3-off M3 Allen screws.
7. Replace the new module by locating it against the three dowels and secure to
the baseplate. Secure the screw fixings as follows:
A) Make sure the module is tight against the dowels and the screws are
equally finger-tight.
B) Tighten each screw equally but do not overtighten.
C) Check that the torque setting is approximately 1.4 Nm.
8. Re-connect the module cables using the previous cable routing.
9. Refit the module cover.
PHOTO DIODE PCB

PHOTO DIODE
LASER DIODE
DISTRIBUTION
PCB
PCB
LASER
COVER
FIXING
SCREWS
(3-OFF)
BASEPLATE
DOWELS
DOWELS DOWEL
FIXING SCREW FIXING SCREW
PLAN VIEW LASER DIODE

FIXING SCREW PHOTO DIODE PHOTO
PCB DIODE
PCB DISTRIBUTION
PCB
Figure 4.5 Replacing a laser diode module
4.3.3.2 Setup the Laser Diode

WARNING: Use the manual shutter on the periscope to prevent beams from entering the
drum.
NOTE: Do not switch on the new laser until the new NVRAM parameters, supplied on the
data sheet, are entered.
1. Reboot the machine and stop the application from running by pressing Ctrl-c at
the second reminder message. This will stop the machine software turning on
the laser while the old laser parameters are held in NVRAM.
2. Carry out the setups required for the laser module in Table 4.1. Choose either
the 1-laser or 2-laser machine setups, depending on how many lasers are fitted
in your machine.
4.3.4 Electro-Optic Deflector (EOD)

Replace EOD Module
the optics base.
Complete the procedure below using the information in Figure 4.6:

3. Detach the connector described in Volume 2 Section 5.1.1.16 (note that the red
dots line up when connected).
4. Loosen the 3-off Allen caphead screws.
5. Hold the module in place and start to remove the lower bolt. Lift the module
base slightly to provide enough clearance for removing the bolt, making sure
that the EOD V-block is not dislodged from the EOD baseplate. Carefully lift
off the module from the baseplate.
6. Replace the new EOD by fitting the lower bolt and then the two top
bolts.Tighten each bolt in turn, making sure their washers are in place against
the baseplate.
4.3.4.1 Setup the EOD

1. Carry out the setups for EOD X/Y shown in Table 4.1.
SHOULDER
BOLT
(3-OFF)
EOD (X)
DOWEL (1)
PLAN VIEW ON
A ARROW A
ALLEN
EOD (Y)
CAPHEAD
DO NOT
ADJUST
FACTORY-SET
BASEPLATE DO NOT ADJUST
ALLEN
CAPHEAD
DOWEL (1) (LOWER)
OPTICS BASEPLATE
Figure 4.6 Positioning the EOD module
4.3.5 Position Detector (POD)

NOTE: The POD detector is pre-aligned at the factory and no more adjustments are
required.
4.3.5.1 Replace the POD PCB

the optics base.
Complete the procedure below using the information in Figure 4.7.

2. Access the optics base interior (optics modules).
3. Disconnect the cable connector from the POD PCB.
4. Remove the 2-off M3 Allen caphead screws.
5. Replace the new PCB by aligning the assembly to the two dowels and refitting
the Allen screws (including captive washers).Insert the screws but do not
tighten them.
6. Using your finger, push the base of the module at the furthest corner from the
the two dowels to ensure that the three sides of the POD are hard against the
dowels.Tighten the two Allen screws.
7. Reconnect the cable.
POSITION DETECTOR
BOARD ASSEMBLY
PCB
BASEPLATE
ALLEN SCREW
(& CAPTIVE
WASHER)
DOWEL
Figure 4.7 Positioning the POD module
4.3.5.2 Setup the POD PCB

1. Carry out the setups for the POD shown in Table 4.1.
4.3.6 Electro-Optics Deflector High Voltage (EODHV)

See also Volume 2 Section 5.1.1.16.
4.3.6.1 Replace EODHV PCB

Complete the procedure below using the information in Figure 4.8:
2. Access the optics base interior (EODHV).
3. Remove the module cover by slackening the key slot screw. You will need to
unclip and move surrounding cables.
4. Disconnect all the cables and wires to the EODHV PCB, noting the push-on
connector positions.
5. Remove the 4-off M4 cap head screws holding the PCB to their pillars.
6. Replacing the PCB is the opposite procedure to its removal.
4.3.6.2 Setup EODHV PCB

1. Carry out the setups for the EODHV shown in Table 4.1.
4.3.6.3 Replace the HV Transformer

1. Remove the EODHV PCB, see above.
2. Disconnect the P-clip to the EOD connector cable and detach the cable by
pulling apart the two locking sections of the connector.
3. Remove the M4 cap head screw holding the transformer to the shim and cover.
4. Replacing a transformer is the opposite procedure to its removal.
4.3.6.4 Setup the EODHV Transformers

1. Carry out the setups for the EODHV X/Y shown in Table 4.1.
M4 CAP HEAD
OPTICS SCREW
COVER (4-OFF)
SPACER
DC - DC
CONVERTOR
TRANSFORMERS
TRANSFORMER
SHIM
DETACH
HERE
AMPLIFIER
TO EOD
(X OR Y) M4 CAP HEAD
SCREW
(2-OFF) HEATSINK
EODHV
PCB
Figure 4.8 Replacing the HV EODD PCB
4.3.7 Laser Power Detector (LPD)

See Figure 4.9.
This section describes how to replace the following Laser Power Detector
assemblies:
LPD PCB
Stepper Motor (SM4)
Opto-switch sensor (S6)
After completing any of the procedures below, use IPA and a lintless cloth to
clean the power lens and the ND filter.
ND FILTER
LENS AND
DETECTOR
FILTER MOUNT
PCB
GASKET
MASK
(BOTH SIDES)
PULLEY
SHAFT
MOTOR SUPPORT
BRACKET
TIMING
BELT
SM4 MOTOR
SECURING
SCREW
(4-OFF)
Figure 4.9 Replacing LPD motor (SM4)
4.3.7.1 Replace the LPD PCB

See Figure 4.9.
NOTE: The LPD board is always fitted with a gasket mask to isolate the PCB from chassis
ground. This is to ensure accurate beam power readings.
1. Remove the periscope cover (2-off finger-tight screws).

2. Disconnect the cable lead to the LPD PCB and opto-switch sensor.
3. Loosen the M3 caphead screw holding the lens/filter mount on the pulley shaft.
4. Remove the mount to access the PCB.
5. Remove the PCB (4-off posidrive) and the gasket mask.
6. The replacement procedure is the reverse of the removal.
When replacing the M3 screw, make sure it grips the flat side of the pulley shaft.
4.3.7.2 Setup the LPD

1. Visually check that the filter and lens assembly moves into the light path so that
the detector on the PCB is approximately in the centre of the light path.
2. Carry out the setups for the LPD Assys shown in Table 4.1.
4.3.7.3 Replace the Motor (SM4)

See Figure 4.9.
2. Release the pulley timing belt.
3. Disconnect the cable lead to the motor.
4. Remove the 3-off M2 caphead screws holding the motor to the support bracket.
5. Replace the motor and refit the belt. The screw fixings are in slots that allow you
to slide the motor to a position where the belt is taut.
6. Tighten the capheads and check if the belt can be twisted (in the middle) by
approximately 90. This indicates the correct tension.
7. Reconnect the cable to the motor.
4.3.7.4 Setup the Motor (SM4)

4.3.7.5 Replace the Sensor (S6)

See Figure 4.9.
2. Disconnect the cable.
3. Using a 3mm Allen key, remove the Allen screw securing the sensor to its
mounting point.
4. Replacement is the reverse of the removal.
SENSOR
MOUNTING
BRACKET
SECURING
SCREW
S6 SENSOR
Figure 4.10 Replacing the LPD sensor (S6)
4.3.7.6 Setup the Sensor (S6)

4.3.8 Optics Motors Board (VBOMB)

4.3.8.1 Replace the VBOMB
Replace the VBOMB as follows:
1. Switch off the engine.
2. Remove the laser modules cover on the optics base, see Figure 4.1.
3. Disconnect all the cables to the PCB, see Volume 2 Section 5.1.6.
4. Remove the 4-off M4 Allen screws (front and rear) holding the PCB support
bracket to the base.
5. Detach the PCB from the bracket.
4.3.8.2 Setup the VBOMB

1. Download the PCB firmware from the RIP PC. Ensure you use the correct
version to match the software versions on the other CAN bus boards.
2. Update the registry and confirm that the VBOMB has been changed using the
command:
diagnostics/test/registry> update_registry
1. Carry out the setups for the VBOMB shown in Table 4.1.
4.3.9 Fast Photo Detect (FPD) Sensor

See Volume 2 Section 5.1.5 showing the location of the sensor.
4.3.9.1 Replace the FPD

NOTE: The value of the FPD_GAIN is written on the new FPD PCB. This will be needed for
setting up the FPD. Record this value into the Machine Logbook for future reference.
1. Switch off the engine.

2. Fully-Automatic: Remove the PTM service side cover to gain access to the back of
the drum and the FPD.
3. Manual/Semi-Automatic: Remove the plate loader platen to gain access to the
back of the drum and FPD.
4. Disconnect the cable to the FPD.
5. Remove the FPD assembly.
6. Note the FPD gain value on a label attached to the replacement PCB. It should
be typically 10.0 (mA per Watt).
7. Make sure the filter lens is clean using an air duster, if necessary.
8. Fit the new FPD assembly and connect the cable.
4.3.9.2 Setup the FPD

1. Carry out the setups for the FPD shown in Table 4.1.
4.4 Exposing Test Strips

4.4.1 Introducing the Test Strip Macros
While in diagnostics (service/optics> optics_mmi) you can generate and expose a
range of stepped test strip patterns to verify the alignments and operational set-
tings of the various optical devices. Test strips, generated as macros from a Test
Pattern Setup screen (see Figure 4.11), are divided into two types:
Automatic: These have test names prefixed with the term àuto'. Each auto
test produces and ejects sets of test strips for all resolutions on one or more
plates. Note that the default values cannot be overridden.
Manual: These produce sets of test strips for one resolution on a single plate
using default values that can be overridden.
The results of measurements on each test strip pattern determine optimum set-
tings from where you can enter new NVRAM data values.
NOTE: Test strips can be run at any of the 8 resolutions that the Engine supports. How-
ever, only test strips at 48, 72 and 96 resolutions are required to perform a 2-beam setup.
Strip patterns are run from the following macros selected on the Test Pattern
Setup screen:
Auto Quick Focus
This pattern determines the coarse focus at 48 and 96 resolutions using vertical
lines and Y-beam only.
Auto Focus
This pattern determines the focus at 48 and 96 resolutions in more detail than
the Auto Quick Focus. It generates 5 sets of strips:
1. 96 vertical X-beam
2. 96 horizontal X-beam
3. 96 vertical Y-beam
4. 96 horizontal Y-beam.
5. 48 vertical Y-beam.
Auto ND Wedge Density
This pattern is used to find the best ND Wedge setting for equal mark/space
ratio for 1ON 1OFF vertical lines at 48, 72 and 96 resolutions. These values are
used in the ND settings field of the Final Values table.
Auto Threshold Wedge Density
This pattern is used to find the best ND Wedge settings for black at 48, 72 and 96
resolutions. These values are used in the Threshold ND Settings field of the
Final Values table.
Auto Coincidence X/Y
These patterns are used to determine the drum coincidence values for X- and Y-
beams at 48, 72 and 96 resolutions.
Auto Abs Phase

This pattern has 2 sets of strips, the first set is used as a diagnostic for deflector
system failure, and the other is used to determine absolute phase.
Auto Deflection Amp X/Y
These patterns are used to determine the deflection amplitude of X- and Y-
beams at 48, 72 and 96 resolutions.
Focus (Manual)
Allows you to step through all the Focus lens settings for each resolution.
Wedge Density (Manual)
You can step through all the ND wedge settings for each resolution to find a
threshold level.
Coincidence Beam X/Y (Manual)
Allows you to apply DC bias to deflectors X or Y to make the beams lie on top of
each other with no AC deflection applied.
Deflection Absolute Phase (Manual)
Allows you to alter the phase relationship of the sine and cosine waves relative
to the spinner index signal. Line X must write to the plate first, followed by
line Y. If the absolute phase is 180 out, then lines X and Y are reversed. If the
phase is 90 out, then deflection occurs along the fast direction and not the slow
direction.
Amplitude Beam X/Y (Manual)
Allows you to vary the AC deflection voltage for deflectors X and Y to obtain
equi-spacing between lines.
4.4.2 Using the Optics_MMI Options

4.4.2.1 Accessing Options
There are four screens available: Test Pattern Setup, Final Values, Extra Options
and Machine Setup opened from an engineering terminal window when the fol-
lowing option is entered:
main> diagnostics/service/optics/optics_mmi
4.4.2.2 Navigating Between Options

Use the following keys to select options from any one of the setup screens:
A) Up- and Down-Arrow keys to move to each item field in a screen in a set order
left to right, top to bottom.
B) Left and Right-Arrow to select from a list of options within a field.
C) Return, Tab, Up or Down to exit from a field.
Note that the Final Values screen wraps around for ease of use.
All the operator controls for creating and exposing the strips are from the Test
Pattern Setup menu. You can select a default screen for a macro and edit the set-
tings for exposing a setup strip.
4.4.2.3 Optics Test Pattern Setup Screen

This screen is used for generating sets of test strips, with each strip differing
from the previous one by an amount equal to the Step Value entered, see
Figure 4.11. From the Test Pattern Setup menu you can access three screens:
Extra Options, Final Values and Machine Setups.
Figure 4.11 Optics Test Pattern Setup screen - typical setup
4.4.2.4 Final Values Screen

This screen is used for entering optimum values into NVRAM, see Figure 4.12.
On entering the program, the screen values shown are the current values held
on NVRAM.
Figure 4.12 Final Values screen - typical setup
When the values have been modified and checked, select:

4 Y for Save and Exit to write all the values on the screen to NVRAM and
return to the Test Pattern Setup screen.
4 Y for Cancel will return you to the Test Pattern Setup screen and leave the
NVRAM parameters unchanged.
4.4.2.5 Machine Setup Screen

This screen shows the NVRAM parameters that are normally changed by the
service engineer.
Figure 4.13 Machine Setup screen - typical setup
When the values have been modified and checked, select:

4 Y for Save and Exit to write all the values on the screen to NVRAM and
return to the Test Pattern Setup screen.
4 Y for Cancel will return you to the Test Pattern Setup screen and leave the
NVRAM parameters unchanged.
4.4.2.6 Extra Options Screen

This screen is used for accessing parameters not normally required to be
changed in the field, see Figure 4.14. It includes the options:
Line Length: the height of the test strip in mm.
Image Y Offset: the Y offset from the Base Offset in mm.
Strip Gap: distance between test strips in mm.
Scan Start X Pos: the default position for the Start Scan. It has no effect on the
first expose.
Figure 4.14 Extra Options screen - typical setup

4.4.2.7 Selecting Options from Test Pattern Setup

Test Macro
This allows you to select the test program from the list above.
Set Defaults
Initially sets all the menu options to their default test values. For manual pat-
terns you can override any of these values from the keyboard; for automatic pat-
terns, the values cannot be overridden.
Scan Start Position
Sets the distance in millimetres from the edge of the plate to the start of the first
test strip along the slow scan axis (see Figure 4.15). Note that the first test strip
starts on the right and successive strips are shown towards the left.
Strip Width
Sets the width of each test strip in millimetres.
Start Value
The start number for any optical device (stepper motor, etc) which determines
the physical position of the device from the home position. The home position is
designated as 0, (see Figure 4.15) which shows the ND filter with a Start Value of
60.
Step Value
The number which determines the incremental change in the position from the
Start value for a motor, deflection, etc (see Figure 4.15 which shows the ND filter
with a step value of 2).
Number of Steps
This is the number of positions that the optical device is moved. A test strip is
exposed at each position.
START
VALUE
76 74 72 70 68 66 64 62 60
SCAN
8 mm 2 mm
START
STRIP WIDTH STEP VALUE
POSITION
(mm)
Figure 4.15 Test strip - menu set-up terms

NOTE: These values are not intended to be typical values. They are for example purposes
only.
Resolution
Select a resolution: 48, 72, 96, 100 144 l/mm 1200, 1800 or 2400 lpi.
Pattern Type
Select a pattern type: Vertical Lines, Horizontal Lines, Static Align Pattern, Grid,
Dots or Black.
Lines
The line pattern generated can be from 17 different selections (including
BLACK):
1 ON 15 OFF to 15 ON 1 OFF.
Beam X/Y
Decide if Beam X and Beam Y are ON or OFF for the test. If a beam is Not Avail-
able, the display shows N/A
Traverse
Set the speed of the traverse: 1 beam speed or 2 beam speed where 2 beam speed
is twice as fast as 1 beam speed.
Use Threshold
Selecting Y to this option forces the exposure to use the threshold wedge posi-
tion specified in the Final Values screen. This exposure gives the best separation
of black lines.
Selecting N to this option forces the exposure to use the ND wedge position
specified in the Final Values screen. This exposure gives more laser power for
equal mark/space ratio 1ON 1OFF lines on a plate.
Start Scan
Selecting Y starts the scan.
Media Eject
Choose Y to eject a plate to the processor after the scan.
Extra Options
Selecting Y opens the Extra Options screen when the cursor is moved down, see
Figure 4.14.
Final Values
Selecting Y opens the Final Values screen when the cursor is moved down.
Machine Setup
Selecting Y opens the Machine Setup screen when the cursor is moved down.
Run Beam-co(incidence)
Runs an automatic procedure which aligns Beams X and Y to be co-incident on
the POD.
Exit
Choose this option to exit from the program after the scan.
4.4.3 Running Test Strips

You can run a set of exposure test plate strips for checking the overall optics per-
formance of the machine and setting new exposure values to NVRAM. These
are practical steps that allow you to select a test for each of the main optics mod-
ules listed in Table 4.1.
4.4.3.1 Manual and Semi-Automatic Machines (B1 & B2)

For these machines follow the steps below when running test strips:
1. Enter PAUSE mode on the MMI and load a plate.
2. After the plate loads into the drum return to RUN mode.
3. Output the test strip from optics_mmi as shown in the section below and eject
the plate from the MMI.
4.4.3.2 Starting the Tests

Running Tests Strips
Use the information in Table 4.2 to run plate exposures for checking Focus,
Wedge Density, etc. Each test (1 to 8) results in a plate with a set of strips. Make
sure you follow any pre-requirements before starting a test.
Table 4.2 Start test strips (B1 and B2)

Plate
Output Test Strip Macro Pre-Requirement See Page
Tests
1 Auto Focus Run exposure calibration from the MMI at Page 4-38
50 J setting. Enter 48 and 96 ND values into
the ND settings fields of the Final Values
table
2 Auto ND Wedge Final Values set for ND Page 4-41
Density
3 Auto Threshold Run Power Balance 48, 72 & 96 before start- Page 4-42
Wedge Density ing these tests
4 Auto Coincidence Run Beam-co from optics_mmi Page 4-42
Beam Y
5 Auto Coincidence Run Beam-co from optics_mmi Page 4-44
Beam X
6 Auto Deflection Run Beam_co from optics_mmi Page 4-45
Absolute Phase
7 Auto Deflection Run Beam-co from optics_mmi Page 4-47
Amplitude Beam Y
Table 4.2 Start test strips (B1 and B2) (Continued)

Plate
Output Test Strip Macro Pre-Requirement See Page
Tests
8 Auto Deflection Run Beam-co from optics_mmi Page 4-49
Amplitude Beam X
1: Auto Focus
See Table 4.4 below.
This procedure allows you to verify and change the NVRAMs for the focus lens
so that it moves to the optimum focus position for all resolutions (res) and plate
thicknesses.
Use the largest available plate for these checks, making sure the minimum plate
height is:
A) B1: 770 mm
B) B2: 600 mm.
1. Calibrate the platesetter at a setting of 50.
2. Find the ND settings values for 96 and 48 resolutions from the MMI ND Settings
screen.
3. From Main diagnostics open the test pattern setup screen:
main> diagnostics/service/optics/optics_mmi
4. Enter the 96 and 48 res values into the Final Values table for the ND 96 and ND
48 resolution fields.
5. Expose 5 blocks of 9 test strips (right to left) from the Auto Focus macro. This will
use the values shown in the table below.
2-Beam machine: runs the five test strips (A to D at 96 and E at 48 resolution).
1-Beam Machine: this only runs tests C to E.
Table 4.3 Auto Focus settings and strips

RUNS TEST STRIPS:
AUTO FOCUS MACRO: Focus A Focus B Focus C Focus D Focus E
Set Defaults? Yes N/A N/A N/A N/A
Scan Start Posn (mm) 10 N/A N/A N/A N/A
Strip Width (mm) 8 8 8 8 8
Start Value 900 900 900 900 900
Step Value 50 50 50 50 50
Number of Steps 9 9 9 9 9
Resolution 96 l/mm 96 l/mm 96 l/mm 96 l/mm 48 l/mm
Pattern Type Vert Hor Vert Hor Vert
Table 4.3 Auto Focus settings and strips (Continued)

RUNS TEST STRIPS:
AUTO FOCUS MACRO: Focus A Focus B Focus C Focus D Focus E
Lines 2on2off 2on2off 2on2off 2on2off 2on2off
Beam X On On Off Off Off
Beam Y Off Off On On On
Traverse Speed 1 Beam 1 Beam 1 Beam 1 Beam 1 Beam
Use Threshold? No No No No No
Start Scan Yes Yes Yes Yes Yes
6. Eject and process the plate.

7. Check Strips A to D at 96 Resolution: Using a densitometer, find the lightest
density strip for each focus test strip shown in Figure 4.16. This should be in the
range of 1000 to 1200. Check the top and bottom of the plate, and ensure that:
A) The 2 lightest values, top and bottom, from each block of test strips
should be within 1 strip of each other (ie adjacent). Obtain a single
average value.
B) The average value of the 4 blocks (A to D), top and bottom, should be
within 2 strips of each other.
8. Enter the 96 value into the 1800, 72, 2400, 96, 100 and 144 positions for the plate
thickness used.
9. Check Strip E at 48 resolution: find the lightest strips, top and bottom, and
obtain the average value.
10. Enter the 48 resolution value into the 1200 and 48 positions for the plate
thickness used.
11. Save the focus step positions in the Final Values table.
12. Find the focus step positions for each remaining plate thickness by calculating
the offset values from Table 4.4.
:
Table 4.4 Focus positions for plate type thickness

Tested Plate Offset for Focus Offset Value:
Thickness (mm): Plate:
0.15 0.2 Subtract 15

0.24 Subtract 27
0.3 Subtract 45
0.2 0.15 Add 15
0.24 Subtract 12
0.3 Subtract 30
Table 4.4 Focus positions for plate type thickness (Continued)

Tested Plate Offset for Focus Offset Value:
Thickness (mm): Plate:
0.24 0.15 Add 27

0.2 Add 12
0.3 Subtract 18
0.3 0.15 Add 45
0.2 Add 30
0.24 Add 18
NOTE: The focus offset is 30 steps per 100 m change in the plate thickness. Thinner
plates should have higher focus numbers.
For instance, if the 0.3 plate is set at 1200 steps the other plate steps are:
A) 0.24 mm = 1218
B) 0.2 mm = 1230
C) 0.15 mm = 1245.
BLOCK OF TOP VALUE

TEST STRIPS
BOTTOM VALUE BEST AVERAGE FOCUS
Figure 4.16 Selecting best block focus test strip
13. If any of these focus conditions cannot be met then:

A) Try a different value for ND and check the processor setup.
B) Finish the required setups as well as possible and check the resulting quality
using an S&T page. If it is unsatisfactory and cannot be improved, consult
FFEI Customer Services.
NOTE: focus conditions are only important if there is unacceptable image quality for the
customer.
14. Store all focus positions for all resolutions in NVRAM using the Final Values
menu.
2: Auto ND Wedge Density

These test patterns find the ND wedge positions that give distinct 1 ON 1 OFF
vertical line images. These numbers are important since 1 ON 1 OFF vertical
lines are used for Coincidence X/Y.
EQUAL LINE AND

GAP WIDTHS
DENSITY READING IS ABOUT 50%
1 ON/
1 OFF
Figure 4.17 Checking the line/gap patterns
1. Output test strips using the settings below.

2. Check for lines of 1 beam width with equal width gaps between them, see
Figure 4.17.
3. Enter these ND setting values into the Final Values table.
Table 4.5 Auto ND Wedge settings and strips

RUNS TEST STRIPS:
AUTO ND WEDGE DENSITY Wedge Density Wedge Density Wedge Density
Set Defaults? Yes N/A N/A
Scan Start Posn (mm) 10 N/A N/A
Strip Width (mm) 8 8 8
Start Value 140 140 120
Step Value 5 5 5
Number of Steps 11 11 11
Resolution 48 72 96
Pattern Type Vert Vert Vert
Table 4.5 Auto ND Wedge settings and strips (Continued)

RUNS TEST STRIPS:
AUTO ND WEDGE DENSITY Wedge Density Wedge Density Wedge Density
Lines 1on1off 1on1off 1on1off
Beam X Off Off Off
Beam Y On On On
Traverse Speed 1 Beam 1 Beam 1 Beam
Use Threshold? No No No
3: Auto Threshold Wedge Density

See Page 4-41
1. Output a plate using the settings below:
2. Select the strips which show black lines on both beams clearly from the top to
bottom of the plate. Enter the values into the 48, 72 and 96 Final Values table for
ND Threshold.
Table 4.6 Auto Threshold settings and strips

RUNS TEST STRIPS:
AUTO THRESHOLD WEDGE Wedge Density Wedge Density Wedge Density
DENSITY:
Set Defaults Yes N/A N/A
Scan Start Position 10 N/A N/A
Strip Width 8 8 8
Start Value 90 90 80
Step Value 2 2 2
Resolution 48 72 96
Pattern Type Black Black Black
Lines Black Black Black
Beam X Off Off Off
Beam Y On On On
Traverse 1 Beam 1 Beam 1 Beam
Use Threshold No No No
4: Auto Coincidence Beams Y

This test is used to make the two beams (at the drum) lie on top of each other at
the Y deflection position when AC deflection is not applied. Run beam_co from
the Test Pattern Setup menu first to ensure co-incidence on the POD.
Since it is difficult to visually check if two beams are on top of each other, a spe-
cial test pattern is used. This pattern generates beam X on one rotation of the
spinner followed by a one line gap on the second. On the third rotation, beam Y
is put down followed by a one line gap on the fourth. This is then repeated. The
result is a 1 ON/1 OFF vertical line pattern using alternate beams. When the
lines are equal spaced, then drum coincidence is achieved.
PLATE LEADING EDGE (REG PINS)
96 72 48 96 72 48
320 mm (PUNCH)
298 mm (NO PUNCH)
DEFLECTOR
POINT (Y)
432 mm
DEFLECTOR
POINT (X)
X-BEAM Y-BEAM
TEST STRIPS TEST STRIPS
Figure 4.18 Auto Coincidence check test strips
For a B2 machine (Vx-6000), open the Final Values screen and set X Off EOD to 0
for resolutions 48, 72 and 96.
1. Output test strips using the table below (after running beam_co):
Table 4.7 Auto Coincidence Beam Y settings and strips

RUNS TEST STRIPS:
AUTO COINCIDENCE Coin Coin Coin
BEAM Y: Beam Y Beam Y Beam Y
Start Value -250 -250 -250
Step Value 50 50 50
Resolution 48 72 96
Table 4.7 Auto Coincidence Beam Y settings and strips (Continued)

RUNS TEST STRIPS:
BEAM Y: Beam Y Beam Y Beam Y
Lines 1on3Off * 1on3off * 1on 3off *
Beam X On On On
Beam Y On On On
Use Threshold? No No No
NOTE: * indicates a special test pattern producing 1 ON 1 OFF lines.
2. Check at the Y deflector point for best equal spaced lines.

3. Enter values into the Final Values table.
A) Enter the 48 resolution value into the 1200 and 48 positions for Y OFF
EOD line.
B) Enter the 72 resolution value into the 1800 and 72 positions for Y OFF
EOD line.
C) Enter the 96 resolution value into the 2400, 96, 100 and 144 positions for
the Y OFF EOD line.
NOTE: * indicates a special test pattern producing 1 ON 1 OFF lines.
5: Auto Coincidence Beam X

1. Run beam_co.
2. Output a set of test strips using the table below:
Table 4.8 Auto Coincidence Beam X settings and strips

RUNS TEST STRIPS:
BEAM X: Beam X Beam X Beam X
Start Value -250 -250 -250
Step Value 50 50 50
Resolution 48 72 96
Table 4.8 Auto Coincidence Beam X settings and strips (Continued)

RUNS TEST STRIPS:
BEAM X: Beam X Beam X Beam X
Lines 1on3Off * 1on3off * 1on 3off *
Beam X On On On
Beam Y On On On
Use Threshold ND? No No No
Check at the Y deflection point for the best equal spaced lines. On a B2 machine,
the plate is not high enough to view the patterns at the X-deflector operating
point. Instead, find the best equal spaced lines at the top and bottom of the plate
and take the average. Note that the co-incidence Y numbers must be inserted
into the Final Values table before doing Auto Coincidence Beam X.
3. Enter values into the Final Values table.
A) Enter the 48 resolution value into the 1200 and 48 positions for the X OFF
EOD line.
B) Enter the 72 resolution value into the 1800 and 72 positions for the X OFF
EOD line.
C) Enter the 96 resolution value into the 2400, 96, 100 and 144 positions for
the X OFF EOD line.
6: Auto Absolute Phase

The first pattern is used to check that all the components in the deflection sys-
tem are working properly. The second pattern is used to set up Absolute Phase.
The items checked are the EODD board sine and cosine wave generation, the
EODHV board, the HV transformers and the EODs. For a working deflection
system there should be two dark vertical bands down the plate at Deflector
Absolute Phase settings of approximately 400 and 1100 (in the first test pattern).
1. Run the test strips using the settings below:
Table 4.9 Auto Absolute Phase settings and strips

RUNS TEST STRIPS:
AUTO Deflection Abs Phase Deflection Abs Phase
ABSOLUTE PHASE:
Set Defaults? Yes N/A
Scan Start Posn (mm) 10 N/A
Strip Width (mm) 8 8
Start Value 0 900
Step Value 100 50
Table 4.9 Auto Absolute Phase settings and strips (Continued)

RUNS TEST STRIPS:
AUTO Deflection Abs Phase Deflection Abs Phase
ABSOLUTE PHASE:
Number of Steps 15 7
Resolution 96 96
Pattern Type Vert Hor
Lines 2on2off 1on3off
Beam X On On
Beam Y On On
Traverse Speed 2 Beam 2 Beam
Use Threshold? No No
1. Examine the plate in the first test pattern to check if there are two vertical bands
with dark lines at approximately 400 and 1100 positions shown in Figure 4.19.
TEST STRIPS
1400 1300 1200 1100 1000 900 800 700 600 500 400 300 200 100 0
LAST STRIP FIRST STRIP
Figure 4.19 Deflection strips for 1st test pattern
2. If the bands run diagonally, then there is a fault in either the X-deflection or Y-
deflection system or setup. For a 1030 x 800 plate, an X-deflection fault produces
a dark band from top right corner to bottom middle of the plate. A Y-deflection
fault produces a dark band from top centre right to bottom centre left of the
plate, see Figure 4.20.
X-DEFLECTION ERROR Y-DEFLECTION ERROR
L D
D
L
L
D
D
L
2 ON/2 OFF 2 ON/2 OFF

L = LIGHT
D = DARK
Figure 4.20 Fault indications on X- and Y-deflections
3. The second test pattern (1ON 3OFF) is for best horizontal lines which should
appear as a line of horizontal dots when examined by a x100 microscope, see
Figure 4.21.
4. Find the best horizontal lines; if the dots are either side of the correct position,
the lines appear jaggied, see Figure 4.21.
BEST HORIZONTAL LINE JAGGIED LINE
Figure 4.21 1 ON 3 OFF horizontal line
5. Enter the setting for the best horizontal lines into the Final Values screen for the
Deflection Absolute Phase field.
7: Auto Deflection Amplitude Beam Y

Beam coincidence is run first from the optics_mmi screen to give coincidence on
the POD.
1. Output test strips using the settings below:
Table 4.10 Auto Deflection Amplitude Beam Y settings and strips

RUNS TEST STRIPS:
AUTO DEFLECTION Amp Beam Y Amp Beam Y Amp Beam Y
AMPLITUDE:
Strip Width 8 8 8
Start Value 0.7 0.7 0.7
Step Value 0.05 0.05 0.05
Resolution 48 72 96
Beam X On On On
Beam Y On On On
Use Threshold Yes Yes Yes
2. Punch machine: Mark a horizontal line across the Y beam test strips at 320 mm
down from the registration pin edge of the plate. The images should only be
inspected at this position. See Figure 4.22.
96 72 48
320 mm (PUNCH)
298 mm (NO PUNCH)
DEFLECTOR
POINT (Y)
Y-BEAM
TEST STRIPS
Figure 4.22 Auto Deflection Amplitude test strips (Y)
Non-punch machine: Mark a horizontal line across the Y beam test strips at 298
mm down from the registration pin edge of the plate. The images should only be
3. Find the strip where the black lines are visible. This may be difficult to see if the
processor is not set up correctly. An alternative method is to increase the ND
Threshold values by 20 and measure the density of the strips. The strips should
have the highest density at 1.1 and be lighter either side. Pick the strip with the
highest density for 48 resolution and repeat this for the 72 and 96 strips.
4. Insert these values into the Y AMP EOD fields of the Final Values table for the
resolutions:
A) 48 into columns 1200 and 48
B) 72 into columns 1800 and 72
C) 96 into columns 2400, 96, 100 and 144.
8: Auto Deflection Amplitude Beam X

1. Output test strips using the settings below:
Table 4.11 Auto Deflection Amplitude Beam X settings and strips

RUNS TEST STRIPS:
AUTO DEFLECTION Amp Beam X Amp Beam X Amp Beam X
AMPLITUDE:
Strip Width 8 8 8
Start Value 0.7 0.7 0.7
Step Value 0.05 0.05 0.05
Resolution 48 72 96
Beam X On On On
Beam Y On On On
Use Threshold Yes Yes Yes
2. Punch machine: Mark a horizontal line across the X beam test strips at 752 mm
down from the registration pin edge of the plate. The images should only be
Non-punch machine: Mark a horizontal line across the X beam test strips at 730
mm down from the registration pin edge of the plate. The images should only be
3. Find the strip where the black lines are visible. This may be difficult to see if the
processor is not set up correctly. An alternative method is to increase the ND
Threshold values by 20 and measure the density of the strips. The strips should
have the highest density at 1.1 and be lighter either side. Pick the strip with the
highest density for 48 resolution and repeat this for the 72 and 96 strips.
4. Insert these values into the X AMP EOD fields of the Final Values table for the
resolutions:
A) 48 into columns 1200 and 48
B) 72 into columns 1800 and 72
C) 96 into columns 2400, 96, 100 and 144.
On a B2 machine, the plate is not high enough to view the patterns at the X-
deflector operating point. Instead, find the correct strip at the top and bottom of
the plate and take the average. If there is a large skew between the top and
bottom, then repeat Coincidence Beam X first. Note that the Amplitude Beam Y
numbers must be entered into the Final Values table before doing the Amplitude
Beam X test.
96 72 48
752 mm (PUNCH)
730 mm (NO PUNCH)
X-BEAM
TEST STRIPS
Figure 4.23 Auto Deflection Amplitude test strips (X)
4.5 Check Raster Quality

Raster quality on the plate can deteriorate if there is a problem in the following
optics settings:
Processor
This has a large effect if the brush roller pressures, the chemistry or the tempera-
tures are incorrect. Ensure that the processor is in good condition. To check for
processor-induced raster, expose the plate then turn it through 90 before
processing. Any processor marks will now be in the other direction.

Focus
Poor focus causes a general degradation of the raster. Check that the focus is
correctly set.
Two Beam Setup
Errors in the two beam setup causes poor raster which may be worse at different
positions in the vertical direction. The parameters most likely to cause raster are
Coincidence X and Y and Amplitude X and Y. This is because there is only a
small overlap of the beams, and errors in beam position cause white gaps to
appear between the lines, so leading to noticeable raster.
Errors in the X beam setup are most likely to cause raster close to 750 mm down
from the punch, which is where the X deflector works with maximum ampli-
tude. Errors in the Y beam setup are most likely to cause raster close to 320 mm
down from the punch.
As a useful test to check for two beam raster, complete the following:
1. Switch the engine to single beam. Change the NVRAM parameter
LASERS_USED from 5 to1 to use the X beam, or to 4 for the Y beam.
2. Run a test image.
3. Ensure that LASERS_USED is set back to 5 afterwards otherwise the
machine will run in single beam mode.
4. Reset the Engine then shutdown and restart the RIP.
Traverse
This produces vertical lines which extend from top to bottom of the plate. To
avoid raster problems, ensure that the traverse encoder track is clean and that
ball cage creep is within specification.
Thermal
Thermal gradients, somewhere in the optics, can produce random dark and
light vertical lines which may extend from top to bottom of the image. Alterna-
tively, localised hotspots around the drum may cause lines which do not extend
top to bottom. Ensure that the mixer fan is working and airflow is not restricted,
as this has a big impact on the raster.
4.6 Calibrate Exposure Level

Exposure calibration sets up a constant exposure level at the drum surface for
each resolution. The correct default level is 50 set on the MMI. This corresponds
to the following exposure and power levels:
Table 4.12 Laser exposure and power levels

Resolution Exposure Level Power (mW)
(J/cm2)
47 50 13.2
Table 4.12 Laser exposure and power levels

Resolution Exposure Level Power (mW)
(J/cm2)
48 50 13.0
71 50 10.6
72 50 10.4
94 65 11.0
96 65 10.8
100 65 10.4
144 65 7.2
1. Display the TOOLS menu and press Exposure Calibration (lower righthand side
button) to obtain the Exposure Calibration screen:
EDIT EXPOSURE
LEVEL
START
CALIBRATION CURRENT
EXPOSURE LEVEL
ND SETTINGS
Figure 4.24 Exposure Calibration screen
2. Press Start Calibration to measure the exposure level at the drum and calculate the
ND settings of the filter wheel for all resolutions.
3. The screen shows a Wait Timer icon during the calculations and then indicates:
A) Successful calibration: a tick appears on the Exposure Calibration screen.
None of the resolutions have failed.
B) Failed calibration: an ND Values screen appears showing a Warning icon
next to the resolution(s) that failed because insufficient power is
available. If any of these resolutions are used by the customer then clean
the spinner mirror and repeat the calibration. Call FFEI Customer
Support (UK) if the calibration fails again.
The ND Values screen only appears automatically if there is a lack of
power. To view this screen, press ND Settings.
Figure 4.25 ND Settings screen
NOTE: The ND settings for exposing RIP images are stored directly on the Engine HDD
and are not supplied by the RIP.
4. When exposure calibration has been performed, linearise the %dots at the
required resolutions and screen rulings using the RIP Calibration Manager.
4.7 B1 and B2 Image Form Adjustments

These procedures show how to check the geometry of an exposed B1 and B2
image on a plate and adjust for errors. Adjustments are based on the following
plate sizes:
A) B1: 865 mm for the fast scan (vertical) and 865 mm for the slow scan
(horizontal) length.
B) B2: 665 mm for the fast scan (vertical) and 665 mm for the slow scan
(horizontal) length.
An image form adjustment is normally carried out when:
A) the laser system is upgraded from one to two beams.
B) a spinner change
C) a laser diode change
D) any other changes or adjustments that alters beam direction.
Requirements for running the adjustments are:
Grid: output a PI (Tests_C) image with (865 mm x 865 mm size grid for B1)
or (665 mm x 665 mm size grid for B2). Alternatively, you can generate a
grid from QuarkXpress.
Plate: minimum size is:
A) B1: 890 mm (H) x 870 mm (W) x (0.3 or 0.24 mm).
B) B2: 670 mm (H) x 670 mm (W) x (0.2, 0.3 or 0.24 mm).
Microscope: with 20 m resolution graticule.
Film comparison ruler: use the method in Section 4.7.1 to create a ruler for
determining errors by measuring grid comparisons on the same plate.
Error adjustments are completed from the M2 mirror shown in Figure 4.26.
M2 SCREW ADJUSTMENT (HORIZONTAL/VERTICAL)

POINTER POINTER
1/20 TURN 1/20 TURN
CLOCKWISE ANTI-CLOCKWISE
HORIZ. = 20 DIVISIONS VERT. = 20 DIVISIONS
ADJUSTING
SCREW (VERTICAL)
LOCKNUT
M2
MIRROR
ADJUSTING
SCREW (HORIZONTAL) HOUSING
Figure 4.26 M2 mirror adjustment
4.7.1 Creating a Film Comparison Ruler

Create a film comparison ruler as follows:
1. Output a grid film strip from an imagesetter and cut four horizontal strips
approximately 100 mm wide, see Figure 4.27.
A) B1 Plate: tape the two strips together on both sides to obtain one long
1,223 mm strip.
B) B2 Plate: use Strip 0, which should be longer than 940 mm.
STRIP 0
CUT
APPROX. 100 mm
STRIP 1 WIDE STRIP
CUT
STRIP 2
CUT
STRIP 3
CUT
1130 mm
STRIP 1
B1 RULER
STRIP 2
TAPE
1223 mm
STRIP 0 B2 RULER
940 mm
Figure 4.27 Cutting/joining the film strips
4.7.2 Determining Horizontal Error

This method uses the film ruler to find horizontal errors.
1. Output a plate with a PI (Test_C) grid and place the plate on a flat table
2. Align a grid cross-point at one end exactly on the corner of the image for
diagonal B and make sure the centre line of the ruler is exactly aligned on the
corner at the other end, see Figure 4.28.
3. Tape the ruler to the plate and mark the grid cross point at one end and the grid
measuring line X.
4. Using a microscope, measure how much the corner at the other end overlaps the
nearest grid cross point from `X', see Figure 4.28. (Take care when measuring
with a microscope - the view is inverted).
5. Repeat steps 2. to 4. for diagonal A.
6. Calculate the difference between A and B diagonals.
7. Complete the correction procedure in Section 4.7.2.1.1 from step 2. onwards.
865 mm (B1) B
A 665 mm (B2)
IMAGE
MEASURE
X
865 mm (B1)
665 mm (B2)
B A
FILM COMPARISON
RULER
GRID CROSS POINT
ON CORNER
Figure 4.28 Measuring horizontal errors with a film strip ruler
4.7.2.1 Correcting Horizontal Error

Use one of the following two methods to measure horizontal error, which is the
difference between the two diagonals (A and B) shown in Figure 4.29.
1. Vernier ruler (1.25 m minimum) to measure the diagonals A and B. This
method is straightforward: measure A and B and subtract the difference to
determine the direction and magnitude of the adjustment.
2. Film Comparison Ruler (see Section 4.7.1) and a microscope.
The specification for the image form horizontal check should be less than 50 m
difference between A and B.
1. Output a plate with a PI (Test_C) grid and check if there is a difference between
the diagonal measurements.
2. If the difference exceeds the specification, then make an M2 adjustment.
3. Remove the cover around the M2 mirror on the user side.
PLATE
GRID IMAGE
A B
865 mm (B1)
665 mm (B2)
865 mm (B1)
665 mm (B2)
Figure 4.29 Horizontal check
4. If B is greater than A, as in Figure 4.30, then adjust the M2 horizontal screw

clockwise.
PUNCH END PLATE
GRID IMAGE
A B
Figure 4.30 Horizontal check - B greater than A
5. If A is greater than B, as in Figure 4.31, then adjust the M2 horizontal screw anti-
clockwise.
PUNCH END PLATE
GRID IMAGE
A B
Figure 4.31 Horizontal check - A greater than B
6. B1 Plate: Loosen the adjuster locknut and re-adjust as follows (see Figure 4.26):
A) One division turn on the horizontal adjuster screw = 50 m correction.
B) Ten divisions turn on the horizontal adjuster screw = 500 m correction.
C) Twenty divisions turn on the horizontal adjuster screw = 1 mm
correction.
A) One division turn on the horizontal adjuster screw = 47 m correction.
B) Ten divisions turn on the horizontal adjuster screw = 470 m correction.
C) Twenty divisions turn on the horizontal adjuster screw = 0.94 mm
correction.
8. After making the adjustment, gently tap the mirror housing to settle the M2
spring mechanism and then re-lock the setting.
9. Replace the periscope cover.
4.7.3 Determining Vertical Error

This method uses the film ruler to find vertical errors.
1. Output a plate with the PI (Test_C) grid and place the plate on a flat table.
2. Using the ruler, check for bow on the vertical centre line.
3. Place the centre line of the ruler on the centre line of the grid, as shown in
Figure 4.32, and measure the bow to obtain value A (for instance, 100 m).
Note the direction of the bow towards or away from the periscope end.
PUNCH END PLATE
GRID IMAGE
SERVICE A MEASURE A PERISCOPE

END (EXAMPLE: END
100 m)
FILM
COMPARISON
RULER
Figure 4.32 Measuring vertical errors with ruler position A
4. Turn the ruler over on its long edge and repeat step 4. to obtain a new
measurement value B (for instance, 60 m).
Measurement B could be slightly different from A because the centre line on the
ruler might be slightly bowed. By taking an opposing ruler reading it is possible
to find the average error value.
PUNCH END PLATE
GRID IMAGE FILM

COMPARISON
RULER
TURNED
SERVICE B MEASURE B PERISCOPE

END (EXAMPLE: END
60 m)
Figure 4.33 Measuring vertical errors with ruler position B
5. Calculate the magnitude of the bow by adding A and B and dividing the result
by two. For example: 100 + 60 = 160/2 = 80 m.
6. Complete the M2 correction procedure in Section 4.7.3.1 from step 3. onwards.
4.7.3.1 Correcting Vertical Error

This measures the amount of vertical line bow from a centre vertical line on a
grid image.
The specification for vertical line bow should not exceed 20 m on the centre
vertical line.
1. Output a plate with a PI (Test_C) grid and find the centre vertical line.
2. Using a horizontal grid line of the B2 ruler, check for bow on the centre vertical
grid line as shown in Figure 4.34.
3. If the bow exceeds the specification, then make an M2 adjustment.
4. Remove the cover around the M2 mirror on the user side.
PUNCH END PLATE
GRID IMAGE
STRAIGHT
LINE OF
SERVICE FILM GRID VERTICAL PERISCOPE
END CENTRE LINE BOW END
LINE
(B2 RULER)
FILM GRID
Figure 4.34 Checking for vertical bow
5. If the vertical bow is away from the periscope end, then adjust the M2 vertical
screw clockwise.
PUNCH END PLATE
GRID iMAGE
SERVICE PERISCOPE
END END
Figure 4.35 Vertical check - away from the periscope

6. If the vertical bow is towards the periscope end, then adjust the M2 vertical screw
anti-clockwise.
PUNCH END PLATE
GRID IMAGE
SERVICE PERISCOPE
END END
Figure 4.36 Vertical check - towards the periscope
A) One division turn on the vertical adjuster screw = 15 m correction.
B) Ten divisions turn on the vertical adjuster screw = 150 m correction.
C) Twenty divisions turn on the vertical adjuster screw = 300 m correction.
A) One division turn on the vertical adjuster screw = 8 m correction.
B) Ten divisions turn on the vertical adjuster screw = 80 m correction.
C) Twenty divisions turn on the vertical adjuster screw = 160 m correction.
9. After making the adjustment, gently tap the mirror housing to settle the M2
spring mechanism and then re-lock the setting.
10. Replace the periscope cover.
4.8 Set up ND Characterisation

1. Set ND_MAX_TRANSMISSION to its maximum possible setting by entering:
main> dev
enter the password:
boxer.dev
and from the r&d_main prompt enter:
r&d_main> nvram
nvram> dnv ND_MAX_TRANSMISSION

ND_MAX_TRANSMISSION 202/$000000ca 160/$000000a0
nvram>snv ND_MAX_TRANSMISSION 240
ND_MAX_TRANSMISSION updated...

ND_MAX_TRANSMISSION 240/$000000f0 160/$000000a0
2. Run the nd_char utility and check that it has run successfully:
diagnostics/service/utils> edbg 33
diagnostics/service/utils> nd_char
Wait a few minutes for the utility to run:
nd pos = 20 , X and Y beam power = 0.000

etc.
etc
etc
ND char table start index = 0 , start value = 0.000000
ND char table end index = 220 , end value = 1650.500000
TIME:Mon Apr 7 11:35:20 2003 (119781) irq_handlers.c:137 (ERROR)
** ERROR: 3205, *** No Isr for expose completed - level 3!.
3. Ignore the error message shown above but do not ignore any other errors.
4. Check that the nd_char table has been correctly generated.
diagnostics/service/disk/dfs> ls
general/tmpReg.txt 6543 Apr 7 10:16:00 2003

general/sysnvram.bin 14451 Apr 2 11:10:44 2003
general/nd_char 512 Apr 7 11:35:20 2003
general/media_dbase 648 Apr 2 14:42:26 2003
general/cassettes 1054 Apr 2 15:34:34 2003
general/elevator 24 Apr 2 13:00:08 2003
general/jm.dat 4530 Apr 2 15:35:32 2003
general/stats.txt 4672 Apr 7 10:16:01 2003
general/sysconfig.txt 1209 Apr 2 11:11:29 2003
5. Check the following:

A) the file size of general/nd_char is not 0
B) the date and time of general/nd_char is the same as Time: recorded near
the end of the nd_char text.
C) the maximum X and Y beam power is at least 800
These checks confirm that the file has been successfully created.
6. If necessary, you can chart the nd_char values obtained in MS Excel. For
instance, the plot of values for above are:
nd_char
1800
1600
1400
Laser Power (LPD)
1200
1000
800
600
400
200
0
20 40 60 80 100 120 140 160 180 200 220 240
ND filter position
NOTE: The working range of the ND filter wheel is from step 20 to the first step where the
power drops (normally 180-220). Above this the power is uneven, then drops sharply to a
low value (corresponding to light being blocked by the edge of the ND filter glass). After
this the laser light passes through a clear section in the ND filter wheel (without glass and
hence no light attenuation). Normally, only the working range is used.
7. Set up the working range of the ND filter as follows:

A) set up in NVRAM the position of ND filter for maximum transmission of
light, which is at the end of the working range.
B) Look at the text generated by nd_char. Starting at nd pos = 170, look at
the values of X and Y beam power. In the working range they should
increase continuously.
Look for the first drop in power. In the example above, it is from step 203
(X and Y beam power = 1550.750) to step 204 (X and Y beam power =
1543.500).
In the example above, the end of the working range is therefore 203. You
may find a different value (<your value>). This value needs to be set up
in NVRAM as follows.
Enter:
main> dev
and enter the password:

boxer.dev
Enter:
r&d_main> nvram
nvram> snv ND_MAX_TRANSMISSION <your value>
to obtain:
ND_MAX_TRANSMISSION updated...

ND_MAX_TRANSMISSION <your value> 160/$000000a0
Volume-Chapt er
POWER AND CONTROL

SERVICE PROCEDURES
This chapter describes how to remove and replace RFI box assemblies and carry out
any setups.
4
4
Starting the Service Procedures ............................................................................... 5-1
4
Replacing RFI Box Modules ...................................................................................... 5-2
Replacing Interlock and Power Modules..................................................................5-2
5.1 Starting the Service Procedures

5.1.1 RFI Box
See Figure 5.2 showing the location of each RFI box module.
The RFI box holds the main system power and control modules previously described in
Volume 2 Section 6.1.
PSU 1: see Section 5.2.1
LSB Fan: see Section 5.2.1.1 (New procedure in Appendix B)
Power Filter PCB: see Section 5.2.1.2
EODD PCB: see EODD PCB Replacement
System PCB (LSB): see Section 5.2.1.3
Hard Disk Drive (HDD): see Section 5.2.1.4.
5.1.2 Engine Service Side

These include the following modules:
Interlock box: see
Mains filter box: see
5.1.3 Accessing the Assemblies

See Volume 2 Section 6.1.1 showing how to power and control assemblies.
VOLUME 3 (5-2) P OWER AND C ONTROL S ERVICE P ROCEDURES
SENSOR DISTRIBUTION
PCB ASSEMBLY 24V DISTRIBUTION
PCB ASSEMBLY
MAINS INLET
DC CABLE
(10A 250V)
PSU POWER
FILTER
PCB
POWER
FILTER PCB
INTERFACE
DONGLE
(OLD PCB ONLY)
EODD PCB DISK DRIVE
EXTERNAL
ALERT
RELAY
DISK DRIVE
MOUNTING
BRACKET
SYSTEM (LSB)
PCB
INTERFACE
SYSTEM (LSB)
PCB
RFI BOX
LSB FAN
Figure 5.1 RFI box modules
5.2 Replacing RFI Box Modules

5.2.1 Power Supply Module (PSU1)
See Figure 5.2.
SLOT 1 SLOT 3 SLOT 4 SLOT 5 SLOT 6
-15V
SENSE
0V
0V
0V 0V 0V 0V
+36V
+5V +24V +24V +15V
WHITE/BROWN RED WHITE/ WHITE/ YELLOW (+15V)

ORANGE ORANGE VIOLET (-15V)
Figure 5.2 PSU1 rear connections
1. Access the assembly inside the RFI box.

2. Disconnect the PSU AC and DC wires by removing their Faston connectors (the wires
are labelled) - see also Volume 2 Section 8.1.73.
3. From underneath the box, remove the 2-off posidrive screws holding PSU 1 mounting
plate and remove the assembly.
4. Detach the mounting plate from the PSU and replace the PSU.
NOTE: There are no setups or voltage adjustments to be made to the new PSU.
5. Start to connect the Power Filter DC wires to the PSU before fixing the plate to the box.
6. Switch on the system and check for the correct voltages listed in Volume 2 Section
6.5.1.
7. Run an image and check for quality.
5.2.1.1 LSB Fan Replacement

See Figure 5.1
1. Access the RFI box.
1. Detach the inline connector.
2. Remove the fan from the mounting bracket (posidrive screws).
3. When replacing the new fan, make sure it has the correct orientation.
5.2.1.2 Power Filter PCB Replacement

See Figure 5.1.
1. Access the RFI box and the Engine service side.
2. Remove the four interface connectors from the service side and detach the cables.
3. Detach the 4-off cables from the inside of the RFI box.
4. Detach the PCB from the rear and the side of the RFI box (4-off posidrive).
6. Switch on the system and check for the correct voltages listed in Volume 2 Section
6.5.1.
7. Run an image and check for quality.
EODD PCB Replacement

CAUTION: Wear an anti-static wrist-strap when handling the EODD.
See Figure 5.1.

1. Disconnect the four cable connectors.
2. Remove the PCB from the box mounting pillars (5-off posidrive screws).
4. There are no special checks for this PCB, but confirm system operation by running beam
coincidence checks and typical customer jobs. See also Volume 3 Section 4.2.
5.2.1.3 System PCB Replacement

NOTE: This section has new been replaced by the Guide Update in Appendix B.
See Figure 5.1.

1. Save the NVRAM parameters to the HDD using the main> command:
diagnostics/log_utils> save_nvram
2. Switch off the machine.
3. Disconnect the LSB interface connectors from the service end and remove the 3-off
posidrive screws to the PCB interface connector.
4. Disconnect the LSB cables from the interior of the RFI box, see Volume 2 Figure 6.15.
5. Remove the LSB by removing the 5-off posidrive screws holding the PCB to the box
pillars.
7. Make sure the Dongle PCB is swapped if it is not supplied.
8. Reboot the machine and download the firmware to the newly-installed LSB ensuring
that it matches the CAN node (slave) PCBs. If they do not match, the system may not
function correctly.
9. Reboot the machine. If the terminal displays the following error message it is because
the the new LSB is not correctly configured for the machine type. If the machine boots
without a problem then move to step 10).
System crash!!
Forcing GDB breakpoint (interrupt masked)....
A) Switch off the machine at the mains and reboot, stopping at the first Ctrl-c message
on your terminal.
B) Type machine at the prompt to get the following options:
main> machine
Use <- or -> to select the machine type
machine type: Luxel Vx96000CTP/b8_auto_web (Violet B1 Auto Web)

C) Use the arrow keys to change the machine type to select the machine type:
Luxel V6000CTPM/b4_manual_punch (Violet B2 Manual Punch)
Luxel Vx6000CTPM/b4_manual_web (Violet B2 Manual Web)
Luxel Vx9600CTP/b8_auto_web (Violet B1 Auto Web)
Luxel V9600CTP/b8_auto_punch (Violet B1 Auto Punch)
Luxel P-9600CTPM/boxer8_manual (Green B1 Manual Punch)
Luxel P-9600CTP/boxer8_plate (Green B1 Auto Punch)
Luxel F4080/sumo4_film (Sumo 4 page config.)
Luxel/production (Production config.)
UNKNOWN
D) select the correct machine type and press [Return].
10. Reboot the machine and stop at the second Ctrl-c.

11. Run the command, restore_nvram, from Log_utils to restore the parameters from HDD.
12. Update Configuration data from the Registry using the diagnostics command:
test/registry> update_registry system
and follow the screen instructions.
13. Check if the revised details are valid by running the Reg_power test:
test/registry> reg_powerup
14. Expose a test page and check for quality.
5.2.1.4 HDD Replacement

See Volume 2 Section 6.6.3.
If the HDD is to be replaced, you will lose all HDD files and will need to regenerate
them after replacement.
If the LSB and HDD is to be replaced, you will lose all NVRAM parameters, as well as
other system information, and this data will need to be entered manually after replace-
ment.
If the two are to be replaced together, then before replacing either assembly, enable cap-
ture text and record the system serial number, build date and final test date using the
diagnostic display_registry, see Volume 2 Section 1.8.3.
After replacement, when running diagnostic update_registry, you will be asked for this
information. Also, you will need to manually restore all NVRAM parameters using the
Savelog NVRAM file and the snv command in the development menu.
Store Required HDD Files
1. Keep a hard copy of the cassette database by enabling capture text and running the
command:
service/dbases/cassette_dbases/dumpc
2. Create a text file containing the NVRAM values using the command:
main> tnv
then transfer the text file to the RIP PC using Savelog.

Replace the HDD
1. Disconnect the PWR and DATA cables from the two drives.
2. Remove the 1-off posidrive screw holding the HDD mounting bracket to the RFI box.
3. From the front of the RFI box, remove the 6-off posidrive screws holding the disk drive
to the bracket and remove the complete assembly.
4. Configure the new drive for the correct ID. The drive's default factory setting should be
correct.
5. Replace the drive and HDD assembly.
Restore and Check HDD Files
1. Save the NVRAM values:
log utils> save_nvram
2. Update the System Registry, see Volume 2 Section 1.11.
3. Restore the PIs, see Volume 2 Section 1.13.
4. Transfer the Media Database from the RIP server using information in the relevant RIP
manual.
5. Restore the Cassette Database from the Change Cassette menu on the MMI. The original
database settings are stored in the old HDD dumpc file.
6. Recreate the ND char file:
log_utils> nd_char
7. Check that the correct file has been replaced on the new HDD.
If the HDD and LSB are being replaced, then before storing the required HDD files,
enable capture text and run the diagnostic display_registry system.
5.3 Replacing Interlock and Power Modules

5.3.1 Mains Filter Box
This box is located at the service end underneath the mains on/off switch. See also Vol-
ume 2 Section 6.2.2.
WARNING: Make sure the power supply is switched off at the mains distribution or the
power cord is detached from the machine before servicing the mains filter box.
In the event of failure replace the complete assembly as an FRU.
5.3.2 Interlock Box

See Figure 5.3 and Volume 2 Section 6.3.5.
FUSEHOLDERS
AND 3-OFF FUSES
(SEE NOTE)
INTERLOCK
CONTACTOR
INTERLOCK PWR 1
COMPRESSOR
MONITORING
RELAY (BV31) INTERLOCKS
MODULE
TERMINAL
BLOCK SHUTTER
(LASER ON/OFF)
END STOP
SURGE
SUPPRESSOR
RAIL
PWR 3
PWR 2
PSU
(30W +24V)
POWER IN
PSU MAINS EMERGENCY

COVER
VAC
OVERCURRENT
ON/OFF SWITCH CIRCUIT BREAKER
(CIRCUIT 24V FUSE
BREAKER) (0.5A 250V)
VAC PUMP
RELAY (BV5)
LED
DIAGNOSTICS
VAC PUMP (2) MAINS_RFI_IN COMPRESSOR
MAINS_DIST
VAC PUMP (1)
Figure 5.3 Interlock box - general view
Items inside this box are replaced as separate FRUs.

APPENDIX
QUICK REFERENCE DATA

This appendix provides a quick reference for the service engineer to operate sensors,
solenoids and motors.
4
4
Useful Service Commands ..................................................................................................... A-1
4
Useful Service Sensor Tests .................................................................................................. A-2
4
Sensor Listing.......................................................................................................................... A-2
4
Solenoid Listing....................................................................................................................... A-4
Motor Listing ............................................................................................................................ A-4
A.1 Useful Service Commands

Table A-1 to Table A-4 list some of the more useful service commands for actuat-
ing motors, sensors and solenoids.
Table A.1 Useful Service commands

Command Device Sensor/Motor Result
actuators/set bm28 on Z-direction BM28,BS63,BS70 Z-direction up
actuators/set bm28 off Z-direction BM28,BS63,BS70 Z-direction down
actuators/set bm27 on X-door BM27,BS62,BS71 X-door up
actuators/set bm27 off X-door BM27,BS62,BS71 X-door down
actuators/set bm20 on Cassette forward BM20,BS41,BS42 Cassette forward
actuators/set bm20 off Cassette forward BM20,BS41,BS42 Cassette reverse
actuators/set bm23 off Nudger lift BM23,BS45,BS46 Nudger down
actuators/set bm23 on Nudger lift BM23,BS45,BS46 Nudger up
actuators/set_drv bm22 on Nudger rollers BM22 Nudger rollers rotate
actuators/set_drv bm22 dis Nudger rollers BM22 Nudger rollers stop
actuators/set bm25 off Retard BM25,BS56,BS57 Retard down
actuators/set bm25 on Retard BM25,BS56,BS57 Retard up
actuators/set bv20 on Diverter BV20 Diverter down
actuators/set bv20 off Diverter BV20 Diverter up
actuators/set_drv bm24 on Interleave rollers BM24 Interleave rollers rotate

A-2 Q UICK R EFERENCE DATA
Table A.1 Useful Service commands (Continued)

actuators/set_drv bm24 off Interleave rollers BM24 Interleave rollers stop
motors/set stack Stack height BM21 Select stack motor
motors/move 2000 f 400 Stack height BM21,BS61 Moves stack up
motor/offstation 0 400 Stack height BM21,BS44 Moves to home
A.2 Useful Service Sensor Tests

Table A.2 Useful service sensor tests
Command Device Sensor/Motor Result
sensors/read_s bs47 Stack position BS47 Paper in front (on); paper removed (off)
sensors/read_s bs65 Cassette at nudger BS65 Hold in microswitch (off); release microswitch (on)
actuators/set bv20 on Diverter BV20 Paper under diverter (down); remove paper (up)
sensors/read_s bs53 Paper tensioner BS53 Paper under diverter (on); remove paper (off)
sensors/read_s bs66 Interleave nip clear BS66 Paper under diverter (on); remove paper (off)
sensors/read_s bs43 Cassette empty BS43 Paper in front (off): remove paper (on)
sensors/read_con ip Cassette IDs BS36 to BS40 Paper in front (off); paper removed (on)
A.3 Sensor Listing

Table A.3 Sensors
Sensor Description FHMB Sensor Description FHMB Sensor Description FHMB
BS1 INPUT FHMB 1 BS41 CASS FWD FHMB 2 BS81

ENTRANCE LIMIT
BS2 INPUT EXIT FHMB 1 BS42 CASS REV FHMB 2 BS82

LIMIT
BS3 PLATE IN FHMB 4 BS43 CASS FHMB 3 BS83

PUNCH EMPTY
BS4 OUTPUT FHMB 4 BS44 STACK FHMB 3 BS84

ENTRANCE HEIGHT
HOME
BS5 OUTPUT FHMB 4 BS45 NUDGER FHMB 3 BS85

EXIT DWN
BS6 PUSH BAR FHMB 4 BS46 NUDGER UP FHMB 3 BS86

HOME
BS7 BS47 STACK FHMB 3 BS87

HEIGHT
BS8 PUNCH FHMB 1 BS48 NUDGER FHMB 3 BS88

MOTOR ON DETECT
BS9 PUNCH MTR FHMB 1 BS49 RETARD FHMB 3 BS89

OFF MADE
BS10 REG FHMB 4 BS50 PLATE PRE FHMB 3 BS90

MOTOR DIV
OUT
BS11 REG MTR IN FHMB 4 BS51 PAPER POST FHMB 3 BS91

DIV TOP
L UXEL P LATESETTER A-3
Table A.3 Sensors (Continued)

BS12 CENTER- FHMB 4 BS52 PARK PRE FHMB 3 BS92
ING RH INPUT
BS13 CENTER- FHMB 4 BS53 LAZY LOOP FHMB 3 BS93

ING LH
BS14 CENTER- FHMB 4 BS54 BS94

ING HOME
BS15 PUSH BAR FHMB 1 BS55 PAPER POST FHMB 3 BS95

FWD DIV UND
BS16 BS56 RETARD UP FHMB 3 BS96
BS17 BS57 RETARD FHMB 3 BS97

DOWN
BS19 BUFFER FHMB 4 BS59 PLATE PAST FHMB 3 BS99

ENTRANCE DIVERTER
BS20 BUFFER FHMB 4 BS60 BS100 REG PIN HOME FHMB 4

EXIT (WEB)
BS21 FAST FHMB 4 BS61 STACK FHMB 3 BS101

PHOTO DET HEIGHT TOP
BS22 BS62 X DIR DOOR FHMB 2 BS102

UP
BS23 BS63 Z DIRECTION FHMB 2 BS103 REG PIN OUT FHMB 4

UP (WEB)
BS24 BS64 BS104 REG PIN CONTI- FHMB 4

NUITY (WEB)
BS25 BS65 CASSETTE FHMB 3 BS105

AT NUDGER
BS26 BS66 INTER NIP FHMB 3 BS106

CLEAR
BS29 BS69 BS109 SWING ROLLER FHMB 4

HOME (WEB)
BS30 ELEVATOR FHMB 2 BS70 Z DIR DOWN FHMB 2 BS110 SWING ROLLER FHMB 4
OVER TOP IN (WEB)
BS31 ELEVATOR FHMB 2 BS71 X DIR DOOR FHMB 2 BS111

OVER BTM DWN
BS32 ELEVATOR FHMB 2 BS72 CASS DOOR FHMB 2 BS112 PUSH BAR FWD FHMB 4
SHELF 1 CLOSED (WEB)
BS33 ELEVATOR FHMB 2 BS73 ELVATOR FHMB 2 BS113 MANUAL FHMB 1

SHELF 2 MTR DISA- CENTERING
BLED HOME
BS34 ELEVATOR FHMB 2 BS74 VECTOR FHMB 2 BS114 MANUAL FHMB 1

SHELF 3 ALARM CENTERING
CONT
BS35 BS75 VECTOR FHMB 2 BS115

OVERLOAD
BS36 CASS ID 1 FHMB 2 BS76 FRONT FHMB 2 BS116 MANUAL PLATE FHMB 1
DOOR PUSHER HOME
BS37 CASS ID 2 FHMB 2 BS77 DOCKING RH FHMB 2 BS117
BS38 CASS ID 3 FHMB 2 BS78 DOCKING LH FHMB 2 BS118 MANUAL PLATE FHMB 4
ON PLATEN
OPTO
BS39 CASS ID 4 FHMB 2 BS79 CHAD TRAY FHMB 4 BS119

Table A.3 Sensors (Continued)

BS40 CASS ID 5 FHMB 2 BS80 MIXER FAN FHMB 1 BS120 DRUM TEMPER-
DETECT ATURE
A.4 Solenoid Listing

Table A.4 Solenoids
Sole- Description FHMB Sole- Description FHMB Sole- Description FHMB
noid noid noid
BV1 BV21 BV41 AIR KNIFE SOL FHMB 4
BV2 BV22 CASS DOOR FHMB 2 BV42

LOCK
BV3 MIXER FAN FHMB 1 BV23 PLATE FEED FHMB 3 BV43

RELAY PUMP
BV4 BV24 24V ON/OFF FHMB 3 BV44
BV5 DRUM VAC FHMB 4 BV25 DOCKING FHMB 2 BV45

SOL LIGHT
BV8 EXT ALERT FHMB 1 BV28 BV48

RELAY
BV9 BV29 BV49
BV10 BV30 DIVERT FHMB 4 BV50

VALVE
BV11 BV31 BLOW COM- FHMB 4

PRESSOR
BV20 DIVERTER FHMB 3 BV40 LEADING FHMB 1

EDGE VALVE
A.5 Motor Listing

Table A.5 Motors
Motor Description FHMB Command Motor Description FHMB Command
BM1 INPUT BAND FHMB 1 actuators>set_drv BM21 STACK FHMB 3 motors>setmotor

HEIGHT
BM2 PUSH BAR FHMB 1 motors>setmotor BM22 NUGER & FHMB 3 actuators>set_drv
TAKAWAY
BM3 CENTERING FHMB 4 motors>setmotor BM23 NUDGER FHMB 3 actuators>set

LIFT
BM4 PUNCH FHMB 1 actuators>set BM24 INTER- FHMB 3 actuators>set_drv

LEAVE
DRIVE
BM5 REG PIN FHMB 4 actuators>set BM25 RETARD FHMB 3 actuators>set

(PUNCH) DROP
BM6 OUTPUT (DC) FHMB 4 actuators>set_drv BM26 ELEVATOR FHMB 2 medtran>move_elevat

or
BM7 BUFFER FHMB 4 motors>setmotor BM27 X DIR DOOR FHMB 2 actuators>set
BM8 BM28 Z DIR CTRL FHMB 2 actuators>set

L UXEL P LATESETTER A-5
Table A.5 Motors (Continued)

BM10 MAN/SEMI FHMB 1 motors>setmotor BM30
PLATE
CENTERING
BM11 MAN/SEMI FHMB 1 motors>setmotor BM31

PLATE
PUSHER
BM16 BM36 REG PIN FHMB 4 actuators>set

(WEB)
BM17 BM37 SWING FHMB 4 actuators>set

ROLLER
(WEB)
BM18 BM38 MAN/SEMI FHMB 4 motors>setmotor

OUTPUT
(STEPPER)
BM19 BM39
BM20 CASSETTE FHMB 2 medtran>load_cas BM40

FWD sette
APPENDIX
GUIDE TECHNICAL UPDATES

This SIO appendix provides the latest technical descriptions and procedures to current
Issue 04 for engineers previously trained with Issue 03 (or earlier).
Once the pages are downloaded and printed, insert them into your Engineers Reference
Guide.
4
4
Luxel System PCB Replacement ........................................................................................... B-1
4
Laser Temperature and Humidity Control............................................................................. B-4
4
Aperture Control Replacement .............................................................................................. B-6
4
Punch, Registration and Centerer (Fuji)................................................................................ B-9
Vacuum and Air Control........................................................................................................ B-16
B.1 Luxel System PCB Replacement

CAUTION: Wear an anti-static wrist-strap when handling the System PCB.

1. Save the NVRAM parameters to the HDD using the main> command:
diagnostics/log_utils> save_nvram
2. Switch off the platesetter and the RIP PC.
3. Disconnect the LSB interface connectors from the service end and remove the 4-off
posidrive screws to the PCB interface connector.
Loosen the LSB fan mounting screws and remove the LSB fan for access to the
LSB.
4. Disconnect the LSB cables from the interior of the RFI box, see Volume 2 Figure 6.15.
5. Remove the LSB by removing the 5-off posidrive screws holding the PCB to the box
pillars.
NOTE: The dongle, if fitted on the old PCB, is not required on the new PCB.
7. Power on the RIP PC and start the diagnostics Hyperterminal.

B-2 G UIDE TECHNICAL U PDATES
8. Reboot the Engine and stop at the first [Ctrl-c] message.

A) Type machine at the prompt to get the following options:
main> machine
Use <- or -> to select the machine type
machine type: Luxel Vx96000CTP/b8_auto_web (Violet B1 Auto Web)
B) Use the arrow keys to change the machine type:
Luxel Vx9600CTP/b8_auto_web (Violet B1 Auto Web)
Luxel V9600CTP/b8_auto_punch (Violet B1 Auto Punch)
Luxel P-9600CTPM/boxer8_manual (Green B1 Manual Punch)
Luxel P-9600CTP/boxer8_plate (Green B1 Auto Punch)
Luxel/production (Production config.)
UNKNOWN
NOTE: Web refers to a machine without a punch; manual refers to a Manual or Semi-
Automatic machine; Auto refers to a Fully-Automatic machine.
C) Select the correct machine type and press [Return].

D) Type y at the Reset Now? prompt, then stop at the first [Ctrl-c] message.
9. Download the firmware to the LSB only.
A) Make sure the boot firmware is the same as the other CAN BUS PCBs. If not,
download the correct boot firmware to match the other PCBs. This is the file
named b8_auto_punch_ssb_boot.hex for all variants (V-9600, Vx-6000,
Semi-Automatic, Manual and Fully-Automatic).
B) Download the application firmware to the LSB to match the other PCBs. The
filename for this file includes the machine variant and ends as
_ssb_recorder.hex.
CAUTION: Make sure the firmware on the newly-installed LSB matches the CAN node
PCBs. Failure to match will cause the system to malfunction.
10. Reboot the machine and stop at the second [Ctrl-c].

11. Run the following command to restore the parameters from HDD:
log_utils> restore_nvram
12. Update Configuration data from the Registry using the diagnostics command:
test/registry> update_registry
and follow screen instructions.
Check for the message: Update Registry: PASSED.
13. Check if the revised details are valid by running the Reg_power test:
test/registry> reg_powerup
L UXEL P LATESETTER B-3
14. Reboot the machine and the RIP PC.

15. Expose a test page and check for quality.
B.2 Laser Temperature and Humidity Control

B.2.1 Operation
See Volume 2 Figure 5.3 showing the location of the temperature and humidity
module inside the optics base.
Temperature and humidity levels of air around the laser blocks, shown in Vol-
ume 2 Figure 5.3, are monitored from a Temperature/Humidity Sensor PCB
mounted on a bracket located inside the laser enclosure. The PCB includes sepa-
rate temperature and humidity sensors shown in Figure B.1.
The purpose of the module is to detect when the moisture content of air in con-
tact with the laser block is high enough to cause condensation. The laser block is
regulated at 25C so that air surrounding the block surface will be cooled to
25C.
Moisture content of air is measured by its dew point temperature. Dew point
temperature is defined as the temperature to which air would have to cool in
order to reach saturation. A state of saturation exists when air is holding the
maximum amount of water vapour possible at the existing temperature and
pressure. If the dew point of air surrounding the laser block is above 25C, water
will condense onto the surface of the block.
The system uses measured air temperature to calculate the air humidity at
which condensation would occur. If measured humidity is within 10% RH of a
calculated value then the laser temperature regulator is switched off. Switching
off the regulator allows the block to warm up to the same temperature as its sur-
roundings, so that air coming into contact with the block is no longer cooled.
Since air is not cooled, condensation does not occur.
The humidity sensor in each module is individually calibrated and has two
associated NVRAM parameters:
RH ZERO OFFSET: voltage out at 0% RH
RH SLOPE: the rate of change of output voltage with relative humidity.
If the module is replaced, new NVRAM values are always re-entered, see Sec-
tion 2.3 on page B-5.
Current temperature and humidity levels are read using the main diagnostics
laser menu (development) commands:
read_optics_temp
read_optics_humidity
Specific error codes for indicating dew point warning levels are described in the
MMI Errors Guide.
See also Volume 2 Figure 5.18 showing the module connection to the VBOMB.
TP1 TP2
TEMP
SENSOR
HUMIDITY
SENSOR
PL2
Figure B.1 Temperature and humidity PCB layout
B.2.3 Module Replacement

CAUTION: Always switch off the machine BEFORE removing the disconnecting the Tem-
perature/Humidity PCB.
CAUTION: Do not touch the humidity sensor shown in Figure B.1.

2. Note the new NVRAM values marked on the replacement module.
3. Access the laser modules enclosure (fit the PAT and optics service manifold).
4. Disconnect the connector from the temperature/humidity module.
5. Remove the 2-off Allen screws holding the module to the base.
6. Refit the new module and the module enclosure.
7. Switch on the platesetter and enter the new NVRAM values for:
RH_ZERO_OFFSET
RH_SLOPE
B.3 Aperture Control Replacement

The aperture mechanism will be supplied fitted with a 48 res lens. During manufacture
the optics base V-groove stands are optimised for the fitted lens. It will be necessary to
move the original lens (L3) to the new aperture mechanism, otherwise there may be an
excessive 48 res registration error visible on the plate.
B.3.1 Preparation
1. Record the Power Margin figures in NVRAM.
log_utils> disp_nvram POWER_MARGIN_LO
log_utils> disp_nvram POWER_MARGIN_MID
log_utils> disp_nvram POWER_MARGIN_HI
Record the Power Balance working drive figures in NVRAM.
log_utils> disp_nvram LD*DRIVE*DAC
2. Save a text copy of the NVRAM as a precautionary measure, using the RIP
Savelog function.
3. Prepare the PAT Optics Service Manifold and turn on the PAT.
B.3.2 Replacement Procedure

1. Set the aperture to the 96 res position
optics/motors/move_motors> beam_res_pos 96
2. Power down the machine.
3. Remove the 11-off screws holding the optics lid in place and immediately fit the
PAT Optics Service Manifold to prevent optics contamination.
4. Remove 5-off screws from the Aperture cover and take out carefully, to avoid
snagging the cables. These are most easily removed using straight-ended T-bars.
5. Disconnect the Aperture Home sensor cable (red sleeve) from the sensor.
6. Disconnect the Aperture motor cable (black sleeve) from the motor.
7. Remove the 4-off screws holding the Aperture mechanism to the Optics Base
and remove the mechanism.
8. Note the orientation of the lens before removing as it is possible to fit it on
backwards. Mark the lens holder to indicate its orientation.
9. Using a flat-bladed screwdriver, supporting the lens from below, undo the
shoulder bolt and retain the spring and washer. Repeat with the new
mechanism.
10. Replace the old lens into the new mechanism.
CAUTION: Do not to cross thread the shoulder bolt in the lens hole and fit the lens the
correct way around.
11. Replace the mechanism into the optics, locating on the dowel pins and replace
the fixing screws.
12. Attach the Aperture Home and Aperture motor cables to the mechanism.
B.3.3 Setting up Procedure

1. The following operations assume a 2-beam machine. If it is a single beam, use
the available beam.
2. The X and Y beams need to be centered on the 72 res aperture.
3. From diagnostics run:
development/nvram> snv LD_X_MRES_WORKING_DRIVE_DAC 1000
development/nvram> snv LD_Y_MRES_WORKING_DRIVE_DAC 1000
4. Switch on both the X beam (LD1) and the Y beam (LD3) lasers, set the ND
mechanism to 80. This is to allow laser light to pass, but will reduce the power of
the beam and hence the laser hazard. A higher ND reading can be chosen if
necessary to view the beams easily. The LPD is closed to avoid laser light
entering the drum, and so it is ready to read laser power.
optics/motors/move_motors> close_pos_lpd
optics/laser> lenable 1 drive 72
optics/laser> lenable 3 drive 72
optics/laser> x_beam_enable
NOTE: The lasers may turn off after some time (software timeout). If this happens then
you will need to repeat the 3 optics/laser> commands above to restore laser light.
motors> setmotor nd
motors> offstation 80 600
5. Set both deflectors to 800 (a hexadecimal value, equivalent to zero deflection).
development/optics/eodd> eodx_deflect 800
development/optics/eodd> eody_deflect 800
6. Set the aperture mechanism to the 72 res position.
optics/motors/move_motors> beam_res_pos 72
7. Block the X beam using a card so that only the Y beam passes through the optics.
8. Observe the laser light falling on the aperture.
9. Adjust the aperture position by eye to centre the Y laser beam halo around the
aperture.
The two screws holding the aperture to the bracket will need to be loosened but
still retain some spring pressure.
10. Increase the ND position to 150:
motors> offstation 150 600
11. Read the Y beam LPD value:
sensors> read_sensor pdet
NOTE: If a single beam machine, adjust the aperture position to maximise the LPD read-
ing, then continue from step 27.
12. Move the card to allow the X beam to pass and to block the Y beam
13. Read the X beam LPD value and compare with the Y beam value
sensors> read_sensor pdet
14. Alter the position of the aperture until the X beam and Y beam values are within
5% of each other.
15. Tighten the screws holding the aperture to the bracket.
16. Set the aperture to the 48 res position (step 630).
17. Visibly check on L5 that the small 48 res beam is fairly well centred on the L5
lens and the washer underneath the shoulder bolt is free-moving (this means
that the lens is firmly sitting on the V-grooves). The lens position will have been
set correctly in the factory.
18. Turn off the lasers:
laser> ldisable 1
laser> ldisable 3
19. Refit the aperture cover.
20. Refit the optics cover.
21. Run the set-up procedures (see Volume 3 Table 4.1), for the aperture assemblies,
in order to correctly set up the optics and NVRAM.
22. Run exposure calibration again (run it as part of the aperture assemblies set up
procedures, see Volume 3 Table 4.1.
23. Check the Power Margin figures in NVRAM.
log_utils> disp_nvram POWER_MARGIN_LO
log_utils> disp_nvram POWER_MARGIN_MID
log_utils> disp_nvram POWER_MARGIN_HI
A significant improvement in any of the power margin figures indicates that a
problem in that resolution, caused by the aperture mechanism, has cleared. The
Power Margin figures should all be positive numbers for successful exposure
calibration.
B.4 Punch, Registration and Centerer (Fuji)

This punch (referred to as Fuji In-house) is an advanced design on the old and new ver-
sions of the Billows punch. It uses similar ID numbering for motors and sensors, and
includes the registration, centerer and punch modules that operate in a similar way to the
Billows punch. New features for the Violet punch include:
Fabricated in aluminium as a complete casting.
Chad control using Beryllium copper wiper strips to prevent chad collecting inside
the die.
Accessible sensors and motors for improved servicing.
Facility to extend the service life of the punch crop pins.
B.4.1 Punch Assembly Removal

B.4.1.1 Accessing the Assembly
See Figure B.2 and Figure B.3.
A complete punch assembly (including motors, cables and drag chain) is supplied if the
old punch needs to be replaced.
The assembly sits on two dowels fitted to the drum casting to allow for accurate
location. You do not need to remove the punch motor beforehand.
1. Move the traverse to the user end.
2. Lower the Buffer to its service position, see Volume 3 Section 2.5.1.
5. Remove the output module, see Volume 3 Section 2.4.4.1.
B.4.1.2 Removing the Assembly

CAUTION: If you are replacing a Billows on a Green machine with a Fuji punch, then the
output exit guide needs to be replaced and the output raised to avoid fouling the center-
ing arms.
CENTERING
S10 MOTOR
S14
(BM3)
REG PIN
ARM (LH) ARM (RH)
S13
BS3
PIN/DIE/ A
S12 CHAD WIPER
PUNCH
MOTOR
CENTERING (BM4)
MOTOR BS8/9
S11
REG PIN
CAM

CENTERING FINGERS
ON HIDDEN SIDE
REG PIN
REG PIN DC MOTOR
ACTUATING (BM5)
ARM
UNDERNEATH
Figure B.2 Punch, registration and centerer assemblies
6. Remove the punch motor (optional).

A) punch motor and sensors (service side)
B) registration motor and sensors (rear of Engine)
C) centering motor and sensors (rear of Engine and both ends)
A) Remove the 8-off M6 bolts set in pairs.
B) Using one person at each end, lift out the assembly. Lift by first raising the
user end slightly. Avoid lifting from the drag chain.
C) Check that the two dowels are still in position in the drum.
9. The complete assembly is serviced by laying it between the two cutouts on the
wooden transit fittings used for the Autofeeder.
M6 BOLTS M6 BOLTS
LOWER
BEAM
SUPPORT
DRUM
CASTING
DOWEL LOWER
BEAM
SUPPORT
SERVICE
SIDE
Figure B.3 Removing the punch assembly
B.4.1.3 Complete Punch Replacement

2. Make sure the drum surface is fully protected by heavy cardboard.
4. Screw in (but do not tighten) the 8-off M6 bolts from the outside towards the
middle of the punch.
5. Manually check that a large plate can enter and exit the punch correctly without
scratching. Check that the leading edge is picked up by the first output module
roller.
6. Tighten the M6 bolts from the centre outwards. Do not overtighten the bolts -
the aluminium fixing hole threads in the drum are easily damaged.
B.4.1.4 Punch Adjustments and Checks

tions have been completed. Use the command to check the NVRAM parameter:
diagnostics/log_utils> dis_stats
Note that the punch pins can be removed and replaced with the opposite end
operating as the punch surface. See`Replacing the Punch Pins' on page B-12.
Volume 3 Figure 2.21 shows a typical view of the pins, guide and die for a full
punch mechanism.
B.4.1.4.1 Visual Plate Punch Check

last service visit.
2. Run a punch job from the RIP.
tion is 50 microns)
4 crops are cleanly cut without debris in corners or burrs (See `Replacing
the Punch Pins' on page B-12.
4. Check for correct chad removal, making sure the chad is `flicked' off each pin by
the strips.
NOTE: Refer to Fujifilm Customer Support for more information on removing pins, dies
and guides if there is a problem in setting up the punch mechanism.
NOTE: Do not operate BM4 and BM5 manually. This could cause the wiper to be damaged
and chad to drop into the drum.
B.4.1.4.2 Punch Checks

B.4.1.5 Replacing the Punch Pins

See Figure B.4.
The Fuji punch pins are able to cut at both ends by removing, turning and replacing them
during a service visit after checking if there are signs of burring around the punch holes.
Use the following procedure to obtain a clean cutting edge:
1. Remove the punch support plate and motor using the procedure in See `Removing the
Punch Motor' on page B-13.
2. Gradually move the actuating lever until the stud appears at the stud clearance hole
(top).
3. Using an 8 mm Allen key (T-bar or right-angled key) remove the stud from the hole.
NOTE: The stud is secured by Loctite and requires extra force to break the seal.
4. Extract the pin from the pin clearance hole directly behind, turn the pin around and
replace.
5. Refit the stud (with Loctite) and screw down until it stops, then wind back one half
screw turn.
6. Replace the punch motor support plate.
7. Check that the punch operates (without a plate) by manually operating the punch from
the actuating lever.
CAUTION: Do not operate BM4 and BM5 from Diagnostics or manually. This could cause
damage to the wiper and eventually lead to chad inside the drum.
ACTUATING
LEVER
ACTUATING
SHAFT
REMOVE
STUD
REMOVE
PIN
Figure B.4 Servicing the punch pins
B.4.1.6 Removing the Punch Motor

This procedure is completed from the service side without removing the com-
plete punch assembly.
See Figure B.5.
1. Disconnect the inline cables to the motor and sensors (BS8 and BS9).
2. Remove the punch motor support plate assembly with its motor and gear (4-off M5
bolts). You do not need to retract the pins beforehand.
3. When replacing the motor and plate assembly, add a small amount of light engineering
grease to the cam/lever slot hole. Make sure the DC wires are correctly orientated.
4. Check that the punch pins actuate correctly by moving the actuating arm.
CAUTION: Do not operate BM4 and BM5 from Diagnostics or manually. This could cause
damage to the wiper and eventually lead to chad inside the drum.
PUNCH MOTOR
BS8
SUPPORT PLATE
(ON)
MOTOR/GEAR BS9
(BM4) (OFF)
Figure B.5 Punch bracket and motor
B.4.1.7 Replacing the Chad Wipers

See Figure B.6.
Chad wipers, made of Beryllium copper, are replaced every six months to avoid the
build-up of chad at the punch exit. Use the following procedure:
1. Remove the punch deflector shield (3).
2. Remove the wiper with its snap rivet.
If the punch is a a DS type then trim the wiper for the round punch holes, as
shown in Figure B.6.
3. Refit the wiper and rivet making sure it is seated on top of the bracket.
Refit the shield.
4. Run a punch job from the RIP and check that chad does not drop into the drum.
CHAD
WIPER
SNAP
RIVET
PUNCH DIE
6 mm
CHAD
CUT CUT WIPER
WIPER
MOUNTING
BRACKET
DS (ROUND) CHAD DEFLECTOR
WIPER TRIM SHIELD
Figure B.6 Removing the chad wiper

B.5 Vacuum and Air Control

NOTE: Replace the old version of Volume 2 Chapter 7 with the new version issued in this
Guide (04).
I NDEX
functional description, 2-5-12
A Billows
Absolute Limit sensor check, 3-1-12 Centerer
assembly, 2-3-96
Absolute Phase description, 2-3-93
check, 3-4-45 Punch
Actuators control mechanism, 2-3-94
description, 2-4-13 Registration Module
Air Knife description, 2-3-93
compressor version, 2-7-18 Registration Pins
assembly, 2-3-95
fan blower version, 2-7-19
replacement, 2-7-20 Booting
Antistatic brush, 2-3-56 sequence, 2-1-4
Antistatic kit, 1-3-25 Booting up
earthing (grounding), 1-3-25 sequence of loading, 2-1-2
enclosures, 1-3-25 Buffer
field handling station, 1-3-25 accessing assemblies, 3-2-60
Aperture Buffer to Engine interconnections, 2-3-
functional description, 2-5-15 106
replacement, 1-B-6 control assemblies, 2-3-102
drive belts, 3-2-62
Application lowering the buffer, 3-2-57
loading firmware, 2-1-66 plate handling, 2-2-11
Autofeeder plate handling assemblies, 2-3-102, 2-3-
alignment with PTM, 3-2-7 104
plate handling operations, 2-2-20
control box, 2-3-9 plate handling sequence, 2-2-42
drive assemblies, 2-3-27 upper cover removal, 3-2-60
elevator assemblies, 2-3-24
inverter, 2-3-11
motors, 2-3-22
multi-cassette housing, 2-3-25 C
plate handling, 2-2-1
plate handling assemblies Cables
accessing, 3-2-4 Alert, 2-8-26
plate handling sequence, 2-2-21 CAN 2, 2-8-3
PTM interconnections, 2-3-105 CAN3, 2-8-10
sensors, 2-3-23 CAN3 INT, 2-8-13
solenoids, 2-3-22 CAN5, 2-8-8
disk drive power, 2-8-2
Elevator Control, 2-8-28
B Elevator In, 2-8-29
Elevator Lock, 2-8-30
Baffle EOD, 2-8-2
Feed Interlocks, 2-8-11
operation, 2-4-8 FHMB Power, 2-8-8
replacement, 3-3-4 interlocks, 2-8-1, 2-8-5
Ball Cage Mains, 2-8-2
replacement, 3-3-11 Mains Elevator In, 2-8-29
MMI, 2-8-4
Beam Co-incidence, 2-1-30 Power 3, 2-8-12
auto setup, 3-4-42 Processor, 2-8-32
Beam Combiner Processor Comms, 2-8-44
Vac Pump, 2-8-11
1-2 I NDEX
VBOMB optics cabling, 2-5-28 Error Codes, 2-1-10

Calibration global commands, 2-1-14
initialisation, 2-1-4
exposure, 3-4-51 introducing, 2-1-1
CAN log utilities, 2-1-19
Configuration files, 2-1-62 scripts, 2-1-18
network control, 1-2-33 see Main Diagnostic
Cassette see Main Diagnostics
introducing, 2-1-12
assemblies, 2-3-30
database diagnostics, 2-1-58 self tests, 2-1-8
starting, 2-1-13
Cassette Door system output data path checks, 2-1-9
solenoid, 2-3-20 Test Menu, 2-1-27
Cassette Forward Disk Drive
assembly, 2-3-52 replacement, 3-5-5
Cassette ID PCB, 2-3-45 description, 2-6-29
diagnostic commands, 2-1-46
CAUTIONS functional description, 2-6-29
disposable wrist strap, 1-3-25 storing config data, 2-1-64
exposed components, 1-3-24 Distribution PCBs
Health and Safety at Work, 1-3-1 Engine, 2-3-71
unearthed surface, 1-3-25 PTM, 2-3-43
Chad Tray, 2-3-101 DLA Curtain, 1-3-5
Coincidence Beam X laser radiation hazard, 1-3-5
setup, 3-4-44 opacity to blue light, 1-3-5
Coincidence Beam Y Warnings, 1-3-5
setup, 3-4-42 DLA Room, 1-3-4
Configuration Data Files laser warning notice, 1-3-4
red warning light, 1-3-4
menu commands, 2-1-22
using the utilities, 2-1-60 Dongles
Covers description, 2-6-29
opening, 3-1-3 Drive Rail Wiper
cleaning, 3-1-7
replacement, 3-3-7
D Drum
assembly, 2-3-90
Database removing end caps, 3-2-28
diagnostic commands, 2-1-58 Drum Vacuum
introduction, 1-2-15 interlock box circuits, 2-6-11
Debug Dust Contamination
using, 2-1-16 Dust contamination, 1-3-18
Deflection Absolute Phase, 3-4-45
Deflection Amplitude Beam Y
setup, 3-4-47 E
Devices Edge Detect
Safety, 1-3-17 description, 2-4-18
Diagnostics function check, 3-1-24
Boot-up tests sensor offset, 3-1-26
description, 2-1-4 Edge Detect PCB
Commands laser, 3-3-13
scripts, 2-1-18 replacement, 3-3-13
debug, 2-1-16 setup, 3-3-16
L UXEL P LATESETTER 1-3
Electro-Optic Deflector Feed Head

functional Description, 2-5-11 assembly, 2-3-55
replacement, 3-4-22 FHMB
Elevator operation, 1-2-7
absolute limit safety switch, 2-3-22 PCB description, 1-2-5
chains, 3-2-13 replacement, 3-2-3
contactor, 2-3-14 FHMB (1)
control box, 2-3-9
drive, 2-3-27 connectors, 2-3-62
Elevator Control PCB, 2-3-16 device controls, 2-3-65
Elevator Distribution PCB, 2-3-18 PCB description, 2-3-62
frame, 2-3-26 FHMB (2)
interlock controls, 2-3-14 connectors, 2-3-35
motor, 2-3-22 device controls, 2-3-37
Emergency Stop Control PCB description, 2-3-34
functional description, 2-6-9 FHMB (3)
Engine connectors, 2-3-40
see Imagining Engine, 1-1-7 device controls, 2-3-42
PCB description, 2-3-38
Environment
FHMB (4)
SSB monitoring, 1-2-30
connectors, 2-3-66
EODD device controls, 2-3-70
replacement, 3-5-4 PCB description, 2-3-66
EODD PCB Film Comparison Ruler
connectors, 2-6-24 creating, 3-4-55
functional description, 2-6-23 Firmware
EODHV upgrading, 2-1-66
functional description, 2-5-17 Focus Adjust
replacement, 3-4-25
Transformer (HV) functional description, 2-5-14
replacement, 3-4-25 setup, 3-4-38
Focussing Lens
Equipment
cleaning, 3-1-5
Unattended, 1-3-17
Fuses
Error Codes
FHMB (1), 2-3-36, 2-3-41, 2-3-63
listing, 2-1-10 FHMB (4), 2-3-68
self tests, 2-1-7 LSB, 2-6-27
sets of, 2-1-7 SSB, 2-6-24
Error Handling system fuses, 2-6-20
fatal error closedown sequence, 2-1-11
recovering from, 2-2-45
EVT G
diagnostic commands, 2-1-31
Gear Segment
Exposure Calibration, 3-4-51 replacement, 3-2-36
F H
Fans Hazards, 1-3-17
RFI box, 2-6-20 Chemical, 1-3-18
Fast Photo Detect Laser Radiation, 1-3-17
description, 2-5-25 Spinner, 1-3-18
replacement, 3-4-30 HDD
1-4 I NDEX
configuration files, 2-1-64

Health and Safety at Work, 1-3-1
L
Cautions, 1-3-2 Labels
Clothing and Jewellery, 1-3-2 Mains Rating, 1-3-5
Equipment and Tools, 1-3-2 Warning, 1-3-5
site safety, 1-3-2
Warnings, 1-3-2 Laser, 1-3-2
aging, 2-1-34
aging control, 2-5-30
I alignment, 1-3-4
attenuation, 1-3-4
Image beam, 1-3-4
enable/disable, 2-1-34
base offset check, 3-1-25 extinction ratio, 2-1-35
position and skew checks, 3-1-19 manual shutter, 1-3-2
set base offset, 3-1-22 module
set traverse centre, 3-1-21 functional description, 2-5-5
start position check, 3-1-24
replacement, 3-4-20
Image Form radiation, 1-3-3, 1-3-17
adjustments, 3-4-54 replacement commands, 2-1-24
horizontal check, 3-1-16 safety
Image Manager Safety, 1-3-2
diagnostic commands, 2-1-52 safety goggles, 1-3-4
service checks, 2-1-32
Imaging Engine Temperature and Humdity module, B-
accessing assemblies, 3-2-27 4
accessing modules, 2-6-1 temperature and humidity control, B-4
Distribution PCBs, 2-3-71 Temperature and Humidity module, 2-
motors, 2-3-75 5-9
plate handling, 2-2-7, 3-2-27 temperature and Humidity module
plate handling assemblies, 2-3-81 replacement, B-5
plate handling controls, 2-3-61 using test strips, 3-4-31
plate handling operations, 2-2-19
plate handling sequence, 2-2-26 Laser Power Detector
sensors, 2-3-77 functional description, 2-5-21
solenoids and relays, 2-3-77 replacement, 3-4-27
Input Module Linear Encoder
assembly, 2-3-87 description, 2-4-10
description, 2-3-87 Linear Scale
removal, 3-2-31 functional description, 2-4-11
Interleaf Diverter and Drive Loading Platform
assembly, 2-3-58 removal, 3-2-29
Interlock Box Log Utilities
functional description, 2-6-6 menu commands, 2-1-19
replacement, 3-5-6
Interlocks LSB
replacement, 3-5-4, 1-B-1
checking, 3-1-9 replacements, B-1
DLA external connector, 2-6-16
functional description, 2-6-11 LSB PCB
how to override, 3-1-2 connectors, 2-6-26
protective covers, 1-3-20 functional description, 2-6-26
safety features, 1-3-19 Luxel CTP
Inverter, 2-3-11 antistatic precautions, 1-3-24
configuration data files, 2-1-60
introducing, 1-1-2, 1-1-3, 1-1-6, 1-1-7, 1-
1-8
Buffer module, 1-1-9 schedules, 3-1-4

cassette, 1-1-6 Media
drum, 1-1-8 scanning system, 3-3-1
features, 1-1-1 Media Expose System
input/output modules, 1-1-8
accessing, 3-4-2
interleaf bin, 1-1-7 image optical path, 1-2-20
MMI console, 1-1-8 introducing, 1-2-17
optics base, 1-1-7 Media Scan System
plate processor, 1-1-9 Functional Description
plate stacker, 1-1-9 Spinner Control, 2-4-8
Plate Transport Module, 1-1-7 Traverse Initialisation, 2-4-17
RFI box, 1-1-8 operating description, 2-4-7
traverse carriage, 1-1-8 Media Tools
trolley, 1-1-6
using, 2-1-70
Luxel CTP Mirror (M2)
introducing adjusting, 3-4-54
Autofeeder module operation, 2-5-22
Autofeeder, 1-1-5 Mixer Fan, 2-3-81
MMI
M connectors, 2-6-31
console assembly, 2-6-30
Main Diagnostics Error Codes
accessing, 2-1-13 description, 2-1-10
Commands persistent images, 2-1-9
Test Menu, 2-1-27 replacement, 3-2-57
configuration files self tests, 2-1-7, 2-1-69
updating, 2-1-60 test image output, 2-1-9
touchpanel cleaning, 3-1-5
data base service, 2-1-58
Diagnostics menu, 2-1-6 MMI Setup menu, 2-1-37
disk service, 2-1-46 Modules
EVT menu, 2-1-31, 2-1-32
introducing, 2-1-6 plate handling, 2-2-1
media transport service, 2-1-54 Motors
NVRAM, 2-1-21 DC
optics menu, 2-1-32 tests, 2-1-9
optics motors service, 2-1-35 diagnostic commands (step), 2-1-37
optics service, 2-1-32 elevator (synchronous), 2-2-17
processor service, 2-1-53 Engine
remote menu, 2-1-32 assemblies, 2-3-75
sensors service, 2-1-39 optics
soak tests, 2-1-16 replacements, 3-4-16
spinner service, 2-1-45
stepper motors service, 2-1-37, 2-1-52 plate handling DC, 2-2-17
time service, 2-1-43 plate handling stepper, 2-2-16
traverse service, 2-1-43 stepper
verbose command, 2-1-15 tests, 2-1-8
Mains traverse, 2-4-13
filter box, 2-6-3
machine pre-requirements, 2-6-2 N
Maintenance
cleaning, 3-1-5 ND_char
procedures, 3-1-9 running, 2-1-60
procedures for punch machine, 3-1-17
procedures for Web machine, 3-1-23 Neutral Density
1-6 I NDEX
set up characterisation, 3-4-63 PCB

setting up characterisation tables, 2-1- plate handling, 1-2-5
60
setup, 3-4-41 Periscope
Neutral Density Filter functional description, 2-5-20
functional description, 2-5-12 Persistent Images
NVRAM installing on to HDD, 2-1-67
configuration files, 2-1-65 PIs
diagnostic commands, 2-1-21, 2-1-23 see Persistent Images, 2-1-9
saving/restoring, 2-1-65 Plate
image form check, 3-1-16
tint checks, 3-1-16
O Plate Guides
Optics assemblies, 2-3-59
calibration, 3-4-51 Plate Handling
diagnostic commands, 2-1-30 assemblies, 2-3-1, 2-3-51, 2-3-81
introducing, 1-2-17 Buffer, 2-3-104
lens common assemblies, 2-2-13
functional description, 2-5-16 handling sequence, 2-2-21
light-tight checks, 3-1-13 introducing, 1-2-3
media expose, 2-5-29 motors
mirrors description, 2-2-16
functional description, 2-5-16 operations, 2-2-18
optics_mmi setup menu, 2-1-37 reversing the cassette, 2-2-43
precautionary check, 3-1-11 sensors, 2-2-13
replacement setups, 3-4-3 Plate Transport Module
selecting macros, 3-4-35
system tests, 2-1-9 accessing assemblies, 3-2-15
test strips, 3-4-31 contamination control, 2-7-18, 2-7-19
VBOMB, 2-5-26 Distribution PCBs, 2-3-43
plate feed controls, 2-3-33
Optics Base plate handling, 2-2-4
modules, 2-5-1 plate handling assemblies, 2-3-4, 2-3-51
replacements, 3-4-1 plate handling operations, 2-2-18
Optics MMI plate handling sequence, 2-2-22
sensors, 2-3-47
Extra Options screen, 3-4-34 solenoids and relays, 2-3-47
Final Values screen, 3-4-33
Machine setup screen, 3-4-34, 3-4-35 Platen
tests, 3-4-31 removal, 3-2-30
Optics_MMI Position Detector (POD)
using the menu, 3-4-32 functional description, 2-5-13
Optics_mmi replacement, 3-4-23
running test strips, 3-4-37 Post-Failure Analysis
Output Module commands, 2-1-26
assembly, 2-3-88 Power
removal, 3-2-32 DC distribution, 2-6-4
DC generation, 2-6-19
inter-module cabling, 2-6-3
P Power balance
service check, 2-1-32
Paper Detect sensor check, 3-1-13 Power Filter
PAT replacement, 3-5-3
description, 2-7-21 Power Filter PCB
servicing, 2-7-22 connectors, 2-6-21
functioal description, 2-6-21 image form on plate, 3-4-54

Precautions Registration Module
antistatic, 1-3-24 replacement, 3-2-57
exposed components, 1-3-25 servicing, 2-3-99
Processor Registry
diagnostic commands, 2-1-30 see System Registry, 2-1-27
interface commands, 1-2-16 Remote Login
See Plate Processor, 1-1-9
system tests, 2-1-9 diagnostic commands, 2-1-32
PSU modules Retard Pad
functional description, 2-6-19 assembly, 2-3-57
replacement, 3-5-2 RFI Box
Punch assemblies/layout, 2-6-16
adjustments after refitting, 1-B-11 DC generation, 2-6-19
Billows RFI Filter, 2-3-10
accessing, 3-2-37
adjustments after refitting, 3-2-40, 3-
2-51 S
assembly, 2-3-93
Centerer Safety
checking, 3-2-45 chemical
pin checks, 3-2-42 Chemical, 1-3-19
Registration Pins electrical
checking, 3-2-44, 3-2-48 Electrical, 1-3-18
Centerer emergency stop, 1-3-22
laser
checking, 3-2-49 Laser, 1-3-2
centering, 3-1-20 mechanical
Fuji In-house Mechanical, 1-3-18
adjustments, 3-2-51
override key, 1-3-4
chad wipers, 3-2-54 signs, 1-3-5
download text, B-9 Spinner, 1-3-19
removal, 3-2-49 warnings, 1-3-4
remove motor, 3-2-53 Safety Warnings
replace punch pins, 3-2-52 designated laser area, 1-3-4
replacement, 3-2-51 SaveLog
visual checks, 3-2-52
accessing, 3-2-49 using, 2-1-11
Push Bar Scanning
assembly, 2-3-91 system description, 2-4-7
gear segment SCSI drives
replacement, 3-2-36 see Disk Drives, 2-6-29
removal, 3-2-33 Self Tests, 2-1-7
MMI running, 2-1-69
system tests, 2-1-8
R Sensors
Raster Image diagnostic commands, 2-1-39
quality check, 3-4-50 Engine, 2-3-77
inductive, 2-2-16
Readhead magnetic reed, 2-2-16
cleaning, 3-1-6 micro-switch, 2-2-16
functional description, 2-4-11 optical
replacement, 3-3-11 replacements, 3-4-15
Registration Checks opto-reflective, 2-2-13
1-8 I NDEX
opto-slotted, 2-2-15 spinner, 2-1-29

PTM, 2-3-47 traverse, 2-1-29
reflective/diffused, 2-2-16 Threshold Wedge
removal of opto-slotted, 3-2-2
removal of reflective-opto, 3-2-1 setup, 3-4-42
vane, 2-3-27 Tint Checks, 3-1-16
Service Menu Tools, 1-3-2
memory, 2-1-31 approved, 1-3-2
Signs Transport Push Bar
laser warning, 1-3-5 see Push Bar, 2-3-91
Software Traverse
traverse initialisation, 2-4-17 accessing, 3-3-2
Spinner aligning carriage and ball cage, 3-1-14
braking, 1-2-15 cage creep
control, 1-2-13 setup, 2-1-26
description, 2-4-8 cleaning scale and readhead, 3-1-6
diagnostic commands, 2-1-45 diagnostic commands, 2-1-29, 2-1-43
functional description, 2-5-23 fitting the extenders, 3-3-3
mirror cleaning, 3-1-5 functional description, 2-4-10
replacement, 3-3-9 level check, 3-1-14
system tests, 2-1-9 motor, 2-4-13
replacement, 3-3-6
Spring Shoes
PCB, 2-4-5
replacing, 3-2-34 servo control, 2-4-12
Stack Height traverse, 2-4-13
assembly, 2-3-54 traverse carriage assemblies, 3-3-1
stacker Trolley
see Plate Stacker, 1-1-9 assemblies, 2-3-29
docking indicator, 2-3-20
STB PCB, 2-4-5
connectors, 2-4-5
replacement, 3-3-6 U
Swing Roller Module
checks, 3-2-56 Umbilical cable
description, 2-3-100 replacement, 3-3-8
introduction, 2-3-81 Updates
replacements, 3-2-55
revisions to 03, B-1
System PCB
see LSB, 2-6-26
System Registry V
displaying, 2-1-64, 2-1-66
tests, 2-1-27 Vacuum System
updating, 2-1-63, 2-1-65, 2-1-66 assemblies, 2-7-4
using the utilities, 2-1-63 configurations, 2-7-7
contamination control, 2-7-3
download, B-16
T introduction, 2-7-1
VBOMB
Terminal Diagnostics User Interface connectors, 2-5-26
entering commands, 2-1-13 functional description, 2-5-26
Tests replacement, 3-4-29
setup, 3-4-30
menu commands, 2-1-27
optics motors, 2-1-28
processor, 2-1-30
W
Warning Notices, 1-3-4
WARNINGS
hazardous voltages, 1-3-4, 1-3-18
Health and Safety at Work, 1-3-1
laser radiation, 1-3-3
laser safety officer
Laser Safety Officer, 1-3-21
unqualified personnel, 1-3-21
Waveplate
functional description, 2-5-11
1-10 I NDEX

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LUXEL V/VX-SERIES

FUJIFILM Electronic Imaging Ltd.

About this Guide

Volume 1 Chapter 2 Introducing Luxel Modules

Image Data and Optical Path ..............................................................................2-20

Volume 1 Chapter 3 Servicing Safety Practice

Mechanical Safety .................................................................................................3-18

Volume 2 Chapter 1 Platesetter Diagnostics

Describing MMI Error Codes .............................................................................1-10

service/optics menu .............................................................................................1-32

Deleting and Editing a PI (Celebrant RIP) .........................................................1-68

Volume 2 Chapter 2 Plate Handling Control

Plate Handling Flowcharts ..................................................................................2-46

Volume 2 Chapter 3 Plate Handling Modules

FHMB PCB (2) Assembly....................................................................................3-34

Registration Mechanism Assembly ................................................................3-95

Volume 2 Chapter 4 Traverse Scan Modules

Volume 2 Chapter 5 Media Expose Modules

Volume 2 Chapter 6 Power and Control Modules

Drum Vacuum Control ........................................................................................6-11

MMI and External Alert ........................................................................................6-30

Volume 2 Chapter 7 Vacuum and Air Control

Volume 2 Chapter 8 System Cabling Descriptions

CAN5_ENG (9970-0145) ........................................................................................8-8

INT_M20/M27 (9970-0255) .................................................................................8-37

ENG_BLOW (9970-0446) .....................................................................................8-59

SEMI_S109/110 (9970-0501) ................................................................................8-82

Volume 2 Chapter 9 System Cabling Views

Volume 3 Chapter 1 Routine Maintenance

Push Bar (Cleaning)..........................................................................................1-8

Set Image Base Offset..........................................................................................1-25

Volume 3 Chapter 2 Plate Handling Service Procedures

Stack Increment ....................................................................................................2-20

Setting up the Push Bar.......................................................................................2-35

Punch Adjustments and Checks .........................................................................2-51

Volume 3 Chapter 3 Traverse Scan Service Procedures

Replacing the Laser Diode ..................................................................................3-15

Volume 3 Chapter 4 Optics Service Procedures

SM3 (Aperture Control)......................................................................................4-18

Manual and Semi-Automatic Machines (B1 & B2)..............................................4-37

Volume 3 Chapter 5 Power and Control Service Proce-

Volume 1 Chapter A Quick Reference Data

Solenoid Listing ....................................................................................................... A-4

Volume 1 Chapter B Guide Technical Updates

INTRODUCING THE LUXEL

1.1 Luxel CTP Features

1.1.1 Introducing the Luxel CTP Configuration

RIP SOFTWARE IMAGES FROM

Figure 1.1 Typical Luxel CTP configuration: fully-automatic

1.2 Introducing the Luxel Modules

Table 1.1 Main Luxel equipment modules

Table 1.1 Main Luxel equipment modules (Continued)

Figure 1.3 Luxel 6000 CTP platesetter modules: B2 fully-automatic

Figure 1.4 Luxel 9600 CTP platesetter modules: B1 semi-automatic

1.2.1.2 Trolley and Cassette

Figure 1.6 Trolley and cassette: general view

1.2.2 Plate Transport Module (PTM)

1.2.2.1 Interleaf Bin

1.2.2.2 Plate Handling Mechanisms

1.2.2.3 Air Knife

1.2.3 Imaging Engine

1.2.3.1 Optics Base and Periscope

detect beam misalignments: position detector (POD)