Celix 4000 (MK II) Recorder Engineer's Reference Guide (Issu

Celix 4000 (Mk II)
Recorder
Engineer’s Reference Guide
6700887000
IMPORTANT
T
Fujifilm products are so designed and constructed as to be safe and 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 document was produced by the Technical Publications Department, FUJIFILM Electronic
Imaging Ltd.
 1998
Head Office: Registered Office:
FUJIFILM Electronic Imaging Ltd. Fuji Film House
Three Cherry Trees Lane 125 Finchley Road
Hemel Hempstead London NW3 6HY
Hertfordshire HP2 7RH England
England
Tel: 01442 213440
Fax: 01442 345432 Registered Number: 3244452
Preliminaries
This document must not be copied without prior written authorization, and although correct at the
time of writing is subject to change without notice. For further information contact the Customer
Services Manager, FUJIFILM Electronic Imaging Ltd, at the Head Office address given on the
front page of this manual.
(ii) Celix 4000 (MkII) Recorder

Preliminaries
WARNING
All precautions mentioned in this document must be
strictly observed at all times. Personnel MUST therefore
read the contents of the document BEFORE commencing
any work on the equipment described in the document.
Improper use of controls and switches, failure to comply
with warnings, and the performance of adjustments or
procedures not specified in this document, may expose
personnel to danger.
WARNING
This equipment includes a recorder which uses a Class 3B
laser (IIIb USA), and has the following potential hazards:
• Extra high tension charges that are lethal.
• Lasers that can blind or damage skin.
• High pressure air and moving parts that can injure.
• Auxiliary equipment that can become hot and burn skin.
This equipment uses a Class 3B laser (IIIb USA).
WARNING
All precautions mentioned in this document must be
strictly observed at all times. Personnel MUST therefore
read the contents of the document BEFORE commencing
any work on the equipment described in the document.
Engineer’s Reference Guide 6700887000 (iii)

Preliminaries
Improper use of controls and switches, failure to comply

with warnings, and the performance of adjustments or
procedures not specified in this document may expose
personnel to danger.
CAUTION
FUJIFILM Electronic Imaging Ltd cannot be held
responsible for any loss or damage to customers’ data by
unauthorised third parties accessing this system. In the
event that Fujifilm becomes 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.
(iv) Celix 4000 (MkII) Recorder

Preliminaries
Note: This equipment has been tested and found to be

compliant with the limits for a Class A digital device,
pursuant to part 15 of the FCC Rules. These limits are
designed to provide reasonable protection against harmful
interference when the equipment is operated in a commercial
environment. This equipment generates, uses and can radiate
radio frequency energy and, if not installed and used in
accordance with the instruction manual, may cause harmful
interference to radio communications. Operation of this
equipment in a residential area is likely to cause harmful
interference in which case the user will be required to correct
the interference at his own expense.
Engineer’s Reference Guide 6700887000 (v)

Preliminaries
Electromagnetic Compatibility Information - Europe

This product has been found to satisfy the Class A limits for
radio interference of information technology equipment.
Class A equipment is intended for use in a light industrial or
commercial environment for which the 30 metre protection
distance is used. Operation of this equipment in a domestic or
residential environment may result in interference to other
equipment, in which case the user will be required to correct
the interference at his own expense. In some countries this
equipment may be subject to restrictions on its use. Where
applicable the user should inform the relevant local authority
that Class A Information Technology Equipment has been
taken into service.
This equipment may also be susceptible to strong
electromagnetic fields and should not be sited close to high
power radio transmitters or radar installations. If the intended
site of operation is prone to electromagnetic disturbances due
to lightning strikes, additional precautions should be taken to
protect the equipment from the resulting electromagnetic
disturbance. Typical examples for the intended environment
of this equipment would include:
• business premises, for example, offices, banks, etc.
• retail outlets, for example, shops, supermarkets, etc.
• light industrial locations, for example, workshops,
service centres, etc.
Locations which are characterised by being supplied directly
at low voltage from the public mains are considered to be
residential, commercial or light industrial.
This equipment conforms to the requirements of EC
directives:
(vi) Celix 4000 (MkII) Recorder

Preliminaries
73/23/EEC - Low Voltage Directive

89/392/EEC - Machinery Directive
89/336/EEC - EMC Directive.
Engineer’s Reference Guide 6700887000 (vii)

Preliminaries
About this Document

The purpose of this Guide is to provide suitably qualified service personnel with sufficient
information to maintain a Celix 4000 with a Mark II recorder. Information includes details
of the system and PCB configurations, field replacements, setup procedures, fault
diagnosis, and the routine maintenance procedures. There is also gives a comprehensive
technical description of the main sub-systems (film handling, expose and scanning) for use
by engineers during an approved training course.
• Chapter 1 - System Overview. Describes the main features of the Celix 4000
imagesetter, shows its configuration and construction, and how it connects to peripheral
equipment.
• Chapter 2 - Safety Requirements. Explains the Fujifilm recommended safety
guidelines for completing an upgrade on-site, describes the Celix 4000 interlock
strategy and the antistatic precautions. This chapter must be read before operating,
installing or working on the equipment.
• Chapter 3 - Electronic Assemblies Physical Description. Provides a brief physical
description of the main assemblies (PSU, PCBs, etc) on the recorder, giving general
information on test points, fuses, connector ports, LEDs, and switches with their default
settings.
• Chapter 4 - Equipment Functional Description. Gives an overal system description,
a more detailed functional description of each PCB, and a summary of how each of the
media sub-systems (film handling, expose and scanning) operate.
• Chapter 5 - Vacuum Services and Maintenance. Describes the overall pneumatic
services, how the system is maintained, and the operation of the solenoids.
• Chapter 6 - Fault Diagnosis and Utilities. Shows how to access the embedded
diagnostics, describes the Celix Diagnostic menu system, useful commands running
under the Application Monitor (Moon) and DSP Log Checks.
• Chapter 7 - Media Handling Replacements and Setups. Describes how to access,
remove and re-install the main replaceable parts used for media handling, and adjust the
film setups.
• Chapter 8 - Expose System Replacements and Setups. Describes how to access,
remove and re-install the main replaceable parts used for the expose system, and adjust
the expose setups.
• Chapter 9 - Scan System Replacements and Setups. Describes how to access,
remove and re-install the main replaceable parts used for scanning, and adjust the scan
system setups.
(viii) Celix 4000 (MkII) Recorder

Preliminaries
• Chapter 10 - Electronic System Replacements and Setups. Describes how to access,

remove and re-install the main replaceable parts used for the electronics system, and
adjust the electronic setups.
• Chapter 11 - NVRAM Parameters. Explains some of the more useful parameters
stored in NVRAM, and how they are updated from Celix Diagnostics (the preferred
method) or the Application Monitor. These parameters are only typical and may alter
for later production machines;some machine-specific parameters are also adjustable
on-site.
• Chapter 12 - Routine Maintenance. Describes the main cleaning procedures for a six
monthly and twelve monthly service visit.
• Appendix A - Useful Utilities. Explains the Recorder Utilities program under
Windows NT .
• Appendix B - Celix 4000 Specifications. A reference list of Celix 4000 specifications
useful for the service engineer.
• Appendix C - Servicing Equipment and Special Tools. A list of useful service tools.
Associated Documents
Celix 4000 Recorder Pre-Installation Manual . . . . . . . . . . . . . . . . . . . . . . . . 67007840
Celix 4000 Recorder Installation Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . 67007420
Celix 4000 Recorder Illustrated Parts Catalogue . . . . . . . . . . . . . . . . . . . . . 67008880
Celix 4000 Recorder User’s Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67007430
HQ RIP User’s Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67008190
Celix Plug-in For HQ RIP Installation Manual . . . . . . . . . . . . . . . . . . . . . . . 67008180
FC Plug-in For HQ RIP Installation Manual . . . . . . . . . . . . . . . . . . . . . . . . . 67008740
PI-Series PPD For HQ RIP User’s Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . 67008700
HP Plug-in For HQ RIP User’s Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67008720
CSI Plug-in For HQ RIP Installation Guide . . . . . . . . . . . . . . . . . . . . . . . . . 67008730
PI-Series Plug-in For HQ RIP Installation Guide . . . . . . . . . . . . . . . . . . . . . 67008690
Engineer’s Reference Guide 6700887000 (ix)

Preliminaries
CelebraNT RIP Installation Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67008140

CelebraNT RIP Setups User’s Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67008200
CelebraNT RIP User’s Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67008260
PCShare for Celix Installation Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67003220
Celix and WorldView Booklet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67002170
Trademarks and Copyright

Celix and CelebraNT are trademarks of FUJIFILM Electronic Imaging Ltd that may be
registered in certain jurisdictions.
FUJI and FUJIFILM are trademarks of FUJI Photo Film Co., Ltd that may be registered
in certain jurisdictions.
Adobe, Accurate, PageMaker, Illustrator, PostScript, Photoshop and Type Manager are
trademarks of Adobe Systems Inc. that may be registered in certain jurisdictions.
Apple, AppleShare, AppleTalk, , System 7, Power Macintosh and Macintosh are

trademarks of Apple Computer Inc. that may be registered in certain jurisdictions.
QuarkXpress is a trademark of Quark Inc. that may be registered in certain jurisdictions.
Atlas Copco is a trademark of Atlas Copco Airpower n.v. that may be registered in
certain jurisdictions.
DuPont, Cromalin and Eurosprint are trademarks of E.I. Du Pont De Nemours and Co.
(Inc.) that may be registered in certain jurisdictions.
All other company names, products or brand names are trademarks of their respective
holders.
(x) Celix 4000 (MkII) Recorder

Preliminaries
Contents
Chapter 1 System Overview
1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–1

1.1.1 RIP Server . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–4
1.2 Celix 4000 Recorder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–5
1.3 Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–7

1.3.2 Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–9
1.4 Ancillary Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–10

1.4.2 Film Processor . . . . . . . . . . . . . . . . . . . . . . . . . . 1–10
1.4.3 Remote Diagnostics . . . . . . . . . . . . . . . . . . . . . . 1–10
Chapter 2 Safety Requirements
2.1 Health and Safety at Work . . . . . . . . . . . . . . . . . . . . . . . . 2–1

2.1.1 Warnings and Cautions . . . . . . . . . . . . . . . . . . . . 2–1
2.2 Clothing and Jewellery . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–2
2.3 Servicing Equipment and Special Tools . . . . . . . . . . . . . . 2–2
2.4 Site Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–3

2.4.1 Signs, Labels, and Indicators . . . . . . . . . . . . . . . 2–3
2.4.2 Safety Devices . . . . . . . . . . . . . . . . . . . . . . . . . . 2–7
2.4.3 Unattended Equipment . . . . . . . . . . . . . . . . . . . . 2–8
2.4.4 Dust Prevention . . . . . . . . . . . . . . . . . . . . . . . . . . 2–8
2.5 Electrical Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–8
2.6 Mechanical Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–9
2.7 Safety Interlocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–9
Engineer’s Reference Guide 6700887000 (xi)

Preliminaries
Chapter 2 Continued
2.8 Acoustic Noise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–13
2.9 Spinner Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–13
2.10 Laser Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–14

2.10.2 Safety Warnings . . . . . . . . . . . . . . . . . . . . . . . . . 2–14
A DLA Room . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–15
A DLA Curtain . . . . . . . . . . . . . . . . . . . . . . . . . . 2–15
2.10.3 General Precautions . . . . . . . . . . . . . . . . . . . . . . 2–16
2.11 Antistatic Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–17

2.11.1 Field Service Antistatic Kit . . . . . . . . . . . . . . . . . 2–18
2.11.2 Disposable Antistatic Wrist Strap . . . . . . . . . . . . 2–18
Chapter 3 Equipment Physical Description
3.1 Location of PCBs in the Recorder . . . . . . . . . . . . . . . . . . 3–2
3.2 ECU Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–4

3.2.1 I/O Panel Description . . . . . . . . . . . . . . . . . . . . . 3–6
3.3 PSU Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–11

3.3.1 ECU PSU Modules Description . . . . . . . . . . . . . 3–11
3.4 System Data Manager (SDM) Board . . . . . . . . . . . . . . . . 3–16

3.4.1 SDM Board Description . . . . . . . . . . . . . . . . . . . 3–16
General Information . . . . . . . . . . . . . . . . . . . . . . 3–16
Port Connections . . . . . . . . . . . . . . . . . . . . . . . . . 3–16
3.5 Digital Signal Processor (DSP) Board . . . . . . . . . . . . . . . 3–19

3.5.1 DSP Description . . . . . . . . . . . . . . . . . . . . . . . . . 3–19
Links . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–19
Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–21
(xii) Celix 4000 (MkII) Recorder

Preliminaries
Chapter 3 Continued
Cable Connections . . . . . . . . . . . . . . . . . . . . . . . 3–21
DSP Board Checks . . . . . . . . . . . . . . . . . . . . . . . 3–21
Test Point Signals . . . . . . . . . . . . . . . . . . . . . . . . 3–22
3.6 Motion Control Board . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–26

3.6.1 MCB Description . . . . . . . . . . . . . . . . . . . . . . . . 3–26
3.7 Power Amplifier Board . . . . . . . . . . . . . . . . . . . . . . . . . . 3–29

3.7.1 Power Amplifier Board Description . . . . . . . . . . 3–29
Test Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–30
3.8 Spinner Controller Board . . . . . . . . . . . . . . . . . . . . . . . . . 3–32

3.8.1 Spinner Controller Board (FFEI-Westwind) . . . . 3–32
Test Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–32
Spinner Controller Board On-line Checks . . . . . 3–34
3.9 Media Handling Sensors and Distribution Boards . . . . . . 3–35

3.9.1 Input Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–35
3.9.2 Output Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . 3–36
3.9.3 Sensor Distribution Boards . . . . . . . . . . . . . . . . . 3–38
Chapter 4 Equipment Functional Description
4.1 System Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–2

4.1.1 RIP Communications . . . . . . . . . . . . . . . . . . . . . 4–2
4.1.2 Image Data Reception . . . . . . . . . . . . . . . . . . . . . 4–4
4.1.3 Media Exposure . . . . . . . . . . . . . . . . . . . . . . . . . 4–4
Traverse Control Speed . . . . . . . . . . . . . . . . . . . . 4–5
Control Console (MMI) . . . . . . . . . . . . . . . . . . . 4–5
Engineer’s Reference Guide 6700887000 (xiii)

Preliminaries
Chapter 4 Continued
Safety Interlocks . . . . . . . . . . . . . . . . . . . . . . . . . 4–5
Celix Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . 4–6
Motion Control . . . . . . . . . . . . . . . . . . . . . . . . . . 4–6
On-line Processor . . . . . . . . . . . . . . . . . . . . . . . . 4–6
ECU Cooling and Filtering . . . . . . . . . . . . . . . . . 4–7
4.2 System Electronics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–8
4.3 PSU Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–10

4.3.1 Power Supplies . . . . . . . . . . . . . . . . . . . . . . . . . . 4–10
230 VAC Supplies . . . . . . . . . . . . . . . . . . . . . . . . 4–10
DC Distribution . . . . . . . . . . . . . . . . . . . . . . . . . . 4–12
ECU Power Supply Assemblies . . . . . . . . . 4–12
4.4 System Data Manager Board (SDM) . . . . . . . . . . . . . . . . 4–13

Power-on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–13
Diagnostic Facilities . . . . . . . . . . . . . . . . . . . . . . 4–13
Data Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–13
Interfaces and Control . . . . . . . . . . . . . . . . . . . . . 4–14
4.4.1 System Control and Data Path . . . . . . . . . . . . . . 4–14
4.4.2 Control Functions on Power-on . . . . . . . . . . . . . 4–16
4.4.3 Control Section Description . . . . . . . . . . . . . . . . 4–16
68332 Processor . . . . . . . . . . . . . . . . . . . . . . . . . 4–17
Flash Memory . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–17
Non-Volatile RAM (NVRAM) and
Real-Time Clock (RTC) . . . . . . . . . . . . . . . . . . . 4–18
DRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–18
Motion Control Board (MCB) Interface . . . . . . . 4–18
Spinner Controller Interface . . . . . . . . . . . . . . . . 4–18
DSP Board Interface . . . . . . . . . . . . . . . . . . . . . . 4–19
Media Processor Interface . . . . . . . . . . . . . . . . . . 4–19
MMI Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–19
(xiv) Celix 4000 (MkII) Recorder

Preliminaries
Chapter 4 Continued
CAN Bus Interface . . . . . . . . . . . . . . . . . . . . . . . 4–19
Diagnostics Interface . . . . . . . . . . . . . . . . . . . . . 4–19
4.4.4 Data Path Interface . . . . . . . . . . . . . . . . . . . . . . . 4–20
Data Path Interface Operation . . . . . . . . . . . . . . . 4–20
4.5 Digital Signal Processor (DSP) Board . . . . . . . . . . . . . . . 4–22

Digital Signal Processor Controls . . . . . . . . 4–23
Encoder and Sensor Inputs . . . . . . . . . . . . . 4–23
Control Outputs . . . . . . . . . . . . . . . . . . . . . 4–23
Interface to SDM Board . . . . . . . . . . . . . . . . . . . 4–24
Traverse Control . . . . . . . . . . . . . . . . . . . . . . . . . 4–24
Watchdog Timer . . . . . . . . . . . . . . . . . . . . . . . . . 4–25
4.6 Motion Control Board . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–26

4.6.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–26
Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–27
4.6.2 Interlock Relays . . . . . . . . . . . . . . . . . . . . . . . . . 4–28
4.7 Spinner Controller Board . . . . . . . . . . . . . . . . . . . . . . . . . 4–30
4.8 Power Amplifier Board . . . . . . . . . . . . . . . . . . . . . . . . . . 4–32
4.9 MMI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–34
4.10 Laser Modulator Board . . . . . . . . . . . . . . . . . . . . . . . . . . 4–36

4.10.1 CAN Bus Interface (Laser) . . . . . . . . . . . . . . . . . 4–36
4.11 Media Handling Systems . . . . . . . . . . . . . . . . . . . . . . . . . 4–37

4.11.1 Media Handling Components . . . . . . . . . . . . . . . 4–37
4.11.2 Basic Operation . . . . . . . . . . . . . . . . . . . . . . . . . . 4–38
4.11.3 Media Handling Modules . . . . . . . . . . . . . . . . . . 4–38
4.11.4 Input Cassette and Drive . . . . . . . . . . . . . . . . . . . 4–39
4.11.5 Input (Nip) Rollers . . . . . . . . . . . . . . . . . . . . . . . 4–41
4.11.6 Input Film Guide . . . . . . . . . . . . . . . . . . . . . . . . . 4–41
Engineer’s Reference Guide 6700887000 (xv)

Preliminaries
Chapter 4 Continued
4.11.7 Drum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–41
4.11.8 Guillotine and Punch . . . . . . . . . . . . . . . . . . . . . . 4–42
Guillotine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–42
Punch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–42
4.11.9 Output System . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–45
4.11.10 Vertical Output . . . . . . . . . . . . . . . . . . . . . . . . . . 4–46
4.11.11 Output Chute . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–46
4.11.12 Media Type and Input . . . . . . . . . . . . . . . . . . . . . 4–47
4.11.13 Media Handling Sensors . . . . . . . . . . . . . . . . . . . 4–47
Lazy Loop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–47
Post Guillotine . . . . . . . . . . . . . . . . . . . . . . . . . . 4–48
End of Roll . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–48
4.12 Media Handling Sequence . . . . . . . . . . . . . . . . . . . . . . . . 4–49

Media LOAD Sequence . . . . . . . . . . . . . . . . . . . 4–50
Media RELOAD Sequence . . . . . . . . . . . . . . . . . 4–52
Media REWIND/Cassette
REMOVAL Sequence . . . . . . . . . . . . . . . . . . . . . 4–55
4.13 Media Handling Problems . . . . . . . . . . . . . . . . . . . . . . . . 4–56

4.13.1 List of Media Handling Problems . . . . . . . . . . . . 4–56
4.14 Media Expose System . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–61

4.14.1 Optical Components . . . . . . . . . . . . . . . . . . . . . . 4–64
Laser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–65
Laser Diode Module Assembly . . . . . . . . . 4–65
Laser Modulator/Driver . . . . . . . . . . . . . . . 4–65
Shutter and Solenoid . . . . . . . . . . . . . . . . . . 4–65
Illumination Density Wedges . . . . . . . . . . . 4–66
Beam Expander Lens . . . . . . . . . . . . . . . . . 4–66
Focus Lens . . . . . . . . . . . . . . . . . . . . . . . . . 4–67
Optics Stepper Motors . . . . . . . . . . . . . . . . 4–67
(xvi) Celix 4000 (MkII) Recorder

Preliminaries
Chapter 4 Continued
Optics Sensors . . . . . . . . . . . . . . . . . . . . . . 4–67
Optics Distribution Boards . . . . . . . . . . . . . 4–67
Baffles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–70
4.15 Media Scan System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–71

4.15.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–71
4.15.2 Spinner Assembly . . . . . . . . . . . . . . . . . . . . . . . . 4–71
4.15.3 Traverse Control . . . . . . . . . . . . . . . . . . . . . . . . . 4–72
4.15.4 Spinner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–74
4.15.5 Spinner Controller . . . . . . . . . . . . . . . . . . . . . . . . 4–74
4.15.6 Carriage Assembly . . . . . . . . . . . . . . . . . . . . . . . 4–76
Optics Carriage . . . . . . . . . . . . . . . . . . . . . . . . . . 4–76
Leadscrew . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–79
Traverse System Power Supply . . . . . . . . . . . . . 4–79
Power Amplifier . . . . . . . . . . . . . . . . . . . . . . . . . 4–79
Traverse Sensors . . . . . . . . . . . . . . . . . . . . . . . . . 4–80
Home Position . . . . . . . . . . . . . . . . . . . . . . 4–80
Limit Positions . . . . . . . . . . . . . . . . . . . . . . 4–81
4.15.7 Leadscrew Control Description . . . . . . . . . . . . . 4–81
Modes of Traverse . . . . . . . . . . . . . . . . . . . . . . . 4–82
Velocity Loop . . . . . . . . . . . . . . . . . . . . . . . 4–82
Phase Loop . . . . . . . . . . . . . . . . . . . . . . . . . 4–82
Direction and Positional Control . . . . . . . . 4–83
4.15.8 Traverse Initialisation Sequence . . . . . . . . . . . . . 4–85
Sequence From Position Left of Centre Vane . . . 4–86
Sequence From Position Right of Centre Vane . 4–87
4.16 System Cabling and Connections . . . . . . . . . . . . . . . . . . . 4–89

4.16.1 Electronics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–89
4.16.2 Optics Assembly/Spinner Interconnections . . . . 4–89
Umbilical Cable . . . . . . . . . . . . . . . . . . . . . . . . . 4–89
4.16.3 Front/Rear Distribution Boards . . . . . . . . . . . . . . 4–89
Engineer’s Reference Guide 6700887000 (xvii)

Preliminaries
Chapter 5 Air Services Distribution, Maintenance and Setups
5.1 Vacuum System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–1

5.1.1 Removing the Vacuum Pump Assembly . . . . . . . 5–2
5.2 Mains and Signal Distribution . . . . . . . . . . . . . . . . . . . . . 5–4

Accessing the Vacuum Transformer and Relay . 5–4
Changing the Fuse Selection . . . . . . . . . . . . . . . . 5–4
5.3 Solenoid Valves and Switching Ancillaries . . . . . . . . . . . 5–5

5.3.1 Vacuum Line Mini-Filters . . . . . . . . . . . . . . . . . . 5–6
Mini-Filter Servicing . . . . . . . . . . . . . . . . . . . . . 5–7
5.4 Vacuum Pumps Assembly . . . . . . . . . . . . . . . . . . . . . . . . 5–8

5.4.1 Vacuum Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–8
5.4.2 Vacuum Pump Service Routines . . . . . . . . . . . . . 5–8
Removal/Replacement of Vacuum Pump
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–8
5.4.3 Vacuum Pump Assembly - Periodic Service . . . 5–10
Air filtration . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–10
Changing Carbon Brushes . . . . . . . . . . . . . . . . . 5–10
Chapter 6 Fault Diagnosis and Utilities
6.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–1
6.2 Troubleshooting Facilities . . . . . . . . . . . . . . . . . . . . . . . . 6–3

6.2.1 Troubleshooting Features for the Recorder . . . . 6–3
6.2.2 Troubleshooting Features within the
Diagnostics Software . . . . . . . . . . . . . . . . . . . . . 6–4
6.2.3 Troubleshooting - Hints and Tips . . . . . . . . . . . . 6–4
6.3 Power-up Tests and Initialization . . . . . . . . . . . . . . . . . . . 6–5

6.3.1 SDM Board Power-up . . . . . . . . . . . . . . . . . . . . . 6–7
6.3.2 DSP Board Power-up . . . . . . . . . . . . . . . . . . . . . 6–7
(xviii) Celix 4000 (MkII) Recorder

Preliminaries
Chapter 6 Continued
6.3.3 Motion Control Board Power-up . . . . . . . . . . . . 6–7
6.4 Power Up and Diagnostics Access . . . . . . . . . . . . . . . . . . 6–8

6.4.1 Accessing Diagnostic and Boot Systems . . . . . . 6–10
6.5 Remote Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–12
6.6 Celix Diagnostics Window Operations . . . . . . . . . . . . . . 6–14

6.6.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–14
6.6.2 Displaying a Typical Screen . . . . . . . . . . . . . . . . 6–14
6.6.3 Entering Commands . . . . . . . . . . . . . . . . . . . . . . 6–15
6.6.4 Help Facility . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–17
6.6.5 Scroll Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–18
6.6.6 Command Line Editing . . . . . . . . . . . . . . . . . . . . 6–18
6.6.7 Soak Test Operation . . . . . . . . . . . . . . . . . . . . . . 6–19
6.6.8 Monitor Mode Operation . . . . . . . . . . . . . . . . . . 6–21
6.7 Introducing the Diagnostics Menus . . . . . . . . . . . . . . . . . 6–24

6.7.1 Diagnostics Modules (Top Level) . . . . . . . . . . . . 6–24
6.7.2 Test Codes and Functional Blocks . . . . . . . . . . . 6–25
6.8 Electronics Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–27

6.8.1 SDM (System) Board External Tests . . . . . . . . . 6–27
Data Path (DPath) Tests . . . . . . . . . . . . . . . . . . . 6–31
Central Processor Unit Tests (CPU) . . . . . . . . . . 6–32
Environmental Checks (Env) . . . . . . . . . . . . . . . 6–34
Power On Tests . . . . . . . . . . . . . . . . . . . . . . . . . . 6–35
6.8.2 Motion Control Board Test Description . . . . . . . 6–36
Environmental Tests (Environ) . . . . . . . . . . . . . . 6–38
6.9 Mechanics Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–41

6.9.1 Solenoids (Sols) . . . . . . . . . . . . . . . . . . . . . . . . . 6–43
Initialise (Init) . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–43
OnOff . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–44
Engineer’s Reference Guide 6700887000 (xix)

Preliminaries
Chapter 6 Continued
Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–45
Interlocks Status (ILocks) . . . . . . . . . . . . . . . . . . 6–45
6.9.2 Traverse (G_Traverse) . . . . . . . . . . . . . . . . . . . . 6–47
Comms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–47
InitDSP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–48
ShState . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–48
ShPos . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–48
ClLog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–48
Move . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–48
ShLog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–48
6.9.3 Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–49
6.10 Optics Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–52

6.10.1 Start Spinner (Start_sp) . . . . . . . . . . . . . . . . . . . . 6–53
6.10.2 Initialise Motors (Init) . . . . . . . . . . . . . . . . . . . . . 6–53
6.10.3 Sensor Motor Tests (SenMov) . . . . . . . . . . . . . . 6–53
6.10.4 Move and Position Check (MovPos) . . . . . . . . . 6–54
6.10.5 Motor Calibration (MotCal) . . . . . . . . . . . . . . . . 6–54
6.10.6 Calibrate and Check (CalChk) . . . . . . . . . . . . . . 6–55
6.10.7 Shutter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–56
6.10.8 Stop Spinner (Stop_spin) . . . . . . . . . . . . . . . . . . 6–56
6.10.9 MotMov . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–56
Illum(ation) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–56
Iris . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–57
Set_iris . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–57
6.11 Comms Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–58
6.12 PowerOn Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–59
6.13 Utilities Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–60

6.13.1 Disk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–63
6.13.2 Error Log (Errlog) . . . . . . . . . . . . . . . . . . . . . . . . 6–64
(xx) Celix 4000 (MkII) Recorder

Preliminaries
Chapter 6 Continued
6.13.3 NVRAM Parameters (NVPARAM) . . . . . . . . . . 6–64
Init (Initialise NVRAM) . . . . . . . . . . . . . . . . . . . 6–65
NVEdit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–65
View Film Database (ViewFilm) . . . . . . . . . . . . 6–72
Edit Installation (EditInst) . . . . . . . . . . . . . . . . . 6–73
View Recorder Statistics (StatsView) . . . . . . . . . 6–74
6.13.4 Generate Test Pattern (TestPtn) . . . . . . . . . . . . . . 6–74
Select Pattern (SelPatn) . . . . . . . . . . . . . . . . . . . . 6–75
Pattern (Patn) . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–75
Image . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–75
Scan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–76
6.13.5 Focus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–76
6.13.6 Wedge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–77
Edit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–78
Wedge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–79
Show . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–80
Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–80
6.13.7 Display Date (Date) . . . . . . . . . . . . . . . . . . . . . . 6–80
6.13.8 Set Service Date (SetSrvDte) . . . . . . . . . . . . . . . 6–80
6.13.9 Iris . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–81
6.14 Application Monitor (Moon) Commands . . . . . . . . . . . . 6–82

6.14.1 Menu System . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–82
Navigating the Menu System . . . . . . . . . . . . . . . 6–83
6.14.2 Supervisor Handler Menu (Sup) . . . . . . . . . . . . . 6–83
Dump System Status (Command: ssd) . . . . . . . . 6–84
Scanner Status . . . . . . . . . . . . . . . . . . . . . . . 6–85
Media Option Flags . . . . . . . . . . . . . . . . . . 6–85
SupplyCassA (Supply Cassette A Status) . . 6–85
MediaStatus (Media Transport Status) . . . . 6–86
MediaProc (Media Processor Status) . . . . . 6–86
Job Queue Status . . . . . . . . . . . . . . . . . . . . . 6–87
Engineer’s Reference Guide 6700887000 (xxi)

Preliminaries
Chapter 6 Continued
Cover Status . . . . . . . . . . . . . . . . . . . . . . . . 6–87
SpinStatus (Spinner Status) . . . . . . . . . . . . 6–87
TravStatus (Traverse Status) . . . . . . . . . . . . 6–87
Optics Status . . . . . . . . . . . . . . . . . . . . . . . . 6–88
Error Status . . . . . . . . . . . . . . . . . . . . . . . . . 6–88
Dump Media Status (command: mid) . . . . . . . . . 6–88
Set Media Characteristics (Command: mi) . . . . . 6–88
Clear Machine Fail Flag (Command: cmf) . . . . . 6–89
Reset Machine (Command: reset) . . . . . . . . . . . . 6–89
Display NVRAM Contents (Command: dnv) . . . 6–90
Set NVRAM Parameter (Command: snv) . . . . . 6–90
Print NVRAM Parameter (Command: pnv) . . . . 6–91
6.14.3 Log Monitor Menu (Log) . . . . . . . . . . . . . . . . . . 6–91
Display Log (Command: dsl) . . . . . . . . . . . . . . . 6–91
Clear Log (Command: csl) . . . . . . . . . . . . . . . . . 6–91
Append User-entered Message String
to System Log (Command: slo) . . . . . . . . . . . . . 6–92
Dump Temperature Log (Command: dtl) . . . . . . 6–92
Dump Voltage Log (Command: dvl) . . . . . . . . . 6–92
Clear Temperature and Voltage
Log (Command: ctv) . . . . . . . . . . . . . . . . . . . . . . 6–93
Set Real Time Clock (Command: srtc) . . . . . . . . 6–93
Read Real Time Clock (Command: grtc) . . . . . . 6–94
6.14.4 Job Queue Manager (JQM) Dump . . . . . . . . . . . 6–94
Active Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–95
History List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–96
6.14.5 Film Handler Menu (Film) . . . . . . . . . . . . . . . . . 6–96
6.14.6 Optics Handler Menu (Opti) . . . . . . . . . . . . . . . . 6–97
6.14.7 Display Handler Menu (Disp) . . . . . . . . . . . . . . . 6–101
6.14.8 Spinner Handler Menu (Spin) . . . . . . . . . . . . . . . 6–101
6.14.9 Traverse Menu (Tr) . . . . . . . . . . . . . . . . . . . . . . . 6–102
(xxii) Celix 4000 (MkII) Recorder

Preliminaries
Chapter 6 Continued
6.14.10 Event Processing Menu (Evt) . . . . . . . . . . . . . . . 6–103
6.14.11 Test Pattern Menu (Patt) . . . . . . . . . . . . . . . . . . . 6–103
6.15 DSP Log Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–104

6.15.1 Traverse Performance Checks . . . . . . . . . . . . . . 6–104
6.15.2 DSP Traverse Log Errors . . . . . . . . . . . . . . . . . . 6–105
7FE6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–105
7FE7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–105
7FFE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–105
7FF4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–106
7FD1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–106
6.15.3 Traverse Limit Detector Position Checks . . . . . . 6–108
Limit Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–109
6.15.4 Traverse Motor Current Checks . . . . . . . . . . . . . 6–112
6.15.5 Turning DSP Debug Reporting Off . . . . . . . . . . 6–114
Chapter 7 Media Handling Replacements and Setups
7.1 Panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–2

7.1.1 Removing Panels . . . . . . . . . . . . . . . . . . . . . . . . 7–2
Recommended Tools . . . . . . . . . . . . . . . . . . . . . . 7–4
7.1.2 Overriding Interlocks . . . . . . . . . . . . . . . . . . . . . 7–4
7.1.3 Stretcher Cover Removal . . . . . . . . . . . . . . . . . . 7–5
7.2 Input Cassette Assemblies . . . . . . . . . . . . . . . . . . . . . . . . 7–7

7.2.1 Input Cassette Replacements . . . . . . . . . . . . . . . 7–7
Film Cutter Blade . . . . . . . . . . . . . . . . . . . . . . . . 7–7
Drive Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–7
7.3 Input (Nip) Roller Assemblies . . . . . . . . . . . . . . . . . . . . . 7–8

7.3.1 Input Roller Spring Replacements . . . . . . . . . . . 7–8
Engineer’s Reference Guide 6700887000 (xxiii)

Preliminaries
Chapter 7 Continued
7.4 Cassette Drive and Bay Assemblies . . . . . . . . . . . . . . . . . 7–10

7.4.1 Cassette Drive Replacements . . . . . . . . . . . . . . . 7–10
Drive Springs . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–11
Drive Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–12
Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–13
7.4.2 Cassette Bay Removal . . . . . . . . . . . . . . . . . . . . 7–13
7.5 Drum Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–15

7.5.1 Drum Assembly Replacements . . . . . . . . . . . . . . 7–15
Input Film Guide . . . . . . . . . . . . . . . . . . . . . . . . . 7–15
Vanes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–16
Antistatic Brush Strip . . . . . . . . . . . . . . . . . . . . . 7–16
Drum Alignment Checks . . . . . . . . . . . . . . . . . . 7–16
7.6 Media Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–17

7.6.1 Input Sensor Replacements . . . . . . . . . . . . . . . . . 7–17
Input Media Detect . . . . . . . . . . . . . . . . . . . . . . . 7–17
Media at Input Cassette, Drop . . . . . . . . . . . . . . 7–18
End of Roll Sensor, Optic . . . . . . . . . . . . . . . . . . 7–19
7.6.2 Output Sensor Replacements . . . . . . . . . . . . . . . 7–20
Guillotine EOT Left and EOT Right . . . . . . . . . 7–20
Media Detect at Punch . . . . . . . . . . . . . . . . . . . . 7–21
Output EOT (at Processor) . . . . . . . . . . . . . . . . . 7–22
Lazy Loop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–22
Post Guillotine . . . . . . . . . . . . . . . . . . . . . . . . . . 7–23
Punch Position Sensor . . . . . . . . . . . . . . . . . . . . . 7–23
7.7 Distribution Boards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–24

7.7.1 Front Distribution Board . . . . . . . . . . . . . . . . . . . 7–24
7.7.2 Rear Distribution Board . . . . . . . . . . . . . . . . . . . 7–25
(xxiv) Celix 4000 (MkII) Recorder

Preliminaries
Chapter 7 Continued
7.8 Guillotine and Punch Assemblies . . . . . . . . . . . . . . . . . . . 7–27

7.8.2 Guillotine Assembly . . . . . . . . . . . . . . . . . . . . . . 7–27
Guillotine Drive Motor . . . . . . . . . . . . . . . . . . . . 7–29
Guillotine Rotary Blade . . . . . . . . . . . . . . . . . . . 7–31
Guillotine Fixed Blade . . . . . . . . . . . . . . . . . . . . 7–32
7.8.3 Guillotine Setup . . . . . . . . . . . . . . . . . . . . . . . . . 7–33
7.8.4 Punch Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 7–35
Punch and Die . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–36
Punch Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–38
7.8.5 Punch-to-Image Alignment . . . . . . . . . . . . . . . . . 7–40
7.9 Film Output Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . 7–42

7.9.1 Film Output Replacements . . . . . . . . . . . . . . . . . 7–42
Output Drive Motor . . . . . . . . . . . . . . . . . . . . . . 7–42
7.9.2 Vertical Output Assembly . . . . . . . . . . . . . . . . . . 7–43
Vertical Output Removal . . . . . . . . . . . . . . . . . . . 7–43
Vertical Output Replacement . . . . . . . . . . . . . . . 7–45
7.9.3 OutputChute . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–46
Output Chute Removal . . . . . . . . . . . . . . . . . . . . 7–46
Output Chute Replacement . . . . . . . . . . . . . . . . . 7–47
7.9.4 Output Rubber Bands Replacement . . . . . . . . . . 7–50
Output Chute Bands . . . . . . . . . . . . . . . . . . . . . . 7–51
7.10 Reconnecting the Recorder to the Film Processor . . . . . . 7–52
Chapter 8 Expose System Replacements and Setups
8.1 Baffle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–2

8.1.1 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–2
Engineer’s Reference Guide 6700887000 (xxv)

Preliminaries
Chapter 8 Continued
8.2 Optics Carriage Assembly . . . . . . . . . . . . . . . . . . . . . . . . 8–3

8.2.1 Optics Carriage Removal and Replacement (Without
the Jig Removal Tool) . . . . . . . . . . . . . . . . . . . . . 8–3
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–3
8.2.2 Optics Carriage Removal and Replacement (With the
Jig Removal Tool) . . . . . . . . . . . . . . . . . . . . . . . . 8–11
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–11
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–13
8.2.3 Coupling the Optics Carriage to the Leadscrew Gimbal
8–14
8.2.4 RFI Box Assembly (Optics) . . . . . . . . . . . . . . . . 8–16
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–17
8.2.5 Shutter Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . 8–20
Removal, Replacement and Check . . . . . . . . . . . 8–20
8.2.6 Shutter Assembly . . . . . . . . . . . . . . . . . . . . . . . . 8–23
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–23
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–25
Shutter Assembly Checks . . . . . . . . . . . . . . . . . . 8–25
8.2.7 Aperture Motor . . . . . . . . . . . . . . . . . . . . . . . . . . 8–25
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–25
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–27
Aperture Motor Mechanical Checks . . . . . . . . . . 8–27
Aperture Motor Checks with Power Applied . . . 8–28
8.2.8 Focus Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–29
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–29
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–29
Focus Motor Mechanical Checks . . . . . . . . . . . . 8–30
Focus Motor Checks with Power Applied . . . . . 8–31
8.2.9 Illumination Control Motor . . . . . . . . . . . . . . . . . 8–32
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–32
Replacement and Checks . . . . . . . . . . . . . . . . . . 8–33
(xxvi) Celix 4000 (MkII) Recorder

Preliminaries
Chapter 8 Continued
8.2.10 Aperture Sensors . . . . . . . . . . . . . . . . . . . . . . . . . 8–35
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–35
8.2.11 Focus Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–40
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–40
8.2.12 Illumination Control Sensors . . . . . . . . . . . . . . . 8–42
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–42
8.2.13 Distribution Boards (Optics) . . . . . . . . . . . . . . . . 8–45
8.2.14 Spinner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–47
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–48
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–49
Cleaning the Mirror and Focus Lens . . . . . . . . . 8–51
Focus Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–51
Registration Check . . . . . . . . . . . . . . . . . . . . . . . 8–51
8.2.15 Spinner Cooling Fan (24 Vdc) . . . . . . . . . . . . . . 8–52
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–52
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–52
Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–53
8.2.16 Traverse Sensor Home . . . . . . . . . . . . . . . . . . . . 8–53
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–53
Replacement and Check . . . . . . . . . . . . . . . . . . . 8–54
8.3 Optical Alignment Procedures . . . . . . . . . . . . . . . . . . . . . 8–56

8.3.1 Setting/Checking the Illumination Wedge Position . . .
8–56
8.3.2 Focus Procedures . . . . . . . . . . . . . . . . . . . . . . . . 8–59
Focus Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–60
Coarse Focus . . . . . . . . . . . . . . . . . . . . . . . . 8–60
Fine Focus . . . . . . . . . . . . . . . . . . . . . . . . . . 8–61
8.3.3 Registration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–64
Engineer’s Reference Guide 6700887000 (xxvii)

Preliminaries
Chapter 8 Continued
Running a Grid . . . . . . . . . . . . . . . . . . . . . . . . . . 8–65
Measuring Errors in a Grid . . . . . . . . . . . . . . . . . 8–66
Running the PC Grid Program . . . . . . . . . . . . . . 8–70
8.3.4 Possible Causes of Grid Measure error . . . . . . . . 8–76
8.3.5 Shimming a Laser Diode Module . . . . . . . . . . . . 8–77
8.4 Setting the Vertical Offset and Horizontal Trim Values . . 8–79
8.4.1 Checking and Adjusting Horizontal Trim and Vertoff
Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–79
Pre-requisites . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–79
Finding the Current NVRAM Values . . . . . . . . . 8–79
Measuring the Current Horizontal Trim Value . . 8–80
Calculating the Current Vertical Offset on the Media .
8–83
8.4.2 Pattern Generation . . . . . . . . . . . . . . . . . . . . . . . 8–84
Interpretation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–85
Chapter 9 Scan System Replacements and Setups
9.1 Bearing Pads and Retaining Plates . . . . . . . . . . . . . . . . . . 9–1

9.1.1 Installing the Pads . . . . . . . . . . . . . . . . . . . . . . . . 9–1
9.1.2 Cleaning the V-Groove . . . . . . . . . . . . . . . . . . . . 9–3
9.1.3 Pad Replacement . . . . . . . . . . . . . . . . . . . . . . . . . 9–5
9.1.4 Traverse Sensors (Limit) . . . . . . . . . . . . . . . . . . . 9–5
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–6
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–8
Adjustment Procedures . . . . . . . . . . . . . . . . . . . . 9–9
Vane Separation . . . . . . . . . . . . . . . . . . . . . 9–9
Limit Switch Positions . . . . . . . . . . . . . . . . 9–10
Operation Check (Limit Sensors) . . . . . . . . 9–10
Machine Reassembly . . . . . . . . . . . . . . . . . . . . . 9–12
(xxviii) Celix 4000 (MkII) Recorder

Preliminaries
Chapter 9 Continued
9.2 Leadscrew Assembly and Drip Tray . . . . . . . . . . . . . . . . 9–13

9.2.1 Replacing the Leadscrew Motor . . . . . . . . . . . . . 9–13
9.2.2 Leadscrew Assembly . . . . . . . . . . . . . . . . . . . . . 9–14
Removing the Leadscrew Assembly . . . . . . . . . . 9–15
Replacing the Leadscrew Assembly . . . . . . . . . . 9–16
9.2.3 Replacing the Drip Tray . . . . . . . . . . . . . . . . . . . 9–17
9.2.4 Cleaning the Leadscrew . . . . . . . . . . . . . . . . . . . 9–18
9.2.5 Leadscrew Traverse Problems and Causes . . . . . 9–18
Cause 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–19
Cause 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–19
Cause 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–20
Cause 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–20
Chapter 10 Electrical Replacements and Setups
10.1 Electrical Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–2

10.1.1 MMI Keypad Assembly Replacement . . . . . . . . 10–2
10.2 Power Amplifier Assembly . . . . . . . . . . . . . . . . . . . . . . . 10–4
10.3 Electronic Control Unit (ECU) . . . . . . . . . . . . . . . . . . . . 10–7

10.3.1 ECU Box Assembly . . . . . . . . . . . . . . . . . . . . . . 10–7
10.3.2 ECU Board Assemblies . . . . . . . . . . . . . . . . . . . 10–8
System Data Manager (SDM) Board . . . . . . . . . 10–9
DSP (Servo-control) Board . . . . . . . . . . . . . . . . . 10–10
Motion Control Board (MCB) . . . . . . . . . . . . . . 10–10
Spinner Controller Board . . . . . . . . . . . . . . . . . . 10–11
Input/Output Panel Assembly . . . . . . . . . . . . . . . 10–11
10.3.3 Local SCSI Disk Drive . . . . . . . . . . . . . . . . . . . . 10–13
Verify Operation . . . . . . . . . . . . . . . . . . . . . . . . . 10–14
Engineer’s Reference Guide 6700887000 (xxix)

Preliminaries
Chapter 10 Continued
10.3.4 Interlock Relays . . . . . . . . . . . . . . . . . . . . . . . . . 10–14
10.4 PSU Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–16

10.4.1 PSU Wired Assembly . . . . . . . . . . . . . . . . . . . . . 10–16
10.5 Cooling Fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–18

10.5.1 Lower ECU Fans Assembly . . . . . . . . . . . . . . . . 10–18
10.5.2 Upper ECU Ducting Fan Assembly . . . . . . . . . . 10–18
10.5.3 Mixer Fan Assembly . . . . . . . . . . . . . . . . . . . . . . 10–19
10.5.4 Spinner Fan Assembly . . . . . . . . . . . . . . . . . . . . 10–21
10.5.5 Output Chute Fan . . . . . . . . . . . . . . . . . . . . . . . . 10–21
Chapter 11 NVRAM Parameters
11.1 Updating NVRAM Data . . . . . . . . . . . . . . . . . . . . . . . . . . 11–1

11.1.1 From Celix Diagnostics . . . . . . . . . . . . . . . . . . . 11–2
11.1.2 From Application Monitor . . . . . . . . . . . . . . . . . 11–2
11.2 Changing the Spinner Idle Time . . . . . . . . . . . . . . . . . . . 11–4
11.3 NVRAM Parameter Listing . . . . . . . . . . . . . . . . . . . . . . . 11–5

11.3.1 Media and SCSI Parameters . . . . . . . . . . . . . . . . 11–6
11.3.2 Optical Parameters . . . . . . . . . . . . . . . . . . . . . . . 11–6
11.3.3 Spinner Speed Parameters . . . . . . . . . . . . . . . . . . 11–8
11.3.4 Phase Lock Loop Parameters . . . . . . . . . . . . . . . 11–9
11.3.5 Counter and Scale Parameters . . . . . . . . . . . . . . 11–11
11.3.6 Traverse Parameters . . . . . . . . . . . . . . . . . . . . . . 11–11
11.3.7 Environmental Parameters . . . . . . . . . . . . . . . . . 11–12
11.3.8 Media Parameters . . . . . . . . . . . . . . . . . . . . . . . . 11–13
11.3.9 Spinner Loop Gain Parameters . . . . . . . . . . . . . . 11–18
11.3.10 Spinner Final Power Parameters . . . . . . . . . . . . . 11–18
11.3.11 Laser Parameters . . . . . . . . . . . . . . . . . . . . . . . . . 11–19
11.3.12 Machine-Specific Parameters . . . . . . . . . . . . . . . 11–20
(xxx) Celix 4000 (MkII) Recorder

Preliminaries
11.3.13 Servicing Parameters . . . . . . . . . . . . . . . . . . . . . 11–23
11.3.14 Miscellaneous Parameters . . . . . . . . . . . . . . . . . . 11–23
Chapter 12 Routine Maintenance
12.1 Safety Interlock Checks . . . . . . . . . . . . . . . . . . . . . . . . . . 12–1
12.2 Filters - Annual Service . . . . . . . . . . . . . . . . . . . . . . . . . . 12–4

12.2.1 Left-hand ECU Filter . . . . . . . . . . . . . . . . . . . . . 12–4
Lower ECU Filter . . . . . . . . . . . . . . . . . . . . . . . . 12–4
Upper ECU Filter . . . . . . . . . . . . . . . . . . . . . . . . 12–5
Left End Panel Filter . . . . . . . . . . . . . . . . . . . . . . 12–5
Vacuum Pump Filter . . . . . . . . . . . . . . . . . . . . . . 12–6
Solenoid Mini-Filters . . . . . . . . . . . . . . . . . . . . . 12–6
12.3 Input (Nip) Rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–7

12.3.1 Weekly Cleaning Procedure . . . . . . . . . . . . . . . . 12–7
12.3.2 Six Monthly Procedure . . . . . . . . . . . . . . . . . . . . 12–8
12.4 General Routine Maintenance . . . . . . . . . . . . . . . . . . . . . 12–9

12.4.1 Cleaning and Lubricating Fluids . . . . . . . . . . . . . 12–9
12.4.2 Six Monthly Maintenance Procedures . . . . . . . . 12–10
Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–10
Fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–10
Check Log of Film Jams and Film Cuts . . . . . . . 12–10
Drum Maintenance . . . . . . . . . . . . . . . . . . . . . . . 12–11
Chad Collection Tray . . . . . . . . . . . . . . . . . . . . . 12–12
Belt Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–12
Media Handling Setups . . . . . . . . . . . . . . . . . . . . 12–12
Spinner Mirror and Focus Lens . . . . . . . . . . . . . 12–12
Leadscrew . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–14
V-Groove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–14
Input Drive Rollers . . . . . . . . . . . . . . . . . . . . . . . 12–15
Engineer’s Reference Guide 6700887000 (xxxi)

Preliminaries
Voltage and Temperature . . . . . . . . . . . . . . . . . . 12–15
Media Handling Operation . . . . . . . . . . . . . . . . . 12–15
Calibration of Recorder . . . . . . . . . . . . . . . . . . . . 12–15
Registration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–16
Recorder Operation Quality Check . . . . . . . . . . . 12–16
Punch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–16
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Index–1
Appendices
Appendix A Useful Utlities
A.1 Recorder Utilities (Windows NT) . . . . . . . . . . . . . . . . . . A–1

A.1.1 Install Recorder . . . . . . . . . . . . . . . . . . . . . . . . . . A–2
A.1.2 Select Recorder . . . . . . . . . . . . . . . . . . . . . . . . . . A–3
A.1.3 Download Firmware to Selected Recorder . . . . . A–3
A.1.4 Save NVRAM from Selected Recorder . . . . . . . A–5
A.1.5 Open NVRAM Data File . . . . . . . . . . . . . . . . . . A–6
A.1.6 Restore NVRAM Data to Selected Recorder . . . A–6
A.1.7 Save Machine Statistics from Selected File . . . . A–7
A.1.8 Open Machine Statistics . . . . . . . . . . . . . . . . . . . A–7
Appendix B Celix 4000 Specifications
B.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1
B.2 Summary of Specifications . . . . . . . . . . . . . . . . . . . . . . . B-1

B.2.1 Physical Dimensions . . . . . . . . . . . . . . . . . . . . . . B-1
(xxxii) Celix 4000 (MkII) Recorder

Preliminaries
Appendix B Continued
B.2.2 Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-2
B.2.3 Recorder Performance . . . . . . . . . . . . . . . . . . . . B-2
B.2.4 Image Format Size . . . . . . . . . . . . . . . . . . . . . . . B-2
B.2.5 Imaging Area . . . . . . . . . . . . . . . . . . . . . . . . . . . B-3
B.2.6 Media Punching . . . . . . . . . . . . . . . . . . . . . . . . . B-3
B.2.7 Light Source . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-3
B.2.8 Media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-4
B.2.9 Cassette Capacity . . . . . . . . . . . . . . . . . . . . . . . . B-4
B.2.10 DPI (l/mm) Resolutions . . . . . . . . . . . . . . . . . . . B-4
B.2.11 Screen Rulings . . . . . . . . . . . . . . . . . . . . . . . . . . B-5
B.2.12 Dot Types and Shapes . . . . . . . . . . . . . . . . . . . . . B-5
B.2.13 Writing Spot Sizes . . . . . . . . . . . . . . . . . . . . . . . B-5
B.2.14 Recorder Writing Speeds . . . . . . . . . . . . . . . . . . B-6
B.2.15 Traverse Rates . . . . . . . . . . . . . . . . . . . . . . . . . . . B-6
B.2.16 Repeatability . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-6
B.2.17 Registration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-6
B.2.18 RIP-to-Recorder Interface . . . . . . . . . . . . . . . . . . B-7
B.2.19 Environment Operating Specification . . . . . . . . . B-7
B.2.20 On-line Media Processor Options . . . . . . . . . . . . B-7
Appendix C Servicing Equipment and Special Tools
C.1 Tools for Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C–1
Figures
1.1 Celix 4000 system configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–2

1.2 Celix 4000 data/image flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–3
1.3 Celix 4000 recorder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–5
1.4 Major features of the Celix 4000 recorder . . . . . . . . . . . . . . . . . . . . . . . . . . 1–8
Engineer’s Reference Guide 6700887000 (xxxiii)

Preliminaries
2.1 Recorder safety labels and ratings plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–4

2.2 Recorder safety labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–5
2.3 Recorder safety labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–6
2.4 Internal safety labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–7
2.5 Location of recorder interlocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–10
2.6 Laser warning sign . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–15
2.7 Antistatic handling station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–18
3.1 Location of PCBs within the recorder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–2

3.2 Electronics Control Unit (ECU): main components . . . . . . . . . . . . . . . . . . . 3–4
3.3 Electronics Control Unit (ECU): access and connectors . . . . . . . . . . . . . . . 3–5
3.4 Input/Output Panel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–7
3.5 Input/Output Panel connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–8
3.6 PSUs: Cable 89 to Motion Control Board (MCB) . . . . . . . . . . . . . . . . . . . . 3–13
3.7 PSU: Cable 90 to System Data Manager (SDM) board . . . . . . . . . . . . . . . . 3–14
3.8 PSUs: Cable 91 to Input/Output Panel (internal) . . . . . . . . . . . . . . . . . . . . . 3–15
3.9 SDM board plugs and sockets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–18
3.10 DSP board layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–20
3.11 SPOPRT (TP3) and SPTOG (TP4) waveforms . . . . . . . . . . . . . . . . . . . . . . 3–22
3.12 ABPOSN (TP6) waveform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–23
3.13 DSP test-point waveforms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–24
3.14 MCB plugs and sockets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–26
3.15 Power Amplifier assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–29
3.16 Spinner Controller board (FFEI-Westwind) . . . . . . . . . . . . . . . . . . . . . . . . . 3–33
3.17 Media handling sensors/sensor distribution boards . . . . . . . . . . . . . . . . . . . 3–37
4.1 Celix 4000 functional diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–3

4.2 RS-232 on-line processor connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–7
4.3 ECU connectivity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–8
4.4 230 VAC distribution (factory setting) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–11
4.5 DC distribution from ECU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–12
4.6 Control/Data path functional diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–15
4.7 DSP Board functional diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–22
4.8 Motion Control board - functional diagram . . . . . . . . . . . . . . . . . . . . . . . . . 4–27
4.9 Positions of interlock relays in ECU RFI Box - (PSU section) . . . . . . . . . . 4–28
4.10 Interlock relay system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–29
4.11 Spinner controls and drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–30
(xxxiv) Celix 4000 (MkII) Recorder

Preliminaries
4.12 Traverse power amplifier circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–33

4.13 MMI display module and keypad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–34
4.14 Media path mechanisms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–37
4.15 Input cassette . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–39
4.16 Input drive assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–40
4.17 Punch/guillotine assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–44
4.18 Output drive assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–45
4.19 Media handling (cut-out view) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–49
4.20 LOAD sequence 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–51
4.21 LOAD sequence 2 (film at punch) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–52
4.22 RELOAD sequence 1 (at Vertical Output) . . . . . . . . . . . . . . . . . . . . . . . . . . 4–53
4.23 RELOAD sequence 2 (conveyed film) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–54
4.24 Media expose system – schematic view . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–61
4.25 Schematic layout of optical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–62
4.26 Optics: Laser Diode module, motors and solenoid . . . . . . . . . . . . . . . . . . . . 4–63
4.27 Location of spinner and distribution boards . . . . . . . . . . . . . . . . . . . . . . . . . 4–64
4.28 Optics: Internal cabling - Sensor Distribution Board . . . . . . . . . . . . . . . . . . 4–68
4.29 Optics: Internal cabling - Motor Distribution Board . . . . . . . . . . . . . . . . . . . 4–68
4.30 Optics: internal cabling - RFI Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–69
4.31 Traverse subsystem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–73
4.32 Spinner (Westwind) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–74
4.33 Spinner controller loop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–75
4.34 V-groove guide, Optics Carriage (casting) and support bearing . . . . . . . . . . 4–77
4.35 Optics Carriage, C-clamp and gimbal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–78
4.36 Traverse drive - block diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–84
4.37 Traverse speed detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–85
4.38 Recorder cabling: ECU (RFI box) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–90
4.39 Recorder cabling: umbilical to optics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–91
4.40 Recorder cabling: ECU to subsystems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–92
4.41 Recorder cabling: media handling sensors - distribution boards . . . . . . . . . 4–93
5.1 Vacuum pump assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–2

5.2 Solenoids and switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–5
5.3 Vacuum line mini-filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–6
5.4 Vacuum pump serviceable parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–11
5.5 Vacuum pump: insertion of blade into rotor . . . . . . . . . . . . . . . . . . . . . . . . . 5–12
Engineer’s Reference Guide 6700887000 (xxxv)

Preliminaries
6.1 Celix 4000 power-up extent of tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–6

6.2 Power-up and navigating with recorder software . . . . . . . . . . . . . . . . . . . . . 6–9
6.3 Remote diagnostics configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–12
6.4 Celix diagnostics opening screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–15
6.5 A typical help display (xfer) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–18
6.6 MMI display: information types for module under test . . . . . . . . . . . . . . . . 6–19
6.7 Display during test execution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–19
6.8 Display - test passed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–20
6.9 Display - test failed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–20
6.10 ELECTRONICS menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–27
6.11 Sys_Brd menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–28
6.12 Electronics menu tree: System board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–28
6.13 Dpath menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–31
6.14 CPU menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–32
6.15 Enviroment menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–34
6.16 Electronics menu tree: Motion Control board . . . . . . . . . . . . . . . . . . . . . . . . 6–36
6.17 MCB Board Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–37
6.18 Environ Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–38
6.19 Mechanics menu tree . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–41
6.20 MECHANICS menu terminal window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–42
6.21 Solenoids menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–43
6.22 Sensors and Solenoids panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–44
6.23 Sensors Display panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–45
6.24 Interlocks and Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–46
6.25 G_Traverse menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–47
6.26 OPTICS menu tree . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–52
6.27 Set_iris display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–57
6.28 Comms menu tree . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–58
6.29 Power On menu tree . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–59
6.30 Power On Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–59
6.31 Utilities menu tree . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–60
6.32 UTILITIES menu terminal window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–62
6.33 Disk utility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–63
6.34 NVRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–64
6.35 NVRAM Editor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–66
6.36 Wedge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–77
(xxxvi) Celix 4000 (MkII) Recorder

Preliminaries
6.37 System status dump (sysd) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–84
7.1 Celix 4000 recorder panels: front view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–2

7.2 Celix 4000 recorder panels: rear view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–3
7.3 Removing the front stretcher cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–6
7.4 Input roller leaf springs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–8
7.5 Location of cassette drive assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–10
7.6 Cassette drive assembly - replacements . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–12
7.7 Cassette bay mouldings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–14
7.8 Input Film guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–15
7.9 End of Roll sensor position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–19
7.10 Front distribution board connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–24
7.11 Location of rear distribution board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–26
7.12 Rear distribution board connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–26
7.13 Punch/Guillotine assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–28
7.14 Location of guillotine drive motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–30
7.15 Retention of guillotine fixed blade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–32
7.16 Guillotine carriage: sensor magnet protrusion . . . . . . . . . . . . . . . . . . . . . . . 7–33
7.17 Guillotine blade angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–34
7.18 Punch assembly viewed from rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–37
7.19 Location of output drive motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–42
7.20 Vertical Output mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–44
7.21 Setting the Vertical Output-to-film guide distance . . . . . . . . . . . . . . . . . . . . 7–46
7.22 Positioning the support brackets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–48
7.23 Latching the output assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–49
7.24 Replacing Output chute bands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–51
7.25 Locating the film processor and output chute . . . . . . . . . . . . . . . . . . . . . . . . 7–52
7.26 Side-to-side levelling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–53
7.27 Front-to-back levelling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–54
7.28 Levelling the recorder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–54
7.29 Engaged recorder/film processor interface . . . . . . . . . . . . . . . . . . . . . . . . . . 7–55
8.1 Baffle fixings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–2

8.2 Removing the leadscrew drip tray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–4
8.3 Blanking plug for Optics Carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–5
8.4 Location of Gimbal clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–6
8.5 End bearing block and V-groove end plate . . . . . . . . . . . . . . . . . . . . . . . . . . 8–8
Engineer’s Reference Guide 6700887000 (xxxvii)

Preliminaries
8.6 Optics Carriage removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–9

8.7 Aligning the removal tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–12
8.8 Coupling the Optics Carriage to the leadscrew sleeve . . . . . . . . . . . . . . . . . 8–15
8.9 Optics: RFI box assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–17
8.10 Laser Diode assembly blanking plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–18
8.11 Optics: internal cabling - RFI Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–19
8.12 Optics: Laser Diode module, motors and solenoid . . . . . . . . . . . . . . . . . . . . 8–21
8.13 Shutter assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–24
8.14 Aperture limit sensor calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–26
8.15 Focus motor gear phasing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–30
8.16 Location of laser side Baffle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–35
8.17 Set aperture diagnostics window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–37
8.18 Aperture limit sensor calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–39
8.19 Optics - Focus Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–40
8.20 Optics - Illumination Control Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–43
8.21 Location of spinner and distribution boards . . . . . . . . . . . . . . . . . . . . . . . . . 8–46
8.22 Spinner and shroud (side view of the Westwind model) . . . . . . . . . . . . . . . . 8–47
8.23 Orientation of thermal seals and baffle plate . . . . . . . . . . . . . . . . . . . . . . . . 8–50
8.24 Location of Traverse Sensor Home on Optics Carriage assembly . . . . . . . . 8–55
8.25 Typical DMAX characteristic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–58
8.26 Cutting a registration film . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–67
8.27 Fault diagnosis for grid errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–69
8.28 Grid program - Main menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–70
8.29 Grid program - Create a Registration Data File (Option 2) . . . . . . . . . . . . . 8–71
8.30 Grid program - typical data file (Option 3) . . . . . . . . . . . . . . . . . . . . . . . . . . 8–72
8.31 Grid program - expected results for option 7
(Analysis menu, see Figure 8.32) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–73
8.32 Grid program - Analysis menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–74
8.33 Grid program - recommended action for option 11
(Analysis menu, see Figure 8.32) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–75
8.34 Laser Diode Module Shimming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–78
8.35 Test pattern for image offset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–82
8.36 GRID pattern . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–84
8.37 DOT pattern . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–85
9.1 V-groove guide, optics carriage (casting) and support bearing . . . . . . . . . . . 9–2
(xxxviii) Celix 4000 (MkII) Recorder

Preliminaries
9.2 Bearing carrier and pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–3

9.3 Location of traverse RH limit sensor and vane . . . . . . . . . . . . . . . . . . . . . . . 9–6
9.4 Removing the limit sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–7
9.5 Location of limit sensor trip magnet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–8
9.6 Traverse limit sensor and vane setting-up . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–9
9.7 Leadscrew assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–14
9.8 Cleaning the media input rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–7
10.1 Keypad assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–2

10.2 Power Amp mounting tray position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–4
10.3 Power Amplifier assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–5
10.4 PSU wiring harness connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–17
10.5 PSU wiring fan connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–19
10.6 Location of Duct and Mixer fan assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 10–20
12.1 Right-hand panel ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–4

12.2 Left-hand panel (ECU) ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–5
B.1 Imagesetter dimensions with Glunz and Jensen Multiline 860 processor . . B-8
Tables
2.1 Safety Interlocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–12
3.1 Input/Output Panel External Sockets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–9

3.2 Input/Output Panel Internal Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–9
3.3 Input/Output Panel fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–10
3.4 DC voltage tolerances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–12
3.5 SDM board fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–16
3.6 SDM board plugs and sockets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–17
3.7 DSP LED (D1) Indications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–22
3.8 Motion Control Board fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–27
3.9 Motion Control Board plugs and sockets . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–28
4.1 On-line processor indications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–7
Engineer’s Reference Guide 6700887000 (xxxix)

Preliminaries
4.2 Film Punch and die sets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–42

4.3 Front Distribution Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–94
4.4 Rear Distribution Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–94
4.5 ECU Subsystem Cabling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–94
6.1 Global commands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–16

6.2 Standard monitor commands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–22
6.3 SCSI monitor commands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–23
6.4 Test pattern generation commands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–23
6.5 SDM board tests (Sys_Brd) - level 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–31
6.6 External SCSI DMA tests (Ex-SCSI) - level 4 . . . . . . . . . . . . . . . . . . . . . . . 6–32
6.7 Internal SCSI Interrupt tests (In-SCSI) - level 5 . . . . . . . . . . . . . . . . . . . . . . 6–32
6.8 CPU tests (CPU) - level 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–33
6.9 RTC tests (RTC) - level 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–33
6.10 CAN Bus tests (CAN Bus) - level 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–33
6.11 Temperature Sensor tests (TSensor) - level 5 . . . . . . . . . . . . . . . . . . . . . . . . 6–33
6.12 Environmental tests (Env) - level 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–34
6.13 Power On tests (PowerOn) - level 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–35
6.14 Motion Control Board tests (MCB) - level 3 . . . . . . . . . . . . . . . . . . . . . . . . 6–37
6.15 Environmental tests (Environ) - level 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–38
6.16 MCB temperature tests (Temp) - level 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–38
6.17 MCB voltage test (Volt) - level 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–39
6.18 MCB and I/O board fuse tests (Fuse) - level 5 . . . . . . . . . . . . . . . . . . . . . . . 6–39
6.19 Optics Fuse tests (TOFuse) - level 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–39
6.20 Film Fuse tests (TFFuse) - level 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–40
6.21 Mechanical tests (Mechanics) - level 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–42
6.22 Solenoid tests (Sols) - level 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–43
6.23 Traverse tests (G_Trav) - level 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–47
6.24 Motor commands (Motor) - level 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–49
6.25 Optics tests (Optics) - level 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–53
6.26 Sensor Move tests (SenMov) - level 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–54
6.27 Move and position tests (MovPos) - level 3 . . . . . . . . . . . . . . . . . . . . . . . . . 6–54
6.28 Motor calibration tests (MotCal) - level 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–55
6.29 Calibration check (CalChk) - level 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–55
6.30 Motor move tests (MotMov) - level 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–56
6.31 Media processor status messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–58
(xl) Celix 4000 (MkII) Recorder

Preliminaries
6.32 Power On tests (PowerOn) - level 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–59

6.33 Utilities menu (Utilities) -level 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–62
6.34 Disk Utilities (Disk) - level 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–63
6.35 Error Log (Errlog) - level 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–64
6.36 Non-volatile Parameters (NVPARAM) - level 3 . . . . . . . . . . . . . . . . . . . . . 6–65
6.37 Edit Non-volatile RAM (NVEdit) - level 4 . . . . . . . . . . . . . . . . . . . . . . . . . . 6–66
6.38 Media Database and SCSI Parameters (MEdit) - level 5 . . . . . . . . . . . . . . . 6–67
6.39 Optics Database 1 Parameters (O1Edit) - level 5 . . . . . . . . . . . . . . . . . . . . . 6–68
6.40 Optics Database 2 Parameters (O2Edit) - level 5 . . . . . . . . . . . . . . . . . . . . . 6–68
6.41 Traverse Parameters (TEdit) - level 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–69
6.42 Spinner Parameters (SEdit) - level 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–69
6.43 Phase Lock Loop Parameters for 30K Spin Speed (P30Edit) . . . . . . . . . . . 6–70
6.44 Phase Lock Loop Parameters for 20K Spin Speed (P20Edit) . . . . . . . . . . . 6–71
6.45 Counter and Scaler Parameters (CSEdit) - level 5 . . . . . . . . . . . . . . . . . . . . 6–71
6.46 Environmental Parameters (EEdit) - level 5 . . . . . . . . . . . . . . . . . . . . . . . . . 6–72
6.47 Film Processor Database (FPEdit) - level 5 . . . . . . . . . . . . . . . . . . . . . . . . . 6–72
6.48 View Film Handling Parameters - level 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–73
6.49 Edit Installation Values (EditInst) - level 4 . . . . . . . . . . . . . . . . . . . . . . . . . . 6–74
6.50 View Recorder Statistics (StatsView) - level 4 . . . . . . . . . . . . . . . . . . . . . . . 6–74
6.51 Test Patterns (Test Ptn) - level 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–75
6.52 Focus Strips (Focus) - level 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–76
6.53 Focus Dots (Fdots) - level 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–76
6.54 Focus Lines (Flines) - level 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–77
6.55 Wedge Strips (Wedge) - level 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–78
6.56 Calibrate Iris (Iris) - level 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–81
6.57 Traverse error log messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–107
7.1 Punch and die sets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–36
8.1 Possible Causes for Grid Errors > 50 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–77

10.2 IBM Utrastar 9ES DDRS 34560 settings . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–13
10.3 Fujitsu M2952S ID settings (CN7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–14
12.1 Safety Interlocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–2
Engineer’s Reference Guide 6700887000 (xli)

Preliminaries
Issue Records
Chap Pages Issue Date Comments/Changes
Prelim 42 03 08/98 Revised for Mark II Film Handling
1 10 03 08/98 Revised for Mark II Film Handling
App A 8 03 08/98 Revised for Mark II Film Handling
App B 8 03 08/98 Revised for Mark II Film Handling
App C 2 03 08/98 Revised for Mark II Film Handling
Index 10 03 08/98 Revised for Mark II Film Handling
Note: The ISSUE STATE of a document or chapter is indicated by the last two digits of its document number (e.g. the first
re-issue of document 6500123000 becomes 6500123001, and the second re-issue becomes 6500123002 etc.). A
change of issue state indicates that substantial changes have been made to the document or chapter, although this
does not necessarily mean that the contents of each page have changed.
(xlii) Celix 4000 (MkII) Recorder

System Overview 1
This section describes the main features of the Celix 4000
imagesetter (with a Mark II recorder), shows its main
sub-systems, configuration and construction, and introduces the
ancillary/ peripheral equipment.
1.1 Introduction
The Celix 4000 recorder belongs to the Fujifilm Celix family of
systems for imagesetters and platesetters. It houses an expose
engine which is capable of printing directly to film a sequence of
image jobs downloaded from a RIP server. The recorder uses an
internal drum, and a laser with a high-speed spinner, to expose
suitable film.
In this manual, the recorder system is described in more detail as
three separate functional sub-systems:
• Media Handling - all the assemblies that handle film from the
Input cassette to conveyor belts on the Output Chute.
• Expose - all the optical and control assemblies for the expose
laser beam located on an Optics Carriage.
• Scanning- all the mechanical assemblies for traversing the
laser beam across film.
The film exposure area (for 1-Up format) extends as far as
627 mm x 759 mm in size. Images in either portrait, or landscape
mode can be exposed within the limitations of the image area.
Appendix B explains in more detail the Celix 4000 film and
output specifications.
The Celix 4000 recorder receives image data from the RIP server
via a differential SCSI interface and stores a complete image
before starting the exposure process. During an exposure process,
it can receive and store approximately twenty more images. The
exposure mechanism of a laser, spinner and an optical sub-system
Engineer’s Reference Guide 6700887000 1–1

System Overview
traverses the film to ensure a complete coverage of the exposure

area.
After exposure, the film is transferred directly into a film
processing unit closely coupled to the recorder. See Section 1.4.2.
CLIENT STATION
FUJIFILM FM SCREENING (POWER MACINTOSH
RIP SOFTWARE
SOFTWARE OR PC)
ETHERNET
OPTIONAL DRIVES SCSI RIP SERVER
RS232
ON-LINE SCSI
PROCESSOR
TO/FROM
DESKTOP
RECORDER PUBLISHING
NETWORK
OPTIONS
Figure 1.1 Celix 4000 system configuration
To achieve the functionality described above, the Celix 4000

imagesetter, comprises the following major components:
• Raster Image Processor (RIP) server and client
workstation(s).
1–2 Celix 4000 (MkII) Recorder

System Overview
Since there are several RIP software options available from

Fujifilm, you will need to refer to the appropriate RIP user
guide for the system installed.
• Single beam, internal drum expose engine (recorder).
• User control of the recorder from a set of displayed status
icons and a keypad called the MMI (man machine interface).
• Open and adaptable system architecture.
• Comprehensive fault diagnostics and error indicators.
• Choice of screenings, such as, FUJUFILM Quality Screening,
Adobe Accurate Screens and (optional) Lazel FM.
• Direct output to an online film processor.
• Automated film reloading and exposure to an on-line film
processor (not supplied).
Image data path from the networked desktop publishing source to
the processor is summarised in Figure 1.2. This shows one
example of a typical site configuration with a RIP client station
(PC or Macintosh) running the RIP user interface, and a RIP
server managing the output of images to the recorder.
PAGE PAGE
COMPOSITION COMPOSITION
STATION STATION
OTHER DESKTOP
SYSTEMS
SITE NETWORK
OTHER DESKTOP
SYSTEM
ETHERNET SCSI DIFF

RIP RIP ON-LINE
CLIENT STATION* SERVER* RECORDER PROCESSOR
CELIX 4000 IMAGESETTER * SEE THE RIP USER’S GUIDE
Figure 1.2 Celix 4000 data/image flow

System Overview
1.1.1 RIP Server

The RIP serves as a PostScript interpreter which appears to the
desktop systems as an AppleTalk- or PC-compatible PostScript
printer attached to the Ethernet local area network. Desktop
packages, such as, QuarkXPress or PageMaker, are used to create
a page containing text, tints and images. When the page is
complete it can be sent to the imagesetter in the same way as
printing to a PostScript printer.
The RIP server is a high performance, multi-tasking platform for
running the RIP, print spooling, queue management and
controlling the recorder unit. As a separate unit from the recorder,
the RIP server also allows for rapid upgrades in performance to
match the general increases in computer processing power.
Depending on the RIP option and the site network configuration,
a RIP client station provides a graphic user interface (GUI) for
selecting screen rulings, dot angles, media output parameters and
system calibration functions.
PostScript, or proprietary data, is received by the RIP. This data is
interpreted, rasterised, and then transferred to the recorder via the
SCSI bus. RIP software is installed as one of two possible
applications:
• HQ RIP (running on a PC under Windows NT).
• CelebraNT RIP (running on a PC under Windows NT).
A CD-ROM is used for downloading software and browsing
on-line documentation from a local server or client station.

System Overview
1.2 Celix 4000 Recorder

The Celix 4000 recorder (see Figure 1.3) is an internal drum
four-page (B2 size) imagesetter that provides output to either film
or paper. The expose system uses a red laser and a high speed
spinner to provide optimum performance. Media handling is fully
automatic and uses vacuum film location to ensure conformance
and quality output.
MMI (OPERATOR) PANEL OUTPUT CHUTE INPUT CASSETTE
Figure 1.3 Celix 4000 recorder
Media for the recorder is supplied by an input cassette and

transported directly into the processor. This system removes the
need to locate the recorder in a safelight area.
Some key servicing features of the Celix 4000 system with a
Celix 4000 (Mark II) recorder are:
• easier installation and removal of the Film Output Chute
assembly

System Overview
• easier removal of the Punch and Guillotine assemblies

Media input is made via an input cassette assembly. Media output
from the recorder is made via an output assembly and is
transferred to an on-line processor.
The recorder includes a Guillotine assembly and either:
• media Punch (customer option), or
• dummy Punch (standard requirement for recorder not having
a media punch).
The Celix 4000 also has local and remote diagnostics facilities.

System Overview
1.3 Construction
1.3.1 Recorder
The drum assembly of the recorder is mounted on fabricated
base-frames by four anti-vibration (AV) mounts.
The left and right-hand panel frameworks are joined together by
front and rear stretcher bars. Attached to the framework are a set
of panels, which when removed provide access to the internals of
the machine. When all the panels and covers are fitted, the
machine is light-tight. These removeable panels allow access for
the engineer to fault-find and service field replaceable units
(FRUs).
• A left-hand end panel provides access to the side of the
Electronics Control Unit (ECU) RFI Box and to the Power
Amplifier for the traverse system.
• A right-hand end panel is interlocked for safety. This panel
provides access to the Vacuum Pump assembly and the inside
of the drum to clear film jams and to clean the drum.
• A hinged left-hand access door is also interlocked for safety.
This provides access to the I/O panel, power supplies and
Mixer fan.
• An upper rear panel is interlocked for safety. This panel
provides access to the punch/guillotine assembly.
• A top panel gives access to the vertical film output system.
This panel is not interlocked.
The principal features of the Celix 4000 recorder are shown in
Figure 1.4.

System Overview
MMI VERTICAL OUTPUT

ASSEMBLY LEADSCREW
FILM OUTPUT
CHUTE FILM
CASSETTE
POWER
TRAY
VACUUM PUMP
ASSEMBLY
DRUM
LEADSCREW OPTICS
MOTOR CARRIAGE
ASSEMBLY
RFI CARD
CAGE (ECU)
Figure 1.4 Major features of the Celix 4000 recorder

System Overview
1.3.2 Cooling
Forced cooling exists for three areas; the ECU, the Drum cavity,
and the Spinner assembly.
• The ECU is a sheet metal enclosure containing power
supplies, PCBs, etc. An internal fan tray is located at the
bottom of the enclosure with four 24 V DC fans. These draw
air from above the unit, forcing it directly over the
components and exhausting out of the bottom. The air from
these fans is filtered.
• A 24 V Mixer fan and duct assembly is mounted at the
left-hand side of the drum (opposite the hinged door). The
mixer fan assembly supplies filtered cooling air to the drum at
240 cfm.
• A small 24 V fan is ‘piggy-backed’ to the spinner assembly
for additional cooling. A sensor is placed close to this fan to
detect fan failure.

System Overview
1.4 Ancillary Equipment

1.4.1 Vacuum Pumps Assembly
Ancillary functions are provided by a Vacuum Pump assembly for
holding the media to the drum. Vacuum is supplied for the
following:
• Film-to-drum width conformance.
• Engaging the Input cassette drive mechanism.
1.4.2 Film Processor

Exposed film from the recorder is fed directly into an approved
on-line film processing unit (supplied by the customer). An
agreed interface and protocol link the film processor to the
Celix 4000 recorder via an RS232 serial port. The SDM board
monitors the status of the film processor and maintains the correct
media transport movement relationship between the two
machines.
1.4.3 Remote Diagnostics

A modem communications link between the installed
diagnostics-server and a local customer service centre allows the
engineer to run Celix Diagnostics remotely and assess if an
electronic module is at fault. The engineer and the customer will
need to agree on when to run remote diagnostics outside a normal
production timetable.
FFEI Customer Services are able to provide furthet information
on a typical remote diagnostics configuration, recommended
modems and communication setups.

Safety 2
Requirements
This chapter explains the safety conventions used in this manual
and highlights safety practices specific to Celix 4000 Imagesetter.
This chapter must be read before operating, installing or working
on the equipment.
2.1 Health and Safety at Work

All personnel using the this equipment are advised to familiarize
themselves with any local or national legislation relating to health
and safety at work. Particular attention should be given to those
sections which cover personal responsibility regarding safe
working practices which must be observed at all times.
All procedures/all system servicing must be performed by an
authorized service representative.
This chapter explains the safety conventions used in this manual.
Certain precautions specific to the installation of the recorder are
detailed in Chapter 4 (Installation Procedure) of the Celix 4000
Recorder Installation Manual.
2.1.1 Warnings and Cautions

There are two categories of warning given in this manual,
Warnings and Cautions.
Warnings are given for conditions which may endanger the
safety of personnel.

Safety Requirements
WARNING
The instructions in Warnings must
be followed precisely. They are given
to avoid injury or death.
Cautions are given for conditions which may cause damage to

equipment or materials.
CAUTION
Cautions are given to prevent the
equipment or material from being
damaged.
2.2 Clothing and Jewellery

Do not wear clothing or jewellery that could be hazardous when
in contact with any part of the equipment, or which could reflect
laser light into an eye. Ties, watches and rings should be
removed.
2.3 Servicing Equipment and Special Tools

The recommended equipment and special tools - for servicing a
Celix 4000 recorder - are shown in Appendix C.

Safety Requirements
2.4 Site Safety

Most accidents will be avoided if you follow these simple rules.
• Familiarize yourself with the location of the mains isolation
switches and equipment on/off switches.
• Always obey the warnings, cautions, and any other
instructions included in this and relevant equipment manuals
or attached to the equipment.
• Never attempt to perform procedures that are not included in
this manual.
2.4.1 Signs, Labels, and Indicators

Safety labels are fitted to the equipment to warn you of potential
hazards. These labels must not be defaced or removed.
A Serial No., rating and FCC compliance label and laser
conformity label are fitted to the rear panel, as shown in
Figure 2.1.
Positions of laser warning labels are as shown in Figure 2.2 and
Figure 2.3.

Safety Requirements
SWITCH OFF BOTH CIRCUIT BREAKERS

TO ISOLATE MACHINE FROM MAINS.
ELECTRONIC PNEUMATIC
POWER SUPPLY POWER SUPPLY
7546-6770-00
92206
CONFORMS TO
UL STD 1950
Product: CELIX 4000
Model No:
Serial No:
Volts 110/230 50/60Hz ~

Max Current: 10A
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.
This Class A digital apparatus meets all the

requirements of the Canadian Interference-Causing
Equipment Regulations.
Cet appareil numérique de la classe A respecte
toutes les exigences du Règlement sur le matériel
brouilleur du Canada.
This laser conforms to the applicable requirements of

21 CFR Sub chapter J.
FUJIFILM ELECTRONIC IMAGING LTD.

PETERBOROUGH
ENGLAND CLASS 1 LASER
LASER KLASSE 1
LASER DE CLASSE 1
7550 854D 01
Figure 2.1 Recorder safety labels and ratings plate

Safety Requirements
DANGER - Laser radiation when open

Vorsicht!
Hochspannung and interlock defeated
AVOID DIRECT EXPOSURE TO BEAM
Attention!
high tension
Precaution!
haute tension
Precaucion!
alta tension
CAUTION
TURN OFF POWER AND DANGER - Laser radiation when open
WAIT FOR 10 SECONDS and interlock defeated
BEFORE OPENING, TO AVOID DIRECT EXPOSURE TO BEAM
AVOID DISK DAMAGE.
(U.S. SAFETY LABEL SHOWN.
7546–6880–00 THE EUROPEAN VERSION IS SIMILAR)
Figure 2.2 Recorder safety labels

Safety Requirements
DANGER - Laser radiation when open

and interlock defeated
Vorsicht!
Hochspannung
Attention!
high tension
Precaution!
haute tension
Precaucion!
alta tension
Figure 2.3 Recorder safety labels

Safety Requirements
CAUTION
LASER RADIATION WHEN OPEN
LASER RADIATION AVOID EXPOSURE
TO BEAM
675 nm/30 mW
CLASS IIIb LASER PRODUCT
WARNING AVOID EXPOSURE

LASER RADIATION IS
HIGH SPEED SPINNER ROTATION EMITTED FROM THIS
KEEP CLEAR APERTURE
THESE LABELS ARE ATTACHED TO THE OUTER COVER OF THE OPTICS

BASE ASSEMBLY WHICH IS MOUNTED ON THE OPTICS CARRIAGE
Figure 2.4 Internal safety labels
2.4.2 Safety Devices

Ensure that all safety controls, such as those listed below, are
present and working correctly:
• circuit breakers
• brakes
• covers and panels
• guards
• indicators
• interlocks
• warning labels.
Unless essential for commissioning or servicing, and under
prescribed conditions, never override, negate or bypass any of the
above safety devices.

Safety Requirements
2.4.3 Unattended Equipment

Never leave equipment unattended unless in a safe condition with
respect to mechanical, optical, electrical or other hazards.
2.4.4 Dust Prevention

To avoid dust contamination of the machine, it is important to
restrict to a minimum any operation with panel(s) removed or
open.
2.5 Electrical Safety
WARNING
Do not remove panels, unless
instructed to do so by this or other
related manuals. Lethal mains
voltages are present behind panels.
• Do not move or lift the unit while it is switched on or

connected to the electrical supply.
• Check mains cables regularly to ensure that they are not worn
or damaged.
• Ensure that water and other liquids do not come into contact
with the equipment.
• Do not attempt to operate the equipment when flammable or
volatile substances are present in the atmosphere.
• Ensure that electrical servicing is undertaken only by properly
authorized personnel.

Safety Requirements
2.6 Mechanical Safety

The following basic precautions apply to the system, and also to
the equipment with which it is used.
WARNING
Do not attempt to lift heavy
equipment by yourself.
• Always close equipment access panels to prevent unathorised

access.
• Avoid leaving electrical cables trailing where anyone may trip
over them.
• Make sure that mechanical servicing is undertaken only by
properly authorized personnel.
• The spinner mirror is made of Beryllium and care should be
taken to avoid abrasive damage.
• When cleaning the spinner mirror, use a lint-free cloth
impregnated with isopropyl alcohol.
• Do not rotate the spinner in any direction by hand. This could
cause damage to the assembly due to its air bearing.
2.7 Safety Interlocks

The location of each safety interlock for a Celix 4000 is shown in
Figure 2.5 and listed in Table 2.1 with each MMI access hatch
number.

Safety Requirements
SAFETY SAFETY
INTERLOCK INTERLOCK
SAFETY
INTERLOCK
SAFETY
SAFETY INTERLOCK
INTERLOCK
Figure 2.5 Location of recorder interlocks

Safety Requirements
If the recorder software detects an open interlock, the number is

displayed on the Access Panel Open icon:
identifying which of the panels, numbered (1 to 5), listed below is

open (see the Celix 4000 Recorder User’s Guide) and Table 2.1.
1. Left End panel.
2. Right End panel.
3. Output Chute panel.
4. Upper Rear panel.
5. Front Access Door.
The interlock system comprises five double-pole interlock
switches. If any external panel of the recorder is opened, the
operated interlock switch de-energizes the three interlock relays.
This results in power to the laser shutter solenoid and to all media
handling being removed. The status of the interlock switches is
sent to a status register on the SDM board. The laser shutter is
closed by a gravity-assisted spring when the power is removed.
If, during servicing, the recorder must be run with panels
removed and the interlocks overridden, extreme care must be
taken.
A special key (99380404) is inserted into the interlock socket,
revealed when a panel is removed, to override the interlock. The
panel cannot be replaced with the override key in place.
WARNING
Interlocks can only be overridden
using the specially designed key
(99380406). Do not override the
interlocks using any other method.

Safety Requirements
If, when the machine is on-line, one of the interlocked

panels/doors is removed or opened, this fact is indicated on the
MMI liquid-crystal display by a corresponding number as
indicated in Table 2.1.
Table 2.1 Safety Interlocks
FUNCTION LOCATION MMI DISPLAY No.

Left End panel See Figure 2.5 1
Right End panel See Figure 2.5 2
Output Chute panel See Figure 2.5 3
Upper Rear panel See Figure 2.5 4
Front Access door See Figure 2.5 5
When safety interlocks are overridden, the following special

precautions come into effect:
WARNING
All unqualified personnel must be
prohibited from the area, while the
machine is in the overridden state,
The Laser Safety Officer must be

informed when the machine is in this
state.
Make sure the safety interlocks are

re-enabled after a service visit.
Systems left in an over-ridden state
may not reset properly.
See Figure 2.5 for an illustration of the interlock relay system.

Safety Requirements
2.8 Acoustic Noise
WARNING
If the machine is run with panels
removed, the noise level may exceed
90 dB at 500 Hz. It is then essential
that hearing protectors of the
following type are worn:
RS 99902379 or equivalent (design
standard BS6344 Pt 1 7243 DIN
ANSI).
2.9 Spinner Safety

The spinner mirror is made from Beryllium.
WARNING
Beryllium is highly toxic.
Make sure that a replaced spinner is ALWAYS returned to the

FUJIFILM (UK) factory for disposal, and NOT disposed locally.
Do not access the internal drum area while the recorder is
switched on.
WARNING
The spinner rotates at very high
speeds and can cause serious injury
if accidently touched.

Safety Requirements
2.10 Laser Safety

2.10.1 General
Note the following warnings:
WARNING
Never look directly into a laser beam.
Do not attempt to do any alignment

or adjustment to the laser or optics
unless you have been instructed in
safe working with class 3b (IIIb)
lasers.
The protective cover of the laser

must always be in place during
normal operation.
2.10.2 Safety Warnings

Safety warnings must at all times comply with local and national
regulations.
When the laser is being serviced it may be necessary to run with
panels off and safety interlocks over-ridden. Under these
circumstances only the Service Engineer should be in the
Designated Laser Area (DLA). The DLA may be a room, a
curtained area, or the purpose-built DLA tent.

Safety Requirements
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 2.6.
• A red warning light, positioned above the door(s) leading to
the room, illuminated whenever there is a laser radiation
hazard.
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 2.6 Laser warning sign
A DLA Curtain
Local legislation may permit the following alternative:
• Isolation of the expose unit by means of a curtain. The curtain
must be opaque to red light (675 nm) and must extend from
floor to a height of at least 2.1 m (84 in).

Safety Requirements
• Warnings placed where required to ensure that personnel are

aware of the laser radiation hazard inside the curtained area.
The signs shown in Figure 2.6 are recommended.
2.10.3 General Precautions

• Always close the laser shutter before inserting or removing
any optical component or sub-assembly.
• Never have the laser brighter than the laser needs to be to do
any particular alignment task.
• Never place a mirror in the laser beam. This action can reflect
hazardous light to others working in the general area.
• Remove the protective cover of the laser only in accordance
with the instructions given in the service manual.
• 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 is always to be in place
during normal operation.
• Unless the specification requires otherwise, adjust the beam
intensity by altering the drive current so that the beam is just
bright enough to do the required adjustment. Always start
with the intensity at minimum and increase to the point where
the spot is adequately visible.

Safety Requirements
2.11 Antistatic Precautions
CAUTION
Do not handle exposed electronics.
The components may be
electrostatically damaged leading to
equipment errors.
The Celix 4000 recorder contains electronic components which

are susceptible to static damage. Therefore when clearing jams,
cleaning, or performing routine maintenance 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 protective wrapper. Also, do
not place it on the wrapper itself, the
outside of which could be
electrostatically charged.
When removing the board from its antistatic wrapper, take care
not to touch any of the board components or the SCSI and Nubus
connector pins.
Preferably, use a Field Service Antistatic Kit or, if not available, a
disposable antistatic wrist-strap as detailed in this chapter.

Safety Requirements
2.11.1 Field Service Antistatic Kit

The following figure shows the recommended on-site service
station using the Field Service Antistatic Kit, (99987920).
CONDUCTIVE MAT
EARTH
STRAP
CLIPPED TO
EXPOSED
CHASSIS CHASSIS
ANTISTATIC
POWER FIELD SERVICE KIT
OFF (99987920)
MAINS
PLUG
EARTH WRIST STRAP
Figure 2.7 Antistatic handling station
2.11.2 Disposable Antistatic Wrist Strap
CAUTION
Use the disposable antistatic
wrist-strap. Failure to do so may
result in damage to the board.
A disposable wrist strap should be used to connect the user to an

earthed point on the equipment (usually the chassis). To achieve
this the wrist strap is adhesive-backed.
Note: The equipment must be plugged into an earthed socket (but
not switched on) to ensure a path to ground.

Safety Requirements
The main antistatic recommendations are as follows:

• Use documentation referred to in this chapter.
• Always ensure a wrist-strap is connected to earth.
• Personnel not static-protected should not touch boards or
exposed internal components.
• Any board to be fitted should be kept within its anti-static
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. Never place it on a surface that is not static-safe.

Safety Requirements

Electronic 3
Assemblies
Physical
Description
This chapter provides a brief physical description of the main
assemblies (PSU, PCBs, etc) on the recorder, giving general
information on test points, fuses, connector ports, LEDs, and
switches with their default settings.
The assemblies are:
• Location of PCBs on the Recorder - Section 3.1.
• ECU Assemblies – Section 3.2.
• PSU Assemblies - Section 3.3.
• System Data Manager Board (SDM) - Section 3.4.
• Digital Signal Processor Board (DSP) - Section 3.5.
• Motion Control Board (MCB) - Section 3.6.
• Power Amplifier Board - Section 3.7.
• Spinner Controller Board – Section 3.8.
• Media Handling Sensors - Section 3.9.
A more detailed description of how these assemblies function as
part of the system is explained in Chapter 4. Use the Celix 4000
Recorder Illustrated Parts Catalogue for referring to part
numbers.

Electronic Assemblies Physical Description
3.1 Location of PCBs in the Recorder

Figure 3.1 shows the locations of each of the main electronic
assemblies/PCBs on the recorder.
MMI
POWER
AMPLIFIER
LASER MODULATOR
BOARD
SDM, DSP, I/O, MCB AND SPINNER

CONTROLLER IN ECU
Figure 3.1 Location of PCBs within the recorder
3–2 Celix 4000 Recorder

The following printed circuit boards (PCBs) are located within

the recorder:
• SDM board, see Section 3.4.
• Motion Control board, see Section 3.6.
• Digital Signal Processor (DSP) board, see Section 3.5.
• Spinner Controller board, see Section 3.8.
• I/O panel (Internal Connections board), see Section 3.2.1.
• Power Amplifier board (including relays) , see Section 3.7.
• Laser Modulator board, see Section 4.10.
• MMI, see Section 4.9.
Two other PCBs are located beneath the drum for interconnecting
the sensors with the ECU, see Figure 3.17 and Figure 4.41.
• Front Distribution board, see Section 3.9.
• Rear Distribution board, see Section 3.9.

3.2 ECU Assemblies

The Electronics Control Unit (ECU) comprises the RFI box,
power supply modules, an I/O panel/backplane and the boards
shown in Figure 3.2 below.
To access the boards inside the ECU, with the power off, open the
ECU side cover.
SPINNER BRD
CABLE CONNECTOR
MOTION
SPINNER CONTROL
CONTROLLER BOARD
BOARD
I/O PANEL
CONNECTIONS
PSU’s
(2 OFF)
COOLING
FANS
SCSI
DISK
ECU SIDE COVER

(OPENED)
SDM BOARD
DSP BOARD (UNDERNEATH SDM)
Figure 3.2 Electronics Control Unit (ECU): main components

RETAINING CATCH
SCREW (2 POSITIONS)
SCSI DISK
FIXING SCREWS
(4 POSITIONS)
FILM
PROCESSOR
DIAGNOSTICS
(RS 232)
SPARE
(NOT USED)
SCSI IN/OUT
SCSI IN/
OUT
SDM BOARD
FIXING SCREWS
(6 POSITIONS)
FIXING
SCREWS
(14-OFF)
ACCESS
PANEL
Figure 3.3 Electronics Control Unit (ECU): access and connectors

CAUTION
Never open the hinged lid (left-hand
cover) of the ECU RFI Box while
power is applied. The SCSI disk
drive will be damaged if the disk
motor is spinning and the hinged lid
is then opened. When power is
removed from the machine the SCSI
disk drive will ‘park’.
3.2.1 I/O Panel Description

An exterior view of the Input/Output (I/O) panel is shown in
Figure 3.4, with the physical layout of the connections displayed
in Figure 3.5.

RFI BOX
(ECU UNIT)
I/O PANEL ASSY
Figure 3.4 Input/Output Panel Assembly

SK2
SK3
SK1
SK4
PL1
SK5
PL2
SK7
PL3
SK6
SK10
SK8
SK9
PL5
SK11
PL4
SK12
SK14
SK13
SK15
SK16
PL7
SK17
PL6
SK19
SK18
FS1
FS3 FS2
FS6 FS5 FS4
FS8 FS7
FS9
PL8
EXTERNAL CONNECTORS INTERNAL CONNECTORS
Figure 3.5 Input/Output Panel connectors
Table 3.1 to Table 3.3 describe the functions of main cables from
the I/O panel and the fuses.

Table 3.1 Input/Output Panel External Sockets
Plug No. Cable No. Function/Signal
SK1 10 Solenoids
SK2 B Optics motors (part of umbilical)
SK4 7 Media handling motors
SK5 A Optics sensors (part of umbilical)
SK6 9 Media handling sensors - front
SK7 8 Media handling sensors - rear
SK8 16 MMI
SK9 K Traverse home (part of umbilical)
SK10 109 Interlocks
SK11 F Spinner drive (part of umbilical)
SK12 47 Traverse limit
SK13 D CAN Bus/Modulator power (umbilical)
SK14 C Spinner encoder (umbilical)
SK16 21 Traverse comms
Table 3.2 Input/Output Panel Internal Connectors
Plug/ Cable No. Function/Signal

Socket No.
PL1 86 Sensors
PL2 87 Sensors
PL3 85 Solenoids
PL4 27 MMI/CAN
PL5 25 Interlocks/Spinner encoder
PL6 24 Traverse/Spinner control
PL7 6 DSP Comms to Power Amp
PL8 91 Power
SK3 31 Motors
SK15 145 Spinner drive
SK17 Not used
PL9 146 Spinner Controller

Table 3.3 Input/Output Panel fuses
Fuse No. Type Usage
FS1 2A Spare
FS2 2A +12 V to laser modulator
FS3 5A Spare
FS4 2A +5 V to Opto-sensors (apert., illum., foc.)
SK5 pins 3, 7, 12, 15, 20, 24
FS5 2A -12 V to laser modulator
FS6 2A Spare
FS7 2A +5 V to MMI SK8 pins 4, 10, 16
FS8 2A +12 V to interlock switches SK10 pin1
FS9 5A +5 V to laser modulator

3.3 PSU Assemblies

The PSU modules fitted to the recorder are:
• ±5 V, ±12 V and +24 V - Main PSU in the ECU.
• +42 V/30 V - Motor and Spinner PSU in the ECU box.
• +30 V - Power Amp PSU Assy, see Section 3.7.
See also Section 4.3 for a functional description of the PSU
assemblies.
3.3.1 ECU PSU Modules Description

See Table 3.4 and Section 4.3.
This section describes the voltages generated from the ECU.
Schematic information on mains input wiring and how AC/DC
are distributed on the system is given in Section 4.3.
Two regulated PSUs, mounted in the rear of the ECU, supply:
• +5 V and –5 V (40 A); +24V (4 A); and ±12 V (10 A)
• 42 V and 30 V.
These DC voltages are generated for:
• +5 V - logic devices
• –5 V - logic devices
• ±12 V - memory devices
• +42 V - (to the MCB for stepper motor drive signals)
• +30 V - for spinner.
DC voltage tolerances are regulated at ±8% which approximates
to the values in Table 3.4.

Table 3.4 DC voltage tolerances
Voltages Tolerances
5V 5.05 to 5.25 V
12 V 11.4 to 12.6 V
24 V 22.8 to 25.2 V
42 V 40.9 to 44.1 V
Information on how to read wire colour code voltages is given in

the figures below.
The ECU PSU module includes connectors and cable supplying
dc voltages to the main electronic assemblies. The following
voltage outputs are shown:
• Cable 89 to the MCB: see Figure 3.6.
• Cable 90 to the SDM: see Figure 3.7.
• Cable 91 I/O internal panel connections: see Figure 3.8.

+5 V RED
M6
RED +5 V
DGND BLACK PIN 1
M6 BLACK DGND
M5 M5 2
+42 V WHITE/BROWN WHITE/BROWN +42 V
M5 3
WHITE/BROWN +42 V
+42 V WHITE/BROWN 4
M5 BLACK 0 V
M5 M5 5
0 V BLACK BLACK 0 V
M5 M5 M5 6
WHITE/ORANGE +24 V
0 V BLACK 7
M5 WHITE/ORANGE +24 V
8
+24 V WHITE/ORANGE BLACK 0 V
M4 M5 M5 9
BLACK 0 V
+24 V WHITE/ORANGE M5 M5 10
M4
11
0 V BLACK RING TERMINALS
M4 12
ATTACH TO ONE STUD
0 V BLACK
M4
DGND BLACK
M6
+5 V RED
WA 305 PSU
+5 V 0V
(-5.2 V) 5 0
0 +24 NC -12 V 0 0 +12 PF +Se V +So -Se V -So
V V V V V
METAL METAL METAL

LINK LINK LINK
WHITE/ORANGE +24 V
WHITE/ORANGE +24 V WA 402 PSU
M4
BLACK 0 V
BLACK 0 V
30 V 0 V
+42 V WHITE/BROWN
+42 V WHITE/BROWN
NOTE References to M4, M5 M5 0 V BLACK
: and
M6 indicate the respective 0 V BLACK
terminal stud size.
Figure 3.6 PSUs: Cable 89 to Motion Control Board (MCB)

+12 V ORANGE
M4
ORANGE +12 V
GND (12V) BLACK PIN 1
M4 BLACK (12V) GND
M5 M5 2
+5 V ECL RED RED +5 V ECL
M6 3
BLACK ECL GND
ECL GND BLACK M5 M5 4
M6 RED +5 V
5
+5 V RED RED +5 V
M6 6
RED +5 V
+5 V RED 7
M6 BLACK DGND
M5 M5 8
+5 V RED BLACK DGND
M6 M5 M5 9
BLACK DGND
DGND BLACK M5 M5 10
M6
DGND BLACK RING TERMINALS
M6 ATTACH TO ONE STUD
DGND BLACK
M6
RED +5 V ECL
RED +5 V
M6
RED +5 V
RED +5 V
BLACK ECL GND

BLACK DGND
NOTE References to M4, M5 M6
BLACK DGND
: and
M6 indicate the respective BLACK DGND
terminal stud size.
WA 305 PSU
+5 V 0V
(-5.2 V) 5 0
V V V V V
METAL
LINK METAL
LINK
GND (12V) BLACK METAL
M4 LINK
+12 V ORANGE
Figure 3.7 PSU: Cable 90 to System Data Manager (SDM) board

+5 V RED
M6
RED +5 V
+5 V RED PIN 1
M6 RED +5 V
2
+12 V ORANGE ORANGE +12 V
M4 3
BLUE -12 V
-12 V BLUE 4
M4 WHITE/ORANGE +30 V
5
+30 V WHITE/ORANGE WHITE/ORANGE +30 V
M6 6
BLACK GND (30 V)
+30 V WHITE/ORANGE 7
M6 BLACK GND (30 V)
8
GND (30 V) BLACK WHITE/BROWN +42 V
M6 9
BLACK GND (42 V)
GND (30 V) BLACK 10
M6
+42 V WHITE/BROWN
M5
GND (42 V) BLACK +5 V RED
M5 M6
+5 V RED
WA 305 PSU
+5 V 0V
(-5.2 V) 5 0
V V V V V
METAL
LINK METAL
-12 V BLUE LINK
M4 METAL
+12 V ORANGE WHITE/ORANGE +30 V
LINK
WHITE/ORANGE +30 V
M6
GND (42 V) BLACK BLACK GND (30 V)
M5
+42 V WHITE/BROWN BLACK GND (30 V)
NOTE References to M4, M5

: and
M6 indicate the respective
terminal stud size. 42 V 0 V 30 V 0 V
WA 402 PSU
Figure 3.8 PSUs: Cable 91 to Input/Output Panel (internal)

3.4 System Data Manager (SDM) Board

3.4.1 SDM Board Description
See Section 4.4 for a functional description of the SDM board.
General Information
Figure 3.9 and Table 3.6.
Location: ECU - left-hand side panel.
Links: None.
LEDs: None.
Switches: None.
Fuses: FS1 (SCSI, 5V, 2A)
FS2 (Sensors, 5V, 2A) - Traverse and spinner
motor encoders, and traverse Hall-effect
Home sensor on the Optics Carriage. See
Table 3.5.
Table 3.5 SDM board fuses
Fuse No. Type Usage

FS1 2A +5 V to SCSI ports
FS2 2A Traverse motor encoder, and home sensor supplies.
Spinner/Encoder 5 V supply.
The test points on the SDM are for checking signals from a
production test rig only.
Port Connections
These are described in Table 3.6 below.

Table 3.6 SDM board plugs and sockets
Plug No. Cable No. Function/Signal Destination
PL2 1 SCSI Disk Connector 1 SCSI Disk 1

PL3 SCSI Disk Connector 2 SCSI Disk 2
PL4 27 MMI/CAN Bus MMI/Optics module
PL5 24 Spinner control Spinner Controller board
PL6 25 Interlocks and sensors Trav. sys/intlk. sws./spinner
PL7 3 Motion control data Motion control board
PL8 No connection
PL9 32 5 V and 12 V supply SCSI disk
PL10 38 Not Used Film Processor
PL11 36 Diagnostics serial port Diagnostic terminal
PL12 37 Processor serial port
PL13 No connection
PL14 No connection
PL15 Power fail - not connected Future use
PL16 90 Power supplies 5V, 5V ECL, 12V
PL17 26 DSP Bd (+5V, +15V, -15V)
SK1 SE SCSI I/P
SK2 SE SCSI O/P
SK3 39 Differential SCSI Input RIP/External SCSI
SK4 40 Differential SCSI Output Terminator
SK6 34 Optics image Optics module
SK7 – Not Used –
SK8 CPU debug

PL16 PL17
SK5 SK6 SK7
PL21
PL15
PL20
SK8
PL19
PL13 PL14
PL8
PL1
PL18
PL7
PL6 PL12
PL5 PL11
FS2
SK2 SK4 PL4 PL10
PL3 PL9
FS1
PL2
SK1 SK3
Figure 3.9 SDM board plugs and sockets

3.5 Digital Signal Processor (DSP) Board

3.5.1 DSP Description
See Section 4.5 for a functional description of the DSP board.
General Information
See Figure 3.10.
Location: Bolted to SDM board, components facing
right
Links: LK1 and LK4
LEDs: D1
Test Points: TP1 to TP23, TP26, TP28 to TP32 and TP35
to TP38
Switches: None
Fuses: FS1 and FS2 (2 A, 99285417)
FS3 (5 A, 99285423).
Links
LK1: Always connected.
Connects 24 MHz clock to processor (no other positions).
LK2: Not connected.
For R&D purposes.
LK3: Not connected.
For R&D purposes.
LK4: Pins 2 and 3 always connected.
Not used.

TP35
TP30-TP35
TP30 TP38
PL3
TP29
TP26-TP29
TP26
TP25
TP8-TP25
LINK (LK1)
LINK (LK4)
TP37
TP8
FS1 (2 A) FS2 (2 A)
PL2
POWER
CONNECTOR FS3 (5 A)
TP7
TP6
PL1
60-WAY
TP5
D1 (LED)
TP4
TP3
TP2
TP1 TP36
Figure 3.10 DSP board layout

Fuses
FS1: 99285417 2 A fuse after the +15 V supply from the
power connector (PL2).
Note: The +15 V supply is used to generate +5 V for the 24 MHz
crystal, which supplies digital clock signals.
FS2: 99285417 2 A fuse after the –15 V supply from the
power connector (PL2).
FS3: 99285423 5 A fuse after the 5 V supply from the power
connector (PL2), and the L/R limit switch for
the traverse.
Note: The fuses above cannot be checked by Celix Diagnostics;
to check for each fuse, monitor at points TP10, TP11 and
TP15.
Cable Connections
PL1: 60-way connector to SDM board.
PL2: Power cable connector from SDM board.
PL3: 10-way connector to Power Amplifier board.
DSP Board Checks

LED (D1) is checked by opening the front RFI box access door
and viewing the LED at the front edge of the board, see Table 3.7.

Table 3.7 DSP LED (D1) Indications
LED On/Off Status

D1 On A software malfunction has occurred, causing the watchdog circuit to time
out.
or
The DSP Board is being held reset by the SDM Board.
Off Drive to the motors will have been removed.
Normal operation.
or
Fuse FS3 has blown, removing the 5 V supply.
Test Point Signals

See Figure 3.10.
All signals are TTL unless otherwise stated.
Note: Test point signals not used for this application are not
tabulated.
TP2: LSOPR/ (Leadscrew Once-Per-Rev) - low going pulses.
The input from Leadscrew motor encoder index. Period

depends on rotational speed of the Leadscrew (up to 6 s).
TP3
SPOPRT
TP4
SPTOG
Figure 3.11 SPOPRT (TP3) and SPTOG (TP4) waveforms
TP5: GND - Digital ground (0 V).

TP6: ABPOSN (Absolute Position).

The signal goes low when the Optics Carriage Hall effect
vane sensor is detecting a vane. Vanes are positioned at
the centre and right hand end of the Leadscrew, viewed
from the front. See Figure 3.12.
DRUM LENGTH
12 mm
TP6
RH SIDE
ABPOSN
NOMINAL POSITION >28 mm

OF CENTRE OF DRUM
Figure 3.12 ABPOSN (TP6) waveform
TP7: LSOPRTOG (Leadscrew Once-Per-Rev Toggle) - low

frequency square wave.
The signal toggles between high and low values at each

LSOPR/ index pulse.
TP9: LDMEM - signal normally high.
The signal to the SDM board, goes low when the DSP
control software determines that a scan should be started.
The signal stays low until the scan is completed.
TP10: –15 V - after fuse FS1 (2 A).
TP11: +15 V - after fuse FS2 (2 A).
TP12: CRENCQD/ (Carriage Encoder Quadrature Signal)
- approximately a square wave.
The signal is 90° out of phase with CREN/ (TP20) signal.

See Figure 3.13.
TP13: CGPH (Carriage Phase) - high going narrow pulses to
phase detector.
The pulse width = 667 to 1333 ns.

The rising edges of pulses are nearly coincident with the
rising and falling edges of CRENCQD/ (TP12) and
CREN/ (TP20). See Figure 3.13.

TP12
CRENCQD/
TP13
CGPH
TP20
CREN/
Figure 3.13 DSP test-point waveforms
TP14: DRN (Direction) - signal either high or low.
Signal low: carriage moving left to right.

Signal high: carriage moving right to left.
(viewed from the front).
The signal can be high or low when the carriage is
stationary.
TP15: VCC - nominally 5 V (after fuse FS3).
TP16: IBUF (Input Buffer Full) - signal normally low.
The signal goes high while input buffer is full, and has
not yet been read by the DSP board. The input buffer
receives data from the SDM board.
TP17: OBUF (Output Buffer Full) - signal normally low.
The signal goes high while output buffer is full and has
not yet been read by the SDM board. The output buffer
provides data to the SDM board.
TP18: GND.
TP19: CKOUT (Clock Out).
The 6 MHz signal from the ADSP2100 processor output.

The signal is halted while the processor is held reset.

TP20: CREN/ (Carriage Encoder) - approximately a square

wave.
The signal is 90° out of phase with the CRENCQD/

(TP12) signal.
A 180° phase shift occurs relative to CRENCQD/ (TP12)
if the rotational direction of the Leadscrew motor is
reversed to traverse in the opposite direction.
TP22: AGND (Analog Ground).
TP26: CGRFP (Carriage Ref to Phase Detector) - high going
pulses.
The signal frequency relates to the set traverse rate. The

higher the frequency, the faster the traverse rate.
TP28: TSIG (Traverse Signal) - analog signal.
1 V = 0.5 A of motor current.

The signal sent to Power Amp board for driving traverse
motor.
Positive signal: traverse moves left to right
Negative signal: traverse moves right to left (viewed from
the front).
TP35: PDOUT (Phase Detector Out) - analog signal.
Output of traverse loop phase detector. An analog
representation of the relationship between the CGPH
(TP13) and CGRFP (TP26) signals.
TP36: Digital ground.
TP37: Digital ground.

3.6 Motion Control Board

3.6.1 MCB Description
See Section 4.6 for a functional description of the Motion Control
Board (MCB).
PL5
PL4
FS4
FS3 PL3
FS1 FS8 FS1

2
FS2 FS7
PL2
SK1
SK2
FS11
FS10
FS9
FS6
FS5
PL1 PL6
Figure 3.14 MCB plugs and sockets

The MCB provides drive for all the stepper motors and solenoids
associated with the recorder media handling systems and optics
systems.
General Information
Location: Inside of ECU, components facing out
(see Figure 3.1).
See Table 3.8 for a description of the MCB fuses.
Note: These fuses are used to provide a diagnostics ability; they
are not replaceable.
Table 3.8 Motion Control Board fuses
Fuse No. Type Usage

FS1 5A Spare
FS2 5A Spare
FS3 5A Spare
FS4 5A +42 V to Illumination Cont. motor drive
FS5 5A +42 V to media load motor drive
FS6 5A +42 V to Focus motor drive
FS7 5A +42 V to Aperture motor drive
FS8 5A +24 V to shutter solenoid
FS9 5A +42 V to media O/p carriage motor drive
FS10 5A +42 V
FS11 5A +42 V to Guillotine motor drive
FS12 2A Shutter solenoid drive
Cable Connections
Cable connections to the MCB and their functions are shown in
Table 3.9.

Table 3.9 Motion Control Board plugs and sockets
Plug/ Cable No. Function/Signal

Socket No.
PL1 89 Power
PL2 3 SDM board data
PL3 85 Solenoids
PL4 86 Optics sensors and interlocks
PL5 87 Sensors
SK1 31 Optics and media handling motors
SK2 88 Interlocks
PL6 48 Interlocks

3.7 Power Amplifier Board

3.7.1 Power Amplifier Board Description
See Figure 3.1 and Figure 3.15; also Section 4.8 for a functional
description of the Power Amplifier board.
PSU
CIRCUIT
BREAKER POWER AMP
BOARD
RELAY
(RIGHT)
MAINS RELAY
FILTER (LEFT)
TO
DATA TRAVERSE
TO ECU MOTOR
MAINS
TO ECU
Figure 3.15 Power Amplifier assembly

The Power Amp board is fitted to a detachable panel located

internally on the rear left-hand side of the recorder. DC power is
supplied by a PSU module; two mini-relays for motor drive and
braking control are located on the board.
Location: Left-hand side, rear of the recorder (see
Figure 3.1).
Links: None.
LEDs: None.
Test Points: TP1 to TP13.
Switches: None.
Fuses: Pneumatics: 250 V, 5A (located on the IEC
input connector at the rear of the pneumatics
transformer).
Electronics: resetting fuse inside PSU.
Circuit Breaker See Figure 3.15.
Test Points
TP1: Analogue Gnd.
TP2: Not Used.
TP3: TSIG.
TP4: Response.
TP5: Motor Current.
TP6: Stimulation.
TP7: Analogue Gnd.
TP8: Torque Demand.
TP9: –30V.
TP10: +15 V.
TP11: +12 V.

TP12: +5 V.
TP13: +30 V.
Cable Connections
Power Amp Board:
PL1: 12-way to ECU.
PL2: 15-way Traverse Motor Encoder.
PL3: 6-way Traverse Motor Drive.
SK1: Not Connected.
SK2: 6-way to PSU.
Power Amp Assembly:
IEC: External mains input.
IEC: Mains Output to ECU.

3.8 Spinner Controller Board

3.8.1 Spinner Controller Board (FFEI-Westwind)
See Figure 3.16.
Location: Within the ECU with components facing
cover.
LEDs: None.
Test Points: TP1 to TP12.
Switches: None
Fuses: None.
Test Points
TP1 - Spinner Current
TP2 - 30 V
TP3 - Digital Gnd
TP4 - S Reference
TP5 - Demodulation Out
TP6 - Spinner Reference
TP7 - Torque Demand
TP8 - Modulator In
TP9 - Data Clk
TP10 - Analogue Gnd
TP11 - Digital Gnd
TP12 - Modulator Response (HiByte)
TP13 – Modulator Response (LoByte)

TO I/O PANEL
40-WAY
PL2
TP3 SK1
TP9
TP4
TP11
TP6
TP8 TP10
TP5 TP13
TP7 TP12
HEAT SINK
TP2
TP1
PL1
25-WAY
TO I/O PANEL
Figure 3.16 Spinner Controller board (FFEI-Westwind)

Cable Connections
See Figure 3.16.
PL1: 25-way D-type connector to the input/output (I/O) panel.
PL2: 40-way connector to the input/output (I/O) panel.
SK1: ISP program socket.
Spinner Controller Board On-line Checks

Celix Diagnostics tests for the Spinner Controller board cover the
following areas:
1. Spin RAM checks.
2. Delay line generator checks (in test mode only - not while
imaging).
3. Monitor the ststus register for over-temp, overspeed,
spinner-not-at-speed and driver fault tests
These checks are run from the sub-menu option:
Elec .Sys.CPU.Can
See Table 6.10 for further information.

3.9 Media Handling Sensors and Distribution

Boards
This section describes the type, function and location of media
handling sensors on the recorder.
Refer to to Section 4.12 for a description on how the sensors
operate during a normal load/reload sequence.
3.9.1 Input Sensors

See Figure 3.17.
The following types of sensors are used in association with media
input handling:
• Media at Input Cassette (drop): reed (proximity switch) and
lever arm switch with a magnet attached.
– Located on the cassette drive assembly - the lever arm
switch is located in the Input cassette and the reed switch
is on the left-hand side.
– Detects the presence of media edge outside the front of
the cassette during a LOAD.
• Input Media Detect: lever arm switch.
– Located on the front film guide.
– Detects the presence of film inserted through the Input
(nip) rollers.
• End of Roll Detector: optical switch.
– Located on the Cassette drive plate above the drive dog
coupling.
– Detects an empty film/paper roll in the input cassette.

3.9.2 Output Sensors

See Figure 3.17.
output handling:
• Guillotine EOT, Left: reed (proximity switch).
– Located on the left-hand side of the guillotine guide rail.
– Detects that the guillotine has reached its left limit
end-of-travel position.
• Guillotine EOT, Right: reed (proximity switch).
– Located on the right-hand side of the guillotine guide rail.
– Detects that the guillotine has reached its right limit
end-of-travel position.
• Output EOT, (at Processor): lever arm switch.
– Located on rear output film guide.
– Detects that film has reached the end-of-travel limit at the
chute exit near the processor.
• Media Detect (at Punch): lever arm switch.
– Located at the punch in the centre.
– Detects whether media is inserted in the punch.
• Lazy Loop (at Output Rollers): lever arm switch.
– Located behind the upper film guide on the Vertical
Output assembly.
– Detects the difference of speed between the rollers on
Output Chute and the rollers on the Vertical Output for
switching the Chute DC motor on/off.
• Post Guillotine: lever arm switch.
– Located at the rear of the machine on the Vertical Output
cross-member.

– Detects whether film is being fed into the output system.

Provides information for a jam condition.
MEDIA DETECT
(AT PUNCH) LAZY LOOP
POST-GUILLOTINE GUILLOTINE
O/P EOT (AT EOT (RIGHT)
PROCESSOR)
PUNCH
POSITION
END OF ROLL
DETECTOR
GUILLOTINE
EOT (LEFT) INPUT MEDIA
DETECT
REAR FRONT MEDIA AT INPUT
DISTRIBUTION DISTRIBUTION CASSETTE
BOARD BOARD (DROP)
Figure 3.17 Media handling sensors/sensor distribution boards

• Punch Position Sensors: optical switch.

– Locatedon a small PCB opposite the punch cam.
– Detects the cam encoder position, as it rotates
anti-clockwise, to determine whether the punch pins are
engaged or disengaged.
3.9.3 Sensor Distribution Boards

See Figure 3.17.
Two sensor distribution boards are present on the recorder:
• Front: these channel data from the Input sensors to the I/O
Panel, see Section 3.9.1.
• Rear: these channel data from the Output sensors to the I/O
Panel, see Section 3.9.2.
The connections to these boards are illustrated in Figure 4.41.

Equipment 4
Functional
Description
This chapter gives a brief overall system description, a more
detailed functional description of each PCB, and then a summary
of how each of the media sub-systems (media handling, expose
and scanning) operate.
System Introduction and PSU Modules
• System Overview - Section 4.1.
• System Electronics (PCBs, etc) - Section 4.2.
• System Power - Section 4.3.
• SDM Board - Section 4.4.
• DSP Board - Section 4.5.
• Motion Control Board (MCB) - Section 4.6.
• Spinner Controller Board - Section 4.7.
• Power Amplifier Board - Section 4.8.
• Man Machine Interface (MMI) - Section 4.9.
• Laser Modulator Board - Section 4.10.
Main Sub-Systems
The operation of the following main sub-systems are described so
that engineers have adequate background information before
starting to fault-find and replace parts.
• Media Handling Systems (Guillotine and Punch, Output
Carriage) - Section 4.11.

Equipment Functional Description
• Media Handling Sequence - Section 4.12.

• Media Expose System - Section 4.14.
• Media Scan System (Traverse Control, Spinner, Optics
Carriage, Leadscrew) - Section 4.15.
• System Cabling and Interconnections - Section 4.16.
4.1 System Overview

Figure 4.1 provides a functional diagram of the Celix 4000
recorder interfaced to a RIP server.
Although the field repair philosophy for the Celix 4000 recorder
is for module (or sub-assembly) replacement, some detailed
functional descriptions of the PCBs and sub-assemblies are
provided. This level of detail should aid in the effective
troubleshooting of system problems.
Where appropriate, functional diagrams are supplied to support
the text.
This sub-section provides a high-level description of each of the
functions of the system.
4.1.1 RIP Communications

Two-way communication between the RIP server and the Celix
4000 recorder is achieved via a differential SCSI link to the SDM
board.

SCSI DISK
CELIX DIAGNOSTICS ON–LINE PROCESSOR
RIP
SERVER POWER
DSP BOARD AMP TRAVERSE
DIFF
SCSI
CONTROL
SPINNER
(CAN BUS ) CONTROL BOARD SPINNER
SDM
BOARD
IMAGE DATA
LASER
MODULATION TO
CONTROL (CAN BUS ) LASER
MMI
INTERLOCKS
AND RELAYS
MOTORS
MOTION
CONTROL SENSORS
BOARD
SOLENOID
(SHUTTER)
OPTICS MODULE
MOTORS SENSORS SOLENOIDS
MEDIA HANDLING
Figure 4.1 Celix 4000 functional diagram

The SDM board receives control and image data from the RIP
and returns status data to the RIP server via the differential SCSI
link.
The differential SCSI link cable enters the recorder from a
light-tight flap below the ECU and terminates at the ECU panel
(SCSI IN connector). A SCSI OUT connector is normally fitted
with a terminator. The recorder normally has SCSI ID 0 for the
differential SCSI bus.
4.1.2 Image Data Reception

Image data is received from the RIP by the SDM, via the
differential SCSI link. Apart from acting as the interface to the
RIP, the SDM performs the following:
• Compression of received data.
• Using an on-board 4 Gbyte SCSI disk drive, provides storage
for compressed image data.
• After storing a complete image, provides for:
– Decompression of image data.
– Contiguous transfer of image data to the modulator on the
Optics sub-assembly.
If any of the status conditions are incorrect, a message is returned
to the SDM.
4.1.3 Media Exposure

Once the SDM has received a complete image (at least one
separation) from the RIP, media exposure starts:
Data is synchronized and routed to the laser modulator via the
SDM.

Traverse Control Speed

The Traverse motor is controlled from the DSP.
The DSP receives high level commands from, and returns status
messages to, the SDM. The SDM has control over the RESET
function of the DSP.
When a RESET function is asserted, the operation of the DSP
effectively ceases. Beyond that, the DSP controls the traverse
independently of the SDM.
Drive to the Traverse motor is provided from the DSP via the
Power Amp board. Control of this motor is effected by a loop
arrangement on the DSP.
Control Console (MMI)

The control console (MMI or Man-Machine Interface) provides
the facilities for operators to control the flow of media locally,
and to provide icon indications of any machine status or failures.
The control console comprises a sub-assembly: control keys, a
keypad, and LCD display which are connected directly to the
SDM.
Safety Interlocks
See Figure 2.5 and Figure 4.10.
The three Interlock relays in the ECU monitor the recorder’s
safety interlocks and switches OFF power to all moving parts (but
not the laser system) when any one of the four safety interlocks is
activated. It also disables the Laser Shutter solenoid. A second
interlock contact on each switch signals to the SDM board that a
switch is activated. A fifth interlock for the Output Chute panel
does not disable the system.
The SDM board displays (on the MMI panel) the appropriate
switch/panel number and, when the system returns to normal
operation, initiates a film rewind from the drum. After the

operator reloads, the film strip is ejected from the recorder on the
assumption that it has ‘fogged’.
Celix Diagnostics
Diagnostic software (Celix Diagnostics and Application Monitor)
embedded on the SDM checks the electronic, mechanical and
optical subsystems. It also provides various utilities, such as,
displaying and editing NVRAM and exposing a set of test
patterns. See Chapter 6 for a full description on how to use the
diagnostics.
Motion Control
The MCB is directly managed by the SDM board. It provides the
drives for all the stepper motors and solenoids associated with the
optics and media handling systems. See Section 4.6.
On-line Processor
See Figure 4.2 and Table 4.1.
An RS-232 link from the processor to the SDM board monitors
the status of the film processor. Inside the interface plug
connector to the SDM are LEDs with their indications described
in Table 4.1.

Table 4.1 On-line processor indications
LED 4 LED 3 LED 2 LED 1 Signal Description

f f f f Initialise Software is initialising
f f f F Warm Up Bath in processor has not reached correct level
f f F f Ready Processor is ready to receive film
f f F F Busy Processor is not ready to receive film
f F f f Film Not Seen Processor not seen film 10 secs after job sent
f F f F Processor Jam Film lost in processor
LED 4 LED 3 LED 2 LED 1
Figure 4.2 RS-232 on-line processor connector
ECU Cooling and Filtering

Two ECU fans (Upper and lower) pulls in filtered air from the
side panel aperture and forces it across the electronic assemblies.
Air is also diverted by the Mixer fan and a separable ducting unit
to the drum. The filtering system should ensure that particles
greater than 50 µm (max) are excluded.

4.2 System Electronics

Celix 4000 electronics includes the architecture for system
control image, data path, and motor control. The related boards
are contained in the Electronics Control Unit (referred to as the
ECU in this manual). This unit, with a side door, forms an RFI
enclosure.
The following diagram shows the connectivity of the PCBs and
associated modules.
RFI BOX
SCSI DISK
SDM DSP
MOTORS,
SOLENOIDS
AND SENSORS
I/O
PANEL
MCB OPTICS
RIP
ASSEMBLY
SERVER
SPINNER
CONTROLLER
MMI
PSU
Figure 4.3 ECU connectivity

The main electronic modules are:

• PSU assemblies - contained in the ECU and distribute DC
voltages to motors, solenoids and PCBs, see Section 4.3. The
electrical supply system is described in terms of:
– AC input wiring and switching
– AC distribution to system modules
– DC distribution.
• System Data Manager (SDM) board - contained in the ECU,
see Section 4.4.
• Digital Signal Processor (DSP) board - fitted to the SDM as a
daughter board, see Section 4.5.
• Motion Control board (MCB) - contained in the ECU, see
Section 4.6.
• Spinner Controller board - contained in the ECU, see
Section 4.7.
• Power Amplifier board - located at the rear, left-hand side of
the recorder, see Section 4.8
• Man Machine Interface (MMI) - located at the front of the
recorder, see Section 4.9.

4.3 PSU Modules

4.3.1 Power Supplies
230 VAC Supplies

See Figure 4.4, Figure 10.3 and Section 4.8.
The recorder has both AC and DC supplies. The AC mains enters
the recorder through two connections at the rear left-hand side of
the machine. One inlet (PNEUMATICS) feeds the Vacuum Pump
via a circuit breaker, and the other (ELECTRONIC) feeds the
ECU system power supplies via another circuit breaker.
The mains to the Power Amplifier also connects to an associated
+30 VDC power supply attached to the panel. Circuit breakers,
mains filters, PCB and the DC PSU are mounted on a panel.
An auto-ranging transformer for the DC PSU does not require tap
settings to be made for local voltage conditions.

POWER ASSEMBLY
L
MAINS INPUT
(ELECTRONICS) N
E
120 VAC +30 V
AUTO–
CIRCUIT 230 VAC MANAGING
BREAKER PSU
N
0V
RFI CAGE
L MAIN DC SUPPLY
N
E 30 V AND 42 VDC
SUPPLIES
L
MAINS INPUT
(PNEUMATICS) N
E VAC RELAY
VAC ASSEMBLIES
CIRCUIT
N
BREAKER VACUUM PUMP
230 VAC PNEUMATICS ASSEMBLY
120 VAC * TRANSFORMER
Figure 4.4 230 VAC distribution (factory setting)

DC Distribution
ECU Power Supply Assemblies
See Figure 4.5 and Figure 3.6 to Figure 3.8.

DC voltages derived from the two PSUs at the rear of the ECU
supply the ECU boards and motors. The voltages generated are:
• +5 V and –5 V
• "15 V (regulated down to "12 V)
• +24 V (regulated down to "12 V)
• +42 V (supplied for the MCB which requires higher voltages
for driving various motors).
• +30 V spinner supply.
MAIN +30 v PSU

PSU
+5 v +12 v –12 +24 +30 v
+5 v +5 v
+24 v +42 v +5 v +5 v ECL +/-12v
+12 v +30 v +42 v (NOT USED)
PL16 PL8
MAIN POWER FAIL
INPUT/OUTPUT
PL15
MCB SDM PANEL

+42 v POWER FAIL
PL9 PL17 (NOT CONNECTED – SK15 SK8 SK13
SYSTEM WILL NOT
BOOT IF CONNECTED)
+5 v +5 v +5 v
+12 v +30 v +5 v
+/-15 v * +/-12v
PL2 PL2
SPINNER
SCSI CONTROLLER LASER
DRIVE DSP MMI
BOARD MODULATOR
(+5 V FROM +30 V)

*Note: + and -15 v is derived from
+5 v on the SDM board
Figure 4.5 DC distribution from ECU

4.4 System Data Manager Board (SDM)

The SDM acts as the basic ‘engine’ of the system and performs a
majority of the control and processing functions using resident
software and down-loadable firmware. The main functions of the
SDM are described below.
Power-on
• Power-On Self Test (POST) programs are run automatically
when the recorder is powered up. These programs check the
integrity of the recorder hardware and report any malfunction
at the RIP server.
• Initialization of other boards on power-up.
Diagnostic Facilities
• Provision of diagnostic facilities. These embedded facilities
on the SDM are accessed by a suitably qualified engineer to
exercise all or selective operational functions within the
recorder. Celix Diagnostics provide powerful and effective
troubleshooting tools. Diagnostic facilities are described in
Chapter 6.
Data Control
• Reception of image data from the RIP server via an external
differential SCSI interface.
• Compression/decompression of image data.
• Image data integrity check.
• Serialisation of image data for transmission to the Laser
Modulator.

• Reception of downloadable firmware to Flash RAM. See

Section A.1 for details on how to load new firmware.
• Generation of recorder status signals for use by the RIP
server.
Interfaces and Control

• High-level control of the traverse mechanism via the DSP
board.
• High-level control of the Spinner via the Spinner Controller
board.
• Communications interface to/from the Man-Machine
Interface (MMI).
• Control interface to the MCB for media handling and optics.
• Interface between RIP server and recorder.
• Interface between image data and the local SCSI disk drive.
• Interface between software control and the CAN (Controller
Area Network) interface for the Optics module.
• Communications interface for diagnostics access by
engineers.
4.4.1 System Control and Data Path

Figure 4.6 provides an illustration of the functions of the SDM.
The board’s operations are effectively divided into two sections:
• Control
• Data Path.

VT 100
CONTROL SECTION PROCESSOR EMULATOR
RESET COMMANDS AND DATA
68332 MEDIA DIAGNOS

NVRAM + FLASH DRAM MMI PROCESSOR
RTC MEMORY PROCESSOR INTERFACE INTERFACE INT’FACE
CAN DSP SPINNER MCB

INTERFACE INTERFACE CONTROL BOARD
INTERFACE INTERFACE
CONTROL TO RESET TO DSP REFERENCE TO SOLENOID/MOTOR

OPTICS MODULE COMMANDS TO DS CONTROLLER DRIVE
AND SPINNER STATUS FROM DSP ENCODER DATA SENSOR STATUS
CONTROLLER FROM MOTOR ENVIRONMENT DATA
BOARD
INTERFACE
(TO
DMA DMA DMA MODULATOR)
IMAGE
DATA
FIFO FIFO FIFO
EXTERNAL DATA BUFFER DATA

COMPRESSION DECOMPRESSION
SCSI MEMORY SERIALISER
DIFF
SCSI
LINK LOCAL
SCSI DATA A
PLL
INDEX
(NOT ON
IMAGE DATA AND BOARD)
CONTROL TO/FROM RIP
DATA PATH SECTION A M R
Figure 4.6 Control/Data path functional diagram

4.4.2 Control Functions on Power-on

On power-on, the SDM executes the Power on Self-Test (POST)
programs; these perform the following functions:
1. Verify the integrity of the non-volatile RAM (NVRAM) – this
is used to hold system-specific data.
2. Initialize the MCB.
3. Run the self-test diagnostics for the:
– memory and logic circuits on the SDM.
– MCB hardware.
4. Initialize the DSP.
5. Initialize and calibrate the traverse.
6. Initialize the Optics module via the CAN bus.
Any errors encountered by the POSTs are displayed on the RIP
server/station when the Diagnostic window is open, see
Section 6.4.
4.4.3 Control Section Description

This section contains a description of the control, software and
interface logic necessary for the operation of the SDM.
It comprises the following major components:
• 68332 Processor
• Flash memory
• NVRAM and RTC
• DRAM
• MCB Interface
• Spinner Controller Interface
• DSP board Interface

• Media Processor Interface

• MMI Interface
• CAN bus Interface
• Diagnostics Interface.
68332 Processor
The processor executes the software instructions resident in
DRAM memory. On power-up, the processor carries out the
following functions:
• Performs a hardware reset which initializes all data and
address lines to a default state.
• Initiates a Power on Self-Test (POST) routine to determine
correct operation of the board’s components.
• Initializes a boot sequence which loads the system software
from Flash memory to DRAM.
Flash Memory
The applications software is held permanently in (non-volatile)
Flash memory; the software is transferred to DRAM on
power-up.
The contents of the Flash memory can be updated at any time via
the RIP server and a differential SCSI link. This facility is used
for field software and configuration updates.
There are 4 Mbytes of Flash memory resident on the SDM.
Use the Recorder Utilities menu to download new firmware or
file a copy of the currently installed fimware. See Section A.1.

Non-Volatile RAM (NVRAM) and Real-Time

Clock (RTC)
The NVRAM is used for storing and retrieving of the frequently
changing system parameter and status information. The real-time
clock provides time of day information. This clock is set from
Celix Diagnostics Electronics menu and is powered by a battery
on the SDM board (built into the NVRAM electronic
component).
DRAM
System software is loaded into DRAM ( from Flash memory) at
power-up. Thereafter the processor fetches and executes the
instructions held there. There are 4 Mbytes of DRAM available.
Motion Control Board (MCB) Interface

The MCB can be considered as an extension to the SDM board. It
is directly controlled by the SDM and provides the drive for the
solenoids/motors and routing for the sensors in the optics module
and media handling system.
The SDM sends signals to the MCB, via the I/O panel, which
specify the motor to be controlled. It sets the direction, speed and
ON time for the motor. Information is returned to the SDM from
the MCB when a moving assembly has reached its Home
position.
Spinner Controller Interface

This parallel interface provides 8-bit access to the Spinner
Controller for the transfer of spinner motor drive 3-phase
reference data; the SDM PLL also receives motor encoder Index
signals directly from the spinner motor.

DSP Board Interface

The SDM provides high level control over the DSP via a RESET
signal which causes the DSP to cease operation (normally on
power-on and in the event of a system malfunction).
The SDM issues commands to (and receives status reports from)
the DSP over a parallel interface.
Media Processor Interface

This is an RS-232 communications interface used to transfer
status information from the film processor to the recorder. It
requires a recommended FUJI processor which is obtained and
installed separately by the customer.
MMI Interface
Provides an interface to the MMI panel for transfer of data for
status display, and to directly receive data generated from the
keypad.
CAN Bus Interface

This serial interface:
• Transfers set-up and calibration data to the Optics module. It
also transfers status data from the module to the SDM board.
• Controls the Spinner Controller board.
Diagnostics Interface
This is an RS-232 communication interface using VT100
commands to enable access to Celix Diagnostics. It also enables

the Application Monitor to run Moon commands. See Chapter 6

for a full description.
4.4.4 Data Path Interface

The data path section provides all of the hardware necessary to
provide the following functions:
• Receive control and image data from the RIP server via a
differential SCSI link.
• Compression of received image data.
• Use an on-board 2 Gbyte disk drive, to provide buffer storage
of image data.
Note: The size and type of drive could vary.
• After storing a complete image, provide for:
– Decompression of image data.
– Contiguous transfer of image data (via a serialiser) to the
laser modulator.
The data path section is capable of receiving image data from the
RIP server while transferring data to the laser modulator.
Data Path Interface Operation

1. An image is sent from the RIP server via the SCSI link.
2. The received data transferred to a data compression circuit in
consecutive words, 16-bits wide. This is achieved using direct
memory access (DMA) techniques and a first-in first-out
(FIFO) buffer.
3. The compressed data is transferred to a buffer memory in
consecutive words, 16-bits wide and 128 kbits at a time. This
is achieved using direct memory access (DMA) techniques
and a first-in first-out (FIFO) buffer and from there to the disk
via an internal SCSI interface.

4. Steps 2. to 3. are repeated until the complete image is

received.
5. Data is taken off the image storage disk, one Mbits at a time,
decompressed, and transferred to the serialiser by DMA and
FIFO buffers.
6. Data is transferred via the serialiser under the control of a
spinner synchronization signal and data clock for use by the
laser modulator during the imaging process. During this time,
further image data can be received from the RIP.

4.5 Digital Signal Processor (DSP) Board

See Figure 4.7.
The DSP provides all of the drive, control and monitoring for the
Optics Carriage and the Leadscrew.
This functionality is achieved using a control loop operating in
conjunction with amplifiers and motors - control feedback being
provided by motor encoders, sensors and limit switches
The control loops resident on the DSP comprise a combination of
hardware (a micro-controller and associated digital and analog
circuitry) and related software.
SDM BOARD
RESET FROM
SDM BOARD COMMANDS STATUS
SRAM PROCESSOR PROM WATCHDOG TIMER INPUT BUFFER OUTPUT BUFFER
DIGITAL/ANALOG
MICRO- HARDWARE
CONTROLLER PROMs
DACs
VCO
POWER AMP
TRAVERSE TO
TRAVERSE MOTOR
RELAY TO MOTOR
DRIVE
TRAVERSE
ENCODER
Figure 4.7 DSP Board functional diagram

Digital Signal Processor Controls
The digital hardware attached to the digital signal processor is

used to:
1. Generate programmable periods for use by the control loops.
2. Measure various time periods and related information derived
from the motor encoder.
3. Generate analogue voltages via Digital-to-Analogue
Converters (DAC).
4. Control analogue filter operations via analogue switches.
5. Monitor various status lines and sensor inputs.
6. Control relays in the Power Amplifier PSU area to
connect/disconnect the Leadscrew motor from its Power
Amplifier.
Encoder and Sensor Inputs
The following digital inputs are provided to the DSP from the
60-way ribbon cable on the SDM:
• Traverse left/right limit switches.
• Traverse Motor Quadrature Encoder and Once-Per-Rev
signals.
• Traverse Carriage Vane sensor status.
The following digital input is provided to the DSP from the
10-way ribbon cable on the Power Amplifier board:
• Traverse Power Amplifier Over-temperature status.
Control Outputs
The following control signals are provided from the DSP on the
10-way ribbon cable to the Power Amplifier board:

• An analogue voltage signal as input to the transconductance

amplifier which drives the Leadscrew DC motor at the
required speed and direction.
The following control signals are provided from the DSP on the
60-way ribbon cable to the SDM:
• Two TTL-level signals which control the two relays
connected between the Power Amplifier board and the
Leadscrew DC motor.
• One TTL-level signal which indicates to the system software
(via an interrupt) that the position has been reached at which a
scan should start.
Interface to SDM Board

The DSP interfaces directly with the SDM from which it receives
its power. Interfaces comprise:
• Command Interface. This interface receives high level
commands from the SDM such as exposure start position for
the traverse.
• Status Interface. This interface provides status information
to the SDM such as the current position of the traverse
mechanism.
• Control Interface. This is a single line from the SDM which
carries the RESET signal. The line, when asserted, effectively
disables the operation of the DSP and removes all drive to the
traverse motor. It is asserted for a period during power-on or
if a system malfunction occurs.
Traverse Control
The main characteristics of the traverse control are:
• It operates under the control of the micro-controller running
software resident in PROM.

• It drives a DC motor and a rotary incremental encoder,

connected to the Leadscrew.
• The main loop control (phase) is used for driving the motor
during a scanning event, and is an analogue phase locked loop
(PLL) set by the micro-controller.
• A loop control (velocity) is used for positioning functions,
and also to acquire the PLL lock.
• The drive voltage is input to the Power Amplifier board,
which contains a transconductance power amplifier. The drive
voltage is converted to a current, by the transconductance
amplifier.
• Quadrature signals, and an index signal, from the rotary
incremental encoder, are used by both the PLL and the
micro-controller for traverse speed control and positional
information.
Watchdog Timer
Associated with the DSP is a watchdog timer circuit. This device
is a re-triggerable monostable which is addressed (and therefore
re-triggered) by the DSP software at regular intervals.
The interval at which the monostable is re-triggered is within its
time constant. If it is not re-triggered within this time, it will
time-out and the DSP software will be regarded as having failed.
The time-out signal output will disable the traverse (Leadscrew)
motor. The resulting status signal, from the watchdog timer, is
provided to the SDM.

4.6 Motion Control Board

4.6.1 Introduction
See Figure 4.8.
The MCB is directly managed by the SDM board. It provides the
following drives for all the stepper motors and solenoids
associated with the optics and media handling systems.
Stepper Motors:
• Cassette Drive Motor.
• Guillotine Motor.
• Output Media Motor (Vertical Output).
• Wedge Motor.
• Aperture Motor.
• Focus Motor.
Solenoids:
• Shutter.
• Vacuum Solenoids.
The MCB also provides monitoring circuitry for:
• Wedge Sensors.
• Aperture Sensors.
• Focus Sensors.
• Cassette Drop Sensor.
• Guillotine Sensors
• Machine Interlocks.
Resident on the board is a Watchdog circuit which monitors the
communication between the SDM. If communication ceases
(indicating a failure), the Watchdog times out and all outputs from
the MCB are disabled.

MOTORS:
MOTORS: SDM INPUT CASSETTE FEED

BOARD GUILLOTINE
ILLUMINATION
IRIS MEDIA OUTPUT
FOCUS PUNCH
SOLENOIDS:
SOLENOIDS:
SHUTTER MOTION VACUUM
CONTROL
BOARD
SENSORS
SENSORS
ENVIRONMENT
AND FUSES
ENVIRONMENT
MACHINE
AND FUSES
INTERLOCKS
OPTICS MODULE
MEDIA HANDLING
Figure 4.8 Motion Control board - functional diagram
The MCB is connected to the SDM and under the control of the
applications software. It contains a software controlled timing
processor unit along with dedicated hardware.
Diagnostics
Diagnostic facilities are included to test the functionality and
status of the overall system. These monitor the power supply
voltages and the status of the fuses. With this additional data, and
the normal sensor inputs, the high level software can diagnose
fault conditions such as, blown fuses and jammed motors.
Details of the MCB diagnostic features are provided in
Section 6.8.

4.6.2 Interlock Relays

There are three 12 V, 16 A interlock relays (99137372) located in
positions as shown in Figure 4.9. Each of these can be replaced
by carrying out the following procedure in Section 10.3.4.
INTERLOCK
RELAYS
3
PANEL & PSUs
REMOVED
FOR ACCESS
PSU SECTION VIEWED FROM FRONT
Figure 4.9 Positions of interlock relays in ECU RFI Box -

(PSU section)

9 TO FUSE 6 B
RELAY 3
REGISTER 4
2
PANEL 12V A 7 4 1 MCB A
INTERLOCK B
SWITCHES FS8
RELAY 2
(CLOSED) 2A B 9 6 3
1 9
RELAY BASE A
PL4 PL6
FRONT B
RELAY 1
5
LEFT
40-WAY 3
39 1 A
BACK
OUTPUT
FS10 5A
1 4
+42 V
RIGHT 10 39 7
CARRIAGE 2
MOTOR DRIVE RELAY 1
IOP BOARD SDM BOARD
SK10 FS9 5A
1 1 3 6
+42 V
14 9
LEFT L L
15 3 3 OUTPUT 4
MOTOR DRIVE RELAY 1
16 FS11 5A SK2
RIGHT L L 5 4
17 5 5 +42 V
STATUS REGISTER
7
PL5 50-WAY PL6 GUILLOTINE 6
18
FRONT L L MOTOR DRIVE RELAY 2
19 7 7
CARRIAGE LOCK 7 6
20 SOLENOID DRIVE
BACK L L 9
21 9 9
8
TO RELAY 2
22
OUTPUT L L SOLENOID
23 11 11
SHUTTER 9 4
SOLENOID DRIVE
7
10
NOTE: SYSTEM SHOWN IN NORMAL OPERATING CONDITION TO RELAY 3
SOLENOID
Figure 4.10 Interlock relay system

4.7 Spinner Controller Board

See also Figure 4.11, Section 3.8 and Section 4.15.5.
This functional description applies to the Spinner Controller
board (FFEI version).
SRef
Index
Data A Note: Indexcopy (Single-ended)

SDM BOARD LK1 Pins 2 & 3
Brake
(See Note) Indexcopy becomes Bspin FB
Lock
CAN Bus
IOP
Index
Data A ENCODER SPINNER
CAN Bus
SPINNER
CONTROLLER SRef
BOARD Index 3 Ph Motor Drive
Data A Hall Effect Motor F/B
Brake
Hall Effect Motor F/B
3 Ph Motor Drive
Lock
Fault
Data A
Drive
From Electronic 3-Phase

SDM Commutation to
TP8 Spinnrer
Board
720 KHz
Sense
Figure 4.11 Spinner controls and drive

The SDM board operates as the Spinner Controller manager for

stopping and starting the spinner. Signals from the spinner
encoder (DATA A and S Index) are relayed from the controller to
the SDM pixel clock PLL. This closed-loop control system
operates in the following way:
• A reference clock speed on the Spinner Controller board gives
a fixed clock rate.
• An encoder signal (DATA A) from the spinner is returned to
the Spinner Controller board and the error difference is
sensed.
• The difference signal goes through a compensatory circuit for
dynamic stability, and this sets a duty cycle. Spinner motor
current is then regulated by a varying cycle.
• Current is passed to the motor via a 3-phase bridge on the
bSpinner Controller board. The board applies motor braking
from the 3-phase bridge whenever mains power is accidently
switched off or a mains failure occurs.
• Hall effect sense signals are routed back from the spinner
motor to provide a commutation sequence applied to the
bridge (which replaces the need for brush motors on the
motor).
The board compares two frequencies (DATA A and 720 KHz) and
adjusts power to the motor so that the two frequencies are at the
same rate and phase.

4.8 Power Amplifier Board

See Section 4.3.1 and Figure 4.12.
The Power Amplifier board provides drive for the Leadscrew
traverse. Note that the traverse output is a single current drive
with the return routed back to the Power Amplifier board
connector.
TSIG signals from the DSP board are fed to amplifiers which
produce direction and torque demand outputs. The Power Amp
receives TSIG and produces direction and torque demand signals
from it that are passed to a pulse width modulated amplifier. The
outputs from this amplifier are an ‘On’ and ‘Drive’ signal for
clockwise or counter clockwise motor rotation.
The ‘On’ and ‘Drive’ signals control a bridge of four power
FETs. One of the pair of FETs is switched fully on; the other is
used to control the current flowing through the Leadscrew motor,
which is connected across the centre of the bridge.
The left and right relays are controlled by the SDM board to
provide regenerative braking and to ‘disconnect’ the drive to the
Leadscrew motor. Feedback of the motor current through low
value resistors controls the range of motor drive. Overheating of
these resistors is sensed and the pulse width modulator is
shutdown during this condition.
The Power Amp board is supplied with 30 V from an
auto-ranging PSU; operating DC voltages required by the board
are:
• +15 V
• –15 V
• +5 V.
See Section 3.7.1 for a list of the DC test points.
The board also includes over-temperature sensing that shuts down
the pulse width modulated amplifier.

+30 V
DIRECTION
CW ON RL1 RL2 0R1
PULSE
TORQUE DEMAND CCW ON
3 4 WIDTH M
8 MODULATOR CW
DRIVE 0R22 RL1
T SIG
1 7 6 CCW
DRIVE RL2
An Gnd
CAN BUS I/F

(DIAGNOSTICS
ONLY)
13
FEED
+30 V BACK
+30 V
10
+15 V
ON-BOARD 11
VOLTAGE –12 V MOTOR CURRENT F/B
GENERATION
12
+5 V RL2
RELAY
RL1
LEFT
TEMPERATURE O TEMP DISABLE
0R07
SENSE RELAY
RIGHT
9
–30 V RTN
TEST POINT KEY
TP1 An Gnd TP8 Torque Demand

TP3 TSIG TP9 –30 V
TP4 Response TP10 +15 V
TP5 Motor Current TP11 –12 V
TP6 Stimulation TP12 +5V
TP7 An Gnd TP13 +30 V
Figure 4.12 Traverse power amplifier circuit

4.9 MMI
See Figure 4.13.
The MMI (Man Machine Interface) panel includes MMI display
module and keypad. The MMI functions provide:
• An iconic display reports the current machine status, which
includes machine failures due to film jamming, processor
failures and mechanical problems.
• A 4-key interface for rewinding (releasing) the film Input
cassette, loading media and resetting the machine.
• An audible tone in cases of error or warning. Press any key to
stop the alarm.
A full description of how the recorder system operates from the
MMI is given in the Celix 4000 Recorder User’s Guide. Make
sure you are familiar with the procedure for switching the
recorder off to ensure that the spinner brakes properly before
power is removed.
Note: The Release Output Cassette function is not supported
on a Celix 4000. Output cassettes are not fitted.
STATUS
DISPLAY
POWER ON
INDICATOR
LOAD FILM RELEASE INPUT RELEASE OUTPUT MACHINE

CASSETTE (REWIND) CASSETTE (SEE NOTE) RESTART
Figure 4.13 MMI display module and keypad

Any information to be displayed on the status LCD panel is

buffered, due to the length of cable from the backplane to the
module. The display interface, on the MMI board, buffers the
data, decodes it and routes it to the LCD drivers. Another buffer
is used to boost signal to the beeper.

4.10 Laser Modulator Board

The Laser Modulator board is contained within an RFI sealed box
mounted above the Laser Diode module located on the Optics
Carriage, and is connected via an umbilical cable to the ECU. The
board provides the following functions:
• ECL buffering of SDM image data output.
• CAN bus interface.
• Laser control and drive.
• Reading of laser power via the shutter detector.
• Reading of Laser levels.
4.10.1 CAN Bus Interface (Laser)

The CAN bus interface decodes control signals from the SDM
board, and provides encoded forward and backward signals to the
SDM board as follows:
1. sets the Laser Diode drive current
2. reads the Laser Diode drive current
3. sets the Laser Diode threshold current
4. reads the Laser Diode threshold current
5. reads the Laser power (from the external shutter photo cell)
6. reads the Laser temperature.

4.11 Media Handling Systems

4.11.1 Media Handling Components
This section describes the basic principles of media handling. An
outline of the basic operation is given. The media path is
illustrated in Figure 4.14.
OUTPUT CHUTE MEDIA ROLL
MMI
(OPERATOR PANEL)
MEDIA
CASSETTE
VERTICAL OUTPUT MEDIA

DETECTOR
GUILLOTINE
INPUT
DRIVE
ROLLERS
PUNCH AND DIE
MEDIA
GUIDE
DRUM
BAFFLES
LASER
ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ
ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ MEDIA PATH
Figure 4.14 Media path mechanisms

4.11.2 Basic Operation

For a more detailed description of the media handling operation
see Section 4.12.
A light-tight cassette, loaded with a roll of film or paper media is
fitted into the front of the recorder.
Motorized feed rollers pull the media lead from the cassette
through the input media guide until it passes into the drum and
under the optics baffle.
At the far edge of the drum, the media is sensed at the slot of the
register-hole punch.
After the image has been exposed onto the media, the Input
rollers advance the media from the drum to the Vertical Output
rollers. Exposed media from the drum is guillotined to a set job
length, punched and conveyed towards the processor while new
media is moved into the drum.
A double belt system grips the exposed media which is
autoloaded to the processor.
At the end of the roll any short lengths of media are ejected
through the processor.
4.11.3 Media Handling Modules

See Figure 4.14.
The media handling system consists of the following modules:
• Input Cassette
• Input Drive Rollers and Drive Assembly
• Register Punch
• Guillotine
• Vertical Output assembly
• Output Chute assembly
• Drum vacuum system.

4.11.4 Input Cassette and Drive

Nominal media widths of 356, 510, 660 or 760 mm can be used,
with moveable left-hand and right-hand side cassette cradles to
accomodate different roll widths.
The cassette is located on two lugs in a cassette bay. These lugs
open the light-tight guide on the underside of the cassette.
CUTTER
END OF ROLL
SENSOR
MEDIA DROP
SENSOR
CRADLE
LOCATING
NOTCH
RIGHT HAND
CRADLE
RELEASE
BUTTON
MEDIA DROP
ACTUATOR
(IN LID)
LEFT HAND
CRADLE
DRIVE
END OF ROLL SHAFT
ENCODER MEDIA
TAKE-UP DRIVE
Figure 4.15 Input cassette
The drive assembly for the cassette is on the left-hand side. It uses
a stepper motor to drive a toothed belt around the two gears, and

tension is provided by an adjustable idling gear. A

vacuum-operated, single-action cylinder moves a push plate
which causes a drive wheel to mate with the cassette.
This drive is engaged at any time that media is rewound (and is
often referred to as the rewind wheel). The drive is disengaged for
cassette removal after completion of a media rewind. It is also
engaged during a media load to insert film into the Input rollers.
A second drive wheel, not held by the push plate, is permanently
engaged with the Input (Nip) rollers.
A reed switch (drop) senses the position of the drop plunger
inside the cassette and informs the system if film is protruding
from the front of the cassette, or fed down to the Input rollers.
END OF ROLL
SENSOR
(ON BRACKET)
VAC
CYLINDER
MOTOR
BELT
TENSIONER
DROP SENSOR
(ON BRACKET)
Figure 4.16 Input drive assembly
An opto sensor returns pulses detected from 26 black/silver

encoder segments around the cassette take–up drive (‘dog
wheel’). If the encoder stops for a set period while film is suppose
to be LOADing (ie the input rollers are rotating), then there is an
“end of roll” flag sent to the software. A set period is included to

allow for inertia after film is pulled off from a roll and a degree of
slack is produced on the next LOAD.
4.11.5 Input (Nip) Rollers

See also Section 7.3.1
These rollers ‘push’ film into the drum during the LOAD and
RELOAD sequence, see Section 4.12.
The rollers can be removed from their housing assembly and
replaced. Note that the rollers need to be kept constantly clean for
successful loading, and this procedure is usually carried out by
the operator, see the Celix 4000 Recorder User’s Guide, and also
Section 12.3.1.
4.11.6 Input Film Guide

This assembly guides film from the Input rollers into the drum.
An Input Media Detect sensor detects the presence of film fed
from the Input rollers.
4.11.7 Drum
Film is conformed to the shape of the drum for scanning by the
action of a vacuum which is drawn on the film via a number of
small holes and grooves in the drum. The vacuum is created at the
punch side of the drum, and then moves forwards along the
grooves towards the front of the recorder.
Drum vacuum widths (356, 509, 660 and 760) are set to the film
widths selected by the operator. See Also Section 5.3.

4.11.8 Guillotine and Punch

See Figure 4.17.
Guillotine
The guillotine is located at the rear of the recorder. A stepper
motor drives a toothed band, via a reduction belt drive, to move a
cutting wheel with a knife blade, along a metal bar allowing the
guillotine to cut in both directions. It is important that the cutting
wheel rotates, as it moves from side to side, otherwise damage to
the wheel can cause uncut film.
Two reed switches, one at each end, detect the end positions of
the guillotine: on the right-hand side (front view) for the Home
position, and on the left for end-of-travel.
Punch
See Figure 4.17.
The four punch protocols, shown in Table 4.2, are fitted to a DC
motor-driven Billows casting.
Table 4.2 Film Punch and die sets
Punch and Die Set Punch Assembly

Billows Protocol 99504643 75427760
German Bacher 99504644 75427740
American Stoesser 99504646 75427750
Japanese Kamata 99504645 75427770
Note: Other film punches supplied include customized specials

and a dummy punch (with no holes required).
A punch can be customised to suit a particular need once a
template is supplied of the protocol; very often a standard casting
is machined and adapted. A dummy punch can also be fitted.

The punch is operated as a 6 W DC (running at 42 V) motor and a

200:1 gearbox that drives a cam and lever assembly.
The cam drive shaft is constrained by two roller bearings to
support radial and axial loads, with the motor shaft fixing secured
by 2-off grub screws.
An encoder disc on the cam triggers two optosensors fixed to a
small PCB. There are two stop points: pins fully engaged and pins
fully disengaged:
• pins engaged - encoder in (ie covers) both sensors
• pins disengaged - encoder out of both sensors.
Dynamic braking ensures that the cam stops quickly after the
optosensors are triggered. The sensors are used to inform the
software that the pins are either engaged (that is, in the punch) or
the film path is clear. It also indicates whether the pins have
jammed. No adjustments are required.
If there is a punch jam, the motor reverses in an attempt to clear
the fault. After three attempts, when the fault is not cleared, the
punch mechanism needs further investigation.
The punch mechanism is very accurately set up at the factory.
Correct pin and die alignment is crucial for reliability and hole
quality. Adjusting pins and dies is NOT recommended.
However, if you have to replace a pin then carefully follow the
procedure in Section 7.8.4.

GUILLOTINE EOT SENSOR

GUILLOTINE
DRIVE BELT
GUILLOTINE
ASSEMBLY
SPINDLE
DRIVE MOTOR SLIDER

BRACKET
GUILLOTINE
EOT SENSOR
CHAD
ROTARY COLLECTION TRAY
KNIFE BLADE
GUILLOTINE GUIDE
GUIDE RAIL SCREWS (6 OFF)
GUILLOTINE
WHEEL
LOCATION
SCREWS
(4 OFF) BLADE
LOCATIO
N SCREW
BALL-ENDED
DRIVE BELT BOLT
PULLEY
DIE
DRIVE BELT GUILLOTINE

GUIDE RAIL
A PUNCH
VIEW A ASSEMBLY
PUNCH
GUILLOTINE
FIXED BLADE
MEDIA DETECTION
NOTE: INSIDE VIEW FROM FRONT
SENSOR
Figure 4.17 Punch/guillotine assembly

4.11.9 Output System

See Figure 4.18.
The Output system consists of two film handling sub-assemblies
that operate an autoloading belt and roller conveyor:
• Vertical Output: this mechanism moves film from the drum
(after it has been punched) to the Output Chute.
• Output Chute: this mechanism forms the bridge to the
processor.
The following sensors/switches are fitted to the output system:
a) Lazy Loop
b) Post Guillotine
c) Output EOT (at Processor).
MOUNTING BLOCK
TOP COVER LAZY

LOOP
OUTPUT CHUTE
UPPER
FILM
GUIDE
OUTPUT FIXED SPEED O/P CHUTE

EOT MOTOR FAN
SWING BOLT STEPPER
MOTOR
VERTICAL OUTPUT
LOWER
FILM GUIDE
GUILLOTINE
Figure 4.18 Output drive assembly

Film is transported through a set of rollers and rubber bands from

the punch into the chute assembly, and then delivered to the
processor. The speed of the rollers on each assembly are
synchronised, via a lazy loop sensor, so that film strips are
conveyed without excessive slack.
4.11.10 Vertical Output

Film is pushed up and guided into the Vertical Output assembly,
through a set of twin rubber belts, then steered around an upper
film guide into the Output Chute conveyor. Motion is provided by
a stepper motor. One sensor (Post Guillotine) detects the arrival
of film in the assembly. Another sensor (Lazy Loop) synchronises
the speed of belts with the Output Chute, see Section 4.11.13.
The assembly is easily removable from its mounting blocks
without having to remove the Output Chute assembly. Two swing
bolts provide a means for adjusting the assembly horizontally to
create a 3 mm gap between the lower film guide and the belts.
4.11.11 Output Chute

The chute feeds film from the recorder to the processor. It
includes:
• A 12 V fan to increase internal positive pressure that prevents
fumes from the processor entering the recorder.
• An end-of-travel sensor to detect film at the processor.
• A DC drive motor that runs at variable rates to move the
media conveyors.
• A top cover interlock that triggers an indicates to the user if
the cover is removed. The cover needs to be properly seated
on the chute to avoid the problem of ‘fogging’.
The weight of the chute is fully supported by two brackets. A
locating T-block and dowel mechanism allows a single person to
easily lift the entire assembly in and out of the recorder. See

Section 7.9.2. The conveyor assembly mounted inside the chute

casing can be removed if a rubber belt needs replacing.
4.11.12 Media Type and Input

Red sensitive film rolls - FUJI HSR (High Contrast) or LS 4500
(low contrast) types - are specified as:
• Thickness: 0.1 mm (4/1000 in) - gloss, or 0.17 mm (7/1000 in)
• Width: 356/509/660/760 mm "2 mm - (14/20/26/30 in)
• Length: 60 m (200 ft) max for 0.1 mm, or 30 m (100 ft) for
0.2 mm.
The rolls should be able to take 70.5 mm (2.8 in) mandrels fitted
at each end to hold film within the cassette.
Cut lengths from the chute are 260 mm (10.2 in) to 703 mm
(2.3 ft).
4.11.13 Media Handling Sensors

See Figure 3.17.
The Mark II recorder has three new film handling sensors that
provide extra functionality to the system.
Lazy Loop
This sensor provides on/off switching to the Output Chute DC
motor control circuit. When any slack is detected at the guide
‘junction’ between the two output assemblies, the lazy loop
operates the switch which, in turn, increases the speed of the DC
motor (average of DC pulses) and so reduces slack at the loop.
This effectively synchronises speed between the two conveyors.

Post Guillotine
Film inserted into the Vertical Output pushes the Post Guillotine
switch, indicating that a cut strip has entered the conveying
mechanism.
End of Roll
See Figure 4.15.
The End of Roll sensor is an infra-red diode that provides a
stream of pulses (with changing frequency) as film is pulled
through to the drum. Pulses cease when film is not detected.
An opto sensor returns pulses detected from 26 black/silver
encoder segments around the cassette take-up drive (‘dog wheel’).
If the encoder stops for a set period while film should be
LOADing (ie the input rollers are rotating), then there is an ‘end
of roll’ flag sent to the software. A set period is included to allow
for inertia after film is pulled off from a roll and a degree of slack
is produced on the next LOAD.
Power for the diode and control circuitry is provided from the
Front Distribution board. The circuitry applies hystersis to avoid
oscillations when the detector rests between a black and silver
segment. Pulses are routed from the Front Distribution board to
the MCB/SDM interface which controls the display of the Input
Cassette Empty icon.

4.12 Media Handling Sequence

See Figure 4.19 to Figure 4.23.
Media is handled and exposed from the Input cassette to the
Output chute with three software-defined sequences:
• MEDIA LOAD: film is fed into the drum for the first expose
job, and the leading edge is moved to the output system.
• MEDIA RELOAD: new film is automatically fed in while
exposed film is cut and transported to the processor.
• MEDIA REWIND/CASSETTE REMOVAL: media in the
drum is rewound to allow removal of the cassette.
Note: Each sequence assumes that exposed film is transported to
the processor.
O/P EOT
PROCESSOR LAZY LOOP
SENSOR
END OF ROLL
OUTPUT DETECT
SHUTE
TO PROCESSOR
INPUT
CASSETTE
POST (DROP)
GUILLOTINE
SENSOR
INPUT
ROLLERS
INPUT MEDIA
DETECT SENSOR
MEDIA DETECT
(AT PUNCH)
Figure 4.19 Media handling (cut-out view)

Note: None of the film handling procedures outlined below will

start until the spinner has returned to full speed. After a
period of machine inactivity, the spinner takes several
minutes to reach full speed.
Media LOAD Sequence

1. The operator enters media details from the RIP user interface
(see the RIP User’s Guide), or from a Moon command, see
Section 6.14.
2. After pressing the Load button, the immediate action depends
on how the film has been placed into the cassette:
– If the Input Cassette Drop sensor detects film (that is,
protruding from the lip of the cassette), the film is
rewound until the sensor changes state. The film is then
fed forward into the Input rollers until detected by the
Media Detect switch at the Film Guide.
– If the Drop sensor does not detect film present (in the
cassette), the film is fed forward until detected by the
Media Detect switch.
3. The baffles are moved to the centre of the drum and the
spinner achieves full speed.
4. Loading Media icon appears on the MMI.
5. The leading edge of the film is fed quickly into the drum until
it is close to the punch.

FILM
Figure 4.20 LOAD sequence 1
6. The film is advanced 25 mm by the Input rollers until the

Media Detect (at punch) sensor detects film. If the sensor fails
to detect film, the following error is reported on the Celix
Diagnostics terminal, ‘Film failed to reach punch sensor’. The
MMI also displays the icon, Media Jam: Drum.
Once film has been detected by the punch sensor, it is
advanced by a further 30 mm to place it fully into the punch
and near the guillotine.
7. The drum vacuum is switched on and a check made on
whether the level achieved exceeds the requirement.
• If the vacuum does not exceed the requirement, then the
Input rollers feed an additional 2 mm of film. After a
delay of 2 seconds for 0.004 inch/0.1 mm thickness film
the vacuum level is checked.
• Drum vacuum should be achieved after 5 x 2 mm
advances. A failure will mean that film is rewound back

into the cassette and reloaded from step 5. (LOAD

sequence). This LOAD Retry occurs once.
• If the vacuum has succeeded, the Recorder Ready icon
appears on the MMI.
FILM
Figure 4.21 LOAD sequence 2 (film at punch)
Media RELOAD Sequence

1. The Loading Media icon is displayed, the drum vacuum is
released, and the Mixer fan is switched off.
2. The Input rollers rewind the film 45 mm to lift the film from
the drum surface and break the vacuum.
3. After a delay of 2 seconds, the Input rollers advance the film
47 mm into the drum to return it to the drum surface.

4. The status of the processor is checked.
FILM
Figure 4.22 RELOAD sequence 1 (at Vertical Output)
5. The Input rollers advance the film 40 mm until it is close to

the Vertical Output belts.
6. The Vertical Output belts and Input rollers advance film by
the length of the image (less the distance already advanced).
Film being fed into rollers is detected by Post-guillotine
sensor.
The Output conveyor motor also starts in case the image
length is long enough to take it past the vertical guides into
the horizontal belts.
7. The drum vacuum is switched on to hold the film, and after a
delay of 2 seconds the film is guillotined.
The Input rollers and conveyor motors advance the cut film
until the end-of-travel (at processor) sensor is activated.
8. The exposed sheet of film is slowly fed the processor.

EXPOSED AND
CUT FILM
Figure 4.23 RELOAD sequence 2 (conveyed film)
9. While the cut film is being output, the drum vacuum is

released.
10. The drum vacuum is switched on and a check made on
whether the level achieved exceeds the requirement.
• If the vacuum does not exceed the requirement, then the
Input rollers feed an additional 2 mm of film. After a
delay of 2 seconds for 0.004 inch/0.1 mm film thickness
the vacuum level is checked.
• Drum vacuum should be achieved after 5 x 2 mm
advances. A vacuum failure will mean that film is
rewound back into the cassette and reloaded from step 5.
(LOAD sequence). This RELOAD Retry occurs once.
• If the vacuum has succeeded, the Recorder Ready icon
appears.
11. The Mixer fan is switched on.

12. Film is now loaded and the recorder is available to expose the
next job.
Media REWIND/Cassette REMOVAL Sequence

This sequence is initiated when the operator presses Rewind
Media on the MMI.
1. The drum vacuum is released and the film rewinds back into
the cassette.
2. The leading edge of the film switches the Input Media Detect
sensor.
3. The rewind sequence halts and film is left free of the rollers
with the leading edge in a position ready for the next LOAD.
4. The cassette is ready for removal without the risk of film
‘fogging’.
5. On lifting the cassette, the lugs withdraw and the light-tight
guide closes to prevent film ‘fogging’.

4.13 Media Handling Problems

If there is a problem with media handling, one of the first checks
should ensure that the environment temperature and humidity are
within the specification range set out in Appendix B.2.19. More
difficult failures to track could be due to a machine setup – for
example, to a misaligned drum. Check the latest TIS issues and
Service Information (CBR) for further information.
Some of the more typical film handling faults and their possible
causes are listed in Section 4.13.1 below.
To avoid losing diagnostic information, make sure the recorder is
not initially switched off when the fault is first noticed, since any
information about the problem could be displayed on the Celix
Diagnostic window.
Disable the interlocks first by opening the Supervisor menu in the
Application Monitor and entering:
sup>dilock
Then remove the appropriate cover to view the area at fault.
4.13.1 List of Media Handling Problems

Causes listed below are in likely order of possibility; causes in
italics can be corrected by the operator.
Fault 1: Film fails to insert into cassette?
Possible causes in likely fault order are:
a) Cassette lid is clamped.
b) Cut edge of film is ragged or not straight.
c) Vacuum valve is stuck, preventing the cassette drive dog from
functioning properly.
d) Rewind wheel is very badly worn.
e) Film is very near end of roll (last 2 m or less).
f) Media Detect Sensor is faulty or stuck.

g) Drop sensor/lever is faulty or stuck.

Fault 2: Film fails to feed into drum?
a) Badly cut leading edges on the film catching on the Input
roller housing and the Film guide.
b) Input rollers not clean.
c) Guides in Input roller housing not set correctly.
d) Drum not set correctly and film guides are pinching.
e) Media Detect sensor is broken or stuck.
Problem 3: Film fails to reach punch, or falls out of punch, or
catches in punch?
a) Badly cut leading edge is catching in the punch.
b) Input feed rollers are dirty and are not pushing through
enough film.
c) Input roller motor drive gear is loose on the motor shaft.
d) Input roller nip force is inadequate for feeding film.
e) Floating roller or the film roll is dragging and not feeding
enough film into the drum.
f) Baffle incorrectly positioned and pinching the film as it enters
the punch.
g) Film is catching on the Media detect (at punch) sensor or the
sensor is sticking.
Problem 4: Vacuum (V) or Conformance (C) failure of film in
the drum?
Note: Vacuum failure occurs when the drum vac switch fails to
activate; conformance failure occurs when the switch
activates but the vacuum is incomplete.
a) Wrong film is selected (V).

b) Film is “tight-edged” or heavily curled (V and C).

c) Drum is not parallel to the Input roller housing, especially for
the narrow widths (C).
d) Holes or grooves in the drum are blocked (C).
e) Film is off-centre in the drum and not over the groove (V and
C).
f) Not enough film fed into the drum during reloads (C) – see
Problem 3 b) to e).
g) Large vacuum leak has occured on fittings, groove end filler
or switch (V).
h) Drum vacuum switch is broken or stuck (V and C).
i) Input roller nip force is too high or uneven and causing film
skew (C).
j) 24 VDC supply failure to solenoid valves or vacuum switch
(V).
Problem 5: Punch failure?
a) Punch pins or dies misaligned.
b) Punch travels sensor(s) not operating, so punching is not
detected.
c) Punch motor or sensors ahs failed.
d) Punch crank or lever bar not lubricated.
e) Punch motor or motor power failure.
Problem 6: Film is not released from drum on reload or not
reaching the Vertical output conveyor?
a) Solenoid valve(s) are stuck and the drum vacuum is
permanently on
b) Room humidity is too high (>>70% RH).
c) Drum is contaminated with oil, etc.

d) A previously cut strip of film has not cleared from the

recorder.
e) Film is snagging on the rotary guillotine blade.
f) Film is snagging at the guillotine guides.
Problem 7: Film not moved by Vertical Output conveyor?
a) Motor drive for the conveyor is slipping.
b) Motor or motor power has failed.
Problem 8: Film not fully cut or guillotine fails to travel full
distance?
a) Guillotine belt far too slack and not driving (ie teeth
jumping).
b) Guillotine belt far too tight and motor is losing steps.
c) Guillotine motor or motor power failure.
d) Guillotine drive gear slipping on the motor shaft.
Problem 9: Film not cut or badly cut or guillotine reaches end
of travel?
a) Rotary blade not turning or blunt.
b) Rotary blade spindle bearing is sticking or lifting the blade
and causing a mis-cut.
Problem 10: Film not reaching the processor sensor?
a) Output Chute motor or motor power failure.
b) Vertical Output conveyor is not driving and restraining film.
c) Film guides at the the processor not meshing correctly.
d) Film is not passing properly from one conveyor to the next,
possibly snagging in the diverter extrusions.
e) Guillotine has failed to cut.

Problem 11: Processor is not pulling film from the output

chute?
a) Processor is not switched on.
b) Processor is jammed by previous films.
c) Film strip is not reaching the processor nip rollers.
d) Output Chute conveyor bearings seized.
Problem 12: Film fails to rewind or fails to spool back onto
the roll?
a) Film length is within 5m of the end of the roll (spooling
failure only).
b) Film is crumpled in the Input roller housing, or Input guides,
or in the punch.
c) Rewind wheel is badly worn out.
d) Guillotine has failed to cut the last film output.

4.14 Media Expose System

See Figure 4.24 to Figure 4.27. See also Section 4.4.
The media expose system comprises of two sub-systems:
• Electronic: the electronic sub-system takes the image data
from the SCSI input on the SDM board, buffers it, and then
sends it to the Laser Modulator board which drives the laser
diode on the Optics carriage.
• Optical: the optics sub-system manipulates the laser light to
produce a focussed spot on light-sensitive media in the drum.
RIP SERVER
I/O
PANEL
DIFF SCSI
CAN
BUS
SDM
BOARD
IMAGE
DATA
INTERNAL
2Gbyte
SCSI DISK OPTICS MODULATOR
CARRIAGE
MOTOR DRIVE
AND ENCODER
SPINNER OUTPUT
CONTROL OPTICAL
SPINNER LASER
SYSTEM
MCB
BOARD
MOTOR AND SOLENOID DRIVE AND
SENSORS
Figure 4.24 Media expose system – schematic view
Image data enters the recorder via a differential SCSI link with
the RIP server. Bit map data is received by by the SDM board
where it is compressed and stored on a 2 Gbyte internal SCSI
disk. After a complete image has been received, compressed and

stored, the data is read off the storage disk. It is decompressed

and passed via the serialiser to the laser modulator driver.
Control of the serialiser is achieved using the spinner encoder
once-per-rev signal (S INDEX) and the 1440 lines per rev signal
(DATA A). The signal, S INDEX, is used to reset a counter which
is preloaded with a vertical start offset value. DATA A pulses are
used to count down the counter until at ‘0’ the serialiser output is
enabled to start a scan line output to film.
DATA A pulses are also fed to a phase lock loop oscillator which
multiplies the DATA A frequency to use as the serialiser output
clock. As this clock is different for each resolution, the NVRAM
holds the required multiplying values for each resolution.
Figure 4.25 gives a schematic view of the optical system; the
main components of the optics system is shown as views in
Figure 4.26 and Figure 4.27.
M M
7 10
LASER MODULE TELESCOPE
3 9
4 6 6
S
8
3 5 M
1 2
1. LASER DIODE 675 NM

2. COLLIMATOR LENS
3. ANAMORPHIC CORRECTION LENS
4. MONITOR PHOTOCELL
5. VARIABLE ATTENUATOR (ILLUMINATION STEPPER MOTOR)
6. BEAM EXPANDER TELESCOPE
7. VARIABLE APERTURE (APERTURE MOTOR)
8. VARIABLE FOCUSING OBJECTIVE (FOCUS MOTOR)
9. SPINNER MIRROR
10. AIR BEARING SPINNER (30 000 RPM)
Figure 4.25 Schematic layout of optical system

APERTURE
MOTOR
APERTURE BEAM SHUTTER

PLATE EXPANDER SOLENOID
SHUTTER
PHOTODIODE
CONNECTOR
TO OPTICS
RFI BOX, SK4
(See Figure 8.11)
FOCUS
MOTOR
VARIABLE LASER
ATTENUATOR DIODE
ILLUMINATION MODULE
MOTOR
NOTE: Modulator assembly

removed for clarity. See also
Figure 8.16
Figure 4.26 Optics: Laser Diode module, motors and solenoid

SPINNER MOTOR
15-WAY D-TYPE TO CABLE 14 (UMBILICAL)
SENSOR DISTRIBUTION
COOLING
BOARD
FAN
SPINNER ENCODER
DUST COVER 9-WAY D-TYPE TO CABLE 15 (UMBILICAL)
37-WAY D-TYPE
TO CABLE A2
(UMBILICAL)
HOME SENSOR,
9-WAY D-TYPE
TO CABLE K2
(UMBILICAL)
MOTOR
DISTRIBUTION
BOARD
SPINNER
15-WAY D-TYPE
TO CABLE 11
(UMBILICAL)
Figure 4.27 Location of spinner and distribution boards
4.14.1 Optical Components

All major optical components are carried upon the Optics
Carriage Assembly. These include:
• Field-replaceable components.
• Components which are not normally field replaceable. This
fact is specifically mentioned where relevant.

Laser
Laser assemblies comprise:
• the laser diode module assembly
• laser modulator/driver (optics RFI Box).
These assemblies are not field replaceable.
Laser Diode Module Assembly
A 20 mW laser diode (670 nm red) is mounted in a pre-aligned

assembly. The assembly also contains the collimating lens and the
anamorphic correction lenses.
The assembly is retained to the optics module platform by four
retaining springs and two safety retainers.
Laser Modulator/Driver
The Laser Modulator board is contained within an RFI-sealed box

mounted above the laser diode module. The board is externally
connected to the SDM board (in the Electronics Control Unit) via
the umbilical cable, which carries the imaging data and control
signals.
Internal settings are required on this board.
Shutter and Solenoid
A shutter plate is fitted to block the laser beam for safety

purposes. The plate is counterbalanced so that in the event of
power failure it falls into a position to block the beam. The plate
is positioned between the inboard end of the laser diode module
and the adjacent variable density step wedge.

Energizing the solenoid moves the shutter plate out of the laser
beam. The shutter plate also carries a diode for light-level
monitoring.
Either the complete Shutter Assembly or the solenoid and cable
assembly (within the Shutter Assembly) may be individually
replaced as an FRU.
Illumination Density Wedges
Illumination control (giving exposure adjustment) is carried out

by two variable density wedges that are moved in opposite
directions in the beam path. The change in density varies in
0.01 Neutral Density steps. The illumination control stepper
motor drives a toothed belt which moves the two variable density
wedges on linear bearings.
The variable density wedges are not field replaceable.
Beam Expander Lens
The laser beam spot size is controlled by a beam expander and a

variable aperture plate:
• The beam expander is permanently fixed in the beam’s path
and is not adjustable.
• The position of the aperture plate can be moved to give one of
four apertures (three of the apertures are holes in the plate and
a fourth is the beam expander lens itself. A stepper motor
drives a rack and pinion assembly which moves the aperture
plate.
The beam expander and aperture plate are not field replaceable.

Focus Lens
Focussing is achieved by a focus lens mounted on the optics base

plate. Media thickness may be either 4/1000 or 7/1000 in. (100 or
178 mm).
A means of focus adjustment exists. A focus stepper motor drives
a miniature leadscrew and nut, connected to the focus lens by a
linkage and linear bearings.
The focus lens is not field replaceable.
Optics Stepper Motors
There are three stepper motors used in the optical system, one for
each of the following functions: Illumination control, Aperture
control and Focus control. All of these are of the same type -
4-Phase DC.
Optics Sensors
Three sets of sensors are used on the optics, one set for each
stepper motor. There are three sensors in each set, consisting of:
• A single home position sensor of the Hall effect type.
• Two identical end-of-travel sensors; these are standard slotted
opto sensors.
Optics Distribution Boards

• Cables A2, A1 via the umbilical are routed to the Sensor
Distribution board for the sensors and solenoid from the
Motion Control board.
• Cables B2, B1 via the umbilical are routed to the Motor
Distribution board from the Motion Control board.

PL1 PL2 PL3 PL4 PL5
PL6 PL7 PL8 PL9
PL10 PL11 PL12 PL13 PL14
PL15 PL16
PL1 APERTURE HOME PL9 SHUTTER SUPPLY

PL2 SPARE PL10 TRAVERSE HOME
PL3 ILLUMINATION HOME PL11 APERTURE F
PL4 SPARE PL12 ILLUMINATION R
PL5 FOCUS HOME PL13 SPINNER COOLING
PL6 ILLUMINATION F FAN
PL7 APERTURE R PL14 FOCUS R
PL8 FOCUS F PL15 TRAVERSE HOME
UMBILICAL CABLE K2
NOTE: F = FORWARD PL16 OPTICAL SENSORS
R = REVERSE UMBILICAL CABLE A2
Figure 4.28 Optics: Internal cabling - Sensor Distribution Board
STUD
PL1 1
MOTOR DISTRIBUTION
FOCUS APERTURE ILLUM

9 PL2 1 9 PL3 1 9 PL4 1
Figure 4.29 Optics: Internal cabling - Motor Distribution Board

CAN I/F LASER

EXTERNAL 9-WAY CABLE MODULATOR
MONITOR CABLE D-TYPE D-TYPE BOARD
(CONNECTED TO (UMBILICAL)
PHOTODIODE ON
SHUTTER) SK4
RFI
BOX
TO
UMBILICAL
CABLE
LASER
DIODE
BIAS SK5
SK2
SK3 INTERNAL LASER
DRIVE LASER DIODE BOARD SK7
PHOTODIODE AND MODULE IMAGE H2
(SEE DIAGRAM BELOW)
SK1
LASER DIODE BOARD
SK2
TO INTERNAL
SK3
PHOTODIODE
(SK3)
TO LASER DRIVE
(SK2)
TO LASER DIODE BIAS
(SK5)
Figure 4.30 Optics: internal cabling - RFI Box

Baffles
Baffle plates are mounted on the Optics Carriage assembly to

prevent light scattering from the film surface and exposing other
areas of film.
The baffle assembly is secured by finger-tight screws to allow
removal and access to the spinner mirror and focus lens for
cleaning.

4.15 Media Scan System

4.15.1 Overview
This section describes the controls for the leadscrew/Spinner
position and speed. Refer also to Section 4.5 on the DSP board.
A Watchdog circuit (monostable or one-shot) is constantly pulsed
by the DSP to maintain the LED in the OFF condition. When the
LED turns on, the DSP has stopped working.
Note: To clear the problem, perform a traverse self-check either
from the Application Monitor commands, or by powering
the recorder off and on.
The DSP device is similar to a maths co-processor and is
designed to handle calculations. It also has a program, held in
PROM, which can be changed periodically for new firmware
updates. Local RAM is supplied for storing temporary work.
The scanning system controls the traverse mechanism and the
spinner. It consists of the following components:
• traverse closed-loop servo system
• spinner rotation motor
• servo sensors:
– traverse carriage ‘centre’ and ‘right’ end vane
– traverse motor encoder and vane sensor
– traverse carriage left and right limit switches
• power amplifier and PSU for traverse.
4.15.2 Spinner Assembly

The spinner (assembly) consists of a shaft supported on air
bearings and rotated by an integral electric motor. The bearing air
supply is internally generated by the motor. At one end of the

shaft an incremental encoder is fitted; at the other end, a single

facet 47.5 in mirror.
The spinner is mounted on the optics base assembly using four
retaining springs.
A small 24 VDC cooling fan is fitted to the spinner motor
mounting. The fan has an integral sensor that is polled by a
software routine to automatically switch off the spinner if the fan
fails.
4.15.3 Traverse Control

See Figure 4.31.
The traverse subsystem consists of a Optics Carriage, leadscrew
and motor, power amplifier, dedicated power supply and servo-
control board. The subsystem is illustrated schematically in
Figure 4.31. A carriage sensor and two limit switches are fitted to
provide datum information, and prevent carriage motion at the
limits of travel.
The servo system works in a closed loop, continuously taking
carriage position information from the leadscrew encoder and
comparing it with the required value. Errors are corrected by
adjusting the motor drive current to maintain the carriage at the
desired position.
The encoder and sensor signals are fed to the DSP servo control
board. A combination of hardware and software feed drive signals
to the power amplifier which in turn drives the DC motor.
Software in the SDM board provides scanning parameters and
commands to the DSP board. When a limit condition is active, the
hardware can override whatever movement the software is trying
to initiate.

DSP SDM
PL1 PL1 BOARD
BOARD
PL2 PL17
PL3 PL6
10 50
WAY WAY
PL7 PL5
INPUT/OUTPUT PANEL
SK16 9 SK9 SK12

2
WAY WAY
*
4
WAY
POWER
AMP
LEFT LIMIT RIGHT LIMIT
LEADSCREW
MOTOR HOME SENSOR BLADES
FLEXIBLE LEADSCREW
COUPLING TRAVERSE
OPTICS SENSOR HOME
PL15 DISTRIBUTION PL10 SENSOR
Signals Marked with * are
carried In the Umbilical BOARD
OPTICAL CARRIAGE
Figure 4.31 Traverse subsystem

4.15.4 Spinner
A spinner, consisting of a motor and a 47.5° mirror, is rotated at a
maximum of 30 000 rpm. The mirror rotation directs the
modulated beam onto the drum surface on which the Media to be
exposed is positioned.
The spinner is mounted on the Optics Carriage assembly and is
controlled by the scanning system.
The spinner may operate at 30 000 rpm or less, as required.
MOTOR DRIVE
AND SENSE
SIGNALS
ENCODER
SPINNER SIGNALS
BODY
LASER BEAM
MIRROR COOLING SPINNER

SURFACE FINS MOTOR
DEFLECTED
LASER BEAM
Figure 4.32 Spinner (Westwind)
4.15.5 Spinner Controller

Closed loop control of the Spinner is implemented by the Spinner
Controller board (see Figure 4.33) in order to:

• accelerate the spinner to speed from rest

• run at the required speed
• brake and stop the spinner when required
• stop.
SDM SPINNER
BOARD CONTROLLER
PL5 PL6
50 40 25
WAY WAY WAY
BRAKE COMMAND
500 KHZ REF
720 KHZ DATA D
PL6 PL5 SK15
INPUT/OUTPUT PANEL
SK14 SK11
9 15
WAY WAY
SPINNER SPINNER
ENCODER* MOTOR
DATA A DRIVE*
S INDEX
HALL EFFECT
SENSORS
FEEDBACK
Signals Marked with * are

carried In the Umbilical
Figure 4.33 Spinner controller loop

Spinner Controller operates as follows:

• provides the drive signals to the spinner motor and receives
back the rotor position from the Hall-effect sensors within the
motor body
• the encoder generates the pulses, DATA A and S INDEX,
which are fed back to the SDM board
• the SDM board monitors the pulses and produces appropriate
commands to the Spinner Controller board which governs the
spinner speed. The SDM board provides the reference clock
and brake command.
Interface signals are as follows:
• spinner controller input signals:
encoder feedback
external reference clock
brake enable/disable.
• spinner controller output signals:
fault (not currently available)
speed locked (not currently available).
4.15.6 Carriage Assembly

The traverse section consists of a carriage assembly on which the
spinner is mounted. The carriage traverses on a leadscrew rotated
by a DC motor. Attached to the motor is a quadrature encoder for
feedback. The encoder also has a ‘once-per-rev’ index mark.
Optics Carriage
The Optics Carriage is a machined aluminium casting. It is
supported at the rear on self-aligning bearing pads, which run in a
lubricated V-groove guide (see Figure 4.34). A top-steady cam

follower bearing is fitted at the top of the casting, which bears on

a hardened track. This track and the slideway run the length of the
drum/beam assembly.
BEARING ASSEMBLY –
RETAINING
SCREW
RETAINING
PLATE
BEARING PAD –
RETAINING
SCREW
LEFT-HAND
BEARING
OPTICS
CARRIAGE
(CASTING)
BEARING
PAD
V-GROOVE
V-GROOVE
GUIDE
ENLARGED VIEW
NOTE: VIEW IS FROM LEFT HAND END OF MACHINE.

RIGHT HAND BEARING IS SIMILAR VIEWED FROM OPPOSITE END.
Figure 4.34 V-groove guide, Optics Carriage (casting) and support

bearing
The carriage is connected to the leadscrew nut by a one-piece

gimbal (see Figure 4.35). The gimbal compensates for small
misalignments between the leadscrew and the slideway, without
placing unacceptable loads on either. The gimbal is held to the
leadscrew nut by a single screw and to the carriage by a C-clamp
and a single screws.
A Hall effect sensor is mounted on the carriage so the that vanes
mounted along the travel pass through its detector slot. There is

one vane with its right edge at the nominal centre of travel and
another which extends from before the right limit detector to
beyond the physical end of travel. These detectors provide an
accurate position reference.
A magnet is mounted on the carriage for operating reed switches
positioned as left and right limit detectors. When a limit detector
has been operated the relevant limit state remains active in the
hardware until a vane edge has been passed.
Problems with image ‘patterning’ traced to the Gimbal or the
Leadscrew are described in Section 9.2.5.
OPTICS
CARRIAGE
GIMBAL
FLEXING POINT GIMBAL CLAMP
UPPER SCREW
LEADSCREW
GIMBAL
C-CLAMP
GIMBAL
ALLEN SCREW
Figure 4.35 Optics Carriage, C-clamp and gimbal

Leadscrew
The leadscrew nut is split and fitted with an anti-backlash spring.
The nut and leadscrew are manufactured as a paired item and
cannot be changed individually.
It is supported at either end by angular contact ball bearings. One
bearing set is pre-loaded and sets the position of the Leadscrew in
the machine. The other set allows the screw to ‘float’, taking
account of thermal expansion. The bearing preload is
accomplished by spring washers and does not require field
adjustment.
The Leadscrew is driven by a brushed DC motor through a
bellows-type coupling. An incremental optical encoder is fitted to
the rear of the motor. There are no adjustments to be made to the
encoder.
Traverse System Power Supply

An autoranging, switched-mode power supply is used on the
Power Amplifier assembly to supply current to the Leadscrew.
See Section 4.8 for a description of the drive circuit.
Power Amplifier
Current to the motor is controlled by the power amplifier
contained on the Power Amplifier board. This converts the low
level torque demand voltage to a current capable of driving the
motor and Leadscrew. There are no adjustments in the amplifier.
A self-resetting thermal switch is fitted to the heatsink operating
at 85_C. The state of this switch is monitored on the DSP
(servo-controller) board, which relays it to the SDM board.

WARNING
The heat sinks on the Power
"
Amplifier board are live and may
carry up to 45 VDC at 8 A.
The SDM board communicates with the DSP board, to set the
appropriate Leadscrew rate and monitor the status of the traverse
system. The board accomplishes a number of functions:
• It implements a phase-locked loop scheme for controlling the
Leadscrew speed.
• It provides the system compensation to assure the required
quality of motion.
• It generates the reference clock signal appropriate to the
chosen resolution.
• At initialization or on demand, it carries out a self-check
procedure which attempts to verify correct operation of the
traverse sensors.
The relay braking disconnects the motor from the Power
Amplifier and applies a low impedance load across the motor
terminals. This regeneratively brakes the motor. This action is
initiated whenever either limit switch is activated - in service or
during self-checks. The braking function is wholly controlled by
the DSP board.
Traverse Sensors
Home Position
A slotted Hall effect sensor provides the precise ‘Home’ position

of the Optics Carriage to which all traverse positions are
referenced. The sensor is mounted on the Optics Module Base
and the actuating vanes on the traverse mechanism supporting
beam.

The sensor is wired to connector, PL10, on the optics sensor

distribution board, see Figure 4.28. From the board output
connector, PL15, it is routed via cables K2, K1 to the
Input/Output Panel (SK9).
Limit Positions
Left-hand and right-hand limits of the Optics Carriage travel are

indicated by proximity detector sensors to provide mechanical
protection during Leadscrew operation. These sensors are
standard magnetic proximity-switches and are located at the left
and right-hand ends of the beam at the rear. Either limit switch
sensor, when actuated, causes the motor to stop. In addition,
physical end stops are provided beyond the limit sensors.
The sensor wiring is routed via cable A2/A1 to the Input/Output
Panel (SK12), see Figure 4.40 and Figure 4.39.
4.15.7 Leadscrew Control Description

See Figure 4.36.
The Leadscrew interface block is split into two functions:
• Velocity Loop (fast traverse PLL acquisition).
• Phase Loop (scanning).
The DSP device programs the desired leadscrew speed into the
interface, and the type of traverse action (Velocity or Phase Loop)
is selected. Drive signals are generated and sent to the Power
Amp board and relays to control the motor.
An encoder is fitted to the motor to provide feedback signals to
the DSP which monitors the leadscrew position and speed.
Carriage Encoder (CRENC) and Carriage Encoder Quadrature
(CRENCQ) signals are used to determine direction of travel and
position. Leadscrew Once Per Revolution (LSOPR) is used to
synchronise the linear position to the encoder

Modes of Traverse
• Scan - For use during scanning traverse
operating in Phase Loop mode.
• Move - Option where the engineer specifies a
point to move to, referenced from
0 mm position at the left-hand end.
Traverse starts in Velocity Loop and as
it approaches the required point
switches to Phase Loop mode,
controlled from the DSP software.
• End of Travel - Option where the engineer specifies the
left- or right-end movement. Traverse
operates in Velocity Loop.
Velocity Loop
See Figure 4.36.

In Velocity Loop mode, alignment of the encoder and reference
clock phases is not forced. This mode is for positional changes.
Feedback signals are only monitored for positional control.
The DSP software loads the required motor speed into a DAC via
a latch. The analogue output voltage is amplified and filtered in
stages before being sent to the Power Amp board. Two electronic
switches are used to select either the output from the Velocity
Loop or the Phase Loop. In Velocity Loop, Traverse DAC
(TRVSDACSW) is closed, and Traverse Speed Switch (TRSPD)
is open.
Phase Loop
See Figure 4.36.

Phase Loop is used when accurate control of the Leadscrew is
required.

The DSP software loads the required motor speed into the
Carriage Reference Generator, which provides one input to a
Phase Detector.
A reference signal (CGENCPHS) is generated from both edges of
the motor encoder signals, CRENC and CRENCQ, and is used as
a second input to the Phase Detector. By comparing the desired
and the actual motor speeds, the Phase Comparator determines if
the Leadscrew is rotating too fast or too slow, and produces an
adjustment voltage accordingly.
Switch TRSPD is closed and TRVSDACSW is open. The
analogue output voltage is amplified and filtered in stages before
being sent to the Power Amp board as traverse signal (TSIG).
Direction and Positional Control
See Figure 4.36 and Figure 4.37

Direction control is achieved by inverting (or not inverting) the
output signal from either the Phase or Velocity Loop by means of
the Carriage Direction Switch (CRGDIR). Large electrolytic
capacitors are used in the filter circuits, with the signal SETCAPS
controlling analogue switches to allow initial conditions to be set
up for the capacitors.
The encoder signals, CRENC and CRENQ, produce 1000 pulses
per revolution of the Leadscrew, giving a total of 4200 edges. As
the pitch of the Leadscrew is 4 mm, this gives a positional
accuracy of 1 micron (4mm/4200).
OPENLOOP controls the switching to either connect or
disconnect to the final buffer stage. The Leadscrew motor signal,
TSIG, goes via a ribbon cable to the Power Amp board.

4–84
BYPSVFLTR
VELOCITY LOOP
LBDMD LATCH DAC FILTERS

(0–15)
TO
POWER
AMPS
TRVSDACSW TSIG
CARRIAGE
LBDMD REFERENCE
(0–15)
GENERATOR
PHASE AMPLIFIER FILTERS
DETECTOR
CGENCPHS
TR SPD OPEN
Figure 4.36 Traverse drive - block diagram

LOOP
CRGDIR
SETCAPS
PHASE LOOP
Celix 4000 (MkII) Recorder

CRENC
CRENCQ
TRVSEDGCK
&
CGENCPHS
TRAVERSE
PERIOD
COUNTER LATCH
CK3M CLK
LBDMD 0–15
TRVSEDGCK CLR CLK
Figure 4.37 Traverse speed detection
4.15.8 Traverse Initialisation Sequence

During system initialisation, the Optics Carriage traverse position
is unknown, but could be one of five positions (or conditions)
defined by the Hall effect vane and limit sensors.
1. Left limit activated.
2. Right limit activated.
3. In a vane:
– in the centre vane, or
– in the right vane.
4. Not in a vane:

– between the left limit and centre vane, or

– between the centre vane and the right end vane.
5. Both limits are activated (fatal condition).
The start of an initialisation sequence depends on where the
Optics Carriage is detected by the limit/vane sensors.
• If the left limit is active when initialisation starts, the traverse
is moved right until the left edge of the centre vane is
detected. This clears the latch condition generated by the left
limit.
• If the right limit is active when initialisation starts, the
traverse is moved left until the right edge of the right vane is
detected. This clears the latch condition.
• If the traverse sensor is in a vane, and neither limit is active,
then the traverse is moved left until the sensor is no longer in
the vane. The traverse will now either be left of the centre
vane, or between the centre vane and the right end vane.
Note: The motor drive power amplifiers are disconnected when
the left and right limits are activated. Final traverse
position is defined when the right edge of the centre vane
is detected.
The following two sections describe the traverse initialisation
sequence.
Sequence From Position Left of Centre Vane

1. Move right through the centre vane, into right-end vane until
the right limit is detected, and stop.
2. The right limit position is checked to be within tolerance from
final traverse zero position.
3. Check that traverse cannot be driven further to the right (right
limit relay check).
4. Move left in right-end vane until left edges of vane is detected
(to clear the latch condition), and stop.

5. Move left through centre vane until left limit is detected, and
stop.
6. The left limit is checked to be within tolerance from final
traverse position.
7. Check that traverse cannot be driven further to left (left limit
relay check).
8. Move right until left edge of centre vane is detected (to clear
the latch condition) and stop.
9. Move right in centre vane until right edge of centre vane is
detected, and stop.
10. Traverse at zero position. Initialisation is complete.
Sequence From Position Right of Centre Vane

1. Move right to right-end vane until the right limit is detected,
and stop.
2. A temporary traverse zero position is defined when left edge
of right-end vane is detected. (Required as traverse has not
passed through centre vane).
3. The right limit position is checked to be within tolerance from
temporary traverse zero position.
4. Check that the traverse cannot be driven further to right (right
limit relay check).
5. Move left in right-end vane until left edge of vane is detected
(to clear latch condition), and stop.
6. Move left into centre vane until left edge centre vane is
detected, and stop.
7. Move right in centre vane until right edge is detected, and
stop. (This defines final traverse position).
8. Move left through centre vane until left limit is detected, and
stop.
9. The left limit position is checked to be within tolerance from
from final traverse position.

10. Check that the traverse cannot be driven further to left (left
limit relay check).
11. Move right until left edge of centre vane is detected (to clear
latch condition), and stop.
12. Move right in centre vane until right edge of centre vane is
detected, and stop.
13. Traverse at zero position. Initialisation is complete.

4.16 System Cabling and Connections

The ECU wiring is shown in Figure 4.38. Figure 4.40 shows the
wiring between the ECU and other recorder subsystems.
Figure 4.39 shows connections from the umbilical to the optics
components. Further connections from the sensors to the ECU via
the distribution boards are expanded in Figure 4.41, Table 4.3 to
Table 4.5.
4.16.1 Electronics
The ECU wiring is shown in Figure 4.38. Cables 33 and 34 are
two twin-axial cables carrying Image data and Clock signals from
the SDM board up to the bulkhead (side panel) of the ECU Box.
Later recorders only have an Image data cable fitted.
4.16.2 Optics Assembly/Spinner Interconnections
Umbilical Cable
All electrical connections to the Optics Base assembly from the
ECU RFI box housing the recorder electronics are made up into
an umbilical cable. The wiring of this cable is indicated
diagrammatically in Figure 4.40 and Figure 4.39. Cable D1
carries the CAN bus and modulator power supply from the SDM
board and I/O panel.
Note: The umbilical cable is only available with a new Optics
Carriage Assembly.
4.16.3 Front/Rear Distribution Boards

Figure 4.40 and Figure 4.41 show the interconnection between
the ECU I/O Panel outlets and Front/Rear distribution boards.
Table 4.3 and Table 4.4 describe the cables and connections.

Cable Reference Nos are shown for earlier models of the Celix
4000 range.
RFI BOX COOLING FANS
* = ‘D’ TYPE
See also Figure 4.40
TO PL1, MCB
TWINEX BULK-
HEAD
CONNECTOR,
DATA (BLUE) NEXT TO I/O PANEL
TO UMBILICAL
SPINNER
CABLE 4 DISCRETE SK11 CABLE F1
CONTROLLER 64-WAY SK15
(PCB) HEADER 15-WAY*
25-WAY*
SK18
9-WAY*
DSP CABLE 6 NOT USED
(PCB) SK19
PL3 RIBBON NOT 9-WAY*
USED
PL1 PL2 SK17
25-WAY*
CABLE 2 CABLE 26
CONTROL POWER
H1 PL7
10-WAY
Á
SK6 PL1 PL17
60-WAY 8-WAY
NOT USED SK7 CABLE 24 RIBBON
Á
PL5 PL6
SPIN. BD. COMMS 40-WAY SK16 CABLE 21
40-WAY
25-WAY*
Á
CABLE 1 SK14 CABLE C1
50-WAY PL2
CABLE 25 RIBBON 9-WAY*
DISK 50-WAY PL6 PL5 CABLE K1
DRIVE CABLE 32 PL9 50-WAY SPIN. & TRAV. I/PS 50-WAY SK9
4-WAY 4 -WAY 9-WAY*
SDM
SK12 CABLE 47
(PCB) CABLE 27
CABLE 39 RIBBON PL4 PL4 9-WAY*
SCSI SK4 40-WAY MMI & CAN BUS.
HONDA (HONDA)
40-WAY
CABLE 54 POWER SK13 CABLE D1
CABLE 40 RIBBON SK3
RFI BOX SCSI FAIL(NOT 9W D
REAR PANEL HONDA HONDA CONNECTED)
PL15 CABLE 16
EXTERNAL CABLE 36 RIBBON 2-WAY SK8
CONNECTORS DIAGNS PL11 25-WAY*
25-WAY* 10-WAY CABLE 90
CABLE 38 RIBBON PL16
PL12 TO MULTIRAIL PSU I/O PANEL
FILM 25-WAY*
PROC 10-WAY SK10
25-WAY* CABLE 109
PL7 DATA CABLE

CABLE 3 PL8
60-WAY 91
MCB SK5 CABLE A1

PL2
TO PSU’s 37-WAY*
60-WAY
SK1
37-WAY* CABLE 10
PL4 CABLE 86 PL1
CABLE 89 40-WAY OPT. SENSORS 40-WAY
TO PSU’s PL1 SK6 CABLE 9
PL3 CABLE 85 RIBBON PL3 25-WAY*
40-WAY PUNCH 40-WAY SK7 CABLE 8
CABLE 88 DISCRETE SK2
I/L RELAY PL5 CABLE 87 PL2
25-WAY*
12-WAY SENSORS
50-WAY 50-WAY SK2 CABLE B1
I/L RELAY SK1 CABLE 31 SK3
5-WAY*
CABLE 48 DISCRETE (A3) PL6 50-WAY* MOTORS & SOLEN’s 50-WAY*
SK4 CABLE 7
6-WAY
I/L RELAY 25-WAY*
Figure 4.38 Recorder cabling: ECU (RFI box)

FOCUS APERTURE ILLUMINATION

MOTOR MOTOR MOTOR
RFI BOX (OPTICS)
MODULATOR PL2 PL3 PL4
TWINEX 9W D
MOTOR
DISTRIBUTION
CABLE 81
PCB
SK7 PL1
15-WAY*
DATA CABLE D2 CABLE B2

(H2)
UMBILICAL
CABLE
SPINNER ENCODER
SPINNER DRIVE
CABLE F2 CABLE C2
TRAV. OPTICS
HOME SENSORS
OPTICS 15-WAY* 9-WAY*
MODULE
CABLE K2 CABLE A2
SPINNER SPINNER-
PL15 PL16 MOTOR ENCODER
9WD 37WD
SENSOR
DISTRIBUTION
PL10
PCB
PL11 PL7 PL6 PL12 PL8 PL14 PL1 PL3 PL5 PL13 PL9
* = ‘D’ TYPE
APERTURE ILLUM FOCUS APERTURE FOCUS SHUTTER

F F F HOME HOME SUPPLY
APERTURE ILLUM FOCUS ILLUM SPINNER TRAVERSE

R R R HOME FAN HOME
Figure 4.39 Recorder cabling: umbilical to optics

UMBILICAL CABLE OPTICS

MODULE
CLOCK (I1)
DATA (H1)
CABLE F1
SK11
* = ‘D’ TYPE
SK18
NOT USED
I/O PANEL
CABLE 21 12-WAY CABLE 19 A2 TRAVERSE

SK16 25-WAY* G/MATE MOTOR
POWER AMPLIFIER
CABLE C1 SPINNER ENCODER
SK14
CABLE K1 TRAV HOME
SK9
CABLE 47 TRAV SEN

SK12
CABLE D1 CAN/POWER
SK13
MMI
CABLE 16 MMI 26-WAY
SK8
MINI D-TYPE
CABLE 109 INTERLOCKS

SK10
PUNCH, VACUUM
ASSY, FANS,
SENSORS
25-WAY* FRONT
PL8 DISTRIBUTION
PCB
REAR
25-WAY* DISTRIBUTION
PL14
PCB See Figure 4.41
CABLE A1 OPTICS SENSORS
PL5 9-WAY GUILLOTINE
MATE-N-LOK MOTOR
FILM HANDLING CONTROLS
SK1
9-WAY CASSETTE
CABLE 9 SENSORS FRONT DRIVE MOTOR
SK6 MATE-N-LOK
CABLE 8 SENSORS REAR

SK7 9-WAY OUTPUT
CABLE B1 OPTICS MOTORS MATE-N-LOK CHUTE MOTOR
SK2
CABLE 7 MED./H. MOTORS 9-WAY VERTICAL

SK4
MATE-N-LOK OUTPUT MOTOR
Figure 4.40 Recorder cabling: ECU to subsystems

CABLE 9 PL8 PL4

25-WAY* 6-WAY
I/O PANEL (SK6)
PL2 PL7 CABLE 66

10-WAY 8-WAY
INPUT MEDIA DETECT/EOT
(AT PROCESSOR)
* = ‘D’ TYPE PL3
2-WAY
PL9 PL5
FILM HANDLING 10-WAY 4-WAY
CONTROL CABLE
PL10 PL1 CABLE 69
10-WAY 2-WAY
END OF ROLL DETECT MED. AT INPUT CASSETTE
(DROP)
PL6
2-WAY
(a) FRONT DISTRIBUTION BOARD
CABLE 8 PL14 PL1 CABLE 70

25-WAY* 2-WAY
I/O PANEL (SK7) GUILLOTINE EOT LEFT
PL3 CABLE 71
2-WAY
GUILLOTINE EOT RIGHT
PL8 PL6
4-WAY 2-WAY
PUNCH POSITION BD
PL12 PL13
4-WAY 2-WAY
PL9 PL7
PUNCH POSITION BD 2-WAY 2-WAY
PL10 PL2
2-WAY 2-WAY
PUNCH POSITION BD
PL11 PL4
2-WAY 2-WAY
PUNCH POSITION BD MEDIA DETECT AT PUNCH
PL5
2-WAY
(b) REAR DISTRIBUTION BOARD
Figure 4.41 Recorder cabling: media handling sensors -

distribution boards

Table 4.3 Front Distribution Board
Function PCB Conn.Ref. Cable Ref. Cable Part No

I/P Media Det&O/P EOT&Lazy Loop PL7 66 75515690
Media at Input Cassette (Drop) PL1 69 75454310
Main Connector to I/O Panel PL8 9 75454040
End of Roll Detection PL10 – 75516160
Part of Film Handling Control PL9 – 75514650
Table 4.4 Rear Distribution Board
Function PCB Conn. Ref. CableRef. Cable Part No

Media Detect at Punch PL4 – 75515040
Guillotine at Left EOT PL1 – 75515040
Guillotine at Right EOT PL3 – 75515040
Output at Processor (EOT) PL7 66 75515690
Punch Position Detect PL11 – 75514650
Main Connector to I/O Panel PL14 8 75454040
Table 4.5 ECU Subsystem Cabling
Cable Description Destination Cable Part No

Film Handling Control (SK1) Punch, Vac Assy, 75514650
O/P Chute Fan, RFI Fan
Power Amplifier (SK16) Power Amplifier 75454110
Traverse Sensors (SK12) Traverse 75454170
MMI (SK8) MMI 75454060
Interlocks (SK10) Interlocks 75496090
Front Sensors (SK6) Front Distribution Bd 75454040
Rear Sensors (SK7) Rear Distribution Bd 75454030
Media Handling Motors (SK4) Guill/Cassette/Output 75514620
Chute/Vertical Output

Vacuum Services 5
and Maintenance
This chapter describes the vacuum services distribution, how the
system is maintained, its electrical control, and the operation of
the solenoids.
5.1 Vacuum System

See Figure 5.1.
The vacuum system consists of three subsystems with the main
components assembled on a removable Vacuum Pump tray:
• Electrical and vacuum control signals (transformer, vacuum
relay).
• Solenoids valves, switches and distribution.
• Vacuum pump and air inlet fan.
Vacuum, provided at the rear of the drum, operates through the
grooves to ensure film conformance at the punch end, while film
fed from the front rollers is pushed into the drum at the cassette
end.
Maintenance procedures and useful servicing information for the
vacuum tray units is provided in this chapter. The vacuum pump
assembly, solenoid valves, filters and pneumatics transformer are
supplied as a single field replaceable tray already factory-tested
for the correct vacuum pressure.
If there are any failures traced to any component on the tray, then
replace the complete Vacuum Pump tray.
See the Celix 4000 Recorder Illustrations Parts Catalogue.

Vacuum Services and Maintenance
5.1.1 Removing the Vacuum Pump Assembly

See Figure 5.1.
The vacuum assemblies are mounted on the right–hand side tray
with power/signal cabling and the vacuum lines running in a
compartment underneath. Use the following procedure to replace
the assembly.
TRANSFORMER
BOX
SOLENOID
SWITCHES
MICRO FILTERS
VACUUM PUMP
BOX
Figure 5.1 Vacuum pump assembly
1. Isolate the recorder from the mains supply.

2. Detach the two connectors, vacuum control and power, from
the rear of the tray.

3. Detach all the vacuum lines to the drum and Input cassette
from their filter connectors.
4. Pull out the tray after removing the 3-off fixings located
underneath and on the right-hand side.
CAUTION
The Vacuum Pump assembly is
heavy and may require lifting by two
people.
5. Replacement is the reverse of the removal procedure. A

vacuum setup is not required. Ensure that all the vacuum lines
are firmly inserted into their filters.

5.2 Mains and Signal Distribution

See also Figure 4.4 showing the mains input lines to the vacuum
assemblies, and Figure 4.41 showing the front and rear
distribution boards.
Accessing the Vacuum Transformer and Relay

A covered box on the left-hand side of the tray houses the
following items:
• Transformer: the vacuum transformer runs from 85-260 VAC
(47-63 Hz).
• Fuse: located on the IEC mains inlet connector at the rear of
the transformer. The fuse settings are selectable for 240 V,
220 V and 110 V, see Section, Changing the Fuse Selection,
below.
• Vacuum relay: switches power on/off to the vacuum pump.
Any failures on the tray electrical parts is rectified by removing
and replacing the Vacuum Pump tray assembly.
Changing the Fuse Selection

1. Remove the right-end panel.
2. Detach the rear D-type Vacuum connector and IEC socket
connector.
3. Detach the Vacuum Pump tray from the frame and pull out the
tray to access the rear of the assembly.
4. Remove the fuse selector from the plug chassis and re-align
the fuse insert for the appropriate local voltage (seen from a
small window). Fit the appropriate fuse.
5. Replacement of the fuse selector is the reverse of the removal
procedure.

5.3 Solenoid Valves and Switching Ancillaries

Figure 5.2 illustrates the vacuum distribution and switching
system.
A set of five solenoids provides vacuum switching for the
following functions:
• holding the media in the drum via vacuum grooves –
film-to-drum conformance.
• releasing the Input cassette rewind drive.
H DRUM
L VAC SW
BLACK
356 TO DRUM
GRN
510 TO DRUM
WHT
660 TO DRUM
RED
760 TO DRUM
BLUE MINI FILTER
CASSETTE TO CASSETTE
SOLENOID/
MANUAL SWITCH
OPERATION
FROM
VAC PUMP
SYSTEM
VAC SW
Figure 5.2 Solenoids and switches
Solenoid switching controls the drum vacuum for setting the film-
to-drum conformance widths and the Input cassette clutch:
• 356 mm – Black

• 509 mm – Green
• 640 mm – White
• 760 mm – Red
• Cassette clutch – Blue.
The drum vacuum switch (DVS) has a (H)igh and (L)ow flow
control which does not require field adjustment.
The system vacuum switch (SVS) has a preset screw which is not
field adjustable. An integral LED is ON when the vacuum reaches
a set level. Make sure the LED display is fully covered with black
felt.
5.3.1 Vacuum Line Mini-Filters

See Figure 5.3.
TO DRUM
MINI FILTER
ÄÄ FROM
ÄÄ
FILTER SOLENOID
ELEMENT
CONTAINER
ÄÄ
TURN TO
RELEASE
Figure 5.3 Vacuum line mini-filters

A set of four filters are incorporated in the solenoid vacuum lines

to prevent debris entering the solenoids and pump.
Mini-Filter Servicing
Mini-filters are cleaned every six months by unscrewing the
plastic element bottle one quarter turn clockwise, removing the
filter element and blowing through the bore hole to remove any
debris.

5.4 Vacuum Pumps Assembly

5.4.1 Vacuum Pump
See Figure 5.1.
The Vacuum Pump is in operation for the entire time the recorder
is scanning.
The pump is a rotating carbon blade type with an input filter. The
pump operates continuously when the recorder is in normal use.
Serviceable parts comprise the four carbon blades and the input
filter. It is important that the blades are replaced every six
months.
5.4.2 Vacuum Pump Service Routines

See Figure 5.4.
These procedures apply to routine or fault servicing.
Removal/Replacement of Vacuum Pump

Assembly
WARNING
To prevent danger to personnel from
moving parts or live connections, the
power supply connections to the Vac
Pump assembly must be
disconnected and the Vacuum Pump
assembly removed from the recorder.

Note that the Vacuum Pump assembly only needs removing in the
event of a fan failure. All other items in the assembly may be
removed with the pump in-situ.
1. Ensure that the recorder is switched off and at rest.
Disconnect the mains leads at the rear of the recorder.
2. Remove the right-hand cover of the recorder.
3. Lift off the vacuum pump cover by releasing the quick-release
fastener, pulling away the cover from the right-hand side
U-notch. Lift up the cover.
CAUTION
The earth wire attached to the
Vacuum pump housing lid must not
be removed during the servicing
operation. The length of the wire is
sufficient to allow access to the
pump.
4. Detach the vacuum line from the outlet.

5. Open the junction box and disconnect the mains input to the
pump.
6. Loosen the two quick-release screws situated underneath the
front of the pump unit and remove the unit.
CAUTION
The Vacuum Pump assembly is
heavy.
7. Lift off the two covers by releasing the captive screw and the
2-off M4 screws.
8. Unscrew the earth wires from the cover earth terminals (wing
nut) and remove the pump and transformer covers.

9. Service the Vacuum pump, as required, see Section 5.4.3.

10. After servicing has been completed, refit the cover assembly
of the Vacuum Pump assembly and refit the Vacuum Pump
assembly in the recorder. Refitting is the reverse process to
‘Removal’, described in Steps 1. to 8.
5.4.3 Vacuum Pump Assembly - Periodic Service

If necessary, remove the Vacuum Pump assembly, as described in
Section 5.4.2.
Air filtration
1. Remove the end cover (five screws).
2. Note the alignment of the filter cartridge before it is removed.
3. Remove, clean and replace the filter gasket.
4. Insert new filter cartridge (99330011) ensuring that it is
aligned correctly as noted above.
5. Replace the end cover.
Changing Carbon Brushes

This procedure must be completed every six months.
Use the Vacuum Pump service kit (75510880) which contains
four blades and a filter. Make sure the filter is inserted the correct
way round.
1. Remove the end cover (five screws).
2. Remove the old filter and replace with a new filter and gasket.

3. Pull out and withdraw the four carbon blades from their slots
in the drum rotor.
GASKET
FILTER
CARTRIDGE
GASKET
VACUUM
OUTLET
VACUUM PUMP
MOTOR
CARBON
BLADES
(4 OFF)
ELECTRICAL
JUNCTION BOX
Figure 5.4 Vacuum pump serviceable parts
4. Insert the four new blades (99330012, 4-off) in the slots, such
that:

a) the chamfered sides of the new blades appear outside of

the motor.
b) the outer edges of the blades are flush with the
circumference of the drum.
5. Replace the end cover and slightly tighten the screws.
6. Replace the power supply connection on the Vacuum Pump
assembly and turn on the power supply (if not already on) to
start the pump.
7. Ensure free and smooth running of the blades. Remove the
power supply connection on the Vacuum Pump assembly.
8. Firmly tighten the end cover screws.
9. After servicing has been completed, refit the cover assembly
of the Vacuum Pump assembly, ensuring that the cover earth
connection is remade. Refit the Vacuum Pumps
10. Assembly is the reverse process to ‘Removal’.
11. Indicate in the Log Book or the label inside the vacuum pump
cover the date of the blade replacement.
Note: The Vacuum Pump requires no lubrication as all models
are assembled with sealed-for-life bearings.
DIRECTION
OF ROTATION
Figure 5.5 Vacuum pump: insertion of blade into rotor

Fault Diagnosis 6
and Utilities
This chapter shows how to access the embedded diagnostics,
describes the Celix Diagnostic menu system and the useful
commands running under the Application Monitor (Moon). It also
explains how to access the DSP Log and review the error reports.
6.1 Overview
The following diagnostic functions are available to allow the
location and diagnosis of recorder faults.
• Power on Diagnostics: these tests are run automatically when
the recorder is switched on. If a fault is detected during the
power up sequence, a failure message is displayed on the
recorder LCD and the attached server/station. See Section 6.4.
• Celix Diagnostics: this set of tests are available on the RIP
server/station and run from the Celix Diagnostics
HyperTerminal window. They feature a full range of on-board
diagnostic tests for the electronic, optical, mechanical and
communication (to Processor) subsystems, and include other
useful utilities for identifying and locating faults. See
Sections 6.6 through to Section 6.13.
• Application Monitor (or Moon) Diagnostics: this group of
commands is available from the Celix Diagnostics terminal.
Application diagnostics were originally created to aid the
development of the recorder machine, but they still
complement (and in some cases) expand on Celix
Diagnostics. See Section 6.14.
• Remote Diagnostics: a modem link creates a virtual network
between a local support centre and customer site allowing the
service engineer to run Celix Diagnostics. See Section 6.5.

Fault Diagnosis and Utilities
• DSP Log Checks: this section explains how to access the

DSP Log and obtain error information on:
a) Traverse Errors
b) Limit Detection Positions
c) Traverse Motor Current
See Section 6.15.
Once a diagnostics session is opened from the HyperTerminal
window it can be recorded (to printer or disk) by selecting and
starting the appropriate option from the Transfer menu.
Before accessing Celix Diagnostics and the Monitor
commands, use the instructions in Section 6.4 to set the
communication parameters for a PC Diagnostics terminal.

6.2 Troubleshooting Facilities

The Celix 4000 is designed with a number of in-built features
which provide useful aids when troubleshooting the system.
These features are itemized in the sections below.
6.2.1 Troubleshooting Features for the Recorder

These diagnostics are embodied in a suite of programs which are
run in two ways:
• Automatically on system power-up. On power-up a limited
number of tests are run to ensure the basic operation of the
Recorder machine. Any errors encountered are indicated on
the RIP server/station screen.
• From the RIP server or station terminal using VT100
emulation software. Extensive test of the operation of the
system can be carried out using Celix Diagnostics menu
options.
Testing of individual areas of the equipment can also be
selected and run using the facilities available.
The main areas which are tested using the diagnostic suite
are:
The SDM board including:
• Internal memory, NVRAM, and other on-board hardware.
• Internal image data path.
• Power supplies and associated cabling.
• Interface to the Motor Control board.
• Interface to the DSP.
• Interface to the internal SCSI drive.
The MCB including:
• Drivers and associated motors/actuators.

• Receivers and associated sensors.

• Fuses.
• Cables.
The DSP board including:
• Traverse Servo-Loop Control and associated mechanics.
• Watchdog timer.
6.2.2 Troubleshooting Features within the Diagnostics

Software
There are a number of facilities available from within the
diagnostics software which can be useful when troubleshooting
the system.
These facilities are embodied in a Monitor program and provide
for low-level troubleshooting of the system using Monitor
Commands.
Details of the Monitor Commands are provided in Section 6.6.8.
6.2.3 Troubleshooting - Hints and Tips

The Celix 4000 is a fairly large system and it does have its
inherent complexities. However, with the correct approach to
fault finding and proper use of the designed-in features, it is
possible to achieve fast, effective troubleshooting.
Here are a few tips which may help in a fault-finding situation:
1. When using the recorder’s diagnostics, remember the
following points:
• Any malfunction indicated may be caused by a
component located in an area other than where the failure
occurs. For example, a failure may be indicated on the

Motor Control board when in fact an actuator, solenoid or

sensor has failed to respond to a particular test.
• Always ensure that you have checked associated cabling,
motors, solenoids and sensors and associated mechanical
components before suspecting the Recorder’s electronics.
2. When using the diagnostics, refer the Extent of Test diagrams
provided to identify the area of malfunction.
3. Observe and become familiar with the normal sequence of
events during media movement, bootup, etc, and the
characteristic noises and movement when events occur.
4. Messages displayed on a Terminal window which are not
error messages but normal messages can also be useful in
eliminating problem areas.
6.3 Power-up Tests and Initialization

See Figure 6.1.
On power-up, the system software immediately checks for the
presence of all PCBs,and then automatically initiates limited tests
of the system components.
During this time, appropriate messages are displayed on the RIP
server/station.
If an error is detected, an explanatory message is displayed on the
workstation.
The chain of events is as follows:
1. The application software sets-up the working environment
(creating files etc.).
2. A presence check is made for all fitted PCBs.
3. The SDM board is initialized.
4. The Motor Control board is initialized.
5. The motors and solenoids are initialized.

6. The power-up diagnostics are run.

7. The DSP board is initialized.
8. The spinner system is initialised and run up to normal speed.
9. The traverse mechanism is calibrated.
TO
SPINNER
Checked by DSP Board
MODULATOR TRAVERSE
POWER AMP
RELAY PLATE BOARD
DSP BOARD: RESET BY SDM BOARD

CARRIES OUT SELF CHECKS.
INITIATES: TRAVERSE CARRIAGE
IMAGE DATA
SDM BOARD: RESETS DSP BOARD,

INITIALIZES MCB.
TESTS ALL LOCAL ICS AND ON MCB.
VERIFIES COMMS TO CONSOLE AND SPINNER
SCSI TO RIP SEVER/STATION. CONTROL
BOARD
SPINNER
RIP SERVER
SYSTEM
INTERLOCKS
CONTROL RS232
CONSOLE (MMI) MCB: INITIALIZES
SOLENOIDS AND
SENSORS
UNDER
CONTROL BY
MEDIA RS232 THE SDM BOARD.
PROCESSOR
MEDIA TO FROM
HANDLING SOLENOIDS SENSORS
SENSORS AND
MOTORS
Figure 6.1 Celix 4000 power-up extent of tests

6.3.1 SDM Board Power-up

The SDM board initiates its own power-up tests.
It performs the following:
• The hardware is reset with all of its data and address lines to
the default state.
• The system software is re-booted from Flash memory to
DRAM.
• The Power on Self-Test (POST) routine is initiated, to
determine a correct operation of the components on the SDM
board.
6.3.2 DSP Board Power-up

On power-up, the DSP receives a RESET signal from the SDM
board which initiates a self-test routine. On successful
completion, an acknowledgement is returned to the SDM board.
6.3.3 Motion Control Board Power-up

On power-up, the SDM board initiates the registers and drivers of
the MCB.

6.4 Power Up and Diagnostics Access

When the RIP server is a PC running Celix Diagnostics from a
HyperTerminal window, access. to the terminal is obtained from
the Windows Start menu:
. . .
.
Start Programs FUJIFILM RIP Recorder
Utilities Diagnsotics Terminal
To obtain Celix Diagnostics from the Moon> prompt, or after

powering up the recorder, open and set the HyperTerminal
Properties box as follows:
Connect to (tab)
• Connect using the appropriate COMM setting for the
Diagnostics link to the recorder.
• Configure the terminal Comms settings to the Fujifilm default
values: Bits per second = 9600; Data bits = 8; Parity = None;
Stop bits = 1; Flow Control = None.
Settings (tab)
• Functions, etc, are set to Terminal keys
• Emulation set to ‘Auto detect’ – this will need to be reset each
time Celix Diagnostics is required.

Figure 6.2 summarises the software control for the power-up

sequence and movement between three executable programs
(called systems): Boot Code, Celix Diagnostics and the
Application Monitor (Moon) commands.
Note: Make sure the serial POWER UP

cable between the ECU and
the Diagnostics monitor is
properly connected.
_
mon[return] then go boot
BOOT SYSTEM
FAIL
CHECKSUMS
DIAGS
OK
FAIL
IS A VT100
NO
CONNECTED?
CHECKSUM
YES APPLICATION
YES
IS A
KEYBOARD BUTTON
PRESSED?
NO OK
q to quit then y to confirm
APPLICATION
SYSTEM (MOON)
CELIX
DIAGNOSTICS sup[return] then type reset
SYSTEM
D
evt[return] then go 40004
_
mon[return] then go app
Figure 6.2 Power-up and navigating with recorder software
The power up sequence is as follows:

1. System is Powered on.
2. Boot system checksums the Diagnostics area in Flash memory
(0x40000 to 0xC0000).

3. If it is correct, diagnostics is booted and proceeds to Step 5.

4. If it fails, it copies itself to RAM then runs (0x300000).
5. Diagnostics then looks for embedded version numbers in the
Boot, Application and Diagnostics systems.
6. It then displays ‘ESC [ c’ to detect whether a terminal
(VT100) is connected.
7. Any keyboard button pressed before (or at the same time)
ensures that a terminal is not seen and control proceeds to
Step 9.
8. If a terminal is seen and responds, then Celix Diagnostics is
started (working from Flash).
9. If a terminal is not seen, a checksum is carried out on the
application area (0x100000 to 0x180000).
10. If it is correct, the Application system is run and copies itself
to RAM (0x360000).
11. If it is not correct, the Boot system is run, which copies itself
to RAM (0x300000).
6.4.1 Accessing Diagnostic and Boot Systems

Once a Celix Diagnostics terminal window is opened as a PC
terminal window, a set of commands is used to switch between
diagnostic modes.
To navigate between the software systems carry out the following
(see Figure 6.2):
• From the Application system you can access Celix
Diagnostics by opening a terminal window, and with the evt
prompt displayed, enter:
goD40004. (D = space)
Note: Check that theHyperTerminal Properties are set

correctly if there is a problem in obtaining Celix
Diagnostics.

• From Celix Diagnostics you can access the Application

system, with the mon prompt displayed, by entering:
go_app.
• From Celix Diagnostics you can access the Boot system, with
the mon prompt displayed, by entering:
go_boot.

6.5 Remote Diagnostics

A virtual network between support centres and customer sites is
provided by a link using V34 (28,800 CPS) modems and PPP
(point-to-point protocol). To support the PC or Macintosh, a
communications package is required, such as, Timbuktu Pro or
HyperTerminal.
Full remote diagnostics functionality for a single imagesetter is
available with the following configuration which shows the Celix
4000 recorder and the RIP server/station (that manages remote
diagnostics communications):
RS232
RIP
SERVER
RECORDER
RS232
ETHERNET PPP AND
COMMS
SOFTWARE
MODEM
CLIENT
STATION
CELIX 4000 SITE
SUPPORT
MODEM CENTRE PC
SUPPORT CENTRE
Figure 6.3 Remote diagnostics configuration

To reach all of the customer’s equipment using just one modem a

network interconnection with Ethernet is required. If it is not
networked, then A/B switching or additional modems will need to
be fitted.
Remote diagnostics are normally disabled during the routine
operation of the recorder, and only enabled when the local
support centre requires remote access. This avoids the
problem of accessing the recorder while a job batch is being
exposed.
To enable/disable a remote diagnostics connection, you will need
to setup/enable the modem and PPP software (see the appropriate
user documentation).
Installation and commissioning of remote diagnostics is described
in the Celix 4000 Recorder Installation Manual and the
appropriate RIP user documentation.

6.6 Celix Diagnostics Window Operations

6.6.1 Introduction
CAUTION
Some of the commands that operate
with Celix Diagnostics may cause
damage to the equipment if used
improperly. Only FFEI-approved
engineers should attempt to use the
Celix Diagnostics.
Celix Diagnostics have the following features:

• Soak tests (SOE) can be performed on some test sets (or
sub-sets), and failed tests can be repeated.
• Individual tests can be disabled so that closer monitoring of
particular modules is possible.
• An error-message logging facility allows groups of tests to be
run unattended. Results can then be viewed later.
• The amount of information reported by each test can be
increased or decreased using a Verbose flag.
• A global whereis command is available to locate the position
of a test name within the diagnostics menu.
• A global monitor command that offers a monitoring facility
for lower-level access to the hardware in certain
circumstances.
6.6.2 Displaying a Typical Screen

Enabling the Celix Diagnostics Terminal window before the
recorder is powered-on and in operation provides the engineer

with a scrollable window displaying all system communications

and fault reports since the last power-on.
To access Celix Diagnostics software on the RIP server/station
use the appropriate procedure for the installed RIP option.
The top line of the screen indicates the program title. Below this
is a box which shows the current menu and the command group
available at this level. Each command is followed by a brief
description of the test.
The prompt and all user input appears in the bottom line of the
screen. The prompt changes to indicate the current sub-menu.
The diagnostics software is based on a hierarchical (tree-like)
menu. Options available at any time are restricted to groups. The
members of each group are related logically within the hierarchy.
The tree options are described in detail from Section 6.7.
PROGRAM TITLE
COMMAND GROUP
AVAILABLE UNDER
MENU TITLE
SOAKABLE TEST
SCROLL AREA
COMMAND
OPTIONS
COMMAND
LINE
Figure 6.4 Celix diagnostics opening screen
6.6.3 Entering Commands

There are three types of command for selecting options:

1. Commands which directly select tests or utilities.

2. Commands which select another group (or sub-menu) of
commands. When these are entered the screen is redrawn with
the new group displayed. These commands have the suffix of
> or –>.
3. Global commands, such as ‘help’.

The following notes apply to command entry:
• The commands currently available are displayed on the
screen.
• Global commands, listed in Table 6.1 below, are available at
any time.
• To select a command, type its name, followed by [Return] or
[Enter].
Table 6.1 Global commands
Command Function
QUIT This function moves the display back to the previous menu level. If quit is selected from
the top level then the program is exited, after confirmation of the message.
HELP Typing help or ? gives a list of local and global commands which are currently available.
Typing help followed by the command name gives help on that command.
SOAK This command initiates a soak test. See also Soak Test Operation later in this section.
ENABLE This command enables soak tests. See also Soak Test Operation later in this section.
DISABLE This command disables certain soak tests. See also Soak Test Operation later in this
section.
WHEREIS This command is used to find the location of one or more commands. The data given
shows the path from the top level menu to the command. If several matches are found
all paths are shown.
PATH This command displays the path name of the current menu level.
RLOG This command reports the status of the RAM log (off or on). Rlog on and Rlog off switch
the RAM log on and off respectively. Rlog clear clears data from the RAM log. Rlog
show displays the log data.
REFRESH This command redraws the current screen display.
MONITOR This command calls the diagnostics monitor. See also Monitor Mode Operation later in
this section.
VERBOSE The verbose command controls the messages which appear during soak tests. See also
Soak Test Operation later in this section.

• 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. If
several commands begin with the same letters, then the first
match will be selected. Global commands are searched first,
followed by the current menu. The menus are searched from
top to bottom.
• Some commands can be modified by adding subsidiary
parameters. For example, if Soak SOE is entered the Soak
command is modified so that it Stops On an Error.
• Certain commands require responses to questions. Other
commands require extra data to be entered. This data is
usually but not always in the form of numbers. Any test
which requires additional user input on the command line will
be denoted by the suffix p .
6.6.4 Help Facility

The Help global command provides information on any test
command when the command parameter is entered. For example,
entering help xfer gives the following display:

Figure 6.5 A typical help display (xfer)
6.6.5 Scroll Area

To ensure that the screen is able to scroll properly for displaying
diagnostic information, use the cursor to size the terminal window
so that the list of available options appear just above the menu
prompt. Press [Ctrl-l] afterwards to redraw the window.
6.6.6 Command Line Editing

As an aid to the user, the recorder diagnostics keep a history of
the last ten commands entered. Recall and editing of any of these
commands is possible.
• To move through the history of the commands use the or
cursor keys.
• To edit a line use the [Delete] key to remove characters, then
type in the new characters.

• To remove all characters from a line press .

• To execute a command that has been recalled press the
[Return] key.
6.6.7 Soak Test Operation

The soak command will run all tests that are soak enabled in all
sub-menus below the current level. Soakable tests and sub-menus
are indicated by an S suffix to the command name.
• If the S is in bold, then the test is enabled.
• If it is not in bold the test is not enabled.
To run all soakable tests and sub-menus use soak. By selecting
soak soe the diagnostics executes each soakable test once and
stops if an error occurs. Information is displayed on the MMI
display for the item being tested. The display indicates the
relevant state - this may be ‘Under Test’, ‘Passed’ or ‘Failed’. See
the following examples:
VERSION No. TEST No.
(2 DIGITS) (5 DIGITS)
ACTIVITY
RELEASE No. INDICATOR
MODULE CODE (2 DIGITS)
PASS/FAIL
INDICATOR
B VZZ. XX YYYYY/
MODULE M o t or Control b o a r d
NAMES
Systemboard
Figure 6.6 MMI display: information types for module under test
MODULES UNDER
B VZZ. XX YYYYY/ TEST, TEST NUMBER
M o t or Control b o a r d MODULES UNDER
Systemboard TEST, -NAME(S)
Figure 6.7 Display during test execution

B VZZ. XX YYYYY/ ‘TICK’ INDICATES

PASS
M o t or Control b o a r d
Systemboard
Figure 6.8 Display - test passed
B VZZ. XX YYYYY/ ‘CROSS’ INDICATES

FAIL
M o t or Control b o a r d
Systemboard
Figure 6.9 Display - test failed
Soak commands are applied in the following way:

• To soak more than once use soak x where x is the required
number of repetitions.
• To soak an individual test or sub-menu, enter soak name x,
where name is the name of the test or sub-menu and x is the
number of repeats.
• To select the stop-on-error code use the suffix soe. For
example, soak 10 soe initiates a soak on all enabled tests 10
times and the tests will stop on any error.
• To stop a soak test type [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 :
** An error stopped the soak test! [test name]
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 initiates 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.
• The verbose command controls the messages which appear
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.
d) When Verbose is ON, all messages are displayed and
messages beginning with **, -–, ++ and ^^ are logged to
RAM (if RAM logging is enabled). Only error messages
(indicated with **) are logged to Flash.
e) When Verbose is OFF, only error messages are displayed
and logged to RAM or Flash.
Note: For troubleshooting, always select the Verbose ON
option.
6.6.8 Monitor Mode Operation

Note: Monitor Mode commands and Application Monitor
(Moon) commands are separate and different.
Within the recorder diagnostics menu there is a global command,
monitor, which selects the recorder diagnostics monitor. It allows
low-level access to recorder hardware with facilities, such as,
memory-access routines. See Section 6.4 on how to access the
Monitor commands.
The diagnostics monitor operates in a similar way to the
diagnostic menu system but has a flat rather than hierarchical
structure. This means that all commands are always available.
Commands are entered by typing the command name followed by
[Return]. The same rules of menu searching and abbreviation
handling that apply to the menu system are used. A history stack
of commands and command line editing are also supported. To

obtain a list of the commands available, type help. for more

information on a particular command, type help command_name.
Table 6.2 Standard monitor commands
COMMAND FUNCTION
read Read from a memory location.
write Write to a memory location.
width Set the data width, in bits, for memory operations.
more Switch output paging on or off.
write_verify Write to a memory location and verify that the
write occurred.
read_verify Read from a memory location and check the that
memory location contains the desired pattern.
dump Dump an area of memory to the screen.
fill Fill an area of memory with the desired pattern.
fill_verify Fill an area of memory with the desired pattern
and verify that the fill area occurred.
search Search an area of memory with the desired
pattern.
copy Copy one area of memory to another.
compare Compare two blocks of memory.
repeat Repeat a command a desired number of times.
go Jump to address given.
go_boot Jump to Boot system in Flash
go_app Checksums the application area in Flash and if
OK, jumps to it; otherwise jumps to the Boot
system.
move_traverse Allows moving traverse to a specific position. Must
initialise via Diagnostics first, see Section 6.9.2.

Table 6.3 SCSI monitor commands
COMMAND FUNCTION
test_unit_rdy Monitor test unit ready
start Disk motor on command
stop Disk motor off command
capacity Sets default block size
inquiry Monitor inquiry command
disk_read Read disk command
disk_write Write to disk command
mode_sense Gets requested mode sense page
data.
mode_select Sends mode sense pages to disk.
reassign_block <blk No> Reassigns a bad block on disk.
Table 6.4 Test pattern generation commands
COMMAND FUNCTION
im_params Display/edit image size parameters.
ptn_params Display/edit test pattern parameters.
sel_patn Select test pattern type.
scan Perform a test pattern scan using parameters
set up.
test_strips Perform a test pattern scan, but optics and
traverse not initialised.
op_setup Test optics set-up
focus_strips Focus start and end position or number of
strips
get_focus_posn Get strip focus position
set_spinner_rpm Set spinner rpm
duart_timer Test duart timer
nvram_disk_dump NVRAM disk dump
nvram_read_disk Write data previously written to disk into
NVRAM.
nvram_write_disk Dump contents of the NVRAM to disk.

6.7 Introducing the Diagnostics Menus

This section describes all the tests and utility functions available
from the Celix Diagnostics Top Level menu and gives
descriptions of the tests.
Celix Diagnostics - Gemini V2 Rel V01,00 Mon, 17 Jul 95. 15:49

PROGRAM TITLE TOP LEVEL MENU
MENU TITLE Elec -> S
Mech-> S
COMMAND GROUP Optical-> S
AVAILABLE Comms-> S
PowerOn-> S
Utils->
PROMPT
TOP LEVEL MENU>_
6.7.1 Diagnostics Modules (Top Level)

Note: If a SPARCstation RIP server is used with the Celix 4000 it
must be disabled before entering the Celix Diagnostic
menus. If it is not, then conflicts could occur, leading to
diagnostic failures.
DIAGNOSTICS ENTRY POINT
ELECTRONICS MECHANICS OPTICS COMMS POWER ON UTILITIES

Electronics
This module provides the tests and utilities to initialize, check and
verify the recorder electronics. The Electronics diagnostics are
described in Section 6.8.
Mechanical
This module provides the tests and utilities to set up the
mechanics and test the operation of the media handling and
scanning system. The Mechanics diagnostics are described in
Section 6.9.
Optics
This module allows the interface to the optics system to be tested
and checks the correct operation of the individual optical
components. The Optics diagnostics are described in
Section 6.10.
Comms
This module requests the status of the Film Processor interface
and displays the results. The Comms diagnostics are described in
Section 6.11.
Power On
This module allows the user to select individual Power-On tests.
See Section 6.12.
Utilities
The Utilities menu provides access to disk utilities and the error
log and also allows non-volatile parameters to be changed. The
Utilities diagnostics are described in Section 6.13.
6.7.2 Test Codes and Functional Blocks

When a test is performed with Verbose selected, a code is
displayed to identify the location of the test in the diagnostics
tree. When performing a soak test from a high level it provides a
quick identification of any tests which have failed. The code also
includes an alphabetic prefix to identify the hardware that has
been tested.

A-1.07:0142
ALPHABETIC CODE IDENTIFYING NUMERIC CODE IDENTIFYING

THE HARDWARE WHERE THE THE LOCATION IN THE
TEST WAS PERFORMED. THE DIAGNOSTICS TREE
CODES USED ARE AS FOLLOWS:
A : SYSTEM BOARD I : OPTICS MODULE

B : MOTION CONTROL BOARD J : FILM INPUT
C : INTERNAL SCSI DISC K : FILM OUTPUT
D : KEY PAD (LCD AND MMI L : BAFFLE
BUTTONS) M : PUNCH
E : TRAVERSE MODULE N : FANS
F : SPINNER MODULE O : ALL ELECTRONICS (SYSTEM
G : PSU 42 VOLTS BOARD, MOTION CONTROL
H : PSU 5 VOLTS BOARD AND INPUT/OUTPUT)
The numeric code provides a guide to the location of a function in

the diagnostics tree. The first number indicates to top level menu
of the tree. Subsequent numbers indicate successive lower level
menus. The top item of each menu is numbered 0, the next item, 1
etc. In the example above the number identifies the TempRead
function obtained from the path:
Electron (0) - CPU (1) - TSensor (4) - TempRead (2).

6.8 Electronics Menu

This menu tests two sub-systems: SDM (System) board and the
Motion Control board. Refer to Sections 4.4 and 4.6 for
background descriptions of how these PCBs function.
Figure 6.10 ELECTRONICS menu
This menu provides all the tests and utilities required to initialise,
test and verify the recorder electronics for the:
• SDM (System) board and associated interfaces
• Motion Control board circuitry.
Because of the complexity of the SDM board tests, it is
recommended that they are run as soak (SOE) tests with Rlog
enabled (see Section 6.13.2). This will ensure the isolation of any
SDM board failures.
6.8.1 SDM (System) Board External Tests

See Figure 6.11 and Figure 6.12 .

Figure 6.11 Sys_Brd menu
1 2 3 4 5 6 LEVELS
Electron
Sys_Brd (Table 6.5)
DPath
Access *
Ints *
DRAM *
Ex-SCSI (Table 6.6)
Out
In
In-SCSI (Table 6.7)
Disk
DMA_Flush
Script
LpBack
Comp * * Lower level functions
Decomp * are available but are of
limited use in the field.
DataPth *
Serial *
LpBack *
Figure 6.12 Electronics menu tree: System board

1 2 3 4 5 6 LEVELS
CPU (Table 6.8)

XDuart *
NVRAM *
RTC (Table 6.9)
InitClock
SetClock
Date
TestClock
CAN Bus (Table 6.10)
CC_Init
SpinInit
Loopback
SpinRam
DelayTest
ReadStat1
TSensor(Table 6.11)
InitTSens
SetTLims
TempRead
TestTS
Env (Table 6.12)
12Volt
15Volt
15NVolt
5Volt
SFuse
PowerOn** (Table 6.32)
Splnts
Conten
Spin_init
* Lower level functions are available but are not of use in the field.
** These functions are also accessible from the top-level PowerOn
menu
Figure 6.12 Continued
If you select Sys_Brd from the command line, a sub-menu offers

the following options:

Data Path Tests: this provides a third-level submenu that tests

the image data path functions of the SDM board. Each option has
a further sub-menu of tests:
• Data Path access
• Data Path interrupt electronics
• Buffer (DRAM) memory
• External SCSI
• Internal SCSI
• Data Compression
• Data Decompression
• Data Path data bus
• Serialiser
• SCSI Loopback.
CPU: this provides a further sub-menu which tests the majority of
the Control section of the SDM board to include:
• External RS232 interfaces (DUARTS)
• NVRAM - this test is non-destructive.
• Real-Time Clock (RTC) - various options for setting and
displaying RTC.
• Temperature sensor options for setting, displaying and testing
the sensor on the SDM board.
Environmental: this provides a check for the PSU voltages to the
SDM board to include:
• 12 V dc
• 15 V dc
• –12 V dc
• 5 V dc
• Fuse 2 on SDM for sensor on 5 V supply.

Power On Tests: these test the SDM board in simulated

power-up conditions and look for:
• Generation of spurious interrupts.
• Data Contention - this tests the simultaneous compression,
decompression and disk access DMAs to Buffer memory.
Table 6.5 SDM board tests (Sys_Brd) - level 3
Test Description Soak?
DPath Data Path Tests (See Table 6.6) Yes

CPU CPU Tests (See Table 6.8) Yes
Env Environmental Tests (See Table 6.12) Yes
PowerOn Power On Tests (See Table 6.13) Yes
Data Path (DPath) Tests
Figure 6.13 Dpath menu

Table 6.6 External SCSI DMA tests (Ex-SCSI) - level 4
Out DMA Out External SCSI Tests Yes

In DMA Internal SCSI Tests Yes
Table 6.7 Internal SCSI Interrupt tests (In-SCSI) - level 5
C–FIFO C–FIFO Interrrupt Test Yes

D–FIFO D–FIFO InterruptTest Yes
P–FIFO P–FIFO InterruptTest Yes
Ex–SCSI Ext SCSI Interrupt Test Yes
In–SCSIO Internal SCSI Interrupt Test Yes
Central Processor Unit Tests (CPU)

An outline of these tests are shown in Figure 6.14 and Table 6.8.
Figure 6.14 CPU menu

Table 6.8 CPU tests (CPU) - level 4
XDuart External Duart Tests Yes

NVRAM Non-volatile RAM Tests Yes
RTC RTC Tests (See Table 6.9) Yes
CAN_Bus CAN Bus Tests (See Table 6.10) Yes
TSensor Temperature Sensor Tests (See Table 6.11) Yes
Table 6.9 RTC tests (RTC) - level 5
InitClock Real-Time Clock Initialise Test No

SetClock Set Date and Time No
Date Display Date and Time No
TestClock Real-Time Clock Test Yes
Table 6.10 CAN Bus tests (CAN Bus) - level 5
CC_Init CAN Controller Yes

SpinInit System Board CAN IO Test Yes
Loopback System Board CAN IO Test Yes
SpinRam Spinner Board RAM test Yes
DelayTest Spinner Board delay test Yes
ReadStat1 Spinner Board status test No
Table 6.11 Temperature Sensor tests (TSensor) - level 5
InitTSens Temperature Sensor Init No

SetTLims Set Temperature Limits No
TempRead Display Temperature No
TestTS Test Temperature Sensor Yes

Environmental Checks (Env)
Figure 6.15 Enviroment menu
Table 6.12 Environmental tests (Env) - level 4
12Volt 12 Volt Power Test Yes

15NVolt –5 Volt Power Test Yes
SFuse Sensor Fuse Test (Fuse FS3 on SDM Board) Yes

Power On Tests
Table 6.13 Power On tests (PowerOn) - level 4
Conten Contention Test Yes

6.8.2 Motion Control Board Test Description

1 2 3 4 5 6 LEVELS
Electron
MCB (Table 6.14)

* Lower level functions
Access * are available but are of
SenInits * limited use in the field.
Environ (Table 6.15)
Temp (Table 6.16)
HSink_1
HSink_2
Volt (Table 6.17)
42Volt
24Volt
5Volt
Fuse (Table 6.18)
OFuses
FFuses
TOFuses (Table 6.19)
Focus
Aperture
Illum
Shutter
Opto5V
5VOptics
12Optics
m12vOptic
TFFuses (Table 6.20)
Carriage
FOutput
Guill
FLoad
Spare
Punch
DcMotor
Solenoids
MM15v
Figure 6.16 Electronics menu tree: Motion Control board

1 2 3 4 5 6 LEVELS
ILocks5v
Motors
V_Ref *
Figure 6.17 MCB Board Tests
Table 6.14 Motion Control Board tests (MCB) - level 3
Access Register Access Tests No

SenInits Sensor Interrupt Tests Yes
Env Environmental Tests (Table 6.15) Yes
V_Ref Voltage Reference Tests Yes

Environmental Tests (Environ)
Figure 6.18 Environ Tests
Table 6.15 Environmental tests (Environ) - level 4
Temp MCB Temperature Tests (Table 6.16) Yes

Volt MCB Voltage Tests (Table 6.17) Yes
Fuse MCB and I/O Board Fuse Tests (Table 6.18) Yes
Table 6.16 MCB temperature tests (Temp) - level 5
HSink_1 MCB Heatsink 1 Temperature Test Yes

HSink_2 MCB Heatsink 2 Temperature Test Yes

Table 6.17 MCB voltage test (Volt) - level 5

Table 6.18 MCB and I/O board fuse tests (Fuse) - level 5

OFuses Optics Fuse Status No
FFuses Film Fuse Status No
TOFuses Optics Fuse Tests (Table 6.19) Yes
TFFuses Film Fuse Tests (Table 6.20) Yes
Motors Optics Motors Status No
Note: MCB fuses are not moveable. A blown fuse usually

indicates a damaged integrated circuit.
Table 6.19 Optics Fuse tests (TOFuse) - level 6

Focus Focus Fuse Test (FS6 on MCB) Yes
Aperture Aperture Fuse Test (FS7 on MCB) Yes
Illum Illumination Fuse Test (FS4 on MCB) Yes
Shutter Shutter Fuse Test (FS12 on MCB) Yes
Opto5V Opto-Electronic 5V Fuse Test (FS4 on I/O panel) Yes
5VOptics 5V Optics Fuse Test (FS9 on I/O panel) Yes
12Optics 12V Optics Fuse Test (FS2 on I/O panel) Yes
m12vOptic -12V Optics Fuse Test (FS5 on I/O panel) Yes

Table 6.20 Film Fuse tests (TFFuse) - level 6
Carriage Carriage Fuse Test (FS10 on MCB) Yes

FOutput Film Output Fuse Test (FS9 on MCB) Yes
Guill Guillotine Fuse Test (FS11 on MCB) Yes
FLoad Film Load Fuse Test (FS5 on MCB) Yes
Spare Spare Fuse Test (FS3 on MCB) Yes
Punch Punch Fuse Test (FS2 on MCB, unused) Yes
DcMotor DC Motor Fuse Test (FS1 on MCB) Yes
Solenoids Solenoids Fuse Test (FS8 on MCB) Yes
MMI5v LCD 5V Fuse Test (FS7 on I/O panel) Yes
ILocks12v Interlocks Fuse Test (FS8 on I/O panel) Yes

6.9 Mechanics Menu

This menu provides tests and utilities to enable fault diagnosis of
the MCB Solenoids, Motor drivers and DSP Traverse circuits.
1 2 3 4 5 6 LEVELS
Mechanics (Table 6.21)
Sols (Table 6.22)
Init
OnOff
Sensors
ILocks
G_Trav (Table 6.23)
Comms
InitDSP
ShState
ShPos
ClLog
ShLog
Motor (Table 6.24)
Init
SetMotor
GetMotor
Move
OffHome
Limit
ShPos
ShCond
ConvMove
Punch
RevPunch
Figure 6.19 Mechanics menu tree

Figure 6.20 MECHANICS menu terminal window
Table 6.21 Mechanical tests (Mechanics) - level 2
Sols Solenoid Tests (Table 6.22) Yes

G_Trav Traverse Tests (Table 6.23) Yes
Motor Motordriver commands (Table 6.24) Yes

6.9.1 Solenoids (Sols)
Figure 6.21 Solenoids menu
These are a set of diagnostics utilities for fault diagnosis of the

Motion Control board, Solenoid drivers and Sensors.
Table 6.22 Solenoid tests (Sols) - level 3
Init Sets solenoids to off (un-energised state) No

OnOff Allows Solenoids to be Switched On/Off to Test No
Sensors Sensors Status Display No
ILocks Interlock and Cable Status Display No
Initialise (Init)
You will need to intialize the solenoids to OFF before checking
the state of the sensors or toggling the solenoids ON/OFF.

OnOff
SENSORS AND SOLENOIDS

~~~~~~~~~~~~~~~~~~~~~~~~
Illumination Wedge SM Home . . . . . . . . . . . N | N . . . . . . . . . . .. . . . . . .. . . Punch Die In 1
Focus SM Home . . . . . . . . . . . . . . . . . . . . . . Y | N . . . . . . . . . . . . . . .. .. . . . Punch Die In 2
Aperture SM Home . . . . . . . . . . . . . . . . . . . . Y | N. . . . . . . . . . . .. . . . . . . Drum Vacuum OK
Spinner Fan On . . . . . . . . . . . . . . . . . . . . . . . Y | N . . . . . . . . . . . . . . . . System Vacuum OK
Film at Input Film Sensor . . . . . . . . . . . . . . . N | N . . .. .. Illumination Wedge at Home Limit
Film Conformed . . . . . . . . . . . . . . . . . . . . . . . N | N . . . .. . . . Illumination Wedge at Far Limit
Lazy Loop Sensor . . . . . . . . . . . . . . . . . . . . . N | N . .. . . . . . .. . . . . . . . Focus at Home Limit
Film at Film Punch . . . . . . . . . . . . . . . . . . . . . Y | N . .. . . . .. . . . . . . . . . . . Focus at Far Limit
Film in Output Belts . . . . . . . . . . . . . . . . . . . . N | N . .. . . . . .. . . . . . . Aperture at Home Limit
Film at Processor . . . . . . . . . . . . . . . . . . . . . . N N . .. . . . . . . . . .. . . . . Aperture at Far Limit
Film at Supply Cassette Drop Sensor . . . . N Y . .. . . . . . . . . .. .Supply Cassette Encoder
Guillotine at Left Limit . . . . . . . . . . . . . . . . . . N N . .. . . . . . . . . .. . . Guillotine at Right Limit
A- Laser Shutter D- Drum Vac 510mm G- Mix Fan Pwr J- Compress Pwr
B- Supply Cass Drive E– Drum Vac 640mm H- Mix fan Brake K- Spinner fan
C- Drum Vac 356mm F- Drum Vac 760mm I- Vac Pump Pwr L- 7Thou Sensor Pwr
[ ’ - ’ = off, ’ + ’ = on ] Choose a solenoid to toggle [ A - X or Z to quit ] -
Figure 6.22 Sensors and Solenoids panel
The window obtained from the Solenoid OnOff option is shown

in Figure 6.22 below. It is divided into two parts:
• Sensors: allows you to check the operability of the sensors
and their associated solenoids mapped on the panel. Each
sensor is shown as (Y/N) indicating it’s state (True/Active =
Y and False/Inactive = N).
• Solenoids: solenoids can be set as [+] or [–], indicating ON or
OFF respectively.

Sensors
The Sensors Display panel shows the dynamic state of the sensors
after Init has been selected.
SENSORS DISPLAY
~~~~~~~~~~~~~~~~~
Illumination Wedge SM Home . . . . . . . . . . . N | N . . . . . . . . . . .. . . . . . . . . Punch Die In 1
Focus SM Home . . . . . . . . . . . . . . . . . . . . . . Y | N . . . . . . . . . . . . . . .. . . . . Punch Die In 2
Aperture SM Home . . . . . . . . . . . . . . . . . . . . Y | N. . . . . . . . . . ... . . . . . Drum Vacuum OK
Spinner Fan On . . . . . . . . . . . . . . . . . . . . . . . Y | N . . . . . . . . .. . . . . . . System Vacuum OK
Film at Input Film Sensor . . . . . . . . . . . . . . . N | N . . . . Illumination Wedge at Home Limit
Film Conformed . . . . . . . . . . . . . . . . . . . . . . . N | N . . . . . . . Illumination Wedge at Far Limit
Lazy Loop Sensor . . . . . . . . . . . . . . . . . . . . . N | N . . . . . . . .. . . . . . . . Focus at Home Limit
Film at Film Punch . . . . . . . . . . . . . . . . . . . . . Y | N . . . . . .. . . . . . . . . . . . Focus at Far Limit
Film at Processor . . . . . . . . . . . . . . . . . . . . . . N | N . . . . . . .. . . . . . . Aperture at Home Limit
Film at Supply Cassette Drop Sensor . . . . N | N . . . . . . . . . . .. . . . . Aperture at Far Limit
Guillotine at Left Limit . . . . . . . . . . . . . . . . . . N |
Guillotine at Right Limit . . . . . . . . . . . . . . . . . N |
[ ’ - ’ = off, ’ + ’ = on ] Choose a solenoid to toggle [ A - X or Z to quit ] -
Figure 6.23 Sensors Display panel
Interlocks Status (ILocks)

See Figure 6.24.
This displays a list of the recorder interlocks and their current
status (Closed/Open). It also shows the status (Connected/Not
Connected) of the motor, solenoid and sensor cables.

INTERLOCKS AND CABLES DISPLAY

~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~
Left Cover Interlock . . . . . . . . . . . . . . . . . . . . Closed
Right Cover Interlock . . . . . . . . . . . . . . . . . . Closed
Output Tray Interlock . . . . . . . . . . . . . . . . . . . Closed
Back Cover Interlock . . . . . . . . . . . . . . . . . . . Closed
Front Cover Interlock . . . . . . . . . . . . . . . . . . Closed
Cable 7 Motor Cable . . . . . . . . . . . . . . . . . . . Connected

Cable 8 Film Handling Sensors (rear) . . . . Connected
Cable 9 Film Handling Sensors (rear) . . . . Connected
Cable 10 Solenoids . . . . . . . . . . . . . . . . . . . . Connected
Cable 11 Optics Motors Umbilical B . . . . . . Connected
Cable 12 Optical Sensors Umbilical A . . . . Connected
Cable 21 Power Tray . . . . . . . . . . . . . . . . . . Not Connected
Cable 27 MMI Interface . . . . . . . . . . . . . . . . Not Connected
Cable 31 Internal Motor . . . . . . . . . . . . . . . . Not Connected
Type X to quit – |
Figure 6.24 Interlocks and Cable

6.9.2 Traverse (G_Traverse)
Figure 6.25 G_Traverse menu
Table 6.23 Traverse tests (G_Trav) - level 3
Comms DSP Comms Test Yes

InitDSP Reset DSP No
ShState Displays DSP and Traverse Status No
ShPos Displays Current Traverse Position No
ClLog Clears DSP Log No
Move Move Traverse No
ShLog Displays DSP Log No
Comms
This test checks the DSP to SDM communications using a
message echo. Make sure the DSP is initialised first.

InitDSP
This resets the DSP board and conducts an initialisation of the
traverse, logging all error messages.
ShState
Indicates the state of the traverse - for example, ‘quiescent’.
ShPos
Displays the position of the traverse (Optics Carriage) from the
centre datum where the right edge of the centre vane is the 0 mm
position, see Section 4.15.8. Negative values are displayed as left
of the datum.
ClLog
Clears the DSP log.
Move
Moves the traverse (Optics Carriage) a number of mm set as a
parameter (for example, move 50). A negative distance is
towards Home (if the carrriage is located to the right-hand end of
Home).
ShLog
Displays the contents of the DSP log in scroll-through format.
The log is limited to 501 entries; the earliest entries are
overwritten when the log is full. Commands available for reading
the log are:

b - sets the log backwards
f - sets the log forwards
cr - step 1 line
sp - scroll.
6.9.3 Motor
Use the Motor option to run all the motor commands with the
motor distance specified in millimetres. Enter the command, and
parameter (if it applies), to execute a change of motor state.
Table 6.24 Motor commands (Motor) - level 3
Init Initialises Motion Control Board* Yes

SetMotor Set the current motor (Illumination, Focus,
Aperture, Carriage, Output, Guillotine or Input)
to move Yes
GetMotor Displays the current motor in use Yes
Move Move the current motor a specified number of
steps in a specified direction at a specified rate No
OffHome Homes the motor and leaves it at a specified
signed offset from home. No
Limit Move motor to a limit sensor No
ShPos Shows the current position of the motor No
ShCond Show the current condition of the motor No
ConvMove Move the conveyor (DC) motor No
Punch Operate punch in/out normally Yes
RevPunch Operate punch in/out reversed Yes
Commands in Table 6.24 are implemented as follows:

• Init: this initialises the MCB, which needs to be done before
the first motor command is issued. A warning is given if this
command is not applied.

• SetMotor [motorname]: sets the current motor to the

[motorname] parameter. If the motorname is not entered, or
misspelt, then a message gives a complete list of motor names
for the system. Names can be abbreviated to the first two
letters, for example, setmotor gu sets the guillotine motor.
The current motor is the motor to which all subsequent
commands apply. Motors are named as follows:
– (il)lumination
– (zo)om
– (ou)put
– (gu)ullotine
– (in)put.
• GetMotor: gets the name of the current motor.
• Move [distance] [direction] [frequency]: this command
moves the current motor a specified distance at a specified
frequency. Default distances are in steps, unless millimetres
have been selected. Direction is either f for forward or b for
backwards; frequency is a Hertz value for driving the motor.
• Stop [mode]: stops the current motor from moving. Mode
specifies whether to leave on the holding amps (torque) to the
motor, and has the values of:
– 0: the default for the motor.
– 1: disables the holding torque.
– 2: enables the holding torque.
• OffHome [distance]: moves the current motor to a specified
distance from the Home sensor. The distance is in millimetres.
• Limit [direction]: moves the motor to the appropriate limit:
– f for forward
– b for backward.

CAUTION
If the carriage motor is selected,
ensure the latch solenoid is operated
from the solenoids On/Off menu
(Option D), see Figure 6.22. Failure
may cause damage to the motor,
carriage or track.
• ShPos: gives the distance of the motor referenced to Home,

or (if there is not a Home) then with respect to the back limit.
Distances are in steps or in millimetres.
• ShCond: shows the condition of the current motor.
• ConvMove: Moves the dc motor.
• Punch: operates the punch mechanism as a normal in/out.
• RevPunch: operates the punch mechanism as a reversed
in/out.

6.10 Optics Menu

1 2 3 4 5 6 LEVELS
Optics (Table 6.25)
Start-sp
Init
SenMov (Table 6.26)
illumin
aperture
focus
MovPos (Table 6.27)
illumin
aperture
focus
MotCal (Table 6.28)
illumin
aperture
focus
laser_set
set_ape
CalChk (Table 6.29)
illumin
aperture
focus
Shutter
Startstop
Stop_spin
MotMov
illumin
iris
set_iris
Figure 6.26 OPTICS menu tree
This menu allows parts of the SDM and MCB board and optics
system to be tested, and checks for the correct operation of
individual motors, sensors and components of the Spinner. It also
provides a facility for calibrating the optical components.

Table 6.25 Optics tests (Optics) - level 2
Start_sp Start the Spinner Yes

Init Initialise Motors Yes
SenMov Sensor Move Tests (See Table 6.26) Yes
MovPos Move Position and Check (See Table 6.27) Yes
MotCal Motor Calibration (See Table 6.28) Yes
CalChk Calibration and Check (See Table 6.29) Yes
Shutter Shutter Movement Test Yes
Startstop Stop Spinner Yes
Stop_spin Stop Spinner Yes
MotMov Moves the Motor as Iris Test (See Table 6.30) Yes
6.10.1 Start Spinner (Start_sp)

Starts the Spinner rotating to its normal speed of 30, 000 rpm.
6.10.2 Initialise Motors (Init)

Initialises the MCB and must be executed before the optics are
tested.
6.10.3 Sensor Motor Tests (SenMov)

This utility finds (a) the distance between the Limit sensors, and
(b) the distance from the back Limit Home position (in mm) for
the Illumination and Zoom Control motors.

Table 6.26 Sensor Move tests (SenMov) - level 3

illumin Sensor and Movement Test Yes
aperture Sensor and Movement Test Yes
focus Sensor and Movement Test Yes
6.10.4 Move and Position Check (MovPos)

Provides verification of the positional movement of selected
optics motors.
Table 6.27 Move and position tests (MovPos) - level 3

illumin Move and Position check Test Yes
aperture Move and Position check Test Yes
focus Move and Position check Test Yes
6.10.5 Motor Calibration (MotCal)

Runs a motor between Limits and reports the Limit positions
from Home (in mm). It also updates the NVRAM with the
number of steps for use by the CalChk tests.
• laser_set: a utility to turn on the laser, and with the shutter
closed (see Shutter below) the nominal laser power is read.

CAUTION
Laser_set allows laser light to enter
the optical system. Cover the Baffle
gap to prevent laser light from
exiting.
• Set_ape: a utility to set the position of the aperture Home

sensor and give an accurate positioning of the aperture plate.
Table 6.28 Motor calibration tests (MotCal) - level 3
illumin Note Sensor Position No

aperture Note Sensor Position No
focus Note Sensor Position No
laser_set Utility to turn on laser and read laser power No
set_ape Sets Position of Aperture Home Sensor No
6.10.6 Calibrate and Check (CalChk)

Runs a selected motor twenty times between Limits and checks
the Limit position repeatability within 1% accuracy. Errors are
reported if the error exceeds 1%.
Table 6.29 Calibration check (CalChk) - level 3

illumin Check Calibration of End Positions Yes
aperture Check Calibration of End Positions Yes
focus Check Calibration of End Positions Yes

6.10.7 Shutter
Checks the operation of the laser Shutter solenoid. Since there is
not an electronic feedback for this device, it is checked by
listening for the familiar solenoid operating sound.
6.10.8 Stop Spinner (Stop_spin)

Stops the Spinner rotating.
WARNING
Wait five minutes for the Spinner to
cease rotating.
6.10.9 MotMov
Checks the operation of the motor by moving the iris. This test is
provided for possible future development.
Table 6.30 Motor move tests (MotMov) - level 3
illumin Move the illumin No

iris Resize the iris No
set_iris Utility to set up the iris No
Illum(ation)
Run as a soak test for checking the illumination mechanism on
the Optics Carriage.

Iris
Run as a soak test for checking the iris mechanism on the Optics
Carriage.
Set_iris
Figure 6.27 Set_iris display
This utility runs as a sequence of instructions for moving the iris

sensor vane (or plate) to its mechanical end stop position for
referencing the iris Home position, see Figure 6.27.

6.11 Comms Menu

1 2 3 4 5 6 LEVELS
Comms
FilmProc
Figure 6.28 Comms menu tree
When selected this utility first checks that the NVRAM has been
set up to indicate whether or not an intelligent media processor is
connected. If it has not, a message appears indicating this. Next, a
status request is made to the media processor. Possible responses
and explanations are listed in Table 6.31:
Table 6.31 Media processor status messages
Message Meaning
Ready The processor is O.K. and not active.

Service Required The processor is O.K. but some form of service is required.
Busy The processor is O.K. and processing media.
Busy - Service Required The processor is O.K. and processing media, but some form of service is
required.
Warming Up The processor chemicals are being heated to operating temperature.
Film Not Seen The processor was asked to process media but failed to sense the media
within 10 seconds.
Unhealthy There is a fault.
Comms Failed The processor is reporting a communications failure. (It is persistently
detecting parity or frame errors.)
Error In Received Word The processor is reporting that it did not understand the status request
(probably due to a communications problem).
DUART Comms Fault The recorder detected a parity or frame error in the response from the
processor.
Not Responding No response was received from the processor within approximately
one second of the status request.

6.12 PowerOn Menu

1 2 3 4 5 6 LEVELS
Power On (Table 6.32)
Spints
Conten
Spin_init
Figure 6.29 Power On menu tree
Table 6.32 Power On tests (PowerOn) - level 2
Splnts Checks for Stuck Interrupts Yes

Conten Contention Test Yes
Spin_init Checks for New Spinner Board. If a New Board
is Found the Delay Generator Chip is Loaded
with a Zero Value. Yes
These functions are also accessible from the Electron Sys_Brd .

menus.
Figure 6.30 Power On Tests

6.13 Utilities Menu

This menu differs from the other options in that you can perform
tasks from the options which are available. These tasks are
summarized below:
1 2 3 4 5 6 LEVELS
Utilities (Table 6.33)
Disk (Table 6.34)
Inquiry
Defects
Format
Errlog (Table 6.35)
ramlog
NVPARAM (Table 6.36)
Init
NVEdit (Table 6.37)
MEdit (Table 6.38)
O1Editt (Table 6.39)
O2Edit (Table 6.40)
TEdit (Table 6.41)
SEdit (Table 6.42)
P30Edit (Table 6.43)
P20Edit (Table 6.44)
CSEdit (Table 6.45)
EEdit (Table 6.46)
FPEdit (Table 6.47)
ViewFilm
EditInst (Table 6.49)
StatsView (Table 6.50)
Film_Used_Mtr
Punch_Ops
Guill_Ops
Num_Loads
Num_Reloads
Num_Input_Retries
Num_Output_Retries
Figure 6.31 Utilities menu tree

1 2 3 4 5 6 LEVELS
Num_Rewinds
Num_Rewinds_Fail
Num_Drum_Vac_Fail
Time_on
TestPtn (Table 6.51)
SelPatn
Ptn
Image
Scan
Focus (Table 6.52)
Fdots (Table 6.53)
Type
Width
Coarse
Fine
Program
Show
Flines (Table 6.54)
Type
Width
Coarse
Fine
Program
Show
Wedge (Table 6.55)
Edit
Wedge
Show
Program
Date
SetSrvDte
Iris (Table 6.56)
Edit
Iris
Show
Program
Patn

Figure 6.32 UTILITIES menu terminal window
Instead of running tests and checks, this sub-menu performs a

number of useful tasks which are summarised in Figure 6.32 and
Table 6.33.
Table 6.33 Utilities menu (Utilities) -level 2
Disk System Board Disk Utilities (See Table 6.34) No

ErrLog Error Log (See Table 6.35) No
NVPARAM View and Edit Non-volatile Parameters
(See Table 6.36) No
TestPtn Test patterns (See Table 6.51) Yes
Focus Focus Strips (See Table 6.52) No
Wedge Wedge Strips (See Table 6.55) No
Date Display Time and Date No
SetSrvDte Set Date of Last Service No
Iris Calibrate Iris (See Table 6.56) No

6.13.1 Disk
Disk utilities allows you to interrogate the SDM board Hard disk
for information.
Figure 6.33 Disk utility
• Inquiry: shows manufacturer’s details and the SCSI ID of the

Hard disk.
• Defects: displays a list of defects found on the disk surface.
• Format: performs a check to establish the SCSI ID of the
disk. If the disk responds, it is formatted.
Table 6.34 Disk Utilities (Disk) - level 3
Inquiry Shows Disk SCSI Identity No

Defects Shows Grown Defects List No
Format Formats Disk No

CAUTION
Formatting the disk removes all
current data.
6.13.2 Error Log (Errlog)

Logged errors are stored in RAM when Rlog is enabled. Select
ramlog to display the latest list of error messages. Rlog on and
rlog off can be entered at any diagnostic prompt.
Table 6.35 Error Log (Errlog) - level 3
ramlog Messages output to terminal No
6.13.3 NVRAM Parameters (NVPARAM)
Figure 6.34 NVRAM

See also Section 11.3.
Table 6.36 Non-volatile Parameters (NVPARAM) - level 3
Init Initialise Non-volatile RAM (SEE CAUTION) No

NVEdit Edit NVRAM Database (See Table 6.37) No
ViewFilm View Film Database (See Table 6.48) No
EditInst Edit installation Values (See Table 6.49) No
StatsView View Machine Statistics No
Init (Initialise NVRAM)

The NVRAM initialise utility allows you to selectively initialise
each database.
CAUTION
If you perform an initialisation of
the non-volatile RAM your current
values will be overwritten by
defaults.
NVEdit
The NVRAM Editor allows you to select and modify an NVRAM
parameter. See Table 6.37.

Figure 6.35 NVRAM Editor
Table 6.37 Edit Non-volatile RAM (NVEdit) - level 4
MEdit Edit Med D’base & SCSI Pmtrs (See Table 6.38) No
O1Edit Edit Optics Database 1 (See Table 6.39) No
O2Edit Edit Optics Database 2 (See Table 6.40) No
TEdit Edit Traverse Database (See Table 6.41) No
SEdit Edit Spinner Database (See Table 6.42) No
P30Edit Edit Phase Loop 30k Data (See Table 6.43) No
P20Edit Edit Phase Loop 20k Data (See Table 6.44) No
CSEdit Edit CountScale Database (See Table 6.45) No
EEdit Edit Environmental Database (See Table 6.46) No
FPEdit Film Processor Database (See Table 6.47) No
Each of these options provides access to a set of non-volatile

parameters. The editable parameters are described in Table 6.38
to Table 6.47.
Where a hexadecimal number is used the values are prefixed
with ‘0x’. Zero in Hexadecimal is entered as ‘00’.

CAUTION
The numerical values in the
following tables were correct at the
time of this release but are subject to
change.
Note: Use the sup>dnv option, see Section 6.14.2, to list the
numerical values.
Table 6.38 Media Database and SCSI Parameters (MEdit) - level 5
Option Description Value
A Supply Cassette A Identity

B Supply Cassette B Identity
C Supply Cassette A Media Thickness 100
D Supply Cassette B Media Thickness
E Supply Cassette A Media Type
F Supply Cassette B Media Type
G Supply Cassette A Media Width 660
H Supply Cassette B Media Width
I Supply Cassette A Media Length 60000
J Supply Cassette B Media Length
K Supply Cassette B Drum Length
L Supply Cassette A Covers Eject Length
M Output Process Distribution
M SCSI Identity
On current models only one Input cassette is available; this is

Cassette A.

Table 6.39 Optics Database 1 Parameters (O1Edit) - level 5
A Aperture Position for 48 lines/mm Resolution 0/78/500

B Aperture Position for 72 lines/mm Resolution 0/228/500
C Aperture Position for 96 lines/mm Resolution 0/383/500
D Aperture Position for 144 lines/mm Resolution 65036/65416/65536
E Aperture Position for 192 lines/mm Resolution 65036/65416/65536
F Focus Position for 4 Thou Film 0/2600/10000
G Focus Position for 7 Thou Film 0/2600/10000
H Laser Diode on Reference 0/2560/0xfff
I Laser Diode on Threshold 0/1920/0xfff
J Illumination Position for 48 lines/mm Resolution 25
K Illumination Position for 72 lines/mm Resolution 74
L Illumination Position for 96 lines/mm Resolution 105
M Illumination Position for 144 lines/mm Resolution 142
N Illum. Posn for 192 lines/mm Res. 20K Spin Spd 172
O Illum. Posn for 192 lines/mm Res. 30K Spin Spd 155
P Laser Diode On
Q Laser LF Reference
The values entered as xxx/xxx/xxx in Table 6.39 are

minimum/default/maximum. Note that 65416 = -120.
Table 6.40 Optics Database 2 Parameters (O2Edit) - level 5
A Aperture Plate to Base Reference 0/72/200

B Aperture Distance between Limits 0/600/800
C Illumination Limit Distance 0/300/500
D Focus Limit Distance 0/5000/12000
E Aperture Back Home Distance 0/65386/65136
E Illumination Back Home Distance 0/65476/65336
F Focus Back Home Distance 0/250/1000
H Optics Base Mode

minimum/default/maximum.

Note: Note that 65386 = -150 and 65476 = -60.
CAUTION
These parameters are factory-set
and should not be altered.
Table 6.41 Traverse Parameters (TEdit) - level 5
A Vertical Offset 48 lines/mm Resolution 0xc00

B Vertical Offset 72 lines/mm Resolution 0x900
C Vertical Offset 96 lines/mm Resolution 0xc00
D Vertical Offset 144 lines/mm Resolution 0x900
E Vertical Offset 192 lines/mm Resolution 0xc00
F Horizontal Trim 0
G Scan Cycles 0
Table 6.42 Spinner Parameters (SEdit) - level 5
A Fast Spinner Rate 48 lines/mm Resolution 30000

B Slow Spinner Rate 48 lines/mm Resolution 20000
C Fast Spinner Rate 72 lines/mm Resolution 30000
D Slow Spinner Rate 72 lines/mm Resolution 20000
E Fast Spinner Rate 96 lines/mm Resolution 30000
F Slow Spinner Rate 96 lines/mm Resolution 20000
G Fast Spinner Rate 144 lines/mm Resolution 30000
H Slow Spinner Rate 144 lines/mm Resolution 20000
I Fast Spinner Rate 192 lines/mm Resolution 30000
J Slow Spinner Rate 192 lines/mm Resolution 20000

Table 6.43 Phase Lock Loop Parameters for 30K Spin Speed
(P30Edit) - level 5
A Phase Lock Loop A, 48 lines/mm Resolution 0

B Phase Lock Loop M, 48 lines/mm Resolution 0x39
C Phase Lock Loop R, 48 lines/mm Resolution 3
D Phase Lock Loop A, 72 lines/mm Resolution 0xf
E Phase Lock Loop M, 72 lines/mm Resolution 0x2a
F Phase Lock Loop R, 72 lines/mm Resolution 3
G Phase Lock Loop A, 96 lines/mm Resolution 0
H Phase Lock Loop M, 96 lines/mm Resolution 0x39
I Phase Lock Loop R, 96 lines/mm Resolution 3
J Phase Lock Loop A, 144 lines/mm Resolution 0xf
K Phase Lock Loop M, 144 lines/mm Resolution 0x2a
L Phase Lock Loop R, 144 lines/mm Resolution 3
M Phase Lock Loop A, 192 lines/mm Resolution 0
N Phase Lock Loop M, 192 lines/mm Resolution 0x39
O Phase Lock Loop R, 192 lines/mm Resolution 3
The input frequency, F, is obtained from the formula:

F = (20 x M) + A
R
where A, M and R are dividers. A and M are entered directly into

NVPARAM but R is twice the value of the entry value, r, in
NVPARAM. Halve the calculated value of R and enter.

Table 6.44 Phase Lock Loop Parameters for 20K Spin Speed
(P20Edit) - level 5
A Phase Lock Loop A, 48 lines/mm Resolution 0

B Phase Lock Loop M, 48 lines/mm Resolution 0x39
C Phase Lock Loop R, 48 lines/mm Resolution 3
D Phase Lock Loop A, 72 lines/mm Resolution 0xf
E Phase Lock Loop M, 72 lines/mm Resolution 0x2a
F Phase Lock Loop R, 72 lines/mm Resolution 3
G Phase Lock Loop A, 96 lines/mm Resolution 0
H Phase Lock Loop M, 96 lines/mm Resolution 0x39
I Phase Lock Loop R, 96 lines/mm Resolution 3
J Phase Lock Loop A, 144 lines/mm Resolution 0xf
K Phase Lock Loop M, 144 lines/mm Resolution 0x2a
L Phase Lock Loop R, 144 lines/mm Resolution 3
M Phase Lock Loop A, 192 lines/mm Resolution 0
N Phase Lock Loop M, 192 lines/mm Resolution 0x39
O Phase Lock Loop R, 192 lines/mm Resolution 3
Table 6.45 Counter and Scaler Parameters (CSEdit) - level 5
A Pixel Count, 48 lines/mm 0x42ca

B Pixel Scale 48 lines/mm 4
C Pixel Count, 72 lines/mm 0x3217
D Pixel Scale, 72 lines/mm 2
E Pixel Count, 96 lines/mm 0x42ca
F Pixel Scale, 96 lines/mm 2
G Pixel Count, 144 lines/mm 0x3217
H Pixel Scale, 144 lines/mm 1
I Pixel Count, 192 lines/mm 0x42ca
J Pixel Scale, 192 lines/mm 1

Table 6.46 Environmental Parameters (EEdit) - level 5
A Environmental Polling Interval 30/60/3600

B Over Temperature Timeout Interval 30/60*5/60*60
C Log Update Interval 1/5/100
D SDM Board, High Temperature Threshold 0/60/100
E SDM Board, Low Temperature Threshold 0/55/100
F Motion Control Board, High Temp. Threshold 0/70/100
G Laser Board, High Temperature Threshold 0/35/100
H Laser Board, Low Temperature Threshold 0/30/100
I Sup Expose Progress Time

minimum/default/maximum. All times are in seconds (60 x 5 =
5 mins. 60 x 60 = 60 mins).
Table 6.47 Film Processor Database (FPEdit) - level 5
Option Description
0 No Film Processor Fitted

2 Processor Fitted without Comms to the Recorder
3 Processor Fitted with Comms to the recorder
These options are accessed via the only FPEdit function. To

change this option see Section 6.14.2 (Set NVRAM Parameter),
and use the command:
sup> snv film_proc_sel [x]
where x = 0, 2 or 3.
See also Section 11.3.12.
View Film Database (ViewFilm)

View the film handling and error log.

Table 6.48 View Film Handling Parameters - level 4
A Output_SM 1
B Input-SM 1
C Guillotine_SM 1
D Fatal Error 1
E Film_Used_MS 1
F Film_Used_MTR 1
G Punch Operations 1
H Guillotine Operations 1
I SUCA Media Valid 1
J SUCB Media Valid 1
K Machine Fail 1
L Covers Opened 1
CAUTION
Any values greater than 1 for options
A, B or C could cause film handling
errors.
To check and reset, see Section 6.14.2 (Print NVRAM Parameter)

on the Supervisor submenu and enter the following:
sup> pnv *sm*
to display the values of options A, B and C. To reset, use the

command:
sup> snv [parameter name] 1
for any options showing 2 or a higher value.
Edit Installation (EditInst)

Recorders built before V1.04 Diagnostics software was
introduced do not have a spinner-fan operation detector. On these
units Option B must be switched off by setting its value to 2.

Table 6.49 Edit Installation Values (EditInst) - level 4
Option Description
A SCSI Identification Number

B Spinner Fan Detection Status. Enables/Disables detection.
View Recorder Statistics (StatsView)

This section lists all the recorder statistics.
Table 6.50 View Recorder Statistics (StatsView) - level 4
Film_Used_Mtr Media Used (Metres) No

Punch_Ops Number of Punch Operations No
Guill_Ops Number of Guillotine Operations No
Num_Loads Number of Media Loads No
Num_Reloads Number of Media Re-loads No
Num_Input_Retries Number of Media Input Retries No
Num_Output_Retries Number of Media Output Retries No
Num_Rewinds Number of Media Rewinds No
Num_Rewinds_Fail Number of Media Rewind Failures No
Num_Drum_Vac_Fail Number of Drum Vacuum Failures No
Time_on Time that Power Has Been On
(Seconds) No
6.13.4 Generate Test Pattern (TestPtn)

Options in this submenu allows you to expose and process test
outputs from a selection of patterns stored on the recorder.

Table 6.51 Test Patterns (Test Ptn) - level 3
SelPatn Select Pattern Type No

Ptn Edit Patern Parameters No
Image Edit Image Parameters No
Scan Output Test Pattern Yes
Select Pattern (SelPatn)

This option allows you to set the pattern type as one of the
following: Vertical lines, Grid, Dot, Black, Random and
Horizontal lines. The default is Vertical lines. Use [Spacebar] to
toggle between the pattern types.
Selected pattern type: vertical lines [default]
Press Return to set the pattern type.
Pattern (Patn)
Use this option to vary the size of the pattern as lines OFF and
ON.
Lines on = 1 (Default)
Lines off = 1 (Default)
Enter a new value for either one or both Lines and press Return.
Image
Use this option to vary the size and resolution of the test pattern.
The default values are:
image width (mm) = 762
line length (mm) = 990
hor start pos (mm) = 0
ver start pos (mm) = 0
resolution = 96

Scan
Selecting Scan starts to output a test pattern. If the recorder is
unable to output a tests pattern, the DSP will timeout and give a
‘Fail Report’.
generating vertical lines test patterns data
When the system is ready to start scanning, it asks:

Is film loaded? (y)
6.13.5 Focus
Table 6.52 Focus Strips (Focus) - level 3
Fdots Focus using dots procedures (See Table 6.53) No

Flines Focus using dots/lines proc. (See Table 6.54) No
Table 6.53 Focus Dots (Fdots) - level 4
Type Set Film Type No

Width Set Film Width No
Coarse Coarse Focus No
Fine Fine Focus No
Program Update NVRAM No
Show Show Focus Position No
Some of these utilities are used to set up the optics for focus, see
Section 8.3.2.

Table 6.54 Focus Lines (Flines) - level 4
Type Set Film Type No

Width Set Film Width No
Coarse Coarse Focus No
Fine Fine Focus No
Show Show Focus Position No
Some of these utilities are used to perform the Focus procedures,

see Section 8.3.2. Note that Coarse option in this table provides
an alternative access to the Coarse dots option in the Fdots
menu. It does not produce lines as may be expected.
6.13.6 Wedge
Figure 6.36 Wedge

Table 6.55 Wedge Strips (Wedge) - level 3
Edit Edit Wedge Parameters No

Wedge Output Strips at Incrementing Strip Posiitons No
Show Display Wedge Strip Positions No
Program Save Wedge Position of Specified Wedge Strip
to NVRAM No
Patn Select a pattern (See SelPatn above)
These utilities are used to perform the Wedge setup procedures

described in Section 8.3.1. Wedge is performed before the focus
procedures to ensure the correct density on film.
The wedge utility exposes strips at incrementing wedge
positions. If this facility is not available on the RIP user interface,
then apply these Wedge commands to calibrate the laser.
To expose a set of wedge strips or pattern, use the following
procedure:
1. Shutdown the RIP application. Use the following methods:
a) SPARCstation: enter the command, zap rdsrv, from the
terminal wndow.
b) PC: close down the application from Windows.
2. Expose the pattern or strips from Celix Diagnostics (or from
the ‘Pattern’ submenu on the Application Monitor).
3. Quit from the diagnostics mode.
4. Return to Application mode for the machine to rewind film.
5. Press Load Media.
6. Eject the media to the processor by pressing the Load Media
button.
Edit
Use Edit to modify the following wedge settings from their
default values:

wedge start posn = 100

wedge increment = 5
no strips = 20
film width (mm) = 762
resolution = 144
lines on = 1
lines off = 1
Wedge
This option generates the wedge test pattern data. See the section
above on how to expose a wedge test pattern.
Output illumination wedge strips [y] [Ret]
Twenty ‘Output Strips’ are exposed on a film with a message

displayed for each strip.

Show
Shows the strip numbers [1 to 20] and their wedge positions.
Strip No Wedge Posn
1 100
2 105
3 110
4 115
5 120
6 125
7 130
8 135
etc.
Program
Use Program to save the new wedge position to NVRAM.
Enter wedge strip no : 12
Saved wedge res on disk is 33
Write wedge posn 145 to NVRAM [y]
6.13.7 Display Date (Date)

Displays the local date and time set on the recorder. See Table 6.9
on the options to set the Real-Time Clock from the
Electronics/CPU menu.
The date is: Friday 17th August, 1998 18:00:54
6.13.8 Set Service Date (SetSrvDte)

Sets the date of the last service visit.
Set ”Last Serviced” date today – are you sure (y,n)?

6.13.9 Iris
This utility may be used for possible future development.
Table 6.56 Calibrate Iris (Iris) - level 3
Edit Edit Iris Parameters No

Iris Iris Calibration No
Show Display Iris Position No
Patn Select Pattern No

6.14 Application Monitor (Moon) Commands
CAUTION
Some of the Moon commands could
cause damage to the equipment if
used improperly. Only approved
engineers should attempt to use the
commands in this section.
Moon diagnostic commands are primarily for use by R&D and

for factory production testing. Some of the sub-menu options,
however, are still useful for the service engineer, and are
described in the following sections.
6.14.1 Menu System

The (Moon) prompt commands are displayed by a terminal
emulation window when the Applications Monitor program is
running. How to access to the Application system (and Monitor
program) is explained in Section 6.4. The type of terminal
window will depend on the RIP option.
More useful commands are listed in the following sub-menus
with a key reference to the explanatory section. Sub-menus
indicated as ‘not used’ are normally operated by R&D.
scsi - SCSI Handler Menu (not used).
(expo)se - Expose Handler Menu (not used).
(sup)er - Supervisor Handler Menu (see Section 6.14.2).
env - Environment Monitor Menu (not used).
log - Log Monitor Menu (see Section 6.14.3).
jqm - Job Queue Handler Menu (see Section 6.14.4).
(diag)s - Diagnostic Handler Menu (not used).

dnld - Download Handler menu (not used).
expc - Expose Control Menu (not used).
film - Film Handler Menu (see Section 6.14.5).
(opti)cs - Optics Handler Menu (see Section 6.14.6).
(disp)lay - Display Handler Menu (see Section 6.14.7).
(spin)ner - Spinner Handler Menu (see Section 6.14.8).
(tr)av - Traverse Menu (see Section 6.14.9).
evt - Event Processing Menu (see Section 6.14.10).
patt - Test Pattern Menu (see Section 6.14.11).
Navigating the Menu System

From the Moon> prompt (Main Menu), enter the submenu
command required, for example, the Supervisor menu:
Moon> sup
To move from one sub-menu to another, enter the new menu

name and the prompt changes to the new sub-menu.
You can exit from Application Monitor while in any sub-menu by
entering:
super> main
which returns you to the Moon> prompt.

Use the Help command at the sub-menu level for a list of the
options and their parameters.
6.14.2 Supervisor Handler Menu (Sup)

The Supervisor sub-menu has a number of useful commands that
allow you to:
• check the system status

• set media characteristics

• clear the machine fail flag in NVRAM
• display NVRAM parameters
• set NVRAM parameters
• print NVRAM parameters
• View log of film handling information.
Dump System Status (Command: ssd)

The command displays the system status store and gives a
summary of the current status of the recorder.
Parameters : none to be entered.
The system status store is accessible to the server via the SCSI
bus. It contains the fields shown in Figure 6.37.
ssd
Figure 6.37 System status dump (sysd)

Scanner Status
Expose 1 if scan in progress

CodeDnld 1 if code download active
ImageDnld 1 if image download active
FilmHandling 1 if media transport active
SCSIDiags 1 if SCSI diags active (currently not used)
OverTemp 1 if OverTemp warning active
CodeDnldFail 1 if code download failed
SetterFail 1 if ‘machine fail - press self test’ fault
TotalFail 1 if ‘machine fail - call engineer’ fault.
Media Option Flags
SUCAVal 1 if Supply Cass A option

SUCBVal 1 if Supply Cass B option
TUCVal 1 if Take-Up Cass option
TUCSel 1 if Take-Up Cass in use
SUCAMediaVal 1 if media info valid for Supply Cass A
SUCBMediaVal 1 if media info valid for Supply Cass B
MediaProcVal 1 if media processor option
MediaSecVal 1 if media processor in use.
SupplyCassA (Supply Cassette A Status)
Not In Use
Present Present and media information valid
Absent
Empty
Media Unknown Present, but media information invalid
Not Loaded.

MediaStatus (Media Transport Status)
Not Loaded
Fail (SUCA)
Fail (SUCB)
Fail (TUC)
Fail (Input)
Fail (Drum)
Fail (Output)
Fail (Punch)
Fail (Guillotine)
Fail (Drum Vac)
Fail (Uncleared Error)
Fail (Media Loose in Drum)
Fail (Lost Control of Media)
MediaProc (Media Processor Status)
Not In Use
Ready
Ready, Service Required
Warm Up
Comms Fail
Fail
Busy
Busy, Service Required

Job Queue Status
Qheld - 1 if queue held by workstation

command.
Qstop - Non-zero if queue stopped due to
recorder problem. Hex code indicates
reason.
QstopJobHeld - 1 if held job is at head of queue.
Cover Status
Opened 1 if media in drum is fogged due to covers

open
LHPan 1 if cover 1 open
RHPan 1 if cover 2 open
OPCov 1 if cover 3 open
RearPan 1 if cover 4 open
LHFdoor 1 if cover 5 open.
SpinStatus (Spinner Status)
Locked
Not Locked
Stopped
TravStatus (Traverse Status)
OK
Aborted
At Limit
Timeout
Home Fail
Position Error

Optics Status
LaserCurrMax 1 if laser current at maximum permissible

LaserCurrHi 1 if laser current close to max permissible
LaserTemp 1 if laser over temperature
CalReqd 1 if laser power calibration required.
Error Status
CassId
Length
Thickness
NumSheets
Type
Dump Media Status (command: mid)

mid command dumps media information. This is current or last
used media information. Media information may not be valid if
the cassette is empty or missing.
Cassette id cassette id
Length roll length (mm)
Width roll width width (mm)
Thickness film thickness (mm/1000):
4 thou = 100
7 thou = 170
NumSheets set to ‘1’
Type 1 = film, 2 = paper.
Parameters:
none to be entered - they are entered by the command mi.
Set Media Characteristics (Command: mi)

Command mi is used to set media information by manual entry.
Media info should normally be entered at the terminal. For

example:
miD1D60000D1117D100D1D1
Parameters:
CassID (1–9 normally)
Length (of roll) in (mm)
Width (of roll) in (mm)
Thickness - film (mm/1000):
4 thousand inch = 100
7 thousand inch = 170
Sheets (number) set to 1
MediaType (1 = film, 2 = paper).
Clear Machine Fail Flag (Command: cmf)

Command cmf clears the machine fail error code in NVRAM.
It is used to clear the Recorder Failure error condition from the
application software, see the Celix 4000 Recorder User’s Guide.
Error conditions of the Recorder Failure type are indicated by
the telephone icon. They signify that a non-operator recoverable
error such as a punch jam has been detected.
These errors are held in NVRAM and so cannot be recovered by
power cycling the machine. This is to prevent possible damage to
the machine by inhibiting operation until the fault has been
corrected. The machine must be reset after using this command.
Parameters: none to be entered.
Reset Machine (Command: reset)

The command resets the software and hardware.

Display NVRAM Contents (Command: dnv)

The command allows NVRAM parameters to be viewed as signed
decimal and hex values.
The offset address from the start of NVRAM is also displayed.
Each parameter uses 1, 2 or 4 bytes of storage.
Note that although displayed as signed decimal numbers, some
values may be treated as unsigned by the application software.
(The software used to display the values is unable to determine
whether values are signed or unsigned).
Set NVRAM Parameter (Command: snv)

Allows named NVRAM parameters to be set from the application
software. The NVRAM parameter name is that given by the dnv
command.
The machine may need to be reset after changing certain
parameters, since some are only loaded from NVRAM during
initialisation. No range checking is done.
CAUTION
Normally the Celix Diagnostics
Utilities menu is the preferred
method for setting NVRAM
parameters. Changing parameters
without knowing what the effects are
can cause major problems.
Parameters:
name - NVRAM parameter name string
value - decimal or hex is allowed.

Print NVRAM Parameter (Command: pnv)

Displays the NVRAM parameters; for example, pnv *guill* prints
all NVRAM parameters containing ‘guill’ for the guillotine,
where ‘*’ is used as a wildcard.
Parameters: parameter name.
6.14.3 Log Monitor Menu (Log)
Display Log (Command: dsl)

The event history log in Flash memory is downloaded. It contains
time/date stamped strings used to record error conditions detected
by the application software.
It also shows the time when the machine was reset and the
software version.
Clear Log (Command: csl)

The event history log in Flash memory is cleared. This needs to
be cleared when a new SDM board is fitted into a machine or if
new flash devices are installed.
For certain versions of software, it may be necessary to clear the
log when new software is loaded. The command takes a few
seconds to complete since it involves erasing a Flash sector.

Append User-entered Message String to System

Log (Command: slo)
Allows a time/date stamped user entered string to be appended to
the log to record an event such as media changed etc.
Dump Temperature Log (Command: dtl)

This command displays the temperature log contents for the
SDM, MCB1, MCB2 and the laser.
The log is in two sections:
• The first section contains historical statistics information. The
statistics section includes:
– min, max and average values recorded since the log was
cleared
– min, max and average values for the last log full of
values.
• The second section contains time/date stamped records of
temperature readings. When the second section becomes full,
the statistics section is updated before the main log records
section is deleted.
Dump Voltage Log (Command: dvl)

This command displays the voltage log contents.
The log is in two sections:
• The first section contains historical statistics information. The
statistics section includes:

– min, max and average values recorded since the log was
cleared
– min, max and average values for the last log full of
values.
• The second section contains time/date stamped records of
temperature readings. When the second section becomes full,
the statistics section is updated before the main log records
section is deleted.
Clear Temperature and Voltage Log

(Command: ctv)
The Temp and Voltage logs are in Flash ROM.
These need to be cleared when a new SDM board is fitted into a
machine or if new Flash devices are installed. For certain versions
of software it may be necessary to clear the log when new
software is loaded.
The command takes a few seconds to complete since it involves
erasing a Flash sector.
Set Real Time Clock (Command: srtc)

Provision has been made for crossing into the next century. The
year can be entered as the full 4 digits or just 2 digits (tens &
units).
For 2 digits, if value is < 90, 2000 is added,
for example, 89 means 2089.
If value is >/= 90, 1900 is added, for example, 95 means
1995.
Illegal time and date values (taking into account leap years) are
rejected. No cross-check is made for valid weekday for a given
date since weekday is not currently used by application software.

The real time clock is used to time and date stamp entries in the
system log.
The real time clock can also be accessed via the diagnostics
menus.
Parameters:
day
month
year
hours
mins
secs
weekday (1-7) 1=Sunday.
Read Real Time Clock (Command: grtc)

This command displays the current real time clock time & date.
The real time clock can also be accessed via the diagnostics
menus.
6.14.4 Job Queue Manager (JQM) Dump

Obtain the jqm> prompt and display the dump by entering:
jqm>jqm
The Job Queue Manager dump has the following format:

JobQstopped = number (Reason for stoppage in words)
JobQheld = TRUE/FALSE
CurrEngineID = number ExposePerCent = number
Note: Note that ‘engine’ is an alternative name for ‘recorder’.

The Active Table provides a list of jobs that are either queued
(waiting) to be scanned or that are currently being scanned by the
recorder.

The History Table provides a list of jobs that have been

completed by the recorder and the status of each job at
completion.
The Job Queue is considered to be ‘running’ when BOTH
JobQheld = FALSE and JobQstopped = 0.
The CurrEngineId is the ID to be allocated to the NEXT job by

the recorder. The Engine ID is purely for internal purposes of the
recorder and is NOT to be confused with the RIPs job ID which
may be completely different.
If a Job is currently being scanned, ExposePerCent indicates the
percentage of the job that has been exposed.
Active Table
The Active Table contains a list of jobs with format as follows:
valid job id compression status held
valid indicates if the job is valid or not. If it is not valid it will

have been aborted or deleted and will have a corresponding entry
in the History List (see below).
job id is an ID allocated by the recorder for tracking purposes.
The compression ratio is an 8-bit fixed point number that

indicates the compression ratio for that job. The compression
ratio can be 0 indicating that the TOTAL compressed data is less
than an expose buffer so a ratio is not calculated. The top 8 bits of
the compression ratio indicate the integral part of the ratio. The
bottom 8 bits of the ratio indicate the fractional part of the ratio in
1/256 ths. The number is a hexadecimal representation.
For example: c_ratio = 3c0 = 3 + 192/256 = 3.75.
Note that compression ratios of less than 3.0 will slow the
spinner down to a ‘High Complexity’ mode of operation.
‘status’ indicates the current status of an active job namely one of
DNLD (downloading), EXP (exposing), QUE (queued ready for
expose) or OTHER (indicating a software failure has occurred).
held indicates if a job has been put on hold causing the queue to
halt when it reaches the head of the queue.

History List
The History List contains a list of completed/deleted/aborted
jobs with the following format:
job id init id status compression errcode
job id is as per the active job queue.
The status of the job can be any one of ABRT for job aborted by
engine, DEL for job deleted by initiator (RIP), COMP for
successful scan completion, or OTHER (which should never
happen and indicates a software failure which should be reported
at once).
init id is the SCSI id of the initiator that originated the job.
compression is as per the active job entry.
errcode indicates the aborted job error code that the aborted
(ABRT status).
6.14.5 Film Handler Menu (Film)

(sh)ow
displays all configuration data and NVRAM parameters.
(val)ue
sets a configuration value used to temporarily change NVRAM
parameters.
(p)ostevent
Post film handling event.
Parameters:
Name of event to be issued.
(rnv)
Read NVRAM Page Register.
Parameters:
Address to read from.
(snv)
Set NVRAM value.

Paremeters:
Parameter 1, Address to write to; Parameter 2 value to write.
(rmc)
Read motor condition.
(nva)ls
Read FH NVRAM values.
(tic)ks
Set a motor acceleration period
Parameters:
Motor ID (number) Ticks
(move)
Move a motor.
Parameters:
Motor ID numbers: 0 = Focus; 1 = Aperture; 2 = Wedge; 5 =
Guillotine; 6 = Cassette.
(clean)
This command starts the feed roller motor running backwards, to
permit it to be cleaned.
(stopc)
This command stops the feed roller motor after a clean command.
(status)
Displays the film handling status.
(fat)al
Clears the film handling fatal error flag.
6.14.6 Optics Handler Menu (Opti)

(eopti)nit
This must be executed if no scans have been completed since the
machine has been powered up and if there is a need to use any of
the following optics functions. Use (dopti)nit to disable.
(movaph)ome
Moves aperture to its home position. The home position is
actually 10 steps in the forward direction (towards the forward
limit) from the actual home sensor. This command must be used

prior to moving the aperture in the forward direction.
(movapbh)o
Moves aperture to its back home position. This home position is
actually 10 steps in the backward direction from the actual sensor.
This command must be used prior to moving the aperture in the
backward direction.
(movfoh)ome
Moves focus to its home position. This home is 10 steps in the
backward direction. Note that both focus positions are in the
backward direction from home. This command must be used prior
to moving the focus to either of its positions.
(movilh)ome
Moves illumination wedges to their home position. Home is 10
steps in the forward direction from home. This command must be
used prior to positioning the wedges.
(movapp)osn (param)
This command moves the aperture plate in the forward direction
relative to its present position by a number of steps (param), for
example, movapp 26. (parameter may be any value 1 - 500
inclusive).
(movapbp)o (param)
This command moves the aperture plate in the backward direction
relative to its present position by a number of steps (param), for
example, movapbp 34 (parameter may be any value 1 - 500
inclusive).
(movfop)osn (param)
This command moves the focus in the backward direction relative
to its present position by a number of steps (param), for example,
movfop 2600. The focus positions are backward of home. The
motor is never required to move forward from home (parameter
may be any value 1 - 10000 inclusive).
(movilp)osn (param)
This command moves the illumination wedges in the forward
direction relative to its present position by a number of steps
(param), for example, movilp 223. The illumination positions are
forward of home. The motor is never required to move backward
from home (parameter may be any value 1 - 500 inclusive).

(movapr)ep (param1, param2)

This command moves the aperture between home and a specified
distance (param1) forward from home and then back home a
specified number of times (param2), for example, movapr 221 5.
This command moves the motor 221 steps forward from home 5
times. The command is used to test the reliability of the
mechanism.
(movfor)ep (param1, param2)

Similar to movaprep (param1, param2) but focus motor is moved
in backward direction.
(movilr)ep (param1
Similar to movaprep but for param2) illumination wedges.
(soako)pti (param1, param2, param3, param4)

Basically movaprep, movforep and movilrep combined.
(param1) number of steps aperture is to be moved from home.
(param2) number of steps focus is to be moved from home.
(param3) number of steps illumination is to be moved from home.
(param4) number of times the sequence is to be repeated.
(reada)pp
Displays the present position of the aperture, with respect to
home. Backward positions from home are prefixed with ‘-’. Note
that the position will also include the 10 steps from home. See the
following example. movaph - move aperture to home (+10
steps). movapp 80 - move aperture 80steps from present position.
readapp - displays 90.
(readf)op
Displays the present position of the focus with respect to home.
(readi)lp
Displays the present position of the illumination wedges with
respect to home.
(lad)rive (param1)
Sets the laser drive on current to (param1) value. (param1) is a
decimal value. (param1) is normally set to 2560 which should not
be exceeded as there would be a risk of permanent damage to the
laser diode. For example:
lad 2560

(lat)hres (param1)
Sets the laser threshold current to (param1) value. (param1) is a
decimal value. It is normally set to 1920. For example:
lat 1920
(ld)rive
Initialises the optics and switches on the laser at drive level. You
are requested to open or close the shutter. If you close them the
nomimal laser power is reported.
(lt)hres
The same as lt but at laser threshold level.
(lo)ff
Sets the laser to off.
(readdc)oarse
Reads the laser power detector - coarse.
(readdf)ine
Reads the laser power detector - fine.
(lb)test
Reads parameters on Laser Modulator board.
(so)pen
Opens solenoid shutter.
(sc)lose
Closes solenoid shutter.
(readlm)
Reads laser modulation current.
(readlt)
Reads laser threshold current.
(readt)emp
Reads laser diode temperature.
(lasert)est
Enables laser tests prior to a scan.
(ecan)watch
Enables CAN Watchdog.

(dcan)watch
Disables CAN Watchdog.
6.14.7 Display Handler Menu (Disp)

(dis)play (param1)
Used to display an icon which has a (param1) reference number.
These reference numbers are stored in an application file and are
not easily accessable. The (param1) value for Machine Ready is
f42d0000. It is best to execute the clist command prior to
displaying an icon just in case there is a higher priority display
message in the list.
For example, clistdisplay f42d0000 displays the Machine Ready
icon.
(dli)st
Displays the display messages that are currently stored.
(cli)st
Clears the stored display messages.
6.14.8 Spinner Handler Menu (Spin)

(rat)e
Sets the spin rate in rpm limited to between 4000 and 13800.
Parameter:
Spinner rate in rpm (for example, ra 13800 sets a spin rate of 13,
800 rpm).
(ch)eckclock
Checks if the PLL is locked to the spinner;
(sta)rtspin
Starts the spinner and enables it to run if the recorder is set up but
stopped.
(sto)pspin
Stops the Spinner (useful if working with cover off and there is
too much noise).

(h)elp)
Displays general or specific query help;
Parameters:
command query string.
6.14.9 Traverse Menu (Tr)

(ei)nit
This command (‘enable initialize’) initializes the Optics Carriage
traverse as if from power-up – that is, it sets-up comms, sets
correct modes and re-homes the Optics Carriage. It is useful for
recovering from traverse position errors once any mechanical
problems have been corrected.
(di)nit
Disables traverse initialization.
(le)ft
Moves the Optics Carriage to the left-hand end of the Leadscrew.
(ri)ght
Moves the Optics Carriage to the right-hand end of Leadscrew.
(lr)cycle
Continuously moves the traverse left and right.
(sto)cycle
Stops the traverse cycling.
(dsp)log
Reads the DSP log, see Section 6.15;
Parameters:
s(tart), e(nd), n(ext), p(revious), q(uit).
(po)kedsp
Pokes hex numbers directly into the DSP;
Parameters:
High byte, Low Byte. For example, 2A01 = traverse limit switch
test.
(posn)
Moves the Optics Carriage to a position from the left end;
Parameters:
Value in mm.

(h)elp
Parameters:
Command query string.
6.14.10 Event Processing Menu (Evt)

(ed)bg
Enables a specific debug (pokedsp command).
Parameters = debug offset. Useful debug values are:
7 for the Traverse system - afterwards, go to the Traverse menu.
16 for RIP SCSI monitoring - this displays all messages sent on
the SCSI bus.
(dd)bg
Disables a specific debug;
Parameters: debug offset.
go
Reboots the system;
Parameters: boot address in hex. For example: go 40004 boots
the recorder into diagnostics.
(h)elp
Parameters: command query string.
6.14.11 Test Pattern Menu (Patt)

(pat)t
Sets up the test pattern image from a set of options. See also
Section 6.13.3 on how to set menu options.
(h)elp
Displays general or specific query help.
Parameters = command query string).

6.15 DSP Log Checks

The DSP Log stores the latest 256 entries that have occurred on
the DSP board. Each Log entry relates to a communication
between the DSP software and the system software. An entry has
the form of a hexidecimal word and an indication of the direction
of transfer (to/from the DSP board). If all 256 entry spaces are
filled, the oldest entry is over-written by the next event.
Use the Application Monitor sub-menu (Trav and dsp), and the
parameters to move between each entry. See Section 6.14.9.
6.15.1 Traverse Performance Checks

The traverse performance should be investigated if there is
consistently a band of poor image quality appearing on the film or
as part of a major diagnostics test.
Information is only available about the traverse performance
while a scan is being performed or when using the move at scan
rate function (later DSP software versions only).
0E 13 Command for requesting traverse performance.
Note: Traverse reporting is turned off using the command 0E 00

and then 0E 01 to turn back on general DEBUG reporting.
The DSP software responds approximately every 10 seconds with
two values, each flagged with the status code 25. Each set of
values, refer to the peak and mean error during each 10 second
interval as the traverse moves. They may be compared with other
values produced, during the movement.
Performance degradation and its location are recognized by an
increase in the error values being reported during the movement.
Note: At slower traverse speeds, the values of errors reported are
generally larger than at higher speeds.

6.15.2 DSP Traverse Log Errors

Some of the more common DSP traverse error condition codes
are listed below, with useful information so that engineers can
trace a fault during normal machine operation.
7FE6
Error Report and Cause: Traverse encoder timed-out caused by
insufficient or missing pulses from encoder.
Possible Checks:
1. Can the Leadscrew rotate?
2. Loss of +5 V supply to encoder?
3. Encoder lamp out?
4. Leadscrew motor failure?
7FE7
Error Report and Cause: Traverse speed fault caused by
traverse moving faster than the system expects.
Possible Checks:
1. High friction areas in Leadscrew or V-groove?
2. Optics Carriage free from obstructions?
3. Umbilical assembly stopping traverse movements?
7FFE
Error Report and Cause: Traverse Leadscrew OPR time-out
caused by Leadscrew rotating significantly more slowly than the
system expects.

Possible Checks:
1. Leadscrew free to rotate? (Look for loss of Leadscrew OPR
signal).
2. Lubrication of Leadscrew too little or too much?
3. Leadscrew bearings not free?
4. Gimbal incorrectly set?
5. An item rubbing on the Leadscrew?
7FF4
Error Report and Cause: Traverse moving in the wrong
direction detected from encoder information.
Possible Checks:
1. Encoder signals from both channels are correct?
2. Leadscrew motor failure?
7FD1
Error Report and Cause: Traverse goes to position too slowly
during a scan or when moving to Home.
Possible Checks:
1. Leadscrew free to rotate?
2. Leadscrew is correctly lubricated?
3. Leadscrew and/or V-groove lubricants have been mixed
(Maccurat and Slideway 68)?
4. Leadscrew bearings not free?
5. Gimbal incorrectly set?
6. An item rubbing on the Leadscrew or Optics Carriage?

Table 6.57 Traverse error log messages
Checks Description
20 09 Traverse amplifier temperature too high

7f 0d Watchdog hardware failure
7f 0f Dynamic brake pulse-generator hardware failure
7f cc Leadsrew seriously underspeed
7f cf Position information invalid
7f d0 Slew is slow
7f d1 Leadscrew overload
7f d2 Warning Leadscrew overload
7f d3 Left limit stop function fail
7f d5 Right limit stop function fail
7f d7 Selfchecks not OK
7f d8 Right relay not detected
7f d9 Left relay not detected
7f db Encoder has lost synchronisation
7f dd Dynamic braking may not be working
7f de Scan started after correct position
7f df Scan started before correct position
7f e1 Traverse does not have relays for stop/braking
7f e2 Traverse has relays for stop/braking
7f e3 Traverse aborted at travel limit
7f e5 Position not accurate
7f e9 Centre position not in range limits
7f ea In a vane
7f eb Not in a vane
7f ef Right vane early
7f f0 No right vane
7f f2 Centre vane width wrong
7f f5 No left limit switch
7f f6 Left limit early
7f f8 Centre position wrong
7f f9 Switch hardware
7f fa No right limit switch
7f fb Right limit switch early
7f fc Right limit active
7f fd Left limit active
7f ff Both limits active

6.15.3 Traverse Limit Detector Position Checks

Traverse limit detector checks should only be performed if a
detector, or a component that effects a detector is changed.
1. Open the Celix Diagnostics window.
2. Obtain the Moon prompt in the Application Monitor, and the
Evt sub-menu.
3. Type edD7 to enable the DSP Spinner and the Traverse

DEBUG (D = space).
4. Obtain the Trav sub-menu and enter:
Trav> po 0e01 (for general reporting)
Trav> posnD0
to move the traverse to the left end.

5. Run a self-test using the Poke command:
Trav> poD2a01(D = space)
The results are displayed in the Terminal window, for

example:
DSP = 28 0
DSP = 28 0
DSP = 28 53
DSP = 28 C3.
Traverse position = 21443 µm (53C3)
DSP = 7ff1
6. Alternatively, return to the Trav sub-menu and enter dsplog
to view the DSP Log for values, see Section (Limit Check)
below (p = previous; n = next; q = quit).
7. Move the traverse to the right-hand end:
Trav> ri
8. Run a self-test.
Trav> po 2a01
9. Return to the Trav sub-menu and enter dsplog to view the

DSP Log for values, see Section (Limit Check) below.

Limit Checks
Possible limit detector failures during self-test, and their solutions
are:
Left/right limit switch early: Increase detector gap to magnet.
No left/right limit switch: Verify magnet is on the carriage.
Verify limit switch wiring is OK .
Verify limit switch is working.
If no left/right limit switch was detected, and the problem was not
resolved, adjust the detector to move it closer to the magnet.
CAUTION
Make sure the detector does not
protrude into the path of the carriage
and cannot make contact with it.
Repeat self-tests and adjustments, until no limit-switch failures

occur.
The limit detector positions to be validated are:
• Right limit, with respect to centre vane right edge.
• Right limit, with respect to right vane left edge.
• Left limit, with respect to centre vane right edge.
These positions are recorded in the DSP Log, after running a
self-test with no limit switch failures. Two self-checks must be
run to obtain all three limit switch positions. The carriage must be
positioned in the left hand side of the drum before one self-check
and in the right hand side before the second self-check (viewed
from the front). The procedure is as follows:
Left-Hand Side
Carriage positioned, in left-hand side of the drum:

1. View in the Terminal window or enter the DSP log and scroll
backwards, looking for the following two positions. A
position is reported as four consecutive codes in the form
28 NN. The most significant byte is earlier in the log, than
the least significant byte.
Left limit, with respect to centre vane right edge.
Look for 7F EC (left limit position OK). Note the NN part
of the next four consecutive 28 NN position byte values
(while scrolling backwards).
Right limit, with respect to centre vane right edge.
Look for 7F F1 (right limit position OK). Note the NN
part of the next four consecutive 28 NN position byte
values (while scrolling backwards).
2. The left limit position value, with respect to centre vane right
edge, should be in the range:
FF F9 C2 60 to FF F9 C9 60 (-400.8 mm to -407.2 mm).
If the position is LESS than FF F9 E2 60, adjust the left detector
towards the magnet.
If the position value is GREATER than FF F9 C9 60, adjust the
left detector away from the magnet.
If adjustments are required, position the carriage in the left hand
side of the drum and restart the procedure from Step 1.
When adjustments are not required, the limit detector is
operating within a 4 mm window near to the left hand end of the
traverse. At either side of the window there are 1 mm guard
bands, taking the edges of the total window up to the software
check limits.
3. The right limit position, with respect to centre vane right
edge, should be in the range:
00 06 0F 90 to 00 06 2A 68 (397.2 mm to 404.2 mm).
If the position value is LESS than 00 06 0F 90, adjust the right
detector away from the magnet.
If the position value is GREATER than 00 06 2A 68, adjust the
right detector towards the magnet.

If adjustments are required, position the carriage in the left hand

side of the drum, run a self-test and repeat Step 4.
operating within a 4 mm window near to the right hand end of the
traverse (viewed from the front). At either side of the window
there are 1 mm guard bands, taking the edges of the total
window up to the software check limits measured from the right
edge of the centre vane.
Right-hand Side
Carriage positioned in right hand side of the drum:
1. View in the Terminal window or enter the DSP log and scroll
backwards, looking for the right limit position, with respect to
right vane left edge.
Look for 7F F1 (right limit position OK). Note the NN part of the
next four consecutive 28 NN position byte values (while
scrolling backwards).
2. The right limit position, with respect to right vane left edge,
should be in the range:
00 00 43 94 to 00 00 5B 04 (17.3 mm to 23.3 mm).
If the position value is LESS than 00 00 43 94, adjust the right
detector away from the magnet.
If the position value is GREATER than 00 00 5B 04, adjust the
right detector towards the magnet.
If adjustments are required, position the carriage in the left-hand
side of the drum, run a self-check and restart the procedure from
Step 1.
operating within a 4 mm window near to the right-hand end of
the traverse. At either side of the window, there are 1 mm guard
bands, taking the edges of the total window up to the software
check limits measured from the left edge of the right vane.
Note: It may not be possible to make an adjustment to fit
both carriage start positions, if the vanes are
positioned incorrectly.

6.15.4 Traverse Motor Current Checks

1. Open the Celix Diagnostics window.
2. Obtain the Moon prompt in the Application Monitor, and the
Evt sub-menu.
3. Type edD7 to enable the DSP Traverse Debug (D = space).

4. Obtain the Trav sub-menu and enter:
5. Run a self-test using a Poke command:
trav> poD2a01(D = space)
6. Use the Poke command to continue entering values, as shown

in Section (Motor Current Checks) below.
Monitor the test point TSIG (TP28) on the DSP board, with
respect to analog ground. The signal is a voltage reading of
the current required to drive the carriage at various speeds.
Note: The traverse power amplifier is set up to give a current
output of 0.5 A corresponding to 1 V of input signal.
7. Make sure the traverse is inactive, in the centre of the drum,
following self-tests or a re-centre command.
8. Enter the following commands to set the GOTO preset
position as the centre of the drum:
Trav>PO 33 00
Trav>PO 32 00
Trav>PO 31 00
Trav>PO 30 00
9. Enter the command to move left briskly: Trav> PO 2C 04.

10. Monitor the TSIG signal. Make sure the characteristics are:
• An initial narrow negative peak, magnitude <15 V.
• A steady -2 V to -3 V (variation <0.25 V). This is a
typical range for a system with no pre-load spring in the
gimbal nut assembly.

• An immediate drop to 0 V as the carriage reaches the left

limit of travel and drive is removed from the motor.
11. Wait for the traverse to become inactive at the left limit of
travel (40 18 displayed).
12. Enter the command to GOTO the preset position (centre):
Trav> PO 34 00.
• An initial wide positive peak, magnitude <15 V.
• A steady +3 V to +4 V (variation <0.3 V).
• The drive is removed from the motor and the voltage
reduced to 0 V after a series of narrow, small peaks as the
carriage approaches the centre.
Note: The warnings Slew Slow (7F D0) and Slew Overload
(7F D2) should not appear on the display or in the
DSP log. Further investigation is required if this
happens.
14. Wait for the traverse to become inactive in the centre of the
drum (DSP = 40 18 reported).
15. Enter the command to move right briskly: Trav> PO 2C 03.
• An initial wide positive peak, magnitude <15 V.
• A steady +2 V to +3 V (variation <0.25 V). This is a
typical range for a system with no pre-load spring in the
gimbal nut assembly.
• An immediate drop to 0 V, as the carriage reaches the
right limit of travel and drive is removed from the motor.
17. Wait for the traverse to become inactive at the right limit of
travel (40 18).
18. Enter the command to GOTO preset position (centre): Trav>
PO 34 00.
• An initial wide negative peak, magnitude <15 V.

• A steady -3 V to -4 V (variation <0.3 V).

• The drive is removed from the motor and the voltage
reduced to 0 V after a series of narrow, small peaks as the
carriage approaches the centre of its travel.
Note: The warnings Slew Slow (7F D0) and Slew Overload
(7F D2) should not appear on the display or the DSP
log.
20. Wait for the traverse to become inactive in the centre of the
drum (4018).
21. The traverse motor current checks are now complete.
Note: The warning Slew Slow (7F D0) may occur on some units
due to an analog offset voltage, present on the DSP board.
If the warnings are consistently present in one or both
directions, they can be ignored. If the warnings only occur
in specific areas of travel, there may be a mechanical
problem, which should be investigated.
6.15.5 Turning DSP Debug Reporting Off

1. Turn off DSP debug reporting from the Evt menu.
evt> ddD7

Media Handling 7
Replacements
and Setups
This chapter describes how to access, remove and re-install the
main removeable parts used for media handling, and adjust the
media setups. Make sure details of any modifications and
replacements are entered in the Log Book.
Use information in TIS 13449 to set up film handling for the Celix
4000.
WARNING
Rewind the film into the cassette and
switch off at the mains isolator
before starting these procedures.
• Panels - Section 7.1.

• Input Cassette - Section 7.2.
• Input (Nip) Roller - Section 7.3.
• Cassette Drive and Bay - Section 7.4.
• Drum Assemblies - Section 7.5.
• Media Sensors - Section 7.6.
• Distribution Boards - Section 7.7.
• Guillotine and Punch - Section 7.8.
• Film Output Assemblies – Section 7.9.

Media Handling Replacements and Setups
7.1 Panels
7.1.1 Removing Panels
See also the Celix 4000 Recorder Illustrated Parts Catalogue and
Section 2.7 on cover interlocks.
Use an Allen key to operate the panel securing latches:
unlock - turn counterclockwise
lock - turn clockwise.
The terms right-hand (RH) side and left-hand (LH) side are
used when viewing the recorder from the front.
OUTPUT CHUTE TOP FRONT

PANEL PANEL
LH END PANEL
FRONT LOWER
PANEL
ACCESS DOOR
Figure 7.1 Celix 4000 recorder panels: front view

OUTPUT CHUTE
PANEL
RH END
PANEL
UPPER REAR PANEL REAR LOWER

PANEL
Figure 7.2 Celix 4000 recorder panels: rear view
The protective panels are illustrated in Figure 7.1 and Figure 7.2.
• The front left-hand hinged access door, hinged on the
left-hand side, opens outwards.
• The top front panel is secured by four quarter-turn
finger-screw locks on the inside, which are reached after
removing the two end panels. This cover is lifted off as a
separate unit.
• The output chute panel is not secured or hinged and lifts off
as a separate item.
• The upper and lower rear panels are each provided with two
hand-holds for fitting and removal.
The rear panels are each provided with two hexagonal hole
locks; when these are released the respective cover can be
lifted out by the two hand-grips provided.

WARNING
When removing the upper and lower
rear panels, support them by the
handles. Otherwise, they may slip
from the lower latches and cause
injury.
• The left and right-hand end panels are removed by pulling

away to clear.
• The front lower panel is provided with two recessed
hexagonal holes and internal retaining catches; these are
accessed as follows:
• first, undo the two hexagonal hole locks situated along the
underside of the panel.
• then, disengage the catches situated along the top side of
the panel.
Always make sure that the panels are re-secured correctly to
avoid the risk of film ‘fogging’.
Recommended Tools
The recommended equipment and special tools - for servicing a
Celix 4000 recorder - are listed in Appendix C.
7.1.2 Overriding Interlocks

The following panels fitted on Celix 4000 are interlocked:
• Left End panel.
• Right End panel.
• Output Chute panel.

• Upper Rear panel.

• Front Access Door.
The locations of the safety interlocks are described in Section 2.7.
WARNING
All unqualified personnel must be
prohibited from the area, while the
machine is in the overridden state,
To override an interlock, insert special key (99380406) into the

interlock socket, which is revealed when the corresponding cover
is removed. The cover cannot be replaced with the override key in
place. Make sure the override key is removed after the service
procedure.
The interlock screw is tamperproof and requires a special screw
removal tool, see Appendix C.
7.1.3 Stretcher Cover Removal

See Figure 7.3.
The front stretcher cover is removed to access the film guide and
media detect sensor.
1. Remove the left-hand and right-hand end panels. Remove the
front lower cover.
2. Open the front door (on left of the machine) and remove the
2-off left-hand side M5 bolts.
3. Undo the 2-off M5 bolts at the right-hand end and pull the
cover loose. This cover is heavy and will require two people
for removal.

END COVER
FIXING SCREWS
FIXING SCREWS (ACCESS BEHIND END
(ACCESS THROUGH COVER)
STRETCHER
DOOR OPENING)
COVER
Figure 7.3 Removing the front stretcher cover

7.2 Input Cassette Assemblies

7.2.1 Input Cassette Replacements
See Figure 4.15.
Cassettes which are in constant use may need to have the cutter
blade or drive wheel replaced. After completing a replacement
procedure, ensure that the cassette is cleaned and in working
order.
Film Cutter Blade

1. Remove the Allen screw at the front of the film cutter
assembly and dismantle the cutter blade.
2. Replace the blade and reassemble.
3. Make sure the blade cuts evenly.
Drive Wheel
1. Remove the grub screw behind the drive wheel.
2. Prise off the wheel from the drive shaft.
3. Refitting the wheel is the reverse of the removal procedure.
4. Check that film loads into the drum and rewinds correctly.

7.3 Input (Nip) Roller Assemblies

7.3.1 Input Roller Spring Replacements
See Figure 7.4 and also Section 12.3 on cleaning the rollers.
1. Lift off the Input Cassette.
2. The Input roller housing must now be removed. This is not
secured by any fasteners, but is awkward and heavy to lift.
LIFTING HANDLES
HOUSING
SPRING GUARD
LEAF SPRING
LEAF SPRING
Figure 7.4 Input roller leaf springs
3. Obtain the two lifting handles.

4. Screw the lifting handles into the Input (Nip) Roller housing,
one at each end.

5. Tilt and pull the roller assembly forwards while lifting both
ends. This should disengage and clear the assembly from the
drive so that it can be removed.
6. Remove the roller housing (4-off top screws and 6-off side
screws) and replace the leaf spring(s) shown in the Celix 4000
Recorder Illustrated Parts Catalogue.
7. If the springs are bent they should be replaced. As a
temporary measure they can be fitted the other way round
(with the bend towards the roller) while awaiting
replacements.
8. Clean the rollers with antistatic cleaning fluid (99963265) and
replace the rollers.
9. Before refitting the Input roller assembly into the tray, offset
the drive dog pins slightly so that the assembly can be tilted
onto the dog wheel.

7.4 Cassette Drive and Bay Assemblies

7.4.1 Cassette Drive Replacements
2. Remove the Input roller using the procedure in Section 7.3.1.
3. Remove the front top panel.
Prise off the front moulding inside the well without marking
the paintwork.
CASSETTE DRIVE
ASSEMBLY
Figure 7.5 Location of cassette drive assembly
4. Remove the left-hand preformed cassette well end buffer

from its push-fit fixings.

5. Access the Cassette Drive, which is secured inside the left end
of the cassette well, as follows:
a) Turn off the vacuum supply to the recorder, and (if
necessary) disconnect the single line supplying the
cassette drive cylinder.
b) Remove the 8-off M3 bolts located on the cassette drive
plate.
c) Pull the gearbox assembly into the well and disconnect
the stepper motor drive and cassette sensors.
6. Fit the appropriate part and replace the drive using the reverse
procedure. Make sure that the drive coupling spring and
washers are in good working condition.
Drive Springs
See Figure 7.6.
If the Input Cassette is failing, the fault can sometimes be traced
to the drive mechanism which includes the coupling spring. You
do not need to remove the Cassette Drive to replace this spring.
1. Remove the central M5 screw retaining the push plate. If this
screw is difficult to loosen, use a small hammer and punch to
break the Loctite seal.
2. Remove the appropriate drive dog wheel:
a) Cassette drive dog: remove the 2-off self-tapping screws
on the rear of the drive dog attaching it to the push plate.
b) Input roller housing drive dog: grip the square shaft
securely and remove the screw holding the drive dog.
3. Replace the the coupling spring. Note that the cassette drive
dog also has a washer fitted behind the spring, see Figure 7.6.
Refit the appropriate drive dog and tighten securely. If you
have to replace the spring and washer, ensure that it is the
correct part.
4. Use a new M5 screw to refit the push plate.

5. Check that the recorder is operating properly by loading film

and removing the cassette several times.
DRIVE COUPLING PUSH
SPRING PLATE
END OF ROLL NYLON
WASHER M5 CSK
SENSOR
(ON BRACKET)
VAC
CYLINDER
DRIVE
BELT
DRIVE
DOG
DROP
SENSOR
MOTOR
IDLER
GEAR
Figure 7.6 Cassette drive assembly - replacements
Drive Belt
See Figure 7.6.
2. Remove the Cassette Drive, see Section 7.4.1.
3. Slacken the idler gear and remove the belt. This belt does not
have a timing function.
4. Fit the new belt and set the tension, from the idler gear, for
approximately a 90° deflection (1/4 turn).

Motor
See Figure 7.6.
2. Remove the Cassette Drive, see Section 7.4.1.
3. Slacken the drive belt.
4. Remove the 4-off screws to the motor assembly and replace.
7.4.2 Cassette Bay Removal

The Cassette Bay does not need to be removed unless there is a
problem with the input Film Guide.
CAUTION
Make sure that any debris from the
soundproofing material is removed
from the drum at the end of this
procedure.
See Figure 7.7.

2. Remove the two end panels.
3. Remove the top rear moulding and the two end buffer
mouldings. Gently pull them off by hand from their frame
mountings.
4. Remove the front stretcher cover, see Section 7.1.
5. Remove the Input roller (see Section 7.3.1) and pull out the
Cassette Drive assembly (see section 7.4.1).
6. Mark the exact location of the Cassette Bay by fixing
masking tape across the four corner insert points with the

body of the recorder, then pencil in a line that runs across the
well and recorder body. Use these four pencil marks to line up
the bay on reassembly.
TOP
MOULDING
CASSETTE
DRIVE
BUFFER
MOULDING
Figure 7.7 Cassette bay mouldings
7. Remove the 3-off Cassette Bay fixing bolts at either end, and
pull out the bay.
CAUTION
Carefully handle and store the
Cassette Bay without damaging the
film guide ‘lip’.
8. Replacement is the reverse of the Removal.

7.5 Drum Assemblies

7.5.1 Drum Assembly Replacements
You do not need to remove the Cassette Bay to gain access to the
drum sub-assemblies.
See also the drum assembly views in the Celix 4000 Recorder
Illustrated Parts Catalogue.
Input Film Guide

1. Remove the front stretcher cover (but not the Cassette Bay),
see Section 7.1.1.
2. Detach the Film Guide from its three fixing points and
remove.
Note: the guide is slightly ‘lipped’ underneath the drum.
3. Refitting is the reverse of the removal operation. Do not
damage the welds between the two parts of the Film
Guide.
REAR FILM GUIDE
INPUT MEDIA
DETECT SENSOR
ANTISTATIC
BRUSH
FRONT FILM
GUIDE
Figure 7.8 Input Film guide

Vanes
Two vanes, middle and right-hand side, used to sense the traverse
position from a Hall–effect switch on the Optics Carriage, are
screwed to the drum top gantry (main beam).
2. Remove the Film Output Assembly, see Section 7.9.
3. Remove the right-hand side end cover.
4. Remove the 2-off screws and replace the appropriate vane
fixed to the main beam gantry.
5. Switch on power and traverse the Optics Carriage to check
that the switch does not collide with the replaced vane, see
Section 6.14.9.
Antistatic Brush Strip

See Figure 7.8.
This is attached to the Film Guide on the interior, just above the
drum.
1. Remove the front stretcher cover.
2. Unscrew the 3-off fixing screws on the Film Guide and
remove the brush strip assembly.
Drum Alignment Checks

For reliable film handling the drum should be square from
side-to-side and from front-to-back, and at the correct height.
Correct drum alignment will help to ensure the Punch is in the
correct position for the output mechanisms and the Input cassette
and rollers are aligned with the the input media guide.
TIS 13449 explains how to check and adjust the drum alignment.

7.6 Media Sensors

7.6.1 Input Sensor Replacements
input handling:
• Input Media Detect (cable 66): Paper path type switch
• Media at Input Cassette - Drop (cable 69): Reed (proximity
switch).
• End of Roll Detect: Opto-sensor switch.
Technical details are as provided in Section 3.9 - location of the
sensors are indicated in Figure 3.17; details of sensor wiring
connections to the Front Distribution Board are given in
Table 4.3.
Input Media Detect

The Film Detect sensor is mounted on the front Film Guide.
1. Switch off the AC mains at the rear of the machine.
2. Remove the lower front panel and the front stretcher cover,
see Section 7.1.1.
3. Disconnect the sensor by the associated Mate-N-Lok
connector.
4. Unclip and remove the existing sensor.
5. Replacement and reassembly is the reversal of Steps 2. to 4.
The remaining operations are to check the operation of the
newly fitted sensor.
6. Switch on the recorder and check the sensor operation as
follows:
a) Select the top level menu of Celix Diagnostics.
b) Select the options Mechanics and Sensors and a list of
sensor types is displayed on the panel, see Section 6.9.1.

c) Activate the sensor by pushing a piece of film between

the Input rollers (at the centre) and note on the monitor
screen that the appropriate sensor changes state.
Media at Input Cassette, Drop

See Figure 7.6.
This sensor is mounted on the cassette drive assembly, see
Figure 3.17. This sensor is unlikely to fail in normal everyday
use, unless subject to accidental damage.
2. Remove the Input Cassette and roller housing from the
recorder, see Section 7.3.1.
3. From the Input Cassette bay, pull off the rear buffer.
4. Remove the left-hand buffer moulding via push-on fixings.
5. Disconnect the sensor by the associated Mate-N-Lok
connector.
6. The ‘drop’ sensor (reed switch) is mounted on a small bracket
attached to the cassette drive motor plate. Mark the position
of the existing sensor and then remove it. Replace it with the
new ‘drop’ sensor reed switch, fitting it in the same position
as for the removed sensor. This sensor is only
finger-tightened. Reconnect the sensor by the Mate-N-Lok
connector.
7. Check operation of the new sensor. To do this:
a) Refit the roller housing and Input Cassette.
b) With the Input Cassette lid closed but not latched, place a
piece of film under the drop lever.
c) Using a DVM, note that the sensor changes state when the
film is pulled out.
8. Reassemble by carrying out the reverse procedure to that
detailed in Steps 2. to 4.

End of Roll Sensor, Optic

This sensor is located on the left-hand side buffer moulding, next
to the drive coupling, see Figure 7.9.
2. Remove the top moulding on the Cassette Bay and the
left-hand side buffer moulding on the Cassette drive.
3. Mark the bracket to indicate the exact location of the sensor.
Using a 2.5 mm Allen key, detach the sensor bracket and
replace the sensor (single screw fixing).
4. Note the cable routing to the sensor and check that it does not
snag.
5. Remove the two screws securing the bracket, and mark the
exact location of the sensor before replacement.
END OF ROLL
SENSOR
Figure 7.9 End of Roll sensor position
6. Check operation of the new sensor. To do this:

a) Refit the roller housing and Input Cassette.

b) Using a DVM, note the sensor state when film rewinds

with an empty roll and the change of state when there is
film on the roll.
7. Reassemble by carrying out the reverse procedure to that
detailed in Steps 2. to 4.
7.6.2 Output Sensor Replacements

output handling:
• Guillotine EOT Left, (cable 70): reed (proximity switch)
• Guillotine EOT Right, (cable 71): Reed (proximity switch).
• Media Detect at Punch (cable 76): Paper path type switch.
• Media Detect at Processor: Paper path type switch.
• Lazy Loop: Paper path type switch.
• Post-Guillotine: Paper path type switch.
Technical details are as provided in Section 3.9 - location of the
sensors are indicated in Figure 3.17; details of sensor wiring
connections to the Rear Distribution Board are provided in
Table 4.4.
Guillotine EOT Left and EOT Right

These sensors are mounted on the left and right ends of the
guillotine bar.
2. Access to the sensor is gained by removal of the upper rear
panel.
3. Disconnect the EOT sensor(s) at the associated Mate-N-Lok
connector(s).

4. Unscrew and remove the sensor.

5. Fit a new sensor and adjust, see Section 7.8.3.
6. Reassemble in reverse order to Steps 2. to 3.
7. Switch on the recorder.
8. Obtain the top level menu of the Diagnostics as detailed in
Section 6.4.
.
9. Use diagnostic commands: Mechanics Sensors and a list
of sensor types is displayed.
10. Manually run the Guillotine so as to activate each of the
Guillotine End-of-Travel sensors in turn. Each time check on
the monitor that the relevant sensor changes state.
Media Detect at Punch

The sensor is mounted on the Punch, see Figure 3.17 and
Figure 7.18.
2. Access to the sensor is gained by removal of the upper rear
cover.
3. Remove the chad box.
4. Mark the position of the mounting bracket, then unscrew and
remove it.
5. Disconnect the sensor - by raising the clip - at the associated
Mate-N-Lok connector.
CONNECTOR
RAISE CLIP TO REMOVE
6. Unclip the sensor and remove it from the bracket.

7. Replacement with new sensor and reassembly is the reverse

process to Steps 2. to 6.
8. Switch on the recorder and check the sensor operation in the
same way as described for Input Media Detect, see
Section 7.6.1.
Output EOT (at Processor)

This sensor is located at the rear of the Output Chute and
mounted on the output film guide.
2. Separate the recorder from the online processor by pulling out
the recorder.
3. Remove the output film guide assembly, see Figure 7.25, by
removing the 2-off screws holding the guide to the roller
assembly.
4. Detach the electrical connector.
5. Release the sensor from its bracket clip connection.
6. Replacement is the reverse of the removal procedure.
Lazy Loop
This sensor is mounted on the top of the Vertical Output
assembly, behind the angle guide to the Output chute.
2. Remove the top front panel.
3. Remove the top film guide on the Vertical Output by
unloosening the 2-off fixing screws.
4. Disconnect the sensor - by raising the clip - at the associated
Mate-N-Lok connector.

5. Remove the mounting bracket (2-off screw fixings) and

replace the switch sensor.
6. Check that film can pass through the two conveyors and reach
the processor.
Post Guillotine
This sensor is mounted on the rear stretcher bar of the Vertical
Output assembly.
2. Remove the rear top panel.
3. Detach the sensor connector and unscrew the sensor.
5. Check that film can pass through the two conveyors and reach
the processor.
Punch Position Sensor

Two opto sensors are located on a small PCB above the punch
motor, see Figure 3.17.
1. Lift out the Vertical Output assembly from its recorder
location to access the punch motor, see Section 7.9.2.
2. Disconnect the sensor cable and remove the PCB (with cover
plate) from the motor pillars (2-off screw fixings).
3. Remove the opto sensors.
4. Replacement is the reverse of the removal procedure.
5. Check that the punch operates by moving the punch
mechanism several times with the Mechanical menu Motor
command in Celix Diagnostics, see Section 6.9.3.

7.7 Distribution Boards

7.7.1 Front Distribution Board
See Figure 3.17 for the location of this board, Figure 7.10 and
Section 4.14.
2. Remove the lower front cover of the recorder (two hexagonal
screws located beneath the bottom edge).
PL9 PL10
PL1 PL2 PL3 PL4
PL5 PL6 PL7
PL8
Figure 7.10 Front distribution board connectors
3. Each connecting cable has a separate connector - see

Table 4.3. Noting the cable identities, disconnect them from
their corresponding connectors.
4. Undo the board’s retaining screws and remove the board from
the fabricated base (the board is mounted on plastic stand-offs
with retaining clips).

5. Fitting the replacement board and reassembly is in reverse

order to Steps 1. to 4.
7.7.2 Rear Distribution Board

See Figure 7.11 for the location of this board, Figure 7.12 and
Section 4.14.
2. Remove the lower rear cover of the recorder (two hexagonal
screws located beneath the bottom edge).
3. Each connecting cable has a separate cable - see Table 4.4.
Noting the cable identities disconnect them from their
corresponding connectors.
4. Undo the board retaining screws and remove the board from
the fabricated base (the board is mounted on plastic stand-offs
with retaining clips).
5. Fitting the replacement board and reassembly is in reverse

REAR DISTRIBUTION BOARD
Figure 7.11 Location of rear distribution board
PL1 PL2 PL3 PL4 PL5 PL6
PL7 PL8 PL9 PL10 PL11 PL12 PL13
PL14
Figure 7.12 Rear distribution board connectors

7.8 Guillotine and Punch Assemblies

7.8.1 Removing the Guillotine/Punch Assemblies
CAUTION
The Guillotine assembly consists of
a rotary blade with sharp edges.
In this section, procedures for the removal and replacement of the

Guillotine/Punch Assemblies (see Figure 7.13) are given. Neither
the Guillotine or Punch are replaceable assemblies, but removal
may be required for assembly items that are replaceable.
The Punch mechanism is driven by a DC motor which can be
removed without having to remove the Punch/Guillotine
Assembly.
Remove the Guillotine assembly before removing the Punch.
7.8.2 Guillotine Assembly

See Figure 7.13.
1. Rewind the film and power down the recorder.
2. Remove the upper and lower rear panels.
3. Detach the drive band (optional).
4. Remove the rear film guide from the guillotine. It is secured
at each end.

GUILLOTINE EOT SENSOR
GUILLOTINE
DRIVE BELT
GUILLOTINE
ASSEMBLY
SPINDLE
DRIVE MOTOR SLIDER

BRACKET
GUILLOTINE
EOT SENSOR
CHAD BOX
ROTARY
KNIFE BLADE
GUILLOTINE GUIDE
GUIDE RAIL SCREWS (6 OFF)
GUILLOTINE
WHEEL
LOCATION
SCREWS
(4 OFF) BLADE
LOCATION
SCREW
BALL-ENDED
DRIVE BELT BOLT
PULLEY
DIE
DRIVE BELT GUILLOTINE

GUIDE RAIL
A PUNCH
VIEW A ASSEMBLY
PUNCH
GUILLOTINE
FIXED BLADE
MEDIA DETECTION
NOTE: INSIDE VIEW FROM FRONT
SENSOR
Figure 7.13 Punch/Guillotine assembly

5. Disconnect the EOT sensors and the guillotine motor by the

Mate-N-Lok connectors at each end of the Punch/Guillotine
assembly.
6. Disconnect the guillotine motor connector.
7. Remove the guillotine drive belt (optional).
8. Remove the 2-off M6 screws each side holding the Guillotine
assembly to the Punch.
9. While tilting the Guillotine assembly forward, withdraw it
gently from its location on the Punch.
10. Replacement is the opposite of Removal. Note that there
needs to be an approximate distance of 3 mm between the
rubber belts and the film guide, see Figure 7.21.
While the Guillotine is removed there is improved access to the
punch motor, the sensors, punch dies and the guillotine motor.
Guillotine Drive Motor

See Figure 7.14.
1. Switch off power at the rear of the machine, see Section 7.1.1.
2. Remove the upper rear cover.
3. Remove the Guillotine assembly, as described in Section
7.8.2.
4. Unscrew the guillotine drive motor from the base casting,
disengage it from the belt drive and remove it from the
machine.
5. Replacement with the new motor and reassembly is in reverse

GUILLOTINE DRIVE
ASSEMBLY
GUILLOTINE
DRIVE MOTOR
DRIVE BELT
Figure 7.14 Location of guillotine drive motor

Guillotine Rotary Blade

See Figure 7.13.
1. Power down the recorder.
2. Remove the upper rear cover and unplug the guillotine motor.
3. Slide the rotary blade assembly to the middle of the machine.
4. Unscrew and unfasten the ends of the guillotine drive belt
from the blade assembly.
5. Remove the 2-off screws that retain the clamp at each end of
the guillotine shaft. (see Figure 7.13).
WARNING
The rotary blade is spring-loaded
vertically downwards and is sharp.
6. Remove the entire guillotine shaft together with the blade

block assembly; remove the blade block from the shaft.
7. Remove the circlip from the top of the blade spindle, and
remove the spindle from the block.
8. Grip the flats on the blade spindle with the spanner and undo
the blade retaining screw with a flat-blade screwdriver.
9. Fit a new blade and reassemble the blade block assembly.
10. Replace the blade block assembly and shaft in its location,
such that the rotary blade rests on the fixed blade of the
Punch/Guillotine assembly and the guide wheel against the
guide rail.
11. Refit the shaft clamps.
12. Refit the guillotine drive belt.
13. Perform guillotine set-up check, as detailed in Section 7.8.3,
but excluding Step 1.
14. Replace the upper rear cover.

Guillotine Fixed Blade

Should the guillotine fixed blade become blunt or damaged it may
be taken out and reversed to provide a new cutting edge. It should
be replaced after both sides have been used.
ÇÇ
FIXED BLADE
ÇÇÉÉÉÉÉ
ÇÇÉÉÉÉÉ
RETAINING
SCREW
ÇÇÉÉÉÉÉÉ
(6 OFF)
GUILLOTINE
ÇÇÉÉÉÉÉÉ
GUIDE RAIL
RETAINING
SCREW
(6 OFF)
NEW CUTTING
EDGE
Figure 7.15 Retention of guillotine fixed blade
1. Switch off the recorder.

2. Remove the upper rear cover.
3. Release one end of the guillotine drive band but leave the
band in place.
4. Remove the six screws to release the guide rail.
5. Remove the six screws to release the fixed blade.
6. Lift out the fixed blade and turn over to see if the other blade
edge is unused. If so, refit the blade so as to use the other
blade edge. If both edges have been used fit new blade.
Reassemble in reverse order to removal.

7.8.3 Guillotine Setup

Note: The guillotine assembly will not normally require complete
replacement as a single item, in which case the first step of
the guillotine set-up procedure can be omitted.
1. Remove the top rear cover. Note that the guillotine is
assembled on the punch mounting brackets, at a distance of
115 mm from the top face of the drum to the bottom of the
guide bar. Check the dimension at both ends.
2. Check the Tufnol wheel (blade drive roller) float. Press from
underneath and check for 2 to 3 mm of vertical movement.
Adjust by slackening the two securing-block location screws
and moving the assembly as necessary, see Figure 7.13.
15 mm 2 mm 7 mm 2 mm
PRELIMINARY PRELIMINARY
SETTING SETTING
MAGNET MAGNET
PROTRUSION PROTRUSION 1 mm L.H. EOT
R.H. EOT 1 mm SENSOR
SENSOR
RIGHT LEFT SIDE

SIDE OF OF
MACHINE MACHINE
GUILLOTINE
CARRIAGE
ADJUST TO
9 mm 16 mm
VIEW FROM REAR OF
MACHINE
Figure 7.16 Guillotine carriage: sensor magnet protrusion
3. Check that at the guillotine end-of-travel, the clearances

between the carriage and the right-hand and left-hand end
brackets are 9 mm and 16 mm respectively, see Figure 7.16.
Adjust the sensor length, as necessary.

90°
REF
ROTARY
KNIFE BLADE
(HIGHER POSITION) 2 to 3 mm
ROTARY
KNIFE BLADE
(LOWER POSITION)
FIXED
KNIFE BLADE
PUNCH ASSY
CORRECT
INCORRECT
Figure 7.17 Guillotine blade angle
4. Move the Guillotine along the Punch assembly manually.

Check that the Tufnol wheel turns and is in contact with the
guide rail at all times, see Figure 7.17.
Note: If the guillotine motor connector is first disconnected,
a smoother action will be obtained when moving the
rotary drive blade by hand.

7.8.4 Punch Assembly
WARNING
The Punch assembly is heavy and
should not be lifted by one person
alone.
If the Punch needs to be removed, complete the following:

1. Isolate the recorder from the mains.
2. Remove the upper and lower rear panels, and chad box.
3. Remove the Guillotine assembly (see section 7.8.2 above).
4. Before removing the punch, scribe a line along the front and
sides of the drum at each end to give a relocating guide.
5. Raise the clip of the the cable connector to the Media Detect
at Punch sensor to disconnect it from the sensor. See the
diagram below.
CONNECTOR
RAISE CLIP TO REMOVE
The Media Detect at Punch sensor (see Figure 3.17 and

Figure 7.18) is located in front of the chad collection tray.
6. Disconnect the cable to the punch DC motor.
7. While steadying the Punch, remove the 2-off retaining screws
from each end of the Punch.
8. Remove the Punch assembly from the rear of the machine. To
do this, lift the assembly and pull it directly backwards off the
drum.

The replacement of the Punch assembly is basically the reverse of

the Removal procedure but note should be taken of the following:
• Inspect the Punch and check that all machined surfaces are
free of damage and excess filings.
• Ensure that the assembly is refitted at the previously marked
position, and that the Punch is fully pulled back against its
location stops, see Section 7.8.5.
• When replacing the Guillotine, care should be taken to avoid
damaging the rotary blade. Before fitting the guillotine
retaining screws, ensure that the blade is seated on top of the
fixed knife, see Figure 7.15.
• Check the operation of the Punch on film from the SENSORS
AND SOLENOIDS display; then check that the Punch
operates from the RIP application by running a small job.
Punch and Die

Part numbers for the punch and die set are listed in Table 7.1:
Table 7.1 Punch and die sets
Punch and Die Set Punch/Die Assy

Billows Protocol 99504643 75427760
German Bacher 99504644 75427740
American Stoesser 99504646 75427750
Kamata 99504615 75427770

2. Remove the upper rear cover from the recorder using
appropriate ball-ended hexagonal wrench. Remove both
recorder side panels. See Section 7.1.1.
3. Remove the Vertical Output assembly, see Section 7.9.2.
4. Remove the chad box.

5. Remove the guillotine drive belt (optional).

6. Remove the Guillotine (see Section 7.8.2) and guillotine
guide rail to give access to the die plates, see Figure 7.18.
GUILLOTINE
GUILLOTINE DRIVE BAND
BLADE ASSEMBLY
GUILLOTINE
GUIDE RAIL
MEDIA DETECT
(AT PUNCH)
SENSOR
DIE RETAINING
SCREWS (4-PAIRS)
Figure 7.18 Punch assembly viewed from rear
CAUTION
The heads of the die retaining screws
to be removed are visible from the
rear of the machine. It is essential
that these are used and not the
screws on the front of the Punch
assembly.
7. Remove the screws holding the die to be replaced. Then

remove the die from its recess - use of a magnet or pair of
tweezers is recommended.

Note: Do not replace a die without replacing its Punch and

vice versa.
8. Undo the ball-ended bolt for the relevant punch from the
punch actuating cam, until it is clear of the punch pin.
Note: It is not necessary to totally remove the Punch.
9. Withdraw the Punch from its plastic guide (towards the
drum).
10. Fit the new punch and die pair, making sure that the
following method is used to correctly locate the die and
the guide.
a) Fit the new die plate into its recess first and loosely attach
it with the 2-off retaining screws, then fit the new punch
into its guide.
b) Gently push the punch up to the die face, then while
keeping a light pressure on the punch, jiggle the die plate
around until the punch engages in it.
c) Secure the die plate retaining screws finger tight then
recheck the movement of the punch. Tighten the screws
slightly more and repeat the check. Repeat until the
screws are fully tight.
d) Refit the ball-ended bolt into the punch actuating cam.
11. If more than one punch/die is to be replaced repeat steps a) to
d), as necessary.
12. Reassemble the machine and then switch on, performing
Steps 1. to 6. in reverse order.
13. Enable the Punch from the client GUI. (See the appropriate
RIP User’s Guide)
14. Run a sample of film through the machine. See Chapter 4 of
the Celix 4000 Recorder User’s Guide.
Punch Motor
The punch motor is a replaceable item.


2. Remove the upper rear cover from the recorder and remove
both recorder side panels. See Section 7.1.1.
3. Remove the Guillotine and the film guides, see Section 7.8.2.
4. Unscrew the 3-off, M5 bolts, then remove the lever grubscrew
and the entire assembly slides out. Do NOT detach the
shoulder bolt. Slide the lever upwards out of the rocker shaft.
CAUTION
Rotate the cam by hand very
carefully to prevent damage to the
motor gearbox.
5. There are three possible types of failures:

a) The grubscrew on the motor shaft has slipped – if the
shaft is not badly damaged, then re-tighten the screw.
b) The motor/gearbox has failed – this unit is a separate
spares item. See step 6.
c) Punch position sensor failure.
6. The motor/gearbox is attached to a mount bolted (2-off, M5)
to the main housing. These bolts should NOT be removed.
The assembly is set at manufacture to align the drive shaft and
the motor.
7. A new motor is screwed to the mount with 4-off, M2.5 bolts.
Ensure that the motor shaft flat side is facing upwards
towards the 8 mm access hole in the mount, then fully tighten
the grubscrew. Turn the cam 180° carefully and tighten the
other grubscrew. Solder the two motor wires (red to +ve)
8. Before refitting the assembly, operate the Punch a few times
using Celix Diagnostics:
. .
Mech init punch
9. Check that the motor is operating in an anti-clockwise

direction; if it is not, the wires have been soldered incorrectly.

10. Check that the rocker bar and pins are free to move in and
out; it should be possible to move the bar with your fingers. If
any sticking points are felt, or the mechanism is locked, adjust
the dies, as required. See the Section, Punch and Die, above.
If this does not clear the problem, a new Punch is required.
11. Bolt the assembly back to the Punch assembly.
CAUTION
Make sure that any grease or dirt
does not fall into the drum. During a
Punch service procedure, check that
the drum area under the punch is
clean.
7.8.5 Punch-to-Image Alignment

This procedure sets the alignment for the Punch trim.
1. Open the Application Monitor, obtain the Patt> submenu and
enter:
Patt>pat
to expose a grid pattern with the line length set at 100 mm.
2. Eject the pattern and expose/eject another pattern.
3. Place the two films, emulsion to emulsion, on a set of punch
pins at the top.
4. Measure the gap at the far right- and left-hand sides between
the top horizontal grid lines. The specification is less than a
200 micron error, but usually a correction much lower than
the specification can be set by shimming the Punch.
5. Loosen the two retaining bolts at one end of the punch and lift
the punch slightly. Insert a shim strip (99980111) just out
from the retaining bolts. Re-tighten the bolts and retest.

6. If the upper film is high on the left-hand side, then the

left-hand side of the Punch should be shimmed (as viewed
from the rear).
If the upper film is high on the right-hand side, then the
right-hand side of the Punch should be shimmed (as viewed
from the rear).
7. Re-check the error from step 6. above and repeat shimming
until the punch alignment is within specification.

7.9 Film Output Assemblies

7.9.1 Film Output Replacements
See the Celix 4000 Recorder Illustrated Parts Guide when
replacing parts described in this section.
Output Drive Motor

See Figure 7.19.
OUTPUT CHUTE VERTICAL OUTPUT DRIVE
DRIVE MOTOR (DC) MOTOR (STEPPER)
Figure 7.19 Location of output drive motors

2. Remove the right-hand end cover of the recorder.

3. Unplug the 9-way Mate-N-Lok connector to disconnect the
motor.
4. Remove the 4-off pozi-head screws that retain the motor
mounting plate. Withdraw the motor, taking the drive belt
with it.
5. Reassembly is the reverse of removal procedure.
7.9.2 Vertical Output Assembly
Vertical Output Removal

The following screw fixings on the Vertical Output assembly are
factory-set and should NOT be adjusted:
• T-block Allen screws (2-off) holding the block to the
assembly.
• Height adjuster screws underneath the support mounting
blocks.
• Swing bolts (once adjusted at the installation they should not
be altered).
The assembly always needs to be removed before completing the
following procedures:
• replacing the rubber drive bands on the Vertical Output
assembly
• accessing the Guillotine
• accessing the Punch
• accessing the drum film guide at the rear.
The correct Vertical Output assembly position is critical for
fault-free film handling. This position is set at the manufacturing

and installation stage and must not be altered. If removed, make

sure that the assembly is replaced in exactly the same position.
You do not need to remove the Output Chute before removing the
Vertical Output assembly.
1. Mark the position of the two support mounting blocks either
side of the Vertical Output assembly. Use a scriber for the
exact location. See Figure 7.20.
M5 BOLTS
VERTICAL OUTPUT
END PLATE
HEIGHT
ADJUST
NUT &
SHOULDER BOLT
Figure 7.20 Vertical Output mountings
2. Unscrew the two pairs of long M5 bolts holding the blocks in

position.
3. Remove the nut and shoulder bolt connecting the swing bolt
to the Output Chute assembly. Use a 10 mm nut wrench and a
4 mm Allen key on the inside.

The swing bolts will remain locked in place to ensure the

correct positioning of the assembly on refitting.
4. Remove the two long M5 dowel screws from the T-blocks.
5. Partial Removal of the Assembly. Hold the catch on one
side and gently release the dowel from the T-block. Repeat
the operation on the other side. Firmly gripping the two
T-blocks, pull the assembly upwards and out from the
recorder, taking care not to damage the drum film guides. If
necessary, rest the assembly on the main beam without
disconnecting the cables.
6. Full removal of the assembly. Disconnect the following
three cables:
– Lazy Loop sensor
– Post-Guillotine sensor
– Output drive stepper motor.
Physically remove the assembly from the recorder.
Vertical Output Replacement

7. Hold the assembly by the two T-blocks and lower it gently
into the recorder, ensuring that the two swing bolts go inside
the side plates. Be careful not to damage the drum film
guides at the bottom.
8. Screw the support blocks in the correct position to their
respective brackets, using marks made previously. This
should return the assembly to its original position.
9. Double-check that the gap between the rubber bands and the
film guide is at least 3 mm and parallel, see Figure 7.21.
Adjust, if necessary.
10. Re-insert the 2-off dowel screws and the nut and shoulder
bolts.

SWING BOLT
VERTICAL OUTPUT
ASSEMBLY
LOCKNUT CHECK
ACCESS HOLE HERE FOR
GAP (2-3 MM)
FILM GUIDE
RUBBER BAND
ROLLER
Figure 7.21 Setting the Vertical Output-to-film guide distance
7.9.3 OutputChute
Output Chute Removal


The Output Chute does not need to be removed for accessing the
Punch and Guillotine. This can be achieved by removing the
Vertical Output assembly (see Section 7.9.2).
1. De-couple the processor from the Output Chute assembly.
2. Remove the top rear panel.
3. Release the dowels from their T-blocks on both sides by
removing the long M5 fixing screws.
4. Disconnect the four cables: and on the left-hand side and the
on the right.
a) Output EOT sensor.
b) Top panel interlock.
c) Drive motor.
d) Fan.
5. Unscrew the support brackets from the recorder.
6. Lift the chute up and out while holding the two T-block
catches down. This can be a one–man operation, but it is
easier for two people. Do not unscrew or alter the T-block
fixing to the Vertical output assembly.
Output Chute Replacement

This is refitted using the following procedure:
1. Set the support brackets so that they are initially free of the
seal. See Figure 7.22.
Use the same 4-off M4 screws so that there is approximately a
6 mm overhang to ensure a light-tight fit to the rubber seals.
The screw holes are slotted to allow 1.5 mm of movement.
Make sure that the brackets are straight.

OUTPUT
CHUTE
5 mm
OVERHANG
OUTPUT
SUPPORT
BRACKETS
Figure 7.22 Positioning the support brackets
2. Lift the Output Chute assembly and offer it to the recorder.

Push in the assembly and gradually move it upwards so that
the two dowels pass the two catches on the Output Vertical
assembly and the dowels are securely latched, see
Figure 7.23. Once the catches are made, the assembly is safe
and can be left to hang without support.
3. Bolt the support brackets to the recorder using 4-off M5
screws. Lift and push in the chute assembly to its maximum,
ensuring the bolts hold the support brackets as high as
possible so that they take the weight of the chute. If the slots
do not line up with the holes, realign the brackets on the chute
by loosening the four screws.
4. Check that the support brackets are fully supporting the
weight of the bridge. The two locating dowels should be close
(within 1-2 mm) of the registration T-blocks on the Output
Vertical assembly.

5. Screw the dowels to the T-blocks using the long M5 dowel

bolts. Avoid using too much torque – the Output Chute
assembly should not move at all (or very slightly). The dowel
bolts must not support the full weight of the assembly.
6. Reconnect the three cables.
DOWEL
BOLT
T-BLOCK
OUTPUT
CHUTE
GUIDE
CATCH
LOCATING
DOWEL
Figure 7.23 Latching the output assembly
7. Check that the Output Vertical assembly lower roller position

is either side of the drum film guides, see Figure 7.21. Ensure
that the black rubber bands are not touching the guide.
If they are, loosen the locking nuts and adjust the swing bolts
so that the rollers move into the recorder, away from the
rubber bands. Check that these rollers are parallel to the film
guides.
8. Route and link the following cable connectors to their mating
free ends (labelled) on the recorder:
• Left-hand side output EOT (at processor) sensor: connect
the output chute end-of-travel limit sensor cable connector
to the mating connector in the output chute assembly.

Secure the cable with a cable tie so that it is clear of the

belts.
• Left-hand side output chute cover interlock: connect the
output chute home sensor (bottom right as viewed from
the front), ensuring its cable is clear of the belts.
• Right-hand side chute drive motor: connect the
output-chute drive motor to its corresponding connector
above the leadscrew on the right-hand side of the
recorder.
7.9.4 Output Rubber Bands Replacement

See Figure 7.24.
Film is moved from the Vertical Output assembly to the processor
by a set of circulating rubber bands and rollers. Any one of these
bands can be replaced by detaching the rollers from their end
plates.
Vertical Output Bands

1. Remove the Vertical Output assembly and place it on a large
table, or on the floor. See Section 7.9.2.
2. Remove the left-hand side end plate (black) on the non-motor
side by removing:
a) the 4-off screws holding the two extrusion guides
b) the 4-off bolts holding the two tie bars.
The entire end plate is removed, but you do not need to
remove the four needle bearings. This gives you access to the
crowned rollers and rubber bands.
3. Replacement is the reverse of Removal.

Output Chute Bands

1. Remove the Output Chute from the recorder, see Section
7.9.3.
2. Unscrew the 2-off AV mount screws and the 2-off small
screws underneath, at the processor interface end, and slide
out the roller assembly from the chute. (This may require
loosening the DC motor bracket screws).
3. At each end of the crowned roller, loosen the small 2 mm
grub screw. Screw the M6 bolt into the dowel, but not all the
way inside.
4. Using pliers, gently pull the dowel out of the roller and
through the needle bearing.
5. Complete steps 3. to 4. for all four rollers on the left-hand
side, which should allow you to remove the rubber bands.
6. Replacement of the rollers is the reverse of the their removal.
2 mm
GRUBSCREW
M6 BOLT ROLLER
INSERTED
HERE
OUTPUT
CHUTE
Figure 7.24 Replacing Output chute bands

7.10 Reconnecting the Recorder to the Film

Processor
Note: This procedure is used as a general guideline for fitting the
recorder to different types of processors.
When reconnecting the recorder and its processor make sure they
are aligned accurately on the horizontal and vertical planes so that
the film can pass from the output of the recorder into the input
roller of the processor without fouling or the risk of intermittent
failure.
Also. ensure that the recorder is level, otherwise oil may run out
of one end of the V- groove, leading to loss of Optics Carriage
ÉÉ
lubrication.
ÉÉ PLYWOOD
ÉÉ
LEVEL
SEPARATOR
ÉÉ
(OPTIONAL)
ÉÉ
CATCH
OUTPUT LEVER ARM
ÉÉ
FILM GUIDE
FILM
PROCESSOR
ÉÉ
ÉÉ LOWER
ÉÉ
INPUT PLATE
TRAY
ÉÉ
ÉÉ RS-232 I/F CABLE
ÉÉ
BETWEEN RECORDER
AND FILM PROCESSOR
Figure 7.25 Locating the film processor and output chute

1. Move the recorder close to its final location with the output
film guide plate projecting through the hole in the plywood
separator, if fitted (see Figure 7.25).
2. To level the recorder drum from side-to-side, open the top
panel of the recorder and place a spirit level along the top of
the main beam for side-to-side levelling (see Figure 7.26) and
front-to-back levelling (see Figure 7.27).
This is not a machined surface but providing obvious beam
flaws are avoided the levelling accuracy should be sufficient.
Do not use the external frame for levelling the recorder.
Adjust the levelling blocks as required, see Figure 7.28.
Check that the Output Chute exit slot and guides are also
level.
LEVELLING
LOCATION
Figure 7.26 Side-to-side levelling

LEVELLING
LOCATION
Figure 7.27 Front-to-back levelling
BOSS ON
UNDERSIDE
OF RECORDER
HEIGHT COMPENSATING PLATE 15 mm LEVEL

ADJUSTING NUT
Figure 7.28 Levelling the recorder

3. To level the drum from front-to-back, place the spirit level on

the raised machined surfaces at one the end of the top beam.
Adjust the front feet as required, then repeat at the other end
of the beam.
4. Repeat all drum level checks and adjust where required. Make
sure that the recorder is steady at all four corners.
5. Align the Output Chute with the processor entry slot and
adjust the processor height, if necessary, using the procedure
ÉÉ
recommended by the processor manufacturer.
ÉÉ
ÉÉ
ÉÉ
ÉÉ
OUTPUT
FILM GUIDE
FILM
PROCESSOR
ÉÉ
ÉÉ
ÉÉ LOWER
ÉÉ
PLATE
ÉÉ
ÉÉ
Figure 7.29 Engaged recorder/film processor interface
6. Refer to Figure 7.25 and Figure 7.29. Clip the catch lever to
the chute so that the output film guide is temporally raised.
Move the processor forward ensuring that the Output Chute
exit engages the processor as a push-fit and that:
– the labyrinth halves are fully engaged
– the lower plate of the recorder output film guide just rests
on top of the processor input tray.

7. Push the processor towards the recorder to obtain a light-tight

seal. Unclip the catch lever arm and check the following:
• the processor is level
• the output film guide, resting on the processor tray, is able
to ‘wiggle’ freely from the catch lever arm.
If the catch does not drop freely then the guide is fouled and
film will not feed correctly into the processor. This can
happen if the chute or the processor is not quite level.
It may be necessary to readjust the processor height. If so,
recheck the levelling.

Expose System 8
Replacements
and Setups
This chapter describes how to access, remove, re-install and
adjust the main replaceable parts used for media expose:
• Optics Carriage Baffle - Section 8.1.
• Optics Carriage Assembly - Section 8.2.
• Optical Alignment Procedures - Section 8.3.
• Setting the Vertical Offset and Horizontal Trim - Section 8.4.
Make sure any modifications and replacements are entered in the
Log Book.
WARNING
While the machine is idle, the
spinner slows to a very quiet speed.
Ensure that the recorder is powered
down and switched off at the mains
isolator before starting these
procedures.

Expose System Replacements and Setups
8.1 Baffle
8.1.1 Removal
See Figure 8.1 and the Celix 4000 Recorder Illustrated Parts
Catalogue.
The Baffle assembly, which is fixed to the Optics Carriage by a
yoke mount, is divided into two sections for the laser and spinner
sides. It is removeable as a single module.
1. Traverse the Optics Carriage to the far right side using the
Application Monitor command:
Trav>ri
2. Remove the Baffle by unscrewing the two quick-release

screws and withdraw the assembly from its locating pins.
LOCATING PINS
FINGER TIGHT
SCREWS
Figure 8.1 Baffle fixings

Expose Systems Replacements and Setups
8.2 Optics Carriage Assembly

You need to remove the Optics Carriage from the recorder to
carry out the service procedures (except for the spinner
replacement) described in this chapter. The carriage is removed
from the right-hand end of the machine, supported and rotated for
better access to the optics mechanisms. The umbilical cable does
not need to be disconnected from the ECU or the optics base, so
allowing laser and the diagnostic checks to be run while the
carriage is outside the recorder.
CAUTION
Do not run the spinner with the
Optics Carriage removed.
8.2.1 Optics Carriage Removal and Replacement

(Without the Jig Removal Tool)
This section describes how to access, remove the replace the
Optics Carriage fitted to a Celix 4000 machine without the jig
removal tool. See Section 8.2.2 for details on how to use the jig
removal tool.
Removal
Before commencing this procedure, ensure that optics service
tool (75472310) is conveniently sited to support the inverted
Optics Carriage assembly after its removal from the machine.
With this procedure the umbilical cable does not have to be
disconnected from the ECU or the Optics Carriage; this enables
the optics mechanisms to be run while the carriage is outside the
recorder.

Figure 8.6 shows the appearance of the Optics Carriage after

removal from machine and ‘inversion’.
1. Apply mains power and switch on the recorder.
Notes: The metal cover from the replacement Laser Diode is
fitted to the old diode before it is returned. If the cover
is not available, take care not to put any pressure on
the laser-diode heatsink as this may break the thermal
bond and make the whole Optics Carriage useless.
2. Open a Celix Diagnostic Terminal window on the RIP server.
RIGHT END OF DRIP TWIST

TRAY CAPTIVE
SCREWS
DRIP TRAY
DRIP TRAY
CROSS HEAD
LEFT END OF DRIP SCREWS
TRAY
Figure 8.2 Removing the leadscrew drip tray

.
3. Access the Diagnostics program - mech g_trav . InitDSP -
to initialise the traverse system.
4. When the system has initialised, type:
Move 260
to move the Optics Carriage and align the C-clamp of the

Optics Carriage with the access hole.
6. Remove the Input Cassette and the upper blanking plug on the
rear of the cassette bay.
BLANKING
PLUG
Figure 8.3 Blanking plug for Optics Carriage
7. Ensure that suitable worktop is situated adjacent to the

right-hand end of the recorder to support the Optics Carriage
assembly upon removal.
8. Remove the right-hand end cover.

9. Secure the Leadscrew to the top beam using the leadscrew

securing tool (75472760).
10. Remove the leadscrew drip tray, see Figure 8.2.
11. Remove the Baffle by releasing the two finger-tight screws
holding the Baffle to the carriage. (The Baffle is withdrawn
from their locating pins).
GIMBAL CLAMP
OPTICS CARRIAGE
GIMBAL CLAMP
TOP BOLT
Figure 8.4 Location of Gimbal clamp
12. Release the C-clamp from the gimbal by slackening (but not
removing) the upper bolt only, see Figure 8.4, using at least a

170 mm long 4 mm hexagonal wrench through the hole

revealed in step 6.
13. Disconnect the spinner drive at the plug and socket of the
umbilical loom that is on top of the beam.
14. Undo the two screws securing the cable assembly bracket to
the beam. See Figure 8.5.
15. Obtain a convenient box which can be used as a stand for the
inverted carriage assembly when it is removed from the
recorder. Cover the box with a soft cloth or towel. See
Figure 8.6.
CAUTION
Do not let the leadscrew drop when
the bearing block is removed. If it
does drop, the left-hand bearings
could be damaged and patterning
may result.
Do not use strong force when pulling

off the bearing block, the ball race
may be damaged or collapse,
causing the balls to fall out.
16. Undo the two bolts securing the right-hand end bearing block
at the right-hand end of the lead screw and carefully remove
the end bearing block from the machine.
17. Remove the blanking plate from the right-hand end of the
V-groove, see Figure 8.5.
18. Remove the right–hand side bearing pad.
19. Rotate the carriage, making sure you do not pull on or trap
any cables. See Figure 8.6.

CABLE ASSEMBLY
BRACKET
FIXING
SCREWS
END BEARING
BLOCK
V-GROOVE
END PLATE
Figure 8.5 End bearing block and V-groove end plate

RECORDER NEXT
TO TABLE
COVER PLATE
BOX USED AS
SUPPORT
Figure 8.6 Optics Carriage removal

CAUTION
The carriage is rotated 180°
ant-clockwise, end over end. When
refitting it must be rotated back in
the same way. This will avoid
twisting the umbilical cables which
would otherwise put a strain on the
Optics Carriage, causing patterning
or traverse errors.
20. Withdraw the Optics Carriage assembly, see Figure 8.6, from
the machine and place it on the covered box stand. Part field
replacement can now be carried out.
Replacement
1. Before replacing the Optics Carriage, make sure that the
spinner mirror and focus lens have been cleaned. See Section
12.4.2.
2. Replace the Optics Carriage assembly using the reverse
procedure to Removal.
CAUTION
When inverting the orientation of
the Optics Carriage assembly for
returning to the machine, make sure
the umbilical loom is not twisted.
3. Refill the V-groove with Slideway 68 oil, see Section 9.1.2.

8.2.2 Optics Carriage Removal and Replacement (With

the Jig Removal Tool)
Removal
See Figure 8.7.
This procedure is used for accessing an Optics Carriage with a jig
removal tool. The tool is divided into two separable assemblies:
• vertical support – This is bolted to the beam on the recorder
and is fitted to the horizontal support.
• horizontal support – This supports the Optics Carriage and
rotates 180° around the horizontal support shaft.
1. Complete steps 1. to step 17. in Section 8.2.1. See Figure 8.4.
2. Attach the vertical support to the top right-hand end of the
drum beam using the two 8 mm red transit bolts (one bolt is
holding the two assemblies together and the other is on the
front face of the vertical support).
3. Attach the horizontal support of the removal tool to the
vertical support.
Ensure that the V-groove of the removal tool is aligned
laterally with the recorder V-groove. The top beam screw
holes are slotted for adjustment.
4. Slacken the two V-groove securing screws on the horizontal
support slightly so that the V-groove is just free to move
vertically.
5. Look along the tool V-groove and, using the height adjuster
screw, ensure that the front edge of the tool V-groove is
slightly below the V-groove on the recorder. This prevents the
bearing pads from catching the front edge of the V-groove on
the tool.
Note: The front edge of the removal tool MUST NOT be
above the V-groove on the recorder.

RH END OF
BEAM
VERTICAL SUPPORT
SECURING BOLTS
HORIZONTAL SUPPORT
SECURING SCREW
V-GROOVE
(RECORDER)
V-GROOVE
V-GROOVE HEIGHT
SECURING ADJUSTER
SCREWS
HORIZONTAL
SUPPORT
Figure 8.7 Aligning the removal tool
6. Tighten the V-groove securing screws.

7. Withdraw the Optics Carriage from the drum by holding on to
the optics base casting. Do NOT hold the spinner body or
mounting plates. Ensure that the umbilical cable is free to
allow movement of the Optics Carriage.
8. Observe the bearing pads as they approach the end of the
recorder V-groove. If necessary, use your fingers to guide the
pads across and onto the tool V-groove.

9. Guide the top roller of the Optics Carriage into and under the
retaining plate at the top of the tool.
10. When the second (left-hand) pad is positioned onto the tool
V-groove, align the Optics Carriage so that the carriage
securing screw hole (slotted) on the tool retaining plate aligns
with the tapped hole in the Optics Carriage (adjacent to the
top roller).
11. Remove the carriage securing screw from its transit position
on the vertical assembly and secure the plate to the Optics
carriage. Rotate the jacking screw until it touches the spinner
carriage casting. Do NOT overtighten this screw – it is only
used to add rigidity.
12. Firmly hold the Optics Carriage and slowly rotate the carriage
anti-clockwise (when viewed from the right-hand side) to
reach its end-stop. While in position, the carriage will be
supported by the tool and prevented from rotating further.
13. You can now access the optics components.
Replacement
1. Before replacing the Optics Carriage, make sure that the
spinner mirror and focus lens have been cleaned. See Section
12.4.2.
2. Rotate the Optics Carriage (and tool) by reversing the
operation in step 12. in the Removal section above.
3. Carefully slacken the V-groove securing screws and turn the
height adjuster screw until the front edge of the removal tool
is slightly above the V-groove on the recorder. Tighten the
V-groove screws.
4. Slacken the jacking screw and release the carriage securing
screw. Guide the carriage into the drum until the left-hand pad
is at the end of the tool V-groove.
5. Using your fingers, guide the pads across and onto the
recorder V-groove as the carriage enters the drum.

CAUTION
Make sure the umbilical loom is not
twisted at the front part of the drum.
6. Push the carriage into the drum until the Gimbal C-clamp
covers the nut and is against the Gimbal hard shoulder.
7. The remainder of the Replacement procedure is the reverse of
the Removal procedure from step 18. to step 1. in Section
8.2.1. Complete Section 8.2.3 below.
8. Refill the V-groove with Slideway 68 oil, see Section 9.1.2.
8.2.3 Coupling the Optics Carriage to the Leadscrew

Gimbal
This procedure explains how to couple the Optics Carriage to the
Leadscrew after it has been uncoupled as part of the Optics
Carriage removal procedure.
Note: A 4 mm hexagonal wrench is required for this operation.
1. Remove the in-line blanking plug which is offset above the
two blanking plugs, see Figure 8.3.

SLIDE THE OPTIC CARRIAGE TOWARDS

THE LEADSCREW SLEEVE UNTIL THE
GIMBAL ENGAGES THE CLAMP
LEADSCREW
SLEEVE
OPTICS
CARRIAGE
CLAMP
GIMBAL/LEADSCREW VIEW A GIMBAL 4 mm ALLEN KEY

SECURING BOLT
WHEN TIGHTENING THE CLAMP, THE GAPS

IN THE GIMBAL MUST NOT CLOSE-UP
VIEW B TIGHTEN THE UPPER CLAMP

SCREW TO SECURE THE OPTICS
CARRIAGE TO THE LEADSCREW
SLEEVE
Figure 8.8 Coupling the Optics Carriage to the leadscrew sleeve

2. Using the 4 mm hexagonal wrench, slacken the upper

clamp-screw on the Optics Carriage, see Figure 8.8(A) and
Figure 8.4.
3. Rotate the gimbal to bring the gimbal/leadscrew securing bolt
to a position where the head faces the front of the machine.
You may need to also manually rotate the leadscrew to bring
the gimbal/leadscrew securing bolt to a position where the
head is accessible through the holes in the front of the
machine, see Figure 8.8(B).
4. Slide the Optics Carriage towards the leadscrew sleeve until
the gimbal engages with the clamp.
5. Secure the Optics Carriage tight against the shoulder of the
leadscrew sleeve by tightening the upper clamp-screw in the
gimbal.
6. Refit the blanking plug.
8.2.4 RFI Box Assembly (Optics)

The recommended equipment and special tools for servicing a
Celix 4000 recorder are shown at Appendix C. This assembly is
not field replaceable but you may need to remove it for access to
other components.
CAUTION
The diode of the Laser Diode
assembly is particularly susceptible
to electrostatic damage. Ensure the
required precautions are taken
before removing Laser Diode cable
connectors from the optics RFI Box.

CAN I/F CABLE D

(TO UMBILICAL CABLE)
SK5
(TO LASER DIODE
MODULE)
SK4
(TO
PHOTODIODE ON
SHUTTER)
SK2 AND SK3

(TO LASER
DIODE MODULE)
SK7 IMAGE H2
(TO UMBILICAL CABLE)
Figure 8.9 Optics: RFI box assembly
Removal
See Figure 8.9, Figure 8.11 and Figure 8.10.
1. Remove the Laser Diode protective cover.

2. At this stage, prior to the disconnection of the connectors

from the Laser Diode assembly use a wrist strap (99987935)
earthed to the Optics Carriage.
3. See Figure 8.9 and Figure 8.11. Disconnect external
connectors from the (optics) RFI Box as follows:
• Connectors (SK2, SK3 and SK5) from the Laser Diode
assembly. Fit the Laser Diode assembly blanking plugs
(75486280) to these connectors, see Figure 8.10. Remove
them in the sequence SK2, SK3 and SK5.
• The umbilical cable connectors.
• Connector (SK4) from the shutter-mounted monitor
diode.
4. Remove the four retaining screws, two in each horizontal
mounting strip, see Figure 8.9. Now remove the RFI Box.
LASER DIODE
ASSEMBLY
BLANKING PLUG,
3-OFF
(75486280)
Figure 8.10 Laser Diode assembly blanking plugs

CAN I/F LASER

EXTERNAL 9-WAY CABLE MODULATOR
MONITOR CABLE D-TYPE D-TYPE BOARD
(CONNECTED TO (UMBILICAL)
PHOTODIODE ON
SHUTTER) SK4
RFI
BOX
TO
UMBILICAL
CABLE
LASER
DIODE
BIAS SK5
SK2
SK3 INTERNAL LASER
DRIVE LASER DIODE BOARD SK7
PHOTODIODE AND MODULE IMAGE H2
(SEE DIAGRAM BELOW)
SK1
LASER DIODE BOARD
SK2
TO INTERNAL
SK3
PHOTODIODE
(SK3)
TO LASER DRIVE
(SK2)
TO LASER DIODE BIAS
(SK5)
Figure 8.11 Optics: internal cabling - RFI Box

Replacement
1. Fit the RFI Box upon its mounting position with the four
retaining screws.
2. Reconnect external connectors to the optics RFI Box (see
Step 3 of the Removal procedure. The blanking plugs,
(75486280) see Figure 8.10 fitted to the Laser Diode
assembly cable connectors must be removed before the
connectors from the Laser Diode assembly can be connected.
8.2.5 Shutter Solenoid
Removal, Replacement and Check

1. With the Optics Carriage assembly, see Section 8.2, removed:
a) Move the Baffle and Aperture assembly cover.
b) Remove the four retaining screws of the optics RFI Box
(two in each horizontal mounting strip).
c) Disconnect socket connector SK7 and the CAN I/F
connector (Cable D), see Figure 8.9.
d) Disconnect the shutter photodiode termination (at the
shutter solenoid, see Figure 4.26).
2. Lift off the optics RFI Box and place on one side with
remaining cable connection still fitted.
3. Lift off the smaller (illumination) dust cover. See Figure 4.27.
4. Remove the dust cover from from the sensor distribution
board.
Note: If removing the Sensor Distribution board, first remove
the dust cover over the board. To do this undo, without
removing, the two retaining screws located at the foot
of the cover; then lift the dust cover at the top to
remove it. Do not forget to replace this cover after
replacement of the Sensor Distribution board.

APERTURE
MOTOR
APERTURE BEAM SHUTTER

PLATE EXPANDER SOLENOID
SHUTTER
PHOTODIODE
CONNECTOR
TO OPTICS
RFI BOX, SK4
(See Figure 8.11)
FOCUS
MOTOR
LASER
DIODE
ILLUMINATION MODULE
MOTOR
RETAINING
SPRING (4 OFF)
Figure 8.12 Optics: Laser Diode module, motors and solenoid
5. Remove the solenoid connection from PL9 (Shutter Supply)

on the Sensor Distribution board, and cut the tie-wraps
securing the shutter cable.
6. Use a flat metric spanner to slacken-off the nut which retains
the solenoid body. Remove the nut and withdraw the solenoid.
7. Discard the plunger from the new solenoid. Fit the new 24 V
solenoid to the existing plunger.

8. Complete the reassembly of the Optics Carriage assembly in

reverse order to Steps 1. to 7.
9. Insert the safety interlock override keys for the right-hand end
cover and the left-hand hinged door.
11. Select the top level menu of the Diagnostics.
12. To check solenoid initialization, use commands:
. .
mech sol init
13. Now type:

onoff
this displays the SENSORS and SOLENOIDS screen.

14. Type A and at the same time:
a) observe that A- Laser Shutter changes to
A+ Laser Shutter, which means that the laser shutter has
opened
b) listen in order to note the audible indication of the shutter
operation
c) observe the downward movement of the solenoid plunger
d) switch laser on using the following command sequence
from Celix Diagnostics:
. . .
opti init motcal laser_set
and select d then shutter open to operate shutter, and

check for clipping of the laser spot while the shutter is
open.
WARNING
Observe laser safety precautions
detailed in Chapter 2. The laser is a
20 mW at 670 nm. The light beam
can damage your eyes.


16. Refit the Optics Carriage assembly, see Section 8.2.
17. Reconnect the umbilical to the Input/Output Panel (if
removed).
18. Remove the safety interlock override keys.
19. Drive the carriage to the left.
20. Remove the metal cover protecting the Laser Diode.
21. Replace the right and left-hand end covers.
22. Close the left-hand hinged door.
23. Remove the interlock keys.
25. Perform focus check, as detailed in Section 8.3.2.
26. Run the D-Max test (laser calibration) in accordance with the
procedure in the appropriate RIP user’s guide.
27. Perform a Registration procedure, see Section 8.3.3.
8.2.6 Shutter Assembly
Removal
See Figure 8.13.
1. With the Optics Carriage assembly removed, see Section 8.2:
a) Move the Baffle and Aperture assembly cover.
b) Remove the four retaining screws of the optics RFI Box
c) Disconnect socket connector SK7 and the CAN I/F
d) Disconnect the shutter photodiode termination (at the

3. Lift off the smaller (illumination) dust cover. See Figure 4.27.
4. Remove the dust cover from the sensor distribution board.
5. Disconnect the shutter solenoid cable from the sensor
distribution board.
6. Remove the three screws securing the shutter assembly.
TO SENSOR
DISTRIBUTION BOARD
SHUTTER
SOLENOID
SHUTTER PHOTODIODE
CONNECTOR
SHUTTER ASSEMBLY
SCREWS (3OFF)
TO OPTICS
RFI BOX, SK4
(See Figure 8.11)
SHUTTER
ASSEMBLY
Figure 8.13 Shutter assembly removal

Replacement
Re-fit the new shutter in reverse order of the Removal procedure.
Shutter Assembly Checks

Make sure the shutter securing screws are tight and that the
shutter solenoid is operating correctly. See step 11. to 15.
Note: Make sure the laser spot is not clipped, while the shutter is
open.
8.2.7 Aperture Motor
Removal
See Figure 8.14.
Note: Before removing any motor, make sure the appropriate
sensors are operating correctly.
1. With the Optics Carriage assembly dismounted, see
Section 8.2:
• Remove the Baffle.
• Remove the larger dust cover (located above the aperture
and focus assemblies) by removing the four retaining
screws.
2. Disconnect the plug at the Aperture motor.
Note: Disconnection requires you to break the adhesive bond
between the plug and motor.
3. Remove the four screws holding the RFI box (do not
disconnect any cables) and move the optics RFI Box away
from the spinner sufficiently to remove the Aperture motor.
4. Mark the position of the slotted aperture sensor plate with
respect to the support block to ensure accurate reassembly.

APERTURE
MOTOR APERTURE
HOME
APERTURE
LIMIT SENSOR
(BACK END
LIMIT)
APERTURE SENSOR
BRACKET SECURING
SCREW
APERTURE SENSOR
BRACKET
APERTURE PLATE
SENSOR VANE
REF
POINT
Figure 8.14 Aperture limit sensor calibration
Note: The marking must be done accurately to ensure that

re-assembly to within 0.5 mm, or better, is achieved.
5. Remove the aperture sensor plate assembly and the block.
Note: The two block-retaining screws also secure the top of
the sensor.
6. Move the rack of the aperture plate fully to each side in order
to give access to the two lowermost screws of the Aperture
Motor mounting base.
7. Release the retaining screws using a ball-ended hexagonal key
and then remove the motor.

Replacement
Note: Cables are connected to the motor using a ’dots’ of
low-strength epoxy-type adhesive. When re-assembling the
cable to a new motor, make sure the adhesive has dried
before replacing the motor casing.
Fit the new motor in reverse order to Steps 2. to 7. of the
Removal procedure. After fitting the motor, carry out the
Aperture Motor Mechanical checks.
Aperture Motor Mechanical Checks

Note: The motor securing screws give clearance in the bracket to
permit some adjustment of the gear mesh.
1. Set the screws lightly and manually move the aperture plate
across its full range of travel, correcting for any tight spots.
2. Make a final check using a spring balance and a thin cord
attached to the aperture plate.
A pull of no more than 300 g should be sufficient to start the
plate moving and to traverse it across its full range of travel.
3. Complete the checks and replace the aperture sensor
assembly.
4. Replace the aperture dust cover (located above the aperture
and focus assemblies) by fitting and securing the four
retaining screws.
5. Replace the Baffle.

Aperture Motor Checks with Power Applied
CAUTION
Do not attempt this procedure if the
Aperture Plate has end-stop screws
fitted, otherwise the Aperture motor
and motion control board may be
damaged.
Do not remove the linear bearing

(green block) end plate retaining
screws because tiny ball bearings
will fall out, resulting in possible
subsequent damage to the bearing.
1. Apply interlock override keys to override the right-hand end

cover interlock and interlock of left-hand hinged door.
3. Obtain the top level menu of the Diagnostics.
4. Initialise and run the mechanism 10 times, error free, using
the soak diagnostic commands:
.
optics init
optics.sen.s∆ap∆10
5. Re-calibrate the Home sensor using the procedure in

Section 8.2.10 (Replacement Checks).
7. Refit all covers and Baffle.
8. Refit the Optics Carriage assembly, see Section 8.2.
removed).

10. Apply power to the recorder.

12. Remove the interlock override key from the machine.
13. Refit the right and left-hand end panels.
8.2.8 Focus Motor
Removal
sensors are operating correctly.
Section 8.2:
screws.
2. Disconnect the plug at the Focus motor.
3. Release the three screws in the flange of the Focus motor and
remove the existing Focus Motor, see Figure 4.26.
Replacement
Reassemble in reverse order to Steps 2. to 3. of Removal. Then
carry out the following Focus Motor Mechanical Checks.

Focus Motor Mechanical Checks

See Figure 8.15.
Adjustment of the focus motor and its gear to the gear on the
leadscrew is very important. To ensure that this is correct:
PLACE PIECE OF FILM

BETWEEN GEARS
Figure 8.15 Focus motor gear phasing
1. Rotate the motor gear, feeling for any tight spots.

Note: Do not over-tighten the three flange screws at this stage.

2. Leave the gear at the tightest spot, if any are located.
3. Make sure the motor is just moveable vertically.
4. Insert a strip of cellophane (0.005 in. thick) between the two
gears. This strip is supplied with each new motor.
5. Move the motor, to trap the cellophane strip.
6. Tighten the screws holding the motor.
7. Remove the cellophane strip and check the setting by rotating
the gear verifying that there are no tight spots.
Upon completion of these checks, replace the larger dust cover
and the laser side Baffle in reverse order to Step 1. of Removal.
Focus Motor Checks with Power Applied

1. Insert the safety interlock override keys to override the
right-hand end panel interlock and the interlock of the
left-hand hinged door.
3. Obtain the top level menu of Celix Diagnostics.
4. Initialise and run the mechanism 10 times, error free, using
diagnostic commands:
.
optics init
optics.sen.s∆fo∆10

6. Replace the Optics Carriage assembly, see Section 8.2.
removed).
8. Remove the safety interlock override keys from the machine.
9. Refit the right-hand end cover and close the left-hand hinged
door.

10. Power on the recorder.

12. Run a Focus check procedure, see Section 8.3.2.
8.2.9 Illumination Control Motor
Removal
sensors are operating correctly. Then inspect the fuses and
voltage cables.
1. With the Optics Carriage assembly removed, see Section 8.2
from the machine, remove the optics RFI Box, as described in
Section 8.2.4. and the smaller (illumination) dust cover.
2. Disconnect the plug at the motor.
3. Release the four screws retaining the mounting bracket
supporting the Illumination Control Motor, see Figure 4.26.
4. Move the bracket in the direction of the Spinner to slacken the
drive belt.
5. Release the drive belt and raise the bracket with attached
motor clear of the pillar.
Note: On early versions of the optics it may be necessary to
remove the plate from the top of the pillar before the
bracket can be released.
6. Remove the motor from the mounting bracket.

Replacement and Checks

1. Fit the new motor on the mounting bracket and position the
mounting bracket upon its fixing holes.
2. Ensuring the drive belt is looped over the toothed pulley on
the motor, move the mounting bracket slightly in the opposite
direction to the Spinner to take up the slack in the drive belt.
3. Implement the following mechanical checks. Using a spring
balance and a thin cord secured to the wedge mechanism
measure the pull required to move the wedges across the full
range of travel. Tension the belt to a value not exceeding 300g
on the balance.
4. Tighten the retaining screws.
5. Reconnect the motor to its cable.
6. Fit the illumination dust cover and the RFI Box upon its
mounting position with the four retaining screws.
7. Reconnect all external connectors of the RFI Box (see
Figure 8.9).
9. Implement the following checks with power applied:
a) Switch on the recorder.
b) Obtain the top level menu of Celix Diagnostics.
c) Run the mechanism 10 times, error free, using diagnostic
commands:
.
optics init
optics.sen.s∆ill∆10

11. Replace the Optics Carriage assembly, see Section 8.2, in the
machine.
removed).
16. Refit the right-hand end cover and close the left-hand hinged
door.

8.2.10 Aperture Sensors
LASER SIDE BAFFLE
Figure 8.16 Location of laser side Baffle
Removal
Note: The FRU is the sensor bracket complete with sensors and
cable.
1. With the Optics Carriage assembly removed, see Section 8.2,
from the machine:
screws.

2. Disconnect the plug at the aperture motor.

3. Check visually for damage to the sensor wires and
terminations.
4. Disconnect the sensor cables from plugs PL1, 7 and 11
(cutting tie-wraps if necessary) on the Sensor Distribution
board, see Figure 4.28.
5. Mark the position of the slotted aperture sensor plate with
respect to the support block to ensure accurate reassembly.
6. Remove the bracket assembly and the block complete with
sensors and cable.
low-strength epoxy-type adhesive. When re-assembling
the cable to a new motor, make sure the adhesive has
dried before replacing the motor casing.

1. Fit the new bracket assembly in the position previously
marked, reassembling in reverse order to Steps 1. to 5. and
connect the cables to the Sensor distribution board, see
Figure 4.27.
CAUTION
Make sure the sensor vane passes
through the sensors without
touching either the top or sides of the
sensor, see Figure 8.18.



5. Run the mechanism 10 times, error free, using:
optics.init
optics.sen.s∆ap∆10
6. Re-calibrate the Home sensor as follows:

a) From the top level Celix Diagnostics menu, enter
diagnostic commands (see Section 6.10.5 and
Figure 8.17):
optics .motcal.set∆ape
Figure 8.17 Set aperture diagnostics window

CAUTION
Check to ensure that the spinner is
NOT moving, before proceeding.
b) As instructed in the Motor Calibrate window, enter 1 to

select the Gemini (Celix 4000) optics base (carriage), and
remove the aperture back end limit (aperture limit) sensor
as shown in Figure 8.18, and temporarily secure it away
from the path of the aperture plate.
c) Press any key to display the next instruction.
d) Press n to move the position of the aperture plate in
increments (steps) until it reaches the reference point
shown in Figure 8.18. This is the inside face of the
baseplate.
e) Press any key to display the next instruction.
f) Enter the number of steps that were required to move the
aperture plate to the reference point.
g) Follow the on-screen instructions to complete the
procedure.
Note that if the message Move assembly to increase the
number of steps appears, the adjustment range has been
exceeded. If so, loosen the Allen screw securing the
aperture sensor bracket shown in Figure 8.14 and
pre-position the the bracket to the distance specified in the
message, then re-tighten the Allen screw. Repeat the
procedure in Step 6.
8. Refit all covers and Baffle.
9. Refit the Optics Carriage assembly.
10. Remove the interlock override key from the machine.
11. Refit the right and left-hand end panels.

APERTURE
MOTOR APERTURE
HOME
APERTURE LIMIT SENSOR

(BACK END LIMIT)
APERTURE SENSOR
BRACKET SECURING
SCREW
APERTURE
SENSOR BRACKET
APERTURE PLATE
SENSOR VANE
REF
POINT
Figure 8.18 Aperture limit sensor calibration

8.2.11 Focus Sensors

FOCUS LIMIT SENSOR FOCUS LIMIT SENSOR
(FORWARD/EOT1) (REVERSE/EOT2)
FOCUS HOME
SENSOR
Figure 8.19 Optics - Focus Sensors
Removal
cable.
Section 8.2:
• Remove the aperture dust cover (located above the
aperture and focus assemblies) by removing the four
retaining screws.
terminations.

3. Disconnect the sensor cable(s) from PL 5 (Home), or PL8 and

PL14 (limits) on the Sensor Distribution board, see
Figure 4.27.
4. To remove a Home sensor, release the two screws holding the
sensor.
To replace the Limit sensors, mark the position of the focus
end-sensor plate with respect to the mounting block to ensure
accurate reassembly.
5. Undo the retaining screw, and remove the complete block
assembly with sensors, and cable.

Note: Cables are connected to the sensor using a ’dots’ of
cable to a new sensor, make sure the adhesive has dried.
1. Fit the new block assembly or home sensor (as required) in
the position previously marked.
2. Make sure the sensor vane passes centrally through the
sensor(s).
3. Reassemble and reconnect in reverse order to Steps 1. to 4. of
Removal, excluding Step 2.
4. Insert the safety interlock override keys to the right-hand end
panel interlock and the interlock of the left-hand hinged door.
6. Obtain the top level menu of the Celix Diagnostics.
optics.init
optics.sen.s∆fo∆10

8. Re-calibrate the Home sensor as follows.

a) Select the top level menu of the Diagnostics again.
b) Select diagnostic commands:
optics .motcal.s∆fo
recorder.
removed).
15. Replace the right-hand end cover and closing the left-hand
hinged door.
16. Run a Focus check procedure, see Section 8.3.2.
8.2.12 Illumination Control Sensors
Removal
cable.
1. With the Optics Carriage assembly removed, see Section 8.2:
a) Remove the four retaining screws of the optics RFI Box
b) Disconnect socket connector SK7 and the CAN I/F
c) Disconnect the shutter photodiode termination (at the

3. Lift off the illumination dust cover, see Figure 8.20.
terminations, see Figure 8.20.
5. Disconnect the sensor cables from plugs PL3, PL6 and PL12
on the Sensor Distribution board, see Figure 4.27.
6. Remove the sensor bracket, marking its position prior to
removal.
ILLUMINATION/
WEDGE
CONTROL HOME
SENSOR
ILLUMINATION/
WEDGE
CONTROL LIMIT
SENSOR
(REVERSE/EOT2)
ILLUMINATION/
WEDGE CONTROL
LIMIT SENSOR
(FORWARD/EOT1)
NOTE: Shutter Solenoid assembly

removed for clarity.
Figure 8.20 Optics - Illumination Control Sensors


Note: Cables are connected to the sensor using a ’dots’ of
cable to a new sensor, make sure the adhesive has dried.
1. Fit the new bracket and sensor assembly and adjust with
respect to the base, ensuring that the end and home sensor
vanes pass through their respective sensors without touching
any sensor surface.
2. Connect the sensor cables to the Sensor distribution board,
see Figure 4.27. Reassemble by carrying out Steps 1. to 3. of
the Removal in reverse order.
panel interlock and interlock of the left-hand hinged door.
optics.init
optics.sen.s∆ill∆10 .
7. Re-calibrate the Home sensor as follows.

a) Select the top level menu of the Diagnostics again.
b) Select diagnostic commands:
. .
– optics motcal s∆ill
machine.
removed).

14. Replace the right-hand end cover and close the left-hand
hinged door.
15. Run a D-Max calibration in accordance with the procedure in
the appropriate RIP User’s Guide.
8.2.13 Distribution Boards (Optics)

The Sensor and Motor Distribution boards are located as shown
in Figure 4.27.
In the event that it may be necessary to replace either of these
boards:
1. With the Optics Carriage assembly removed, see Section 8.2,
from the machine, disconnect all wiring, see Figure 4.28 or
Figure 4.29, as applicable.
2. Remove the board by its four securing screws.
3. Fit the replacement board and reconnect the wiring.
cover interlock and the interlock of the left-hand hinged door.
6. Obtain the top level menu of the Celix Diagnostics.
7. Check that the plug connections are correct by using
commands:
optics.init
optics.sen.S∆5

9. Replace the Optics Carriage assembly in the recorder.

10. Reconnect the umbilical to the Input/Output panel (if

removed).
hinged door.
SPINNER MOTOR
15-WAY D-TYPE TO CABLE 14 (UMBILICAL)
SENSOR DISTRIBUTION
COOLING
BOARD
FAN
SPINNER ENCODER
DUST COVER 9-WAY D-TYPE TO CABLE 15 (UMBILICAL)
37-WAY D-TYPE
TO CABLE A2 M3 SCREW
(UMBILICAL) (4 OFF)
HOME SENSOR, SPINNER

9-WAY D-TYPE CLAMP
TO CABLE K2
(Umbilical)
MOTOR
DISTRIBUTION
BOARD
SPINNER
15-WAY D-TYPE
TO CABLE 11
(UMBILICAL)
SPINNER CLAMPING M6 CABLE CONNECTOR

SCREW (4 OFF), WASHER BRACKET
AND SPRING
Figure 8.21 Location of spinner and distribution boards

8.2.14 Spinner
The procedures for removal, fitting and checking are described
below. See Figure 4.27 and Figure 8.22.
LOCATING DOWEL
SHROUD SLOT
ACOUSTIC SPINNER THERMAL COOLING

FOAM SHROUD SHIELD FINS
SEAL
NOTE: VIEW OF SPINNER IN OPTICS CARRIAGE ON MACHINE
SPINNER SHROUD SPINNER SHROUD
Figure 8.22 Spinner and shroud (side view of the Westwind model)
After replacing the unit, complete the following checks and

setups:
• Image positioning for centering and vertical offsets.

• Focus checks.
• Registration checks.
Removal
1. With the Optics Carriage assembly dismounted, disconnect
the spinner motor and encoder D-type connectors from the
cable connector bracket. Disconnect the cable connector used
with the spinner cooling fan wiring.
2. Remove the spinner cables connector bracket by its retaining
screws.
3. Remove the spinner fan assembly. Note the orientation of the
fan fixing plate.
4. Remove the spinner clamp (with the fan still mounted upon it)
by removing the four M6 spring-loaded screws, washers, and
springs.
5. Remove the two thermal baffle plates from the baffle support
bracket.
6. Carefully, lift the spinner vertically until its location pin is
clear of the optics base. Then, remove the spinner - with its
shroud - toward the rear of the optics base assembly.
7. Remove the baffle, and thermal baffle plates fitted to the
baffle support bracket.
Note: The thermal baffle plates are fitted to the baffle
support bracket and not to the spinner, see
Figure 8.22.
8. Remove the spinner with shroud, keeping them parallel to the
carriage until the dowel pin is free from its location.
9. Remove the shroud from the spinner.

Replacement
CAUTION
Do not turn the spinner manually or
start the spinner while the Optics
Carriage is inverted.
If you need to run the machine while

the Optics Carriage is removed,
disconnect the spinner and use the
dummy load resistor (Part No.
75490120).
1. Transfer the shroud from the removed spinner and fit it to the
new spinner, locating the shroud slot onto the locating dowel,
see Figure 8.22.
Note: Early shrouds do not have a locating slot - on these
units the shroud has two slots - one of which locates on
the spinner mount pad, while the other is in clearance.
It is very important that the shroud does not interfere
with the seating pads of the optics baseplate and
cause the spinner to lift.
2. Fit the new spinner - with its shroud - to the optics base,
noting the correct shroud position, see Figure 8.22.
3. Lower the spinner into place ensuring that the dowel and slots
in the shroud locate correctly. The location dowel allows for a
small amount of rotational movement of the spinner; so rotate
the spinner back and forth to ensure it has seated correctly
upon the mounting pads - this is very important.
4. Make sure that no evident gap between the spinner body and
any pad.
5. Replace the spinner clamp with the spring-loaded M6 screws,
washers and springs. Ensure that the end of the clamp with
the machined recess fits on the shroud end, see Figure 8.23.

THERMAL BAFFLE PLATE
FOAM BONDED TO BASE

THERMAL SEAL
SPINNER SHROUD SPINNER CLAMP
THERMAL SEAL
VIEW ON TOP OF SPINNER
Figure 8.23 Orientation of thermal seals and baffle plate
6. Replace the thermal baffle plates and baffle, see Figure 8.23.
7. Check that the thermal shields have located correctly with the
thermal seals.
8. Replace the spinner fan assembly, with the same orientation
noted in step 3.
9. Replace the cable connector bracket.
10. Reconnect the spinner and encoder D-type connectors.
11. Replace the cable connector used for the spinner cooling fan
wiring.

12. Make sure that no cable touches any part of the spinner fan
and that the fan can be moved on its anti-vibration mounts
without any obstruction.
13. Replace the Baffle.
14. Replace the Optics Carriage assembly in the recorder (see
Section 8.2).
17. Remove the intermode key.
hinged door.
19. Reset the vertical start position.
20. Perform the registration procedure, see Section 8.3.3.
Cleaning the Mirror and Focus Lens

Follow the procedure in Section 12.4.2.
Focus Check
Switch on the recorder and re-check the focus as detailed in
Section 8.3.2.
Registration Check
Switch on the recorder and check the registration by running the
grid tests described in Section 8.3.3.

8.2.15 Spinner Cooling Fan (24 Vdc)
Removal
See Figure 8.21.
1. With power removed from the machine, remove the
right-hand end panel of the recorder.
2. Remove the Optics Carriage assembly, see Section 8.2.
3. Remove the cable connector bracket (with connectors still
attached). Disconnect the associated cable connector from the
wiring of the spinner cooling fan (fan wiring assembly).
4. Remove the fan from the spinner clamp by the four M3
retaining screws. Note the orientation of the mounting plate.
5. Retain the existing fan guard and M3 screws and discard the
spinner cooling fan (fan wiring assembly).
Replacement
1. Fit the new fan (with its wires positioned to interface with the
spinner), together with the existing fan guard and M3 screws,
to the spinner clamp. Orientate the mounting plate, as noted in
the Removal procedure.
Note: Take care to assemble the fan in the correct
orientation, - an arrow is located on the side of the fan
body to indicate the BLOW direction - make sure the
fan BLOWS air over the spinner, it should not SUCK
air.
2. Fit the associated cable connector to the wiring of the spinner
cooling fan. Make sure the fan cable is secured so that it
does not touch the fan or the metalwork in any way.
3. Replace the cable connector bracket.

Check
1. Fit the safety override key into the interlock of the right-hand
end panel and apply power to the machine.
2. Open the Diagnostic Terminal window.
3. With the top level menu displayed, access Celix Diagnostics -
Sensors and Solenoids menu, see 6.9.1.
mech.sols.init
mech.sols.onoff
4. Select the spinner fan letter and watch for the + or - to toggle.
Note: The Spinner cooling fan is operating when the + symbol
shows next to the letter option.
5. Listen to the fan, for the sound of its blades moving.
6. Select z to quit the Sensors and Solenoids menu.
7. Select q to quit the Diagnostics system.
8. Power-down the machine and remove the override key.
9. Replace the Optics Carriage assembly, see Section 8.2.
10. Refit the right-hand end cover to the recorder.
8.2.16 Traverse Sensor Home

See Figure 8.24 for position of Traverse Home sensor. The sensor
is a Hall-effect sensor.
Removal
1. Remove the Optics Carriage assembly from the machine as
described in Section 8.2. Disconnect the Traverse Home
sensor to be replaced from the Sensor Distribution board
(PL10), see Figure 4.27.

2. Remove the defective sensor.
Replacement and Check

1. Fit the new sensor.
2. Connect the newly fitted sensor to the Sensor distribution
board, see Figure 4.27.
3. Replace the Optics Carriage assembly on the recorder without
securing the gimbal clamp.
4. Move the carriage by hand and observe that the sensor vanes
on the machine are clear of the newly fitted sensor.
5. Refit the gimbal clamp.
removed).
7. Apply the interlock override key to override the right-hand
door interlock.
9. Select the top level menu of Celix Diagnostics.
10. To check that the replaced sensor operates correctly, use:
.g_trav.InitDSP
mech
for checking the Home sensor.

11. Remove the interlock override key from the right-hand end
cover interlock.
hinged door.
13. From the Celix Diagnostics terminal window, select:
.g_trav.shlog
mech
and step back through the log, checking for fault messages.

BAFFLE PLATE
(LASER SIDE)
APERTURE
DUST COVER
BAFFLE PLATE
(SPINNER SIDE)
ILLUMINATION
DUST COVER
OPTICS CARRIAGE
ASSEMBLY
CABLE TO P10 SENSOR
DISTRIBUTION BOARD
TRAVERSE
SENSOR HOME
Figure 8.24 Location of Traverse Sensor Home on Optics Carriage

assembly

8.3 Optical Alignment Procedures

Before commencing these procedure, ensure that there is film on
the drum and a minimum of 5 metres of film left in the cassette.
The following procedures may be required, either as part of a
planned maintenance policy, as part of a fault correction
procedure, or when certain optical equipment has been replaced -
for example:
• After the Optics Carriage assembly has been replaced.
• After an Optics component has been replaced where the
alignment affects the optics performance.
• After the Spinner has been replaced.
• After the V-groove pads have been replaced.
While it is not always necessary to perform all of the following
procedures at the same time, each has a precedence order, when
more than one procedure must be performed; setting the
Illumination Wedge Position is performed before setting the
Focus Quality. Registration is the final test.
8.3.1 Setting/Checking the Illumination Wedge Position

This uses the Illumination Wedge Strips utility, see Table 6.55, to
determine the wedge position giving the most acceptable density
range for focussing.
1. Run the application to load suitable film, from its cassette,
into the drum.
2. Open a Diagnostic Terminal window.
3. With the top level menu displayed, type:
v∆on to set verbose to on
utils [Return] to enter the Utilities menu
wedge [Return] to enter the Wedge menu
4. To change the wedge strip parameters, enter:

edit [Return]
At each stage of the following, type [Return] to enter the

default value, or type the new value followed by [Return]:
• The wedge start position default value = 100. Change this
value to 150.
• The wedge increment is the number of steps to move each
wedge strip (default = 5).
• Number of strips to output (default = 20). Change this
value to 27.
• Film width: this is the width across which the strips are
imaged (default = maximum film width). Change this
value to the width of the media being used.
• Resolution for Focus only; value = 144 .
• Resolution for Grid only; default value = 72 .
• Lines On default = 1.
• Lines Off default = 1.
Note: The maximum allowable wedge position is 310 steps.
5. In the Wedge Strips menu, type:
wedge [Return]
The following prompt appears:-

Output illumination wedge strips? [y]
6. Press y to output the required number of strips representing

the required wedge range.
7. After the wedge strips have ben output, return to the
applications mode by typing:
mon go_app [Return]
This rewinds the film into the supply cassette.

8. Load, eject, and reload the film.

9. Process the ejected film, and measure the density of each

wedge strip with a densitometer.
Note: Figure 1, to indicate strip 1, is exposed after the first
strip.
Then record each density value against the corresponding
wedge strip number.
Note that wedge strip number whose measured density value
is closest to the DMax value (see Figure 8.25) e.g. that point
where a group of strips have similar density values.
Note: Choosing a wedge strip which has a value that is less
than the optimum D Max value, for a particular film,
may cause difficulty in achieving the correct focus
during the next procedure. A higher wedge number
will result in a relatively lower density level on the
exposed film.
DENSITY
DMAX POINT
NOTE: DIFFERENT MAKES AND TYPES

OF FILM MAY HAVE A DIFFERENT
CURVE SHAPE AND D MAX POINT
BLACK
ONE OF MANY
WEDGE STRIPS
CLEAR
WEDGE NUMBER RANGE
Figure 8.25 Typical DMAX characteristic

Note: Ideally, you should have several strips with similar

density values, to identify the optimum DMax point.
10. If satisfactory, go to Step 12. otherwise return to Step 1.
11. If there is not a wedge strip within the optimum DMax density
values, repeat Steps 3 and 4 to return to the Diagnostics and
proceed as follows:
a) Display the strip numbers (1 - 27) showing their
corresponding step numbers (80 - 107) by entering:
show [Return]
b) Repeat Step 4. with the following changes:

• Change wedge start position to the step number of that
strip which has a probable DMax density value.
• Change wedge increment to 1.
• Change the output number of strips to the number of steps
between the nearest lower value of the probable DMax
density and the next higher value after the probable DMax
density.
c) Repeat Steps 5. to 10.
12. Return to Celix Diagnostics, then type:
utils .wedge.program
13. At the prompt, enter the wedge strip number noted in Step 9.
14. At the prompt, enter y [Return] (not just [Return]) to
program the NVRAM with the wedge value. The system
should respond with ‘NVRAM Updated’ if the value has been
accepted.
8.3.2 Focus Procedures

There are two fine focus procedures available, one from the
Fdots and one from the Flines menus. Although the diagnostics
structure suggests that there are also two coarse focus procedures
(see Figure 6.31), whether you use Fdots - Coarse or Flines -

Coarse the same procedure is performed. However, if you intend

to subsequently perform a Flines - Fine procedure you must first
perform a Flines - Coarse. If you try to use Fdots - Coarse a
message appears when you try to enter the fine procedure telling
you that you have not performed a coarse focus.
For many cases the Dot-based method will give satisfactory
results but the Vertical and Horizontal Line method provides more
diagnostic information and is generally recommended.
Before performing a focus check, you must perform the
procedure described in Section 8.3.1 with the resolution set
at 144.
To perform a Coarse Focus and Fine Focus, see below.
Focus Check
Coarse Focus
Use the Flines utility to check for the correct coarse focus.
1. Run the application to load film into the drum.
2. Open a Diagnostic Terminal window.
3. With the top level menu displayed, type:
v∆on [Return] to turn on verbose
utils [Return]
focus [Return]
flines [Return]
4. Type:
type for film thickness.
Depending on the thickness of the film in the cassette, use the

space bar to select either 0.004 in. (100 mm = default value) or
0.007 in. (178 mm). Then enter the selection by pressing
[Return].
5. Type:
width for width (default = 760).

6. Enter required value followed by [Return].

7. Type:
coarse [Return].
A prompt appears:
Output coarse focus strips [y]
8. Enter y. to output the focus strips representing the focus range

of the machine.
9. When the fifteen strips have been output, press y to switch off
the spinner.
10. Return to the applications mode by typing:
mon go_app[Return]

12. Process the ejected film. Measure the density of each strip
with a densitometer.
Note: Figure 1, to indicate strip 1, is exposed after the first
strip.
The best coarse-focussed strip has the lowest density
value. Note the number of this strip.
13. Return to the diagnostics.
Fine Focus
Use the Flines utility to check for the correct fine focus.
1. Type:
v∆on [Return]
utils [Return]
focus [Return]
flines [Return]

2. Type:
type for film thickness.
Depending on the thickness of the film in the cassette. Use the

[Return].
3. Type:
width for width (default = 760).
4. Enter required value followed by [Return].

5. Type:
fine [Return].
6. At the prompt, enter the number of the best coarse-focussed

strip noted in Step 12.
A prompt appears:
Output fine line focus strips [y]
This outputs two sets of fifteen focus strips centred on the

focus position obtained from the entered strip number. The
two sets produced are for:
a) Horizontal lines.
b) Vertical lines.
7. Return to the applications mode by typing:
mon go_app[Return]

9. Process the ejected film.
10. Measure the density of each horizontal lines strip with a
densitometer.
The best fine-focussed horizontal lines strip has the lowest
density value, and the best dot structure will be visible
with a low-power magnifier.

Note: Note the number of this strip.

11. Measure the density of each vertical lines strip with a
densitometer. Note the number of this strip.
The best fine-focussed vertical lines strip has the lowest
density value. Note the number of this strip.
12. Return to the diagnostics.
13. Repeat Step 1. to re-select the Flines utility, and to re-select
the required Film Thickness.
Depending on the thickness of the film in the cassette, use the
[Return].
14. Type:
program [Return]
15. At the prompt, under Horizontal Strip No. enter the strip
number of the best focussed horizontal strip and press
[Return].
Note: Make sure that you do not confuse the film strip
numbers with the corresponding step numbers returned
by the diagnostics program.
16. The step number of this position appears. Note this value.
Note: Ignore the [-] sign in front of the step number.
17. At the prompt, under Vertical Strip No. enter the strip number
of the best focussed vertical strip and press [Return].
18. The step number of this position appears. Note this value.
19. The optimum focus position is found by adding the best
focussed step numbers obtained for the horizontal and vertical
line positions in Steps 10. and 11. and dividing the result by
two.
20. At the prompt Enter best focus position, enter the optimum
focus position value (from Step 19.) and press [Return].
Note: Steps 19. and 20. are very important.

21. At the next prompt, type y to enter the focus position value
into NVRAM. The value is then echoed on the screen as a
Hex number.
22. Repeat the complete focus procedure for the other film
thickness, if required.
The procedure is now complete.
For details of the wedge calibration procedure, see the appropriate
RIP user’s guide; full calibration should be carried out. This
includes:
• full laser (wedge) calibration,
• dot overlap calibration if the recorder has the option for
Fujifilm FM screening,
• linearisation calibration.
8.3.3 Registration
Registration is a procedure for measuring and correcting errors in
the image scanning system by the use of a grid image.
The resulting film, see Figure 8.26, is cut in half and the top half
is superimposed over the bottom half. Then the registration
accuracy is visually checked for any errors between the two
halves of the film.
A DOS-based grid program is used to check the optical resolution
of each value.
The Registration procedure is in two parts:
1. Running a Grid, and measuring the errors in the X and Y
directions.
2. Entering the errors into the PC Grid program on a PC, to
determine the required adjustments for the Laser Diode.
Note: The optics must be calibrated before running a Grid.

Running a Grid
Note: Have the Celix 4000 Recorder User’s Guide available for
reference.
1. Ensure that a 760 mm wide roll of film is available in the
cassette, and that film is loaded into the drum of the recorder.
2. Make sure the recorder software is loaded and that it is in the
application mode.
3. Stop or exit the RIP as appropriate.
4. On the RIP server, (or on a remote VT100 monitor) access
diagnostics, then:
a) type main[Return]
b) At the moon> prompt, type sup [Return]
c) At the sup> prompt, type patt
d) At the patt> prompt, type pat
5. Set up the pattern tests from the following default menu:
Resolution 720
Number of lines on 4
Number of lines off 4
Line length (mm) 100
Image width (mm) 100
Horizontal position (mm) 0
Vertical position (mm) 0
Number of repeats 1
Eject: none = 0, after = 2 2
Pattern Type - Horz 0, 0

Vert 1, Grid 2, Dot 3
6. Type each parameter value (to form a grid).

Resolution: 720

Number of lines on: 1
Number of lines off: 1439
Line length (mm): 620
Image width (mm): 750
Horizontal position (mm): 0
Vertical position (mm): 0
Number of repeats: 1
Eject: 2
Pattern Type 2
Note: It is not possible to edit an incorrectly entered value

by moving the Pg Up/Pg Dn cursor keys, to modify the
parameter values, go to the top of the menu and again
enter the required values..
7. Press the Return key.
Ensure that the following line is displayed:
Send Test Pattern Data ? {N}
Type YES (Note: this entry must be in capitals), and press

the [Return] key.
Note: Any normal display text will be written to the MMI
and it may overwrite the menu before the scan is finished.
Keep pressing the [Return] key to exit the menu and if the
scan is not successful, start again.
8. Obtain the reported test pattern, and cut it in half, see
Figure 8.26.
9. Measure any errors between the grids using the procedure
below.
10. Start the RIP, using the appropriate method.
Measuring Errors in a Grid


WIDTH OF ARRAY (W)
HEIGHT OF
ARRAY (H)
DISTANCE BETWEEN
OVERLAPPING POINTS (S)
MARK OUT TWO

ARRAYS OF NINE
POINTS, MAKING A
NOTE OF DISTANCES
P, H, W, AND S
ALIGNMENT X1
POINT (0.0)
X2
X1
TOP HALF OVERLAYING
BOTTOM HALF AFTER
CUTTING
X2
Figure 8.26 Cutting a registration film

CAUTION
Make sure the light table is not lit,
since its heat can expand the lower
half of the registration film and
cause apparent errors with the upper
half.
1. Orientate the film on the light table so that the corner from the
rear left of the drum (origin point) is at the top left. This can
be found by noting that this corner of the grid comprises a
complete square.
2. Mark a matrix of three columns and three rows on the upper
and lower halves of the drum, see Figure 8.26. Measure and
note the dimensions P, H, W and S.
3. Cut the film horizontally in half to produce two equal halves.
4. Using a light table, for its flat surface, tape the lower half of
the film down (emulsion side up) and overlay the upper half
on top of it.
5. Carefully align the middle left point at (0.0) then along X1
and X2-Axes. Adjust the position of the film, to minimize the
error along the X-Axis.
CAUTION
If taping down the film, take special
care not to stretch the film and cause
possible errors between the two
halves.
6. Mark a matrix of three columns by three rows and circle the

nine points where the lines intersect. Using a x 50 Peak Stand
Microscope (or an instrument with a similar resolution and a
metric graticule), measure the distances between the Grid
lines in the X and Y directions at each circled point.
(Scratching through the emulsion on the top film near the

overlayed points helps with the reading). Do not measure

points < 20 mm from the edge of the film.
7. Record each pair of errors to an accuracy of ± 10 µm as they
are measured, starting with the X error. If the error is
negative, put a minus sign in front of the value (see
Figure 8.27).
Note: Trapezoidal errors cannot be corrected by shimming
the Laser Diode Module, see Section 8.3.5.
Figure 8.27 shows the results as seen through
microscope, with inversion already accounted.
Some microscopes may have a different graticule
scale. Note the pitch of the scale.
X ERROR
(+)
TOP HALF OF GRID Y ERROR
BOTTOM HALF OF GRID (+)
++ -+
EMULSION SIDE
OF FILM UPWARDS
+– --
Viewed through a x50 Magnifier,
taking inversions into account.
Figure 8.27 Fault diagnosis for grid errors
The total error is defined as the differences between the highest

value and lowest value for the X and Y axis.
If the total error for either axis is less than 50 µm then the
machine is within specification and the procedure is complete.

If the total error for either axis is more than 50 µm then the
machine is outside the specification and the Grid program (on the
following page) needs running.
Running the PC Grid Program

See Figure 8.28, Figure 8.30, Figure 8.32, Figure 8.33 and
Figure 8.31.
Run the PC Grid Program (75472370) and enter values from the
Grid. From the results, make any adjustments using the
appropriate shims under the back of the Laser Diode Module, see
Figure 8.34, that may be necessary.
********************************************************************************
*** INTERPRETATION OF GRID MEASUREMENTS, GEMINI ***
********************************************************************************
(C) 1997 FUJIFILM ELECTRONIC IMAGING LTD

This programme and documentation are the property of FUJIFILM Electronic
Imaging Ltd (the Company) and must not be copied without written authorisation from
the Company.
Version 02.00, compiled 6/11/95, M.Roe
MAIN MENU, select required option;-
0. END.
1. SEE GENERAL INFORMATION.
2. CREATE A REGISTRATION DATA FILE.
3. READ A REGISTRATION DATA FILE
Figure 8.28 Grid program - Main menu

Note: Press [Enter] after each selection on the PC.

1. Insert the PC Grid floppy (75472370) into any DOS PC and
select the [A:] drive.
2. Type A:\gridgem [Return] to get the Main menu. See
Figure 8.28.
3. Select 1 for General Information.
4. Select 2 to get the ‘Create a Registration Data File’ menu, see
Figure 8.30.
CREATE A REGISTRATION PATTER DATA FILE, SET UP MENU
Use menu to edit or select required option, <Esc> to exit without saving):–
1 <Enter> ***IMPORTANT INFORMATION***

2 Filename to save data in: GRIDRDGS.GVG
3 Data type (toggle): VERTICAL SUPERPOSITION (2–UP)
4 Spinner type (toggle): SINGLE REFLECTOR
5 ADD COMMENTS (N.B. time, date and filename are inserted automatically):
6 Rewrite comments:*
7 No of data positions across width (2 to 6): 3
8 No of data locations per position (3 to 10): 3
9 Width of data array, mm: 720
10 Height of data array, mm: 280
11 Dist. from top edge of drum to start of data array, mm: 25
12 Dist. around drum between superposed data points, mm: 300
13 ENTER DATA READINGS
14 SAVE TO FILE
Figure 8.29 Grid program - Create a Registration Data File

(Option 2)
5. Select 3 to get the ‘Read a Registration data File’ menu, see

Figure 8.30.

FILE REFERENCE DATA

Filename is 0001_003.GVG VERTICAL SUPERPOSITION (2-UP)
Recorded filename is 0001_003.GVG 05-07-1996 11:24:49
Spinner type: SINGLE REFLECTOR
Comments:
No. of data positions across width of format: 3

No. of data locations per position: 3
Width of data array, mm: 720
Height of data array, mm: 280
Dist. from top edge of drum to start of data array,mm: 25
Dist. around drum between superposed data points,mm: 300
Press <Esc> for menu
<Enter> to process data
or any other key to see data readings.
Figure 8.30 Grid program - typical data file (Option 3)
The Grid co-ordinates are entered or changed from the

following option numbers on this page:
a) 3: ‘VERTICAL SUPERPOSITION (2-UP)’.
Enter 3 again will change the data type.
b) 4: ‘SINGLE REFLECTOR’.
Note: The next 3 values are supplied from the film, see
Figure 8.26.
c) 9: width of the film array (W) - the width of the Grid
array.
d) 10: height of film array (H) - the height of the array.

e) 11: distance from top edge of drum (P) - the distance from
the first Grid point to the top of the drum.
f) 12: distance around drum (S) - the distance between the
two superimposed points.
0001_003.GVG VERTICAL SUPERPOSITION (2-UP)

BEST RMS FIT
Each column lists the horizontal & vertical errors in microns in that section.
+--------------------------------+
||1|2|3|
+--------------------------------+
| 1 | -1 -3 | -1 0 | -1 4 |
| 2 | -1 -3 | -1 0 | -1 4 |
| 3 | -1 -3 | -1 0 | -1 4 |
+--------------------------------+
DATA SUMMARY: RMS Min. Max. Range
Horizontal error (in microns): 2.8 -3 7 10
Vertical error (in microns): 4.8 -6 11 17
Press any key to continue
Figure 8.31 Grid program - expected results for option 7

(Analysis menu, see Figure 8.32)
6. Select 13 to enter on the lists, each of the 9 (3 x 3 matrix)

error reading positions measured from the film.
Note: Any errors introduced at this point, may cause shim-size
errors to the Sa2 and Sb2 advice, see Figure 8.33.
Start with the first ’xy’ pair at the top of the left column,
working down each column, see Figure 8.31, of the matrix
until the last ‘xy‘ pair is entered at the bottom of the right
column. Enter the values together with their ‘–’ sign if a
–ve value is noted.

7. Press [Enter] to save the settings, or any other key to edit and
re-enter the co-ordinates. Pressing [Enter] will return to the
‘Create a Registration Data File’ screen, see Figure 8.29.
8. Select 14 to save the data, and press [Enter].
9. Type in the last four digits of the machine serial number and
press [Enter].
10. Enter a Grid file number, starting from 1, and press [Enter] to
create a file. Numbering error files allows you to keep a check
on the history of each film reading.
********************************************************************************
*** ANALYSIS OF SUPERPOSED REGISTRATION PATTERNS ***
********************************************************************************
DATA FILE IS 0001 003.GVG VERTICAL SUPERPOSITION (2-UP)

Select from menu, (<Esc> for Main Menu);-
1 <Enter> Info and other data
2. See file reference data.

3. See initial data readings.
4. See initial data readings, adjusted for Top Left/Top Right fit.
5. --- --- --- --- , adjusted for Bottom Left/Bottom Right fit
6. --- --- --- --- , adjusted for Top Left/best Bottom Right fit.
7. See data readings after processing for best rms fit.
8. See processed data readings, adjusted for Top Left/Top Right fit
9. --- --- --- --- , adjusted for Bottom Left/Bottom Right fit.
10. --- --- --- --- , adjusted for Top Left/best Bottom Right fit.
11. See required shim pack
12. Data to printer
Figure 8.32 Grid program - Analysis menu
11. From the menu ‘Analysis of Superimposed Registration

Patterns’(see Figure 8.32) select option 7 to see the

registration details after adding the required shims, see

Section 8.3.5. Press any key to continue.
12. From the menu ‘Analysis of Superposed registration
Patterns’, select option 11 to see the required shim pack.
0001_00.3.GVG SHIM VALUES REQUIRED
GEMINI: vertical line sine error to be corrected, wrt drum co-ordinates, has
amplitude = ###.# microns and phase = ####.# degrees
For best rms fit of data fit incremental shim values on the Laser Diode Module
as follows;-
+----------------------+
| Sa1 = 20.0 Sa2 = 0.0 |
|| direction of laser beam ==>
| Sb1 = 15.6 Sb2 = 0.0 |
+----------------------+
Values in microns, viewed from top when in machine.
Note that the best least squares fit will usually (but not always) reduce the
peak registration error.
Press any key to continue;-
Figure 8.33 Grid program - recommended action for option 11

(Analysis menu, see Figure 8.32)
Note: Sa1 = Rear of diode: Rear of recorder.

Sb1 = Rear of diode: Front of recorder.
Remember to add the required shim thickness to the thickness
of any shims that are already in the rear seating area of the
Laser Diode Module. A value of 25 µm corresponds to 0.01
inch. Shims are available from the shim pack (99980111).

If a shim of 25 µm is required to be placed at the front seating

area (Sa2), this can be achieved by reducing the thickness of
the shim at the corresponding rear seating area (Sa1), by
0.001 in..
Note: It is not possible to gain access to the front seating
pads to directly insert shims.
The resulting shim pack should be < 0.006 in. thick (0.001 in.
= 25 µm) in either position Sa1 or Sb1.
If the required corrective shim pack should exceed the
0.006 in. maximum limitation, suspect the fitting of the
spinner in its locating vee, see Figure 8.22.
A good fit for the spinner is critical, see Section 8.2.14, since
even a few microns of error can produce serious
misregistration.
Repeat the registration procedure, see Section 8.3.3, to obtain
a new grid and so measure if the correction process has
improved registration.
8.3.4 Possible Causes of Grid Measure error

Table 8.1 lists the possible causes when measurement errors
greater than 50 µm are found.

Table 8.1 Possible Causes for Grid Errors > 50 µm
Possible Locations Possible Causes

Film Stretching Film Handling error
Film Processor dryer temperature too high
Film/Drum Conformance Film Handling error

Poor vacuum conditions
Optical Misalignment Optics Carriage not seating correctly

V-groove pads damaged
Gimbal clamp under tension / twisted
Optical components misaligned:
Spinner
Laser Diode
Other
Spinner/Optics Carriage loom under tension / trapped
Measurement Error Light table not flat

Film Processor dryer temperature too high
Film not stable
Environmental problems, e.g. humidity / temperature
Other Mechanical problems
8.3.5 Shimming a Laser Diode Module

See Figure 8.34.
1. Perform a Registration procedure, see Section 8.3.3.
2. Run a Grid.
3. Measure the errors of the Grid.
4. Run the DOS PC Grid program (75472370) to determine the
thickness and position of the required shims.
5. Fit the shims, see Figure 8.34.
6. Repeat Steps 1. to 4. inclusive to check the result of fitting the
shims.

GENTLY LEVER DIODE ASSEMBLY

DOWNWARD TO ALLOW SHIM
REMOVAL/FITTING (SEE NOTE)
NOTE Only lever the casing.

: DO NOT under any circumstances
touch the heatsink assembly
or back of the diode itself. A
SHIM
VIEW FROM LEFT-HAND

SIDE OF M/C
PLACE
SCREWDRIVER
HERE
SHIM
SHIM
VIEW ON A
LASER
DIODE
MODULE
Figure 8.34 Laser Diode Module Shimming

8.4 Setting the Vertical Offset and Horizontal Trim

Values
8.4.1 Checking and Adjusting Horizontal Trim and
Vertoff Values
Pre-requisites
The following calibration procedure is applicable to:
• new machines at the factory which need to be calibrated for
the first time
• machines which for some reason need to be re-calibrated, for
instance, if the spinner has been removed and refitted or upon
spinner replacement.
It is assumed that the aperture settings have been calibrated and in
the case of brand new machines, the NVRAM has been
initialised.
Finding the Current NVRAM Values

1. If you are intending to test more than one media type loaded
in separate input cassettes, ensure that the cassette database is
set up on the client GUI for each media type and that the first
media to be used is selected in the recorder control window.
For more information refer to the RIP documentation.
2. Initiate the loading of the media from the client GUI (for
example, click the Load Media button). Wait for the tick icon
to appear below the Recorder Ready icon as shown below,
otherwise the correct media file may not be used.

RECORDER READY
3. Open the Celix Diagnostics terminal window.

4. At the moon prompt, enter sup [Return] to obtain the
supervisor submenu and enter:
sup>pnv∆vertoff*[Return}
A list of vertoff values for each resolution is displayed.

5. Note the decimal values for 48 and 72 Resolution.
6. At the prompt, enter:
pnv∆hor*[Return]
to obtain the current horizontal offset value. Note this value.
Measuring the Current Horizontal Trim Value

1. Ensure that you are using the first image on a new sheet of
film. If necessary, reboot the RIP server to achieve this.
2. Output the Celix Test Pattern/Ruler 4000 image at
48 lines/mm.
• On a PC RIP server:
a) Locate the ruler4000.ps file in the FFEI\user\testpages
folder and copy/paste it to a default drop folder for output.
• On a SPARCstation RIP server:
a) With the middle mouse-button on the background of the
screen, select Terminal Window from the Service Menu.
Note: The entries are case sensitive.
b) Type: zap∆rdsrv [Return]

c) Type: C4000TestPattern (no spaces).

d) At the prompt, press [Return].
e) Type rdsrv&
3. A test page will be printed from the RIP software. Eject and
develop the film. Check the page for image errors. At this
stage if all is well, an image comprising a vertical rule
measuring from 0 mm to 628 mm will be seen on the
left-hand side of the film. A horizontal rule will be seen as
well. This measures from 0 mm to -40 mm. See Figure 8.35.
If an image is not seen, check that the pre-requisites have
been met.
4. To determine how far the horizontal trim is out, check on the
horizontal scale how much of the image is missing.
The correct horizontal trim is where the 0 mm mark on the
horizontal scale aligns with 378 mm measured from the centre
of the punch.
5. Measure the distance in millimetres from the punch centre to
the ‘0’ mm point on the horizontal scale. Subtract this value
from 378 and multiply by 1000 (to convert to microns), then
add this to the current horizontal trim value obtained in step 6.
of Section 8.4.1 (Finding the Current NVRAM Values).
6. Make a note of this value.
7. From the Celix Diagnostics terminal, with the sup> prompt
displayed, enter:
pnv∆horizontal_trim∆[new value obtained in step 5.
above]

PUNCH HOLE
MEDIA THIS DISTANCE SHOULD
EDGE MEASURE 32 mm
(mm) 0
0 mm
-10
-20
-30
-40
THIS POINT IS
INSET 378 MM
FROM THE CENTRE (mm)
OF THE PUNCH 100
(mm)
Figure 8.35 Test pattern for image offset

Calculating the Current Vertical Offset on the

Media
Note: ‘0x’ indicates the associated numbers are hexadecimal.
You now have to calculate the Vertical Offset for all resolutions.
1. Measure the distance from the punch holes to the top of the
image.
2. The top of the image should be 32 mm from the punch holes.
If the image starts further down the film, then subtract the
32 mm from the dimension obtained in Step 1.
For example, if the image starts at 37 mm from the punch
holes, then 37 – 32 = 5.
Note: A hexadecimal calculator might be required. This is
available on a SPARC RIP server by entering calctool in a
terminal window. On a PC there is a Hexadecimal function
on the Windows NT on-screen calculator.
3. Multiply the number obtained in Step 2. by 192. In this

example,
5 * 192 = 960 DECIMAL
4. Subtract this number from the original Vertoff number found

previously in Finding Current NVRAM Parameters. The
default value is 3072, therefore in this example,
3072 – 960 = 2112
5. Enter this number into the 48, 96 and 192 resolution Vertoff
numbers by entering :
pnv∆vertoff_res48∆2112[Return]
for the 48 L/mm resolution. Repeat this for 96 and 192 L/mm
vertoff.
If the top of the image is less than 32 mm from the punch
holes, then the difference in distance is again multiplied by
192 but then added to the original Vertoff value.
6. To calculate the 72 and 144 Vertoff settings, take the number
calculated in Step 4) above, divide it by 4 and multiply the
result by 3. In this example:
2112/4 = 528
528 x 3 = 1584

7. This is the number to be entered in the 72 and 144 vertical

offsets. Repeat step 5. using vertoff_res72 and vertoff_res 144
values of 1584.
8. Output the Celix Test Pattern again, eject and develop the
film. Check that the horizontal trim and vertical offset are
now correct.
8.4.2 Pattern Generation

The performance of the recorder as a system is assessed by means
of a range of test patterns. Six basic patterns (known as Grid, Dot,
Vertical Lines, Horizontal Lines, Black and Random) are
available from Celix Diagnostics (Utility sub-menu) or the
Application Monitor.
Figure 8.36 shows the appearance of a magnified grid pattern
with the dimensions varied from the Pattern menu. The pattern is
repeated to fill the width and depth dimensions.
WIDTH
LINES ON
DEPTH LINES ON
LINES OFF
GRID
LINES OFF
MAGNIFIED GRID
Figure 8.36 GRID pattern

Figure 8.37 shows the appearance of a magnified dot pattern. The

sides of the squares can be set to the equivalent of up to 48 scan
lines/side, and the area covered by the pattern varied for each test
UP TO 48
SCAN
LINE
Figure 8.37 DOT pattern
Interpretation
These test patterns are designed to highlight a particular aspect of
the recorder performance to be investigated by a service engineer.
The patterns are generated in the recorder. Exposing a test pattern
can determine whether a fault appearing on output exposures
results from an external or internal cause.
The grid pattern is used to check the geometric accuracy of the
system.
The dot (or checkerboard) pattern is used to investigate a variety
of problems. The density of the image pattern should measure
approximately 50% and variations would indicate an incorrectly
focussed laser. Variations of the pattern are readily seen, each

cause having its own recognizable characteristic; a sticking

leadscrew produces a regular variation, a lack of drum contact
owing to poor film retention produces an out of focus patch.

Scan System 9
Replacements
and Setups
This chapter describes how to access, remove and re-install the
main replaceable parts used for scanning, and how to adjust the
scan system setups for the:
• Bearing Pads and V-grooves - Section 9.1.
• Leadscrew Assembly, Motor, Drip Tray and Traverse Failures
- Section 9.2.
Make sure any modifications and replacements are entered in the
Log Book.
WARNING
procedures.
9.1 Bearing Pads and Retaining Plates

9.1.1 Installing the Pads
See Figure 2.1.

Scan System Replacements and Setups
The Optics Carriage slides along a precision V-groove on two sets

of pads of a special bearing material. They are changed at regular
service intervals. The pads are mounted on a carrier and are
located under the carriage.
To maintain the required accuracy, the carriers are coded with
indents which must always be fitted to the matching end of the
carriage and must not be rotated about their longitudinal axis.
CARRIER
RETAINING RETAINING
PLATE SCREW
PAD
RETAINING
SCREW
LEFT-HAND
BEARING
OPTICS
CARRIAGE
(CASTING)
BEARING
PAD
V-GROOVE
V-GROOVE
GUIDE
ENLARGED VIEW
NOTE: VIEW IS FROM LEFT HAND END OF

MACHINE. RIGHT HAND BEARING IS
SIMILAR VIEWED FROM OPPOSITE END.
Figure 9.1 V-groove guide, optics carriage (casting) and support

bearing
CAUTION
Take care not to drop any parts into
the drum.

Never lose the pad/carrier

relationship by slackening both end
screws at the same time.
LEFT-HAND CARRIER RIGHT-HAND CARRIER

ONE DOT =
LH CARRIER
CARRIER TWO DOTS =
RH CARRIER
BEARING
PAD BEARING
PAD
RETAINING PAD
PLATE RETAINER
PAD-TO-CARRIER
RETAINING SCREW
Figure 9.2 Bearing carrier and pads
9.1.2 Cleaning the V-Groove

To ensure that the traverse mechanism operates smoothly and
efficiently over a long-period, the V-groove must be clean and
properly lubricated. Change the oil every six months – this should
be adequate for a routine working period.
1. Isolate the system from the mains supply.
2. Disconnect the Optics Carriage from the Gimbal, see Section
8.2.3.
3. Place a protective sheet of film or paper over the drum.

4. Clean the groove with tissues or a lint-free absorbent cloth.

5. Use a suitable amount of fluid, such as IPA, to degrease the
V-groove.
6. Clean the V-groove using 3M ScotchBrite, which can be
purchased locally or ordered from FFEI (Part No 99960453).
Clean the outside of the groove – including the ends, lip and
the underside. Clean the area under the vespal pads; some
effort is required to remove the microscopic particles from the
groove.
7. Lift the carriage, remove the pads and clean them with a
degreasing fluid and clean cloth. Replace the pad set if any
one of them is scored or damaged.
8. Make sure the groove is free of all degreasing fluid. Use a
clean lint-free cloth. The square section base of the groove
requires special attention.
9. Using a syringe, place approximately 4 ml of Slideway 68 oil
along the length of the V- groove, one half each side of the
centered carriage.
10. Move the traverse from end to end and check that oil is not
spilling over the ends. Use the Moon command:
trav>lrcycle
to stop the traverse, enter:

trav>stocycle
11. Check that the oil has spread evenly along the traverse.
12. Remove the protective cover from the drum.
13. Run a test tint to check for banding.
Problems may possibly arise if oil starts to leak and cause one end
of the groove to ‘dry out’. Where this is suspected as a possible
cause of traverse problems, then the level of the recorder gantry
beam ought to be checked with an accurate spirit level.

9.1.3 Pad Replacement

1. Remove each carrier in turn from the Optics Carriage.
2. Release the pads-to-carrier retaining screw (see Figure 2.2)
sufficiently so that the bronze pad retaining clip is loose
enough to release the pair of pads.
3. Fit the new pads so that the two bevelled edges face each
other. Retain with a bronze clip and tighten the pad-to-carrier
retaining screw.
4. Refit the carriage and repeat the procedure for the other side.
All pads must be replaced as a complete set.
9.1.4 Traverse Sensors (Limit)

See Figure 9.3.
The limit switches are proximity reed-type sensors which are
located at the rear of the drum at the left and right-hand ends of
leadscrew travel.
The Home Sensor, which is a Hall effect type, is dealt with in
Section 8.2.16.

R.H. LIMIT SWITCH
R.H. VANE
NOTE
1):To measure travel of carriage, stick
masking tape over beam.
Using a pen, mark carriage travel on tape.
2) LH Traverse Limit sensor is located on
beam in similar position at LH end of
leadscrew
Figure 9.3 Location of traverse RH limit sensor and vane
Removal
See Figure 9.4.
1. Traverse the Optics Carriage assembly to a position slightly to
the left of the central vane.
3. Open the top front panel.
4. Remove the right-hand and left-hand end panels.

5. The sensors are located inside the front face of the beam on
top of the drum.
6. The sensor is connected to a connector from which Cable 47
is routed back to the Input/Output Panel. Disconnect the
affected traverse limit switch sensor connector.
7. Remove the Output Chute assembly to access the left-hand
side sensor, see Section 7.9.3.
BEAM
CABLE 47
SENSOR NUT
CONNECTOR
Figure 9.4 Removing the limit sensor
8. The left-hand sensor connector may be accessed by following

Cable 47 from where it is fixed on the rear left of the beam to
where it enters a hole at the rear of the beam. See Figure 9.4.
Gently pull this cable out of the hole until the sensor
connection is outside the beam. Disconnect the sensor cable
and unscrew the nut on the sensor face where it protrudes
from the beam in line with the Leadscrew.
9. The right-hand sensor connector can be accessed by inserting
your hand into the large right-hand hole on the inside face of
the rear part of the beam, and gently pulling out the cable
until the connector is seen. Discount the sensor cable and

unscrew the nut from the sensor where it protrudes from the
beam in line with the Leadscrew.
10. Access the left/right sensor position(s) and remove the sensor
by unscrewing the hexagonal nut.
LIMIT SENSOR
TRIP MAGNET
Figure 9.5 Location of limit sensor trip magnet
Replacement
Fit new limit sensor(s) as required. Do not yet reassemble the
machine. Proceed with the following Adjustment Procedures.

Adjustment Procedures
See Figure 9.6 which shows the spatial relationship between the
traverse limit switches and vanes.
REFERENCE
EDGE
LEFT LIMIT CENTRE RIGHT HAND RIGHT LIMIT
SWITCH VANE VANE SWITCH
VANE
SENSOR
(MOTOR
END)
MAGNET
A B B C
LEFT HAND LIMIT VANE SENSOR VANE SENSOR RIGHT HAND LIMIT
SWITCH ‘ACTUATING’ ‘ACTUATING’ SWITCH
‘ACTUATING’ POSITION (CENTRE POSITION (RIGHT ‘ACTUATING’
POSITION VANE REFERENCE HAND VANE EDGE) POSITION
EDGE)
ARROWS INDICATE DIRECTION OF CARRIAGE MOTION

WHEN SENSOR ‘ACTUATION’ (CHANGE OF STATE) OCCURS
Figure 9.6 Traverse limit sensor and vane setting-up
Vane Separation
CAUTION
Vane separation adjustment should
not be carried out unless the vanes
have been physically damaged.
Using an approved gauge, set the distance between the right edge
"
of the centre vane and the left edge of the right vane to
(382 0.5 mm).

Limit Switch Positions
Make sure to note the positions of both limit switches before their
removal.
Operation Check (Limit Sensors)
1. Apply the interlock override keys to the interlocks for the

right-hand and left-hand end panels.
3. To validate the traverse limit positions, open the Celix
Diagnostics terminal window the diagnostic window and run
the Application Monitor (Moon). Then perform the following:
a) Obtain the Event submenu:
Moon>evt
and enable the DSP display:

evt>ed 7
b) Obtain the Traverse submenu:

evt>trav
and read the present status (where 18 = READY):

trav>PO 0203
to display:
trav>DSP=40 18
c) Re-centre the traverse position:

trav>PO 2A02
d) Enable travel to limit switches:

trav>PO 2D01
and move to the right limit switch:

trav>PO 2C03

e) Read the result:

date time:625721 File:
traverse.c Line:223
(LOG ERROR)
traverse fault right limit active
DSP = 28 0
DSP = 28 6
DSP = 28 11
DSP = 28 b5
f) Read the limit position (range = 397.2 to 404.2 mm):

Traverse position = 397749 µm (611b5)
DSP = 2a 6d
DSP = 40 0
Traverse Task Idle
date time: 62571 FILE:
std_Traverse_Task_.c
LINE:176 (LOG ERROR)
DSP failure during scan
g) Return to normal limits:

trav>PO 2D00
h) Re-centre the traverse position:

trav>PO 2A 02
i) Enable travel-to-limit switches:

trav>PO 2D01
j) Move to left limit switch:

trav>PO 2C04
k) Read the result:

date time:653852 FILE:
traverse.c LINE:223
(LOG ERROR)
traverse fault left limit active
DSP = 28 ff
DSP = 28 f9
DSP = 28 db
DSP = 28 60
l) Read limit position (range = 400.8 to 407.2 mm):

Traverse position = –4025592 µm (fff9db60)
m) Return to normal limits:

trav>PO 2D00
n) Recentre traverse position:

trav>PO 2A02
o) Re-enter the Events submenu:

trav>evt
p) Disable the DSP display:

evt>dd 7
Machine Reassembly
1. Remove the interlock override keys from the machine.
2. Replace the right-hand and left-hand end panels.

9.2 Leadscrew Assembly and Drip Tray

See the Celix 4000 Recorder Illustrated Parts Catalogue.
See Figure 9.7.
This assembly is a high-precision mechanism which is vital for
the correct exposure registration. Make sure that it is clean, oiled
within its maintenance period, and not damaged. The bearings are
already lubricated with a special grease.
CAUTION
Failure to follow the correct
replacement procedure can cause
minor exposure errors.
CAUTION
Make sure the entire Leadscrew
assembly (motor and screw) are
supported at each end to avoid
bending the flexible coupling. This
coupling is easily damaged.
9.2.1 Replacing the Leadscrew Motor

1. Power down the recorder and remove the left-hand side end
panel.
2. Detach the motor connector.
3. Slacken the 2-off grub screws in the flexible coupling.
4. Remove the 4-off screws holding the motor to its mounting
ring.

5. Gently detach the motor from its flexible coupling.

6. Replacement is the opposite of this procedure.
9.2.2 Leadscrew Assembly

This is an operation for two people.
The Leadscrew assembly is supplied with two bearing blocks and
Gimbal sleeve already fitted.
Special items required: torque wrench for bearing clamp screws
set to 0.75 Nm, leadscrew securing tool (75472760) - optional,
and drum protection material (thick cardboard, etc).
CAUTION
The Leadscrew is heavy and has
sharp edges.
RH BEARING
BLOCK
LH BEARING
BLOCK
LEADSCREW
DRIVE
MOTOR
GIMBAL (SLEEVE)
MOTOR
MOUNTING
FLEXIBLE
COUPLING
Figure 9.7 Leadscrew assembly

Removing the Leadscrew Assembly

See Figure 9.7.
1. Traverse the Optics Carriage to the right-hand side transit
position using Celix Diagnostics. Select the following
submenus:
. .
mech G_trav init DSP
to initialise the traverse position:

2. After the system has initialises, enter:
move 260
3. Remove the two end panels.

4. Remove the Input cassette and the upper rubber plug on the
cassette bay front.
5. Remove the Drip tray, see Figure 8.2.
6. Make sure the drum surface is protected.
7. Release the C-clamp from the gimbal by slackening (but not
removing) the upper bolt only, see Figure 8.4.
8. Move the Optics Carriage to the right and away from the
Gimbal sleeve.
CAUTION
The Leadscrew assembly must never
be supported from the beam by a
single bearing block, as this will
result in damage.
9. Remove the Leadscrew motor (see Section 9.2.1).

10. Install the Leadscrew securing tool at one end of the
Leadscrew, and a second Leadscrew securing tool (or large
ty-wraps) to support the Leadscrew from the top beam.

11. The bearing blocks on the Leadscrew are bolted to the beam.
Remove the 2-off fixing screws from the right-hand bearing
block and keep the assembly supported next to its locating
face, see Figure 8.5. Disconnect the left-hand side block, and
remove the assembly. Make sure the assembly is firmly
secured at both ends and is level.
CAUTION
Do not use strong force when pulling
off the bearing block, the ball race
may be damaged or collapse,
causing the balls to fall out.
12. Return the old assembly using the packaging from the
replacement assembly.
Replacing the Leadscrew Assembly

Make sure that the Leadscrew is kept level and even so that the
end bearings are a square fit, and are easily inserted without
damage.
1. Make sure the Optics Carriage is in a position that is to the
right of the Gimbal sleeve once the new assembly is located
into the recorder.
2. The replacement Leadscrew needs to be carefully inspected
for signs of damage, burrs or dirt around the bearings or
tracks. Ensure that the assembly ‘area’ for the Leadscrew is
clean, especially around the mating surfaces of the bearings.
Do not unpack the assembly until it is required.
CAUTION
The Leadscrew assembly must be
handled with extreme care to prevent
damage to the threads and bearings.

3. Inspect the locating face of the bearing blocks and beam pads
for dirt, damage, etc. Inspect and clean the replacement
assembly.
4. Position the Leadscrew assembly along the axes of the drum.
Manoeuvre the assembly to bring the left-hand bearing block
in line with the location pads of the beam. Use the leadscrew
securing tools (75472760) or large ty-wraps to support the
leadscrew.
5. Secure the left-end bearing block to its location pad using two
screws. Use a torque wrench set to 0.75 Nm, if it is available.
6. Screw the right-hand side bearing block to the beam and
ensure that it is seated correctly. Use a torque wrench set to
0.75 Nm, if it is available.
7. Couple the gimbal on the Leadscrew by pressing the C-clamp
on the optics against the gimbal nut face and secure the clamp
screw.
8. Clean the Leadscrew with a lint-free cloth, then lightly and
evenly oil with Maccurat oil .
9. Check that the Leadscrew operates correctly using the optical
alignment procedure in Section 8.3.
If there are still problems that are revealed as patterning on
film, then refer to Section 9.2.5.
9.2.3 Replacing the Drip Tray

See Figure 8.2.
2. Remove the left- and right-hand panels.
3. Remove the fixing screws at the left-hand end and the finger
screws at the right-hand end, and then slide out the tray.
4. Replacement is the reverse of the removal. Align the slots on
the Drip tray with the studs at either end of the machine. Slide
the tray into position and secure by screwing down the lock
nuts.

9.2.4 Cleaning the Leadscrew

1. Isolate the recorder from the main supply.
2. Clean the Leadscrew with a lint-free cloth, then lightly and
evenly oil with Maccurat oil.
4. Enter the Application Monitor from the Celix Diagnostics
terminal and obtain the Traverse sub-menu. Enter the
command:
lrcycle [Return]
the carriage now moves continuously from left to right.

5. After 5 minutes, enter the command:
stopcycle [Return]
to end the traverse cycling.

6. Examine the Drum, Optics Carriage, Leadscrew and
surrounding areas for signs of oil that has been ‘thrown off‘.
Clean as required.
9.2.5 Leadscrew Traverse Problems and Causes

The function of the Leadscrew assembly is to provide a constant
velocity drive to the Optics Carriage. The rotary drive is
translated as a linear motion at the Optics Carriage via a
pre-loaded nut and gimbal assembly. At the same time, the gimbal
absorbs geometric errors induced by the Leadscrew and transfers
only the required axial movement to the carriage.
The Leadscrew is a high-precision mechanism that is a vital part
of the scanning system. Any small cyclic changes in the velocity
of the Optics Carriage during a scan can result in a visible film
pattern. A common film pattern is often at the same pitch as the
Leadscrew track. Small changes in velocity will result in random
disturbances indicated on film.
Some common causes of change in Leadscrew velocity can be
seen as:

1. Cause 1: Changes in the rate of rotation of the Leadscrew.

2. Cause 2: Axial movement in the Leadscrew.
3. Cause 3: An incorrectly aligned gimbal.
4. Cause 4: Damage to (or dirt in) the Leadscrew and nut
threads.
Cause 1
Changes in the rate of rotation can be due to:
• servo malfunction
• poor lubrication
• damage to the Leadscrew
• dirt in the threads
• gimbal mis-alignment
• incorrectly set pre-loaded leadscrew nut inside the gimbal.
All these problems can produce forces at the nut-screw interface
which are beyond the specification of the servo system.
Cause 2
Axial movement of the Leadscrew is caused by the axial run-out
of the bearing tracks. To minimise this effect, high precision
bearing ‘pairs’, orientated to achieve maximum accuracy, are
fitted.
Unacceptable track run-out on high-precision bearings are often
caused by damage or dirt:
• between the faces of the bearings
• bearing pullers
• clamp rings and clamp nuts

• bearing block and Leadscrew shoulders.

Damage or dirt on the locating faces of the bearing blocks and
beam can also cause run-out.
Cause 3
A Gimbal will not function properly if it is mis-aligned. In this
condition it will transmit all Leadscrew and nut-induced errors to
the Optics Carriage, and also produce large variations in torque
demand resulting on severe patterning on film.
Cause 4
Damage to the thread of the Leadscrew produces areas of pattern
on film: for example, a single point of damage on a thread flank
causes a ‘burst’ of patterning the width of the threaded portion on
the nut. Even very light damage, indiscernible to the eye, can
cause patterning. Damage or dirt on the gimbal nut threadform
can also cause damage to the Leadscrew and make the gimbal
unstable.
If damage or tight points on the Leadscrew are suspected, then
examine the DSP Log. Use the Moon command:
Trav>dsplog
to obtain any error messages. A flat, full-sized tint image (95%)

can be used to identify any leadscrew problem areas from the
exposed film. The pitch of the leadscrew is 4 mm, and this
together with the resolution used, can narrow the problem down
to the Leadscrew or other errors.

Electrical 10
Replacements
and Setups
This chapter describes how to access, remove, re-install and
adjust the main replaceable parts used for the electronics system:
• Electrical Controls (MMI) – see Section 10.1.
• Power Amp Assembly – see Section 10.2.
• ECU (Boards, RFI Box and backplane) – see Section 10.3.
• PSU Assemblies – see Section 10.4.
• Cooling Fan Assemblies – see Section 10.5.
WARNING
procedures.
CAUTION
Make sure antistatic precautions are
observed for an electronics
replacement procedure.

Electrical Replacements and Setups
10.1 Electrical Controls

10.1.1 MMI Keypad Assembly Replacement
See Figure 10.1.
1. Switch off the AC mains on the rear of the Power Amp
assembly at the left, rear of the recorder.
2. Lift off the left-hand end panel.
OPERATOR
PANEL
(MMI)
ÂÂÂÂ
ÂÂÂÂ
ÂÂÂÂ MMI
ÂÂÂÂ
ELECTROSTATIC
DISCHARGE CABLE
FIXING SCREWS
(4 OFF)
Figure 10.1 Keypad assembly

3. Open the hinged left front door of the recorder.

4. Disconnect from the MMI panel the ribbon cable routed to the
RFI box.
5. Remove the Keypad assembly (75436810) - by the four fixing
screws from the top panel at the left-hand end of the machine.
This may be done from the left-hand end panel or from the
open hinged door, whichever is convenient.
6. Disconnect the MMI ESD (Electro-static discharge) cable.
7. Fit the new Keypad assembly.

10.2 Power Amplifier Assembly

See Figure 10.2 and Figure 10.3 and the Celix 4000 Recorder
Illustrated Parts Catalogue.
The Power Amp assembly contains a number of sub-assemblies,
such as, the circuit breaker, PCB and PSU, that can be replaced
in-situ as FRUs.
1. With the recorder mains switched off at the upper rear of the
machine, remove the left-hand end panel of the recorder.
2. Disconnect the two external power connectors at rear of the
recorder.
FIXING SCREW (4 OFF)
EXTERNAL CONNECTORS
Figure 10.2 Power Amp mounting tray position
3. Disconnect the following wiring from the Power Amp

assembly:
• AC lead from the ECU

• the drive cable from the leadscrew motor

• the drive cable from the I/O panel.
POWER
AMP PANEL
PSU
POWER
AMP
MOUNTING
TRAY
CIRCUIT
BREAKER POWER AMP
BOARD
RELAY
RL1
MAINS RELAY
FILTER RL2
TO
DATA TRAVERSE
TO ECU MOTOR
MAINS
TO ECU
Figure 10.3 Power Amplifier assembly
4. From the left-hand end at the rear of the recorder remove the
four external cross-head screws, while supporting the Power
Amp panel from the inside. Then remove the assembly from
the left-hand end of the recorder.

5. Replace the Power Amplifier assembly by reversing the

above procedure, as appropriate. Make sure all the earth leads
are re-attached.

10.3 Electronic Control Unit (ECU)

Always vacuum clean around and inside the ECU when removing
or replacing parts associated with the ECU.
10.3.1 ECU Box Assembly

See Section 3.2.1.
This unit will need to be removed from the recorder to access
components such as the lower ECU fans.
1. Open the left-hand side panel and the front access door, and
remove the cable entry cover.
2. Detach all the rear I/O connectors, mains supply to the PSU,
DC supply to the Mixer fan and front ECU box serial/SCSI
connectors. You may need to label some of the connectors
before removing them from the ECU.
3. Undo the two pairs of fixing screws securing the ECU RFI
box to the base frame. One pair of these is located beneath the
Input/Output Panel. The other pair is located at the base of the
PSU section of the ECU box.
4. Lift out the ECU and the attached Duct and Mixer assembly.
5. Replacement is the reverse of removal. You may need to
partially remove the seal around the left end of the recorder
before re-installing the ECU. Remember to re-instate the seal
afterwards.
6. Reconnect all cables and tighten the locking nuts. Replace the
cable entry cover.
7. Power up the machine and check that it operates correctly by
exposing a film.

10.3.2 ECU Board Assemblies
CAUTION
Make sure the antistatic precautions
are applied before removing any
PCBs.
CAUTION
Do not remove this assembly while
the Mains switch is ON.
The engineer should be fully conversant with the antistatic

protection requirements detailed in Section 2.11.
Board replacement is carried out as detailed in the following
procedures. All boards dealt with in this section, with the
exception of the Keypad assembly (MMI), are located in the
ECU RFI box. See Figure 3.2.
CAUTION
Never open the hinged lid (left-hand
cover) of the ECU box while power is
applied. The SCSI disk drive will be
damaged if the spinner motor is
spinning and the hinged lid is then
opened.
When power is removed from the

machine the SCSI disk drive will
‘park’.

System Data Manager (SDM) Board

See Section 3.2, Section 3.4.1 and Figure 3.2.
This board is contained inside the RFI box of the Electronics
Control Unit (ECU).
If only a fuse replacement is required, refer to Table 3.51 and
Figure 3.9.
Note: This changeover assumes that the old and new SDM
boards operate with the same System software. Check the
issue levels for both boards.
If the SDM board is to be replaced then make sure all the
NVRAM parameters have been logged.
Use the Recorder Utilities options for temporally saving and
restoring NVRAM parameters, see Section A.1, or the
Monitor command described below in step 1.
1. With the RIP server and the recorder switched on, save the
NVRAM parameters from NVRAM on the current SDM
board onto the SCSI disk, as follows:
a) Obtain the top level Celix Diagnostics menu, see
Section 6.4.
b) Enter the global command monitor [Return] to call the
Diagnostics monitor.
c) Enter command nvram_write_disk
assembly at the rear left of the recorder.
4. Shutdown and power off the RIP server otherwise the SCSI
board may be damaged.
5. Remove the left-hand end panel of the recorder.
6. Release the two retaining catch screws on the side cover.
Taking care that the working surface is clear, lower the rear
cover backwards to rest horizontally by its hinged support.
7. Mark, then disconnect the external board cables.

8. Unscrew the six board retaining screws and remove the board.
9. Fit the new board and secure with the board retaining screws.
10. Re-assemble in reverse order.
11. Power up the recorder.
12. If the board requires an SDM firmware update for the
recorder, see Appendix A.
13. Initialise NVRAM before downloading the ‘old’ NVRAM
parameters.
14. If the board replacement is not loaded with a software update,
download the NVRAM parameters from the SCSI disk to
NVRAM on the new SDM board as follows:
a) Obtain the top level menu as described in Section 6.4.
b) Enter the global command monitor [Return] to call the
Diagnostics monitor.
c) Enter command nvram_read_disk
DSP (Servo-control) Board

See Section 3.5.1, Figure 3.2 and Figure 3.10.
To access the DSP board, it is necessary to remove the SDM
board temporarily. Before doing this ensure that the power is
switched off.
To change the DSP board, first, remove the SDM board to gain
access. The DSP board can then be removed and replaced. The
SDM board is refitted above it.
Motion Control Board (MCB)



assembly at the left, rear of the recorder.
panel backwards to rest horizontally by its hinged support.
5. Disconnect the external board cables.
6. Slacken off and remove the eight board retaining screws and
remove the board.
7. Fit the new board.
Spinner Controller Board

See Section 3.8 and Figure 3.2.
1. Switch off the AC mains at the rear of the recorder.
cover backwards to rest horizontally by its hinged support.
4. Remove the two cable connectors on each side of the board.
5. Slacken and remove the four board retaining screws and then
remove the board.
6. Fit the new board.
7. Reconnect the cable connectors.
8. Reassemble in reverse order.
Input/Output Panel Assembly


If only fuse replacement is required, refer to Figure 3.5 and

Table 3.3.
3. Remove the external SCSI/serial cables. Release the two
retaining catch screws on the side panel. Taking care that the
working surface is clear, lower the side panel to rest
horizontally by its hinged support.
4. Open the hinged left front door of the recorder.
5. Disconnect the cables from the internal and external panels of
the Input/Output panel, see Figure 3.4, Figure 3.5 and
Table 3.1.
6. Slacken-off the six external and eight internal panel retaining
screws and remove them from the panel. Then remove the
Input/Output panel from the RFI box.
7. Fit the new I/O Panel assembly and reassemble, in reverse

10.3.3 Local SCSI Disk Drive

See Figure 3.2.
3. Release the two retaining catch screws on the side panel.
panel backwards to rest horizontally by its hinged support.
4. Disconnect the ribbon and power connectors from the SCSI
Disk.
5. Slacken-off the four external screws which secure the SCSI
Disk to the RFI box side panel. Tilt the side panel partly
upwards and remove the fixing screws. Then fully lower the
side panel and remove the SCSI disk.
6. Check the SCSI Option jumper links on the old disk and set
the replacement disk to the same ID value - see Table 10.2
for the currently supplied drive (99443187) and Table 10.3
for an alternative drive.
Table 10.2 IBM Utrastar 9ES DDRS 34560 settings
Pin 21-22 Pin 19-20 Pin 17-18 (SP4) SCSI ID

(SP2) (SP3)
OPEN OPEN OPEN O

OPEN OPEN SHORT 1
OPEN SHORT OPEN 2
OPEN SHORT SHORT 3
SHORT OPEN OPEN 4
SHORT OPEN SHORT 5
SHORT SHORT OPEN 6
SHORT SHORT SHORT 7
Make sure the recorder application and diagnostics software

is at the correct revision level.

Note: Any SCSI ID may be selected, except for ID 7. All

other connector blocks should be left at their default
settings.
Table 10.3 Fujitsu M2952S ID settings (CN7)
Pin 5-6 Pin 3-4 Pin 1-2 SCSI ID
OPEN OPEN OPEN O

OPEN OPEN SHORT 1
OPEN SHORT OPEN 2
OPEN SHORT SHORT 3
SHORT OPEN OPEN 4
SHORT OPEN SHORT 5
SHORT SHORT OPEN 6
SHORT SHORT SHORT 7
Verify Operation
7. Switch on the Celix 4000 system using the procedure in the
Celix 4000 Recorder User’s Guide.
8. Identify and format the newly fitted SCSI disk drive as
indicated in Figure 6.31.
9. Fit the new SCSI disk in position and reassemble in reverse
10.3.4 Interlock Relays

There are three 12 V, 16 A interlock relays (99137372) located in
positions shown in Figure 4.9. Each of these can be replaced by
carrying out the following procedure.
1. Remove the PSU Wired assembly, see Section 10.4.1.

2. Noting the connections, see Figure 4.9, disconnect the

external relay cable connections.
3. Note the mounting orientation of the relay and remove it from
the RFI box (two screws).
4. Fit the new relay in the original mounting attitude as the relay
being replaced.
5. Re-assemble in reverse order to removal.

10.4 PSU Assemblies

10.4.1 PSU Wired Assembly
If a PSU fails, replace the entire PSU wired assembly (75457640)
as follows.
1. Switch off the AC mains on the rear of the recorder.
3. Remove the Duct and Mixer assembly using the procedure in
Section 10.5.3.
4. Disconnect the fan wires connected to the MCB PL 1.
5. Disconnect the mains cable connection on the front panel of
the PSU section of the ECU box (facing the hinged left front
door of the recorder). Cut the cable tie-wraps at the rear of the
I/O panel
6. Undo the two fixing screws securing the ECU box to the base
frame. One pair of these is located beneath the Input/Output
Panel. The other pair is located at the base of the PSU section
of the ECU box.
7. Lift the ECU box and withdraw it from the the left-hand end
of the machine.
8. Unscrew the 14 retaining screws of the PSU box access cover
(see Figure 3.4) and lift it backwards to lie horizontally.
9. At the RFI box frame disconnect the two earth connections
from the PSU wired assembly (75457640) which contains the
two PSUs.
10. Mark all external connections to the PSU wired assembly and
disconnect them.
11. Remove the PSU wired assembly (75457640).
12. Fit the new PSU wired assembly (75457640) in the RFI box,
and reassemble in reverse order to the removal procedure.

IOP BOARD
3 PSU
POWER
LOOMS
TO PSU
UNIT
MOTION
PL16 CONTROL BOARD
TO PSU
UNIT
EARTH
STUD
SDM PL1 TO
BOARD PSU UNIT
Figure 10.4 PSU wiring harness connections

10.5 Cooling Fans

Where necessary, retain the existing fan guard and screws before
discarding the spinner cooling fan (fan wiring assembly).
Take care to assemble the fan in the correct orientation, - an arrow
is located on the side of the fan body to indicate the BLOW
direction. Filtered air is sucked in from the side panel aperture
above the ECU.
10.5.1 Lower ECU Fans Assembly

1. If the fan to be replaced is one of the three in the electronics
part of the ECU box, switch off the AC mains and access the
fans using procedure Steps 2. to 4. detailed earlier for
Motion Control Board replacement.
2. If the fan to be replaced is the one in the PSU section of the
ECU box, then access the fan by removing the box from the
machine and the PSU assembly from the ECU box, as
detailed in Section 10.4.1.
3. Noting the positions, detach the cables connecting the fan(s)
to the MCB board on the centre rear cover.
4. Remove the fan assembly from the RFI box. To do this, free
the vibration mounts, one fitted at each corner of the assembly
mounting platform. The assembly can then be lifted out.
5. Undo the appropriate tie-wraps and remove the fan to be
replaced by unscrewing its fixing screws.
6. Fit the new fan and reassemble in reverse order to removal.
10.5.2 Upper ECU Ducting Fan Assembly



2. Remove the left-hand side panel.
3. Disconnect the two fan wires from the connector inside the
ECU, see Figure 10.5.
4. Remove the 4-off retaining screws that hold the fan and the
duct shield to the assembly.
BLACK (PIN 10)
TO UPPER
RED (PIN 8) ECU FANS
PLUG ON MOTION
PL1 CONTROL BOARD
Figure 10.5 PSU wiring fan connections
10.5.3 Mixer Fan Assembly

See Figure 10.6.
This procedure
1. Traverse the Optics Carriage to the right-hand side using the
Application Monitor command:
Trav>ri

2. Remove the left-hand end panel.

3. Open the front access door of the recorder. Disconnect the AC

mains cable to the ECU and the power connector to the Mixer
fan on the ducting.
4. Open the ECU panel door and disconnect the two upper ECU
fan wires from the connector (PL1), see Figure 10.5.
5. Remove the 6-off, M6 screws securing the Duct and Mixer
fan assembly to the top of the ECU.
6. Withdraw the Duct and Mixer fan assembly through the open
left-hand side of the recorder.
DUCTING
MIXER FAN
CONVERGENT
DUCT TO DRUM
Figure 10.6 Location of Duct and Mixer fan assembly
7. Separate the convergent duct from the assembly by removing

the 1-off screw fixing and sliding out the duct. Remove the
2-off cross-head screws attaching the fan to the assembly.
This gives access to the fan and the connector.

8. Fit the new Mixer fan and reassemble in reverse order to

Steps 1. to 7. Make sure that the duct felt is refitted and is
properly mated to exclude light.
9. Feed the two upper ECU fan leads through the ECU grill to
the MCB connector PL1 – positive (red) to pin 8 and negative
(black) to pin 10.
10.5.4 Spinner Fan Assembly

See Section 8.2.15 for a description of how to Remove/Replace
this fan.
10.5.5 Output Chute Fan

This fan is mounted underneath the Output Chute to provide
positive pressure for protecting film from processor fumes.
1. Disconnect the 12 V supply to the fan.
2. Remove the 4–off fixing screws holding the fan to the chute.
3. Replacement is the reverse of removal. Make sure the fan grill
is re–attached.


NVRAM 11
Parameters
The following chapter lists and explains some of the more useful
parameters stored in NVRAM, and how they are updated from
Celix Diagnostics (the preferred method) or the Application
Monitor.
NVRAM parameter values in this chapter are only typical and
may alter for later production machines;also, some
machine-specific parameters are adjustable on-site.
11.1 Updating NVRAM Data

The current set of NVRAM values should be recorded in the Log
Book, and any changes to these values during the operating life of
the recorder must be updated in the book.
Any new NVRAM data values are entered directly as file edits
from the local RIP server using either Celix Diagnostics (the
recommended method) or the Application Monitor.
Note that for new NVRAM values to take effect, the machine
must be rebooted first.
For a PC running Windows NT it is possible to print or save a text
listing of all the NVRAM values for the current machine by
selecting an appropriate option from the Transfer Menu on the
Celix Diagnostics HyperTerminal window.

NVRAM Parameters
11.1.1 From Celix Diagnostics

Open Celix Diagnostics to get the Top Level Menu and select
Utilities (see Section 6.4 and Section 6.13). Choose NVPARAMS
and View and Edit Non-volatile Parameters from the sub-menu.
11.1.2 From Application Monitor

This utility is only available as an alternative to Celix
Diagnostics.
CAUTION
Because range checking is not
available for this utility, you need to
ensure that the values entered or
changed are correct.
1. Open a Monitor Diagnostics window from the Application

system.
2. From the moon> prompt, enter (see Section 6.14.2):
super [Return]
to obtain the Supervisor menu. From the super> prompt,

enter:
dnv [Return]
to display the NVRAM values. You can press n to display the

next page and q to quit.
3. Alternatively, enter:
pnv [name]
which can contain a wild card [*] for any substring, or [?] for
any single character. For instance, pnv * displays all
parameters and pnv *pll* all the parameters containing the
substring ‘pll’. Note that the name entered is case sensitive.

NVRAM Parameters
4. To set new data values from super>, type the entire line using
the format:
snv∆“Item”∆”data“[Return]
Note: “Item” is case sensitive and “data” can be hex or

decimal.
For instance, to set a new parameter value of 252, enter:
snv∆APP_POS_RES48∆252 [Return]
5. If you need to enter a long list of new data values, then use
the keyboard ‘Cut & Paste’ and ‘Last Command Repeat’
(Sparc) functions. Any deletions can be made with the
[Delete] key.
6. Reset the machine.

NVRAM Parameters
11.2 Changing the Spinner Idle Time

If the spinner idle time needs to changed from its 5 minute
default, then two NVRAM values have to be altered:
NV_BEARING_HOLD_TIME
and
NV_IDLE_TIME
After altering these values, reset or power down the recorder.

NVRAM Parameters
11.3 NVRAM Parameter Listing

All the parameters and their values supplied in this section are
typical of a production machine.
The contents of the NVRAM are arranged logically into the
following groups of parameters that relate to discrete functions of
a recorder:
• SCSI Parameters.
• Optical Parameters .
• Spinner Speed Parameters.
• Phase-Lock-Loop (PLL) Parameters.
• Counter and Scale Parameters.
• Traverse Parameters.
• Environmental Parameters.
• Media Parameters.
• Spinner Loop Gain Parameters.
• Spinner Final Power Parameters.
• Laser Parameters.
• Machine-specific Parameters.
• Service Parameters.
• Miscellaneous Parameters.
CAUTION
The emboldened parameters, shown
below, are specific to a particular
Celix 4000 recorder. They may not be
the same on other recorders.

NVRAM Parameters
The parameters listed below, relate to the physical characteristics

(length, width, thickness etc.) of a typical recorder. They are
currently loaded in to the NVRAM as a set of defaults in decimal
(d) and hex (h).
Different recorders may have variations which better suit the
physical or customer conditions They also refer to the physical
identification details of the external SCSI and the internal media
parameters.
Note: (d) = decimal and (h) = hexadecimal. The offset (o) values
are not shown.
11.3.1 Media and SCSI Parameters

1. SCSI_ID 3 (d) 3 (h)
The above value is established at installation and
should only be changed if the Recorder is
reconfigured within a network.
11.3.2 Optical Parameters

1. APP_POS_RES48 278 (d) 116 (h)
Aperture Position for 48 dpmm The
APP_POS_RES values are used by the test
patterns generated from the recorder, and are
determined by the Laser Calibration program.
2. APP_POS_RES72 451 (d) 1C3 (h)
Aperture Position for 72 dpmm
3. APP_POS_RES96 80 (d) 50 (h)
4. APP_POS_RES144 -120 (d) ff88 (h)

NVRAM Parameters
5. APP_POS_RES192 -120 (d) ff88 (h)

6. 4THOU_FOCUS_POS 500 (d) 1F4 (h)
Refers to 0.004 in. media.
7. 7THOU_FOCUS_POS 500 (d) 1F4 (h)
Refers to 0.007 in. media.
8. LD_ON_REF 2560 (d) a00 (h)
9. LD_THRESH 1920 (d) 780 (h)
10. LD_ON 2560 (d) a00 (h)
Optics parameters required to set up the laser
using the shutter-mounted detector.
11. LF_ON_REF 333 (d) 14d (h)
12. ILL_POS_RES48 25 (d) 19 (h)
13. ILL_POS_RES72 74 (d) 4a (h)
14. ILL_POS_RES96 105 (d) 69 (h)
15. ILL_POS_RES144 142 (d) 8e (h)
16. ILL_POS_RES192_20k 172 (d) ac (h)
17. ILL_POS_RES192_30k 155 (d) 9b (h)
18. HORIZONTAL_TRIM 0 (d) 0 (h)
Moves the image horizontally across the media
for a better fit. Units are in 1/1000 mm.
19. VERTOFF_RES48 4992 (d) 1380 (h)
Vertical offsets used to position the output
vertically on film. Units are 192 per 1 mm change
in the vertical distance.
20. VERTOFF_RES72 3744 (d) ea0 (h)
21. VERTOFF_RES96 4992 (d) 1380 (h)
22. VERTOFF_RES144 3744 (d) ea0 (h)

NVRAM Parameters
23. VERTOFF_RES192 4992 (d) 1380 (h)

Note: Items marked with a * are not presently documented in the
recorder’s logbook. Run the relevant motcal test (see
Section 6.10.5 from the Diags/Optics menu) to find the
NVRAM values.
24. APP_PLATE_TO_BASE_REF * 72 (d) 48 (h)
Used to calculate the position for moving the
aperture plate.
25. APP_LIMIT_DIST * 606 (d) 25e (h)
The distance between two end limits determined
by diagnostics.
26. ILL_LIMIT_DIST * 392 (d) 188 (h)
27. FOC_LIMIT_DIST * 1500(d) 5dc (h)
28. APP_BACK_HOME_DIST * -136 (d) ff78 (h)
29. ILL_BACK_HOME_DIST * -28 (d) ffe4 (h)
30. FOC_BACK_HOME_DIST * 1373 (d) 55d (h)
31. OPTICS_BASE_MODE 1 (d) 1 (h)
The flag used to indicate the type of optics base.
(0 = old; 1 = new).
11.3.3 Spinner Speed Parameters

1. FSP_RATE_RES48 3000 (d) 7530 (h)
Fast spinner rates in rpm.
2. FSP_RATE_RES72 3000 (d) 7530 (h)
3. FSP_RATE_RES96 3000 (d) 7530 (h)
4. FSP_RATE_RES144 3000 (d) 7530 (h)
5. FSP_RATE_RES192 3000 (d) 7530 (h)
6. SSP_RATE_RES48 2000 (d) 4e20 (h)

NVRAM Parameters
Slow spinner rates in rpm.

7. SSP_RATE_RES72 2000 (d) 4e20 (h)
8. SSP_RATE_RES96 20000 (d) 4e20 (h)
9. SSP_RATE_RES144 20000 (d) 4e20 (h)
10. SSP_RATE_RES192 20000 (d) 4e20 (h)
11.3.4 Phase Lock Loop Parameters

1. PLL_A_RES48_30k 0 (d) 0 (h)
Phase lock loop register A settings for a 30k
spinner.
2. PLL_A_RES72-30k 15 (d) f (h)
3. PLL_A_RES96_30k 0 (d) 0 (h)
4. PLL_A_RES144_30k 15 (d) f (h)
5. PLL_A_RES192-30k 0 (d) 0 (h)
6. PLL_M_RES48_30k 57 (d) 39 (h)
Phase lock loop register M settings for a 30k
spinner.
7. PLL_M_RES72_30k 42 (d) 2a (h)
8. PLL_M_RES96_30k 57 (d) 39 (h)
9. PLL_M_RES144_30k 42 (d) 2a (h)
10. PLL_M_RES192_30k 57 (d) 39 (h)
11. PLL_R_RES48_30k 3 (d) 3 (h)
Phase lock loop register R settings for a 30k
spinner.
12. PLL_R_RES72_30k 3 (d) 3 (h)
13. PLL_R_RES96_30k 3 (d) 3 (h)

NVRAM Parameters
14. PLL_R_RES144_30k 3 (d) 3 (h)

15. PLL_R_RES192_30k 3 (d) 3 (h)
16. PLL_A_RES48_20k 0 (d) 0 (h)
Phase lock loop register A settings for a 20k
spinner.
17. PLL_A_RES72_20k 15 (d) f (h)
18. PLL_A_RES96_20k 0 (d) 0 (h)
19. PLL_A_RES144_20k 15 (d) f (h)
20. PLL_A_RES192_20k 0 (d) 0 (h)
21. PLL_M_RES48_20k 57 (d) 39 (h)
Phase lock loop register M settings for a 20k
spinner.
22. PLL_M_RES72_20k 42 (d) 2a (h)
23. PLL_M_RES96_20k 57 (d) 39 (h)
24. PLL_M_RES144_20k 42 (d) 2a (h)
Phase Lock Loop register M settings for a 20k
spinner.
25. PLL_M_RES192_20k 57 (d) 39 (h)
Phase Lock Loop register M settings for a 20k
spinner.
26. PLL_R_RES48_20k 3 (d) 3 (h)
Phase Lock Loop register R settings for a 20k
spinner.
27. PLL_R_RES72_20k 3 (d) 3 (h)
28. PLL_R_RES96_20k 3 (d) 3 (h)
29. PLL_R_RES144_20k 3 (d) 3 (h)
30. PLL_R_RES192_20k 3 (d) 3 (h)

NVRAM Parameters
11.3.5 Counter and Scale Parameters

1. RES48_PIXCNT 17098 (d) 42ca (h)
Pixel count holding register.
2. RES72_PIXCNT 12823 (d) 3217 (h)
3. RES96_PIXCNT 17098 (d) 42ca (h)
4. RES144_PIXCNT 12823 (d) 3217 (h)
5. RES192_PIXCNT 17098 (d) 42ca (h)
6. RES48_PSCALE 4 (d) 4 (h)
Post scaler.
9. RES144_PSCALE 1 (d) 1 (h)
10. RES192_PSCALE 1 (d) 1 (h)
11.3.6 Traverse Parameters

1. SCAN_RATE_RES48 0 (d) 0 (h)
Not used for Celix 4000.
6. SCAN_ACC_RES48 0 (d) 0 (h)
Traverse scan acceleration values for each
resolution. Not used for Celix 4000.

NVRAM Parameters

10. SCAN_ACC_RES192 0 (d) 0 (h)
11. START_OFFSET_RES48 0 (d) 0 (h)
Traverse start offset values for each resolution.
11.3.7 Environmental Parameters

1. ENV_TIME 60 (d) 3c (h)
Environment monitor polling interval in seconds.
2. ENV_OVER_TEMP_TIME 300 (d) 12c (h)
SDM over-temperature timeout interval in
seconds.
3. ENV_LOG_UPDATE 5 (d) 5 (h)

NVRAM Parameters
Determines the environment logging interval.

4. ENV_SDM_TEMPH 60 (d) 3c (h)
SDM upper temperature threshold in degrees
centigrade.
5. ENV_SDM_TEMPL 55 (d) 37 (h)
SDM lower temperature threshold in degrees
Centigrade.
6. ENV_MCB_TEMPH 70 (d) 46 (h)
Motor Control heatsink temperature threshold in
degrees Centigrade.
7. ENV_LASER_TEMPH 35 (d) 23 (h)
8. ENV_LASER_TEMPL 30 (d) 1e (h)
11.3.8 Media Parameters

1. PUNCH_OPS 0 (d) 0 (h)
Counts the number of times the punch has
operated.
2. GUILL_OPS 30 (d) 1e (h)
Counts the number of times the guillotine has
operated.
3. SUP_DRUM_LENGTH 703 (d) 2bf (h)
Defines the length of the drum (in mm) used for
the default media eject length.
4. SUP_EXP_PROGRESS_TIME 2 (d) 2 (h)
5. FILM_LD_FAIL 0 (d) 0 (h)

NVRAM Parameters

6. FILM_USED_MTR 0 (d) 0 (h)
Counts the total amount of media (in metres) fed
into the machine throughout its life.
7. OUTPUT_SM 1 (d) 1 (h)
This indicates where the system currently
believes the film is located on the output path.
Output codings are:
1 – No film in output
2 – Cut film in vertical belts
3 – Cut film lost in output
4 – Cut film at processor
5 – Uncut film past guillotine
6 – Uncut film in vertical belts
7 – uncut film through to horizontal conveyor.
If the engineer has to alter the position of the
media in the output area, for example, to clear a
jam, the value of OUTPUT_SM should be
changed accordingly. For instance, if
OUTPUT_SM is set at 6, and the engineer
manually generates the guillotine to cut the film,
the OUTPUT_SM should be set to 2.
If the film is entirely removed from the output
system, OUTPUT_SM should be set to 1.
Normally, when the film is removed, the
imagesetter will usually recover automatically
even if OUTPUT_SM is not changed.
8. INPUT_SM 1 (d) 1 (h)
Refers to the state of the input media. This is a
Private parameter and must not be modified by
the user.
9. GUILL_SM 1 (d) 1 (h)

NVRAM Parameters
Refers to the state of the guillotine. If the

guillotine is manually moved, the parameter
values should change to reflect the new position:
–1 = LEFT LIMIT
–2 = RIGHT LIMIT.
When the guillotine is moved manually, it should
not be left between the two limits.
10. FH_FATAL_ERR 0 (d) 0 (h)
Indicates a film handling error.
11. FILM_CUT 0 (d) 0 (h)
12. LEN_IN_TUC 0 (d) 0 (h)
13. FILM_USED_MS 0 (d) 0 (h)
Counts the total amount of media (in motor steps)
fed into the machine throughout its life.
The SUCA parameters refer to the media characteristics. Note
that there are separate fields for film and for paper.
14. MI_SUCA_CASSID 1 (d) 1 (h)
Refers to the cassette ID. Not currently used.
15. MI_SUCA_THICKNESS 100 (d) 64 (h)
Film or paper thickness (1/1000 mm)
16. MI_SUCA_PLATE_THICKNESS 0 (d) 0 (h)
17. MI_SUCA_NUMSHEETS 0 (d) 0 (h)
18. MI_SUCA_TYPE 1 (d) 1 (h)
Type of film or paper (0 = unknown; 1 = film;

NVRAM Parameters
2 = paper; 3 = flexiplate).
19. MI_SUCA_WIDTH 660 (d) 294 (h)
Width of each roll in mm.
20. MI_SUCA_PLATE_WIDTH 0 (d) 0 (h)
21. MI_SUCA_LENGTH 60000 (d) aa60 (h)
Length of film or paper roll in (mm).
22. MI_SUCA_PLATE_LENGTH 0 (d) 0 (h)
23. MI_SUCA_MEDIA_VALID 0 (d) 0 (h)
Set to TRUE if the media information above is
valid; set to FALSE if the Input cassette is empty
or removed.
The SUCB parameters refer to the media characteristics of the
second cassette. Note that these are provided for future expansion.
24. MI_SUCB_CASSID 1 (d) 1 (h)
Refers to the cassette ID.
25. MI_SUCB_THICKNESS 100 (d) 64 (h)
Film or paper thickness (1/1000 mm).
26. MI_SUCA_PLATE_THICKNESS 0 (d) 0 (h)
27. MI_SUCB_NUMSHEETS 0 (d) 0 (h)
28. MI_SUCB_TYPE 1 (d) 1 (h)
Type of film or paper.
29. MI_SUCB_WIDTH 660 (d) 294 (h)
Width of each roll.

NVRAM Parameters
30. MI_SUCB_PLATE_WIDTH 0 (d) 0 (h)

31. MI_SUCB_LENGTH 60000 (d) ea60 (h)
Length of film or paper roll.
32. MI_SUCB_PLATE_LENGTH 0 (d) 0 (h)
33. MI_SUCB_MEDIA_VALID 0 (d) 0 (h)
Set to TRUE if the media information above is
valid; set to FALSE if the Input cassette is empty
or removed.
34. MACHINE_FAIL 0 (d) 0 (h)
A non-zero value indicates the machine is
unusable until cleared by a service engineer.
35. MACHINE_TYPE 0 (d) 0 (h)
Configures the machine for film or plate. (0 =
film; 1 = plate). Not used for Celix 4000.
36. COVERS_OPENED 0 (d) 0 (h)
Covers opened flag indicates TRUE if the covers
have been opened and the media may have
‘fogged’.
37. COVERS_EJECT_LENGTH 703 (d) 2bf (h)
Media advance distance to clear ‘fogged’ film
after the covers have been opened.
38. SLEW_VELOCITY 0 (d) 0 (h)
39. SLEW_ACCELERATION 0 (d) 0 (h)

NVRAM Parameters
11.3.9 Spinner Loop Gain Parameters

1. 12k_LOOP_GAIN 0 (d) 0 (h)
Spinner loop gain calibration tables. Not used for
Celix 4000.
2. 11k_LOOP_GAIN 0 (d) 0 (h)
3. 10k_LOOP_GAIN 0 (d) 0 (h)
4. 9k_LOOP_GAIN 0 (d) 0 (h)
11.3.10 Spinner Final Power Parameters

1. 12k_FINAL_POWER 0 (d) 0 (h)
Spinner power gain calibration tables. Not used
for Celix 4000.
10. SPIN_ACCEL_POWER 0 (d) 0 (h)

NVRAM Parameters
Spinner acceleration power. Not used for Celix

4000.
Extensions to spinner values.
14. 13k_LOOP_GAIN 0 (d) 0 (h)
15. 14k_LOOP_GAIN 0 (d) 0 (h)
16. 15k_LOOP_GAIN 0 (d) 0 (h)
11.3.11 Laser Parameters

1. LASER_TYPE 0 (d) 0 (h)
2. LASER_POWER 0 (d) 0 (h)
3. LASER_CURRENT 0 (d) 0 (h)
4. LASER_NEAR_EOL 0 (d) 0 (h)
5. LASER_CONTROL_MODE 0 (d) 0(h)
6. LASER_RATING 0 (d) 0 (h)
7. LASER_ON_TIME 0 (d) 0 (h)

NVRAM Parameters
11.3.12 Machine-Specific Parameters

1. FINGER_RETRACT_DIST 0 (d) 0 (h)
2. CENTERER_SENSOR_DIST 0 (d) 0 (h)
3. PULL_FROM_PUNCH_POSN 0 (d) 0 (h)
4. PLATE_PICKUP_POINT_DIST 0 (d) 0 (h)
5. PUNCH_DEPTH 0 (d) 0 (h)
6. FINGER_HOME_SENSOR_DIST 0 (d) 0 (h)
7. FINGER_LENGTH 0 (d) 0 (h)
8. PLC_SENSOR_DIST 0 (d) 0 (h)
9. DRUM_LENGTH 0 (d) 0 (h)
10. PLATE_RELEASE_MODE 0 (d) 0 (h)
11. PLATE_STATE 0 (d) 0 (h)
12. PLATE_DIR 0 (d) 0 (h)
13. PLATE_PUNCHED 0 (d) 0 (h)

NVRAM Parameters

14. PLATE_EXPOSED 0 (d) 0 (h)
15. MEDIA_EXPOSED 0 (d) 0 (h)
Scanner status flag. (0 = not exposed; 1 =
exposed).
16. MEDIA_PUNCHED 0 (d) 0 (h)
Scanner status flag. (0 = not punched; 1 =
punched).
17. CONFORM_EXTRA_DIST 0 (d) 0 (h)
Film handling ‘tuning’ value which may vary
between machines. Not used for Celix 4000.
18. CONFORM_RETRY_EJECT 0 (d) 0 (h)
Film handling ‘tuning’ value which may vary
between machines. Not used for Celix 4000.
19. PLATE_LENGTH 0 (d) 0 (h)
20. PLATE_WIDTH0 0 (d) 0 (h)
21. PLATE_THICKNESS 0 (d) 0 (h)
22. FILM_PROC_SEL 3 (d) 3 (h)
Processor present flag. (0 = No processor
attached; 1 = Processor present, without
communications; 3 = Processor present, with
intelligent communications).
23. PREV_PLATE_STATE 0 (d) 0 (h)
24. TRAV_HIGH_CURRENT 0 (d) 0 (h)

NVRAM Parameters

25. TRAV_FILM_DIST 0 (d) 0 (h)
26. PLATE_FG_CLAMP_DIST 0 (d) 0 (h)
27. PLATE_CONFORM_DIST 0 (d) 0 (h)
28. PLATE_PLC_SENSOR_ON_DIST 0 (d) 0 (h)
29. FILM_HEADER_DIST 0 (d) 0 (h)
30. FILM_TAIL_DIST 0 (d) 0 (h)
31. PULL_FROM_PUNCH_DIST 0 (d) 0 (h)
32. MERC_IP_SPEED_MODIFIER 0 (d) 0 (h)
33. SMOOTHED_MEAN 0 (d) (h)
34. AMPLITUDE 0 (d) (h)
35. CORRELATION_COEFF 0 (d) 0 (h)
36. LED_CAL 0 (d) 0 (h)
37. SCAN_CYCLES 0 (d) 0 (h)

NVRAM Parameters
Counts the number of scan cycles that have

occured on the machine.
38. C8000_HANG_FILM 0 (d) 0 (h)
39. TUC_LIMIT_FILM 0 (d) 0 (h)
40. FILM_PROC_MIN_LENGTH 280 (d) 116 (h)
Minimum film length that can safely output to the
processor.
11.3.13 Servicing Parameters

1. SERVICED_DAY 0 (d) 0 (h)
These items are updated from within Diagnostics
and give the dates when the machine was last
serviced.
2. SERVICED_MONTH 0 (d) 0 (h)
3. SERVICED_YEAR 0 (d) 0 (h)
11.3.14 Miscellaneous Parameters

1. SPINNER_FAN_STATUS
Indicates whether or not a sensor is fitted to
detect spinner fan failures (1 = Fitted; 0 = Not
Fitted).
2. NUM_LOADS
Number of times new film has been loaded from
the cassette into the drum.
3. NUM_RELOADS

NVRAM Parameters
Nmber of times film has been reloaded through

the drum.
4. NUM_REWINDS
Number of times film has been rewound from the
drum.
5. NUM_REWIND_FAIL
Number of times the film failed successfully to
rewind from the drum.
6. TIME_ON
Cumalative total time in (in minutes) that the
imagesetter has been powered up and running
application software.
7. NUM_DRUM_VAC_FAIL
Number of times the imagesetter has failed to
conform the film correctly after a load or reload.
8. FILM_IN_DRUM
Length of film currently in the drum (in motor
steps).
9. PUNCH_FITTED
Indicates whether or not the imagesetter is fitted
with a punch. (1 = Fitted; 0 = Not Fitted).
10. BEARING_HOLD_TIME
Amount of time (in seconds) that all the
imagesetters motors must be idle before the
spinner is slowed to idling speed.
11. BEARING_TEMP_TIME
Amount of time (in seconds) that is allowed for
the spinner to reach a steady temperature
adequate for exposure.
12. BRAKING_TIME

NVRAM Parameters
Time (in milliseconds) that the spinner brake is

applied continuously before it is pulsed, when
slowing down the spinner.
13. GO_UP_TIME
Minimum time (in milliseconds) that the brake
must be applied before the spinner is permitted to
spin again.
14. IDLE_TIME
Amount of time (in seconds) that the job queue
must be empty before the spinner is slowed to
idling speed. 300 secs is normal; –1 = No Idle.

NVRAM Parameters

Routine 12
Maintenance
This chapter describes the safety interlock checks, filter cleaning,
Input Rollers, and the main cleaning procedures for a six monthly
and twelve monthly service visit.
The Preventative Maintenance information is incorporated in this
chapter as follow:
Safety Interlock Checks - Section 12.1
Filters (Annual Service) - Section 12.2
Input (Nip) Rollers - Section 12.3
General Routine Maintenance - Section 12.4.
The recommended servicing equipment and special tools for
servicing a Celix 4000 recorder are shown at Appendix C.
12.1 Safety Interlock Checks

The Safety Interlocks require routine checking whenever
servicing routines are to be performed. Details of the Safety
Interlocks are described in Section 2.7. See also Section 7.1.1 on
removing panels.
Prepare for Checks
1. Wait until the MMI display shows a Recorder Ready - No
Media icon.
2. Remove the right-hand end panel.

3. Insert the Interlock Override Key (99380406).

Routine Maintenance
CAUTION
Make sure the interlock override key
is removed after these checks.
Table 12.1 Safety Interlocks
FUNCTION LOCATION MMI DISPLAY No.

Left End Panel See Figure 2.5 1
Right End Panel See Figure 2.5 2
Output Chute Panel See Figure 2.5 3
Upper Rear Panel See Figure 2.5 4
Front Access Door See Figure 2.5 5
Safety Interlock 1
1. Remove the left-hand end panel.
2. Check that Interlock 1 flashes on the MMI display.
3. Make sure the laser shutter cannot be operated, see Section
8.2.5.
4. Replace the left-hand end panel.
5. Make sure the MMI display shows a Recorder Ready - No
Media icon.
Safety Interlock 4
1. Remove the upper rear panel.
3. Make sure the laser shutter cannot be operated.
4. Replace the upper rear panel.
Media icon.
Safety Interlock 5
1. Open the front access door.

Routine Maintenance

3. Make sure the laser shutter cannot be operated, see Section
8.2.5..
4. Shut the front access door.
Media icon.
Safety Interlock 3
1. Open the Output Chute panel.
4. Close the Output Chute panel.
Media icon.
Safety Interlock 2
1. Remove the right-hand end panel.
4. Replace the right-hand end panel.
5. Make sure the MMI display shows Recorder Ready - No
Media icon.
Remove the Interlock Override Key (99380406).

Routine Maintenance
12.2 Filters - Annual Service

12.2.1 Left-hand ECU Filter
Lower ECU Filter

See Figure 12.1.
A filter is used on the exhaust ports underneath the ECU. For
annual servicing, this filter should be replaced according to its
condition.
Remove the left-hand panel, pull out the two black filter sleeves
and lightly vacuum the filter.
ÂÂÂÂÂ
ÂÂÂÂÂ
ÂÂÂÂ ÂÂÂÂ
ÂÂÂÂÂÂÂÂÂÂÂÂÂ
ÂÂÂÂ
ÂÂÂÂ ÂÂÂÂ
ÂÂÂÂ
ÂÂÂÂ
ÂÂÂÂ ÂÂÂÂ
ÂÂÂÂ
ÂÂÂÂ LOWER
ECU FILTER
Figure 12.1 Right-hand panel ventilation

Routine Maintenance
Upper ECU Filter

See Figure 12.1.
Pull out the filter element from the top ducting, and replace
according to its condition.
Left End Panel Filter

See Figure 12.2.
FILTER
R.H. END COVER
Figure 12.2 Left-hand panel (ECU) ventilation
A filter is used on the inlet port (behind the slatted air vents) of
the right-hand panel. For annual servicing, this filter should be
replaced according to its condition.

Routine Maintenance
Vacuum Pump Filter

See the procedure in Section 5.4.3.
Solenoid Mini-Filters
Follow the procedure in Section 5.3.1 to clean the mini-filters.

Routine Maintenance
12.3 Input (Nip) Rollers

12.3.1 Weekly Cleaning Procedure
The following software cleaning procedure is normally completed
by the customer each time a new roll is loaded:
1. While the machine is operating normally, rewind the media
and release the cassette by pressing the Release Input
Cassette button.
2. Remove the Input Cassette.

3. Check the rollers for signs of wear.
4. Lightly vacuum the rollers using a hand-held vacuum cleaner.
MEDIA INPUT ROLLERS
Figure 9.8 Cleaning the media input rollers
5. Use a lint-free cloth (or roller cleaning tool) slightly

dampened with with an antistatic cleaner, such as ‘Spray

Routine Maintenance
Tech’, or soap and water. Do not use drum or alcohol-based

cleaners, since these will have an abrasive effect on the
exterior rubber. Clean the rollers as follows:
a) Insert the cloth or roller into the slot, and gently push it
onto the surface of the rollers.
b) Clean the visible part of the rollers by wiping the cloth
along the length of the slot.
c) Disengage the cloth from the rollers.
d) Rotate the rollers a quarter turn by again pressing
Release Input Cassette and repeating steps a) to c) until
the full area of the rollers are cleaned. Alternatively, with
the recorder switched off, the rollers can be rotated by
hand.
e) Repeat the procedure until both rollers are completely
clean. Make sure the rollers are dry before loading more
film.
12.3.2 Six Monthly Procedure

1. Remove the Input roller tray using the procedure in
Section 7.3.1.
2. Remove the metal housing from the roller assembly.
3. Take off the springs which retain the rollers and remove the
top rollers. (The bottom roller is held in place by bearings).
4. Clean the rollers with soap (or mild detergent) and water. Do
not use an alcohol-based cleaning fluid. Dry and replace the
rollers.
5. If the springs are bent they need to be either replaced or fitted
the other way round, see step 7. See Section 7.3.1.
6. Check that the rollers operate correctly by loading film.

Routine Maintenance
12.4 General Routine Maintenance
WARNING
Beware of the hazardous voltages
which exist within the recorder.
Always switch off the system using the procedure in the Celix
4000 Recorder User’s Guide to ‘brake’ the spinner before the
machine is powered-down.
The following checks shall be carried out by the engineer
periodically.
Where applicable, use the Routine Maintenance Check Sheet to
record results.
12.4.1 Cleaning and Lubricating Fluids

Use the following fluids for each of the items below (see also
Appendix C):
Drum
Care Clean L40 (99963262) and WD-40 (99962075).
Input rollers
Antistatic cleaning fluid (99963265)
V–Groove
Slideway 68 Oil
Leadscrew
Maccurat Oil
Spinner Mirror
IPA (99963048)

Routine Maintenance
12.4.2 Six Monthly Maintenance Procedures

These procedures are carried out every six months during a
service visit.
Filters
The filters, listed in Section 12.2, must be cleaned every six
months. Also, check that the fans are operating correctly.
Fans
Twice yearly, check that all the following fans are working
satisfactorily:
• Upper and lower ECU fans.
• Spinner cooling fan.
• Mixer fan.
• Output Chute fan.
Check Log of Film Jams and Film Cuts

1. Select the Celix Diagnostics top level menu (see Section 6.4).
2. From the Utilities module, select ViewFilm [Return] to show
the ViewFilm screen.
3. View and note the number of film cuts, the number of film
jams and the date from which these have been recorded.
4. If any related action is taken, for example, changing the
guillotine rotary blade, reset the counts for film cuts and film
jams to zero. Enter the current date in the displayed window.
5. Exit from Celix Diagnostics.

Routine Maintenance
Drum Maintenance
Clean the inside of the drum twice yearly as follows:
1. Vacuum clean the inside of the drum to remove dust, taking
care not to scratch the drum surface with the vacuum
nozzle. Use a soft brush attachment.
2. Use Slideway 68 oil to clean the V-grooves of the drum.
3. Use Care Clean L40 (99963262) to clean the drum.
CAUTION
Do not use excessive amounts of
WD-40 as it may enter the vacuum
grooves and pipes.
Do not spray WD-40 into the drum or

near the optics. Apply with a cloth.
Avoid ingesting WD-40 spray. Make

sure there is good circulation of air
with all the panels removed when
cleaning the drum.
4. Use WD-40 spray and a lint-free cloth for cleaning and

buffing to a high polish. This will avoid the possibility of rust
forming in the drum.
5. Ensure the grooves are clean and the vacuum input holes at
the rear of the drum are not blocked. Move a strip of film
through the grooves to remove any debris that could block the
vacuum.

Routine Maintenance
Chad Collection Tray

Empty the chad collection tray and box (located in a receptacle
behind the lower rear panel) during a twice-yearly servicing. Use
a small screwdriver to remove the build-up of chad inside the
punch exit holes. Too much chad in the tray will eventually lead
to poor quality film punch holes.
Belt Tension
During a twice-yearly servicing, check and adjust, if necessary,
the rubber belt tension of the output chute assembly. If worn, the
belt(s) will need replacing, see Section 7.9.4.
Media Handling Setups

During a twice-yearly servicing, perform Media Handling Checks
as detailed in Section 4.12, with any setup changes described in
Chapter 7.
Spinner Mirror and Focus Lens

The recommended period for cleaning the spinner mirror is six
months. In some environments, where the measured density on
film falls to a low standard that cannot be corrected by
recalibrating, the mirror should be cleaned every three months.
If the focus lens needs to be cleaned, after checking for dust, then
the Optics Carriage will have to be removed from the machine.
The following items will be required:
• Small flat hand-mirror and hand flashlight
• Isopropyl alcohol (99963048) and lens cleaning tissues
(sourced locally).

Routine Maintenance
• Latex gloves (99960458) to prevent contamination of the lens

and mirror.
CAUTION
Do not turn the spinner manually or
start the spinner while the Optics
Carriage is inverted.
The cleaning procedure is as follows.

1. With the machine powered on, move the Optics Carriage
assembly to its right-hand limit using the Application Monitor
Trav>ri command.
2. Stop the spinner rotating by entering:

spinner>stop
3. Switch off power to the machine.

4. Remove the right-hand end panel. Ensure that the spinner
has stopped rotating before proceeding.
5. Remove the Baffles, see Section 8.1.
6. Use a small flat hand-mirror and flashlight to view the spinner
mirror. Note the position of the spinner mirror surface.
7. Reach with your fingers to the slot in the shroud at the mirror
end of the spinner. Pushing upwards with your fingers, rotate
the spinner mirror clockwise (as viewed from the rear of the
spinner) until it is facing downwards - be careful not to
touch the spinner mirror surface.
8. View the surface of the spinner mirror and inspect it to see if
it needs cleaning.
9. If the spinner mirror surface needs cleaning, clean it as
follows:
a) Wind the focus motor white cog until the focus lens is
fully towards the spinner (the foam around the shroud will
compress).

Routine Maintenance
b) Place a piece of white card or paper between the aperture

plate and the focus lens.
c) Wipe the mirror reflecting surface with a lens cleaning
tissue soaked in isopropyl alcohol (99963048). Avoid
scratching the mirror surface.
d) Wipe dry with a clean dry tissue.
e) Visually check with a torch that the mirror surface is dry
and dust-free.
10. Before cleaning the focus lens, shine the torch at the spinner
mirror so that the light beam is reflected off the mirror,
through the lens and on to the paper placed between the
aperture plate and the lens. You should be able to see any dust
on the lens by viewing the lens in the spinner mirror.
11. Remove the Optics Carriage from the machine, see Section
8.2, if you have to clean the focus lens.
12. Clean the lens with a tissue soaked in IPA.
13. Replace the Optics Carriage.
14. Perform a focus check, see Section 8.3.2, recalibrate the
Dmax and linearise the output using information in the RIP
User’s Guide.
15. Refit the right-hand end panel.
Leadscrew
During a twice-yearly servicing, use a lint-free cloth to clean the
leadscrew and then lubricate it with Maccurat oil. See Section
9.2.4 for the recommended method to lubricate the Leadscrew.
V-Groove
During a twice-yearly servicing, clean the V-groove with a
lint-free cloth and replace the Slideway 68 oil (approximately

Routine Maintenance
3.7 ml). See Section 9.1.2 for the recommended method to

lubricate the V-groove.
Input Drive Rollers

During a twice-yearly servicing, clean the rollers using the
procedure in Section 12.3.1.
Voltage and Temperature

During a twice-yearly servicing, perform voltage and temperature
checks. This can be done by:
• Entering the Electronics menu in the Diagnostics mode, then
viewing the Env menu for the SDM (System) board or
Environ for the Motion Control Board, see Chapter 6.
• Using facilities found in the Log Menu accessible in the

Applications Monitor mode, see Section 6.14.3.
Media Handling Operation

Run a film through the recorder to check the film handling.
Calibration of Recorder
The calibration procedure described in the Celix 4000 Recorder
User’s Guide and the appropriate RIP User’s Guide should be
checked by the service engineer twice yearly.

Routine Maintenance
Registration
Measure registration errors, see Section 8.3.3, twice yearly while
performing an expose operation. Ensure that the registration is
within specification.
Recorder Operation Quality Check

Run a test page to check the quality. Check the dot quality of the
page.
Punch
Check that the holes are within specification and correctly
aligned. Also, check the state of the lever arm slot for wear, etc.

Useful Utilities A
This appendix provides the the following useful utilities:
Recorder Utilities running on client RIP software under Windows
NT.
A.1 Recorder Utilities (Windows NT)

Recorder Utilities are a set of useful servicing tools for the
recorder “engine” usually loaded with the RIP Program Files
during a machine installation. They are used from a PC running
Celix RIP in a Windows NT environment. Once opened, users are
offered the following functions:
• Select a recorder (if the installation has more than one
machine running from the same RIP server).
• Download new firmware to the SDM board.
• Save a copy of the current NVRAM data to a separate file,
open the file to view the data, and restore the data to the
recorder.
• Save a copy of the current NVRAM machine statistics to a
separate file and open the file to review the values.
Before starting Recorder Utilities you need to ensure that:
The required recorder has been installed (see Section A.1.1),
and can communicate with the program via the SCSI bus.
The recorder is idle (ie not running a job) and the Fujifilm
applications have been closed down.
Access to the utilities is from the Start button and the walking
menu:
. .
Programs CelebraNT (or HQ RIP) Recorder Utilities
Engineer’s Reference Guide 6700887000 A–1

Useful Utilities
To select options for this program you can use the top menu bar
or one of the the buttons shown below. The last six options are
only activated when an installed machine has been selected.
SAVE NVRAM DATA
DOWNLOAD FIRMWARE OPEN NVRAM DATA
SELECT RECORDER RESTORE NVRAM DATA

SAVE STATISTICS
INSTALL RECORDER
OPEN STATISTICS
A.1.1 Install Recorder

This option is normally selected for initially installing a new
on–site recorder and making it visible to the RIP. If a recorder has
not been selected, only the first two buttons are active.
Click Install Recorder in the button bar to open the Install
Recorder window.
For a typical site installation of a new recorder, the window first

displays a dummy recorder name which you can either delete or
leave in place.
A–2 Celix 4000 (MkII) Recorder

Useful Utilities
Click New Recorder... to obtain the Name Recorder dialog box

and enter the recorder name, for instance, C4000. The recorder
type and SCSI Id are automatically detected and cannot be
revised. (If a recorder cannot be detected, check the SCSI cable
connection. Also, make sure that the recorder was powered up
before the PC). Click on OK and then close the Install Recorder
window.
A.1.2 Select Recorder

Click the Select Recorder button to open the Recorder Select
box. Highlight the required name and click OK; as a result, the
last six utility menu options are activated.
A.1.3 Download Firmware to Selected Recorder

This option allows the latest version of firmware to be
downloaded to the SDM board from a CD-ROM disc or a floppy.
Three types of hex files are available representing the three
software file systems - Section 6.4:
• application code “ app”

Useful Utilities
• diagnostic code “ diag”

• boot code “ boot” (once loaded, this code is not normally
updated).
Before starting to download new firmware from the PC to the
recorder, the new file(s) must be installed on the PC (preferably in
the EngUtils directory), or selectable over an attached network.
The new file(s) are normally loaded from the CD–ROM using the
Component Installer which automatically runs when the disc is
inserted. If the file(s) are provided on a floppy disk, then copy
them into a selected directory using Windows NT Explorer.
Click the Download Firmware button to open the following box
which will either show the currently installed firmware levels, or
appear as blank if firmware has not yet been installed.
To download new files, click Download Firmware... and open

the window displaying the default location of the firmware files -
normally under the Program Files directory
FFEI/../Data/EngUtils:
Use the Select window to access files from the EngUtils default
store directory, or to access any alternative directory.

Useful Utilities
Choose the File Type filter from the dropdown box to display the
appropriate file for downloading, highlight the file name, and
click OK. Choose Yes to confirm the download on the next box,
and click OK when the Download Complete message appears.
A.1.4 Save NVRAM from Selected Recorder
CAUTION
Only a trained service engineer
should attempt this operation. The
recorder could be damaged if an
incorrect version of NVRAM data is
restored.
If you need to keep a copy of the current NVRAM settings of a

selected recorder for diagnostic reviewing or for changing the
SDM board, click Save NVRAM button. The current NVRAM
file is shown with its default extension (_nv.txt) type; select a
directory location for storing the file and click on Save.

Useful Utilities
A.1.5 Open NVRAM Data File

To open a stored file for reviewing NVRAM data, click the Open
NVRAM button to obtain the following window:
Select the required file (_nv.txt) from a directory and click Open.
A.1.6 Restore NVRAM Data to Selected Recorder

You can return a stored NVRAM data file (_nv.txt) to a selected
recorder by clicking the Restore NVRAM button. Select the
required file from the window below and click Restore.

Useful Utilities
A.1.7 Save Machine Statistics from Selected File

This utility option operates in the same way as Save NVRAM,
allowing you to store the current machine statistics to a directory
file with a different extension (_stats.txt). Click the Save
Statistics button to open the following window and select a
directory for the statistics file, then click Save.
A.1.8 Open Machine Statistics

This utility option operates in the same way as Open NVRAM,
allowing you to open a stored machine statistics file (_stats.txt)
for reviewing. Click the Open Statistics menu button to open a
window, choose a statistics file, and then click Open.

Useful Utilities

Celix 4000 B
Specifications
This appendix outlines the main Celix 4000 (Mark II)
specifications that may be required by a service engineer.
B.1 General
Celix 4000 is a PostScript Imagesetter used for imaging on
suitable media. The system consists of a RIP and a B2-sized
Recorder.
The Celix 4000 Recorder has a 180_ internal drum, automatic
delivery, expose and unload the media to an on-line processor.
B.2 Summary of Specifications

B.2.1 Physical Dimensions
Recorder*: Height: 1220 mm

Depth: 1300 mm
Width: 1800 mm
Weight: 700 kg
Note: * = Recorder machine and Output Chute.
Engineer’s Reference Guide 6700887000 B-1

Celix 4000 Specifications
B.2.2 Power
Recorder: Single-phase, two sockets 1.5 kW
(Electronics) + 0.75 kW (Pneumatics)
B.2.3 Recorder Performance
Resolution Media Handling Time

48 l/mm: 61 e/s 39 p/h
72 l/mm: 91 e/s 29 p/h
96 l/mm: 122 e/s 23 p/h
144 l/mm: 185 e/s 16 p/h
192 l/mm: 369 e/s 9 p/h
Note: Lines per millimetre (l/mm), Expose in seconds (e/s), and

Pages per hour (p/h)
B.2.4 Image Format Size

Maximum: 756 mm x 628 mm - without registration
marks, colour bars, page borders, etc.
Minimum: Constrained by the PostScript application - the
minimum eject length for media handling
through the on-line processor is 260 mm
(Note: There may be differences for on-line or
cassette handling systems not qualified by
Fujifilm).
Orientation: Available functions include: positive,
negative, right reading, wrong reading, and
rotation in 90_ steps.
B-2 Celix 4000 (MkII) Recorder

B.2.5 Imaging Area

Length: 628 mm x width.
Width: Roll width, less 4 mm - to allow a ± 2 mm
tolerance for tracking and skewing.
Note: Width is defined as the slow-scan direction.
B.2.6 Media Punching

Fujifilm will supply a suitable film punch for the Celix 4000
recorder as a customer option. All options are at additional costs.
Normally, four standard factory-fitted options are available along
with any customised layouts and a dummy (no holes) punch.
Location: On the leading edge across the width of the
drum.
Options: Stoesser, Bacher, Billows Protocol, Kamata, or
any customer option .
Occupation Area: Punches outside the image area.
Media Edge to C/ 30 mm.
L:
C/ to Image Edge: 25 mm (registration mark).
L
"
Repeatability to a tolerance of 5 microns is required for each
set of separations with respect to the punched holes.
B.2.7 Light Source

Red Laser Diode, 670 nm.

B.2.8 Media
Type: Roll-fed red sensitive film or paper; 0.004 in.
(100 µm) or 0.007 in. (178 µm) thick.
Daylight or darkroom loading.
Media widths: 356/508/660/760 mm ± 2 mm. (Note: Width is
defined as the slow-scan direction).
Media heights: 260 mm to 703 mm.
Make: Fujifilm: HSR and LS-4500 film,
PR-H100WP.
Paper.
Note: WL1 daylight loading only, not WL3 or WL2.
B.2.9 Cassette Capacity

Film: 0.004 in. (100 µm)
Supply: 61 m roll, emulsion in,
Core size: 71.3 mm (± 0.3 mm), 65.28 mm
(plastic inserts) darkroom or daylight loading.
Film: 0.007 in. (178 µm)
Supply: 30 m roll, emulsion in,
Core size: 71.3 mm (± 0.3 mm), 65.28 mm
(plastic inserts) darkroom or daylight loading.
B.2.10 DPI (l/mm) Resolutions

Note: Lines per millimetre (l/mm)
DPI: 1219 1828 2438 3657 4876

L/mm: 48 72 96 144 192

B.2.11 Screen Rulings

The supported screen rulings are:
CelebraNT RIP
• Fujifilm Quality Screening - 35 to 300 lines per inch.
• Fujifilm FM Screening (Option) - 21 and 28 micron dot size.
• Adobe Accurate Screening - 85 to 600 lines per inch.
HQ RIP
• Harlequin Precision Screening.
• Harlequin Dispersed Screening.
Note: Refer to the HQ RIP User’s Guide for information on
screening.
B.2.12 Dot Types and Shapes

The recorder is capable of producing hard dots in round,
elliptical, square, and euclidian shapes, according to the selected
option in the application package.
Optimised sets of screening parameters are provided for the
following angle families:
• 0_, 15_, 45_, and 75_
• Offset 7.5_, 22.5_, 52.5_, and 82.5_
• Flexo angles: 98_, 158_, 83_, 38_.
B.2.13 Writing Spot Sizes
Resolution: 1219 1828 2438 3657 4876

Spot Size (µm): 19 13 10 7 7

B.2.14 Recorder Writing Speeds
DPI: 1219 1828 2438 3657 4876

in2/min: 608 405 304 202 152
cm2/min: 3 925 2 616 1 962 1 308 981
B.2.15 Traverse Rates

DPI: 1219 1828 2438 3657 4876
mm/s: 10.417 6.944 5.208 3.472 2.604
B.2.16 Repeatability
This is 5 µm over 8 separations imaged consecutively in the same
drum position.
Note: These parameters are for a machine operated at room
temperature of 23°C ± 2°C and a relative humidity of
50% ± 5%. Any distortion of photographic material, due
to variations in temperature and humidity, may be
disregarded.
B.2.17 Registration
"
This is 25 µm for separations imaged in different areas of the
drum on the same sheet of film.
Note: These parameters are for a machine operated at room
temperature of 23°C ± 2°C and a relative humidity of
50% ± 5%. Any distortion of photographic material, due
to variations in temperature and humidity, may be
disregarded.

B.2.18 RIP-to-Recorder Interface

Small Computer System Interface (SCSI).
B.2.19 Environment Operating Specification

Temperature: 18 - 29°C (< 2°C variation / h)
Humidity: 20 - 80% max. wet bulb 26°C
Note: For optimum operating conditions, see sections B.2.16 and
B.2.17.
B.2.20 On-line Media Processor Options

Make: FUJIFILM AP-860
Glunz and Jensen Multiline 860
1220 mm (48 in)
610 mm
24 in)
1800
740 mm mm
(29 in) (71 in)
Figure B.1 Imagesetter dimensions with

Glunz and Jensen Multiline 860 processor


Servicing C
Equipment and
Special Tools
The following servicing equipment and special tools may be
required for performing the relevant preventive maintenance or
repairs tasks which are relevant to the Celix 4000 recorder.
The following special tools/equipment are required by the user.
• Stubby pozidriv No. 2.

• Stubby flat blade 1/4 in.
• Range of open-ended metric spanners (5 - 10 mm, 13 mm,
18 mm, 23 mm).
• Range of ball-ended hexagonal wrenches (for example, Allen
keys), 1.5 to 10 mm.
• Potentiometer Trim tool (99905631).
• Antistatic Kit (99987920)
• Interlock Override Key x 3 (99380406).
• Interlock Screw Removal tool, 4 mm Allen key (99905672)
• Digital voltmeter with probes.
• Set of metric feeler gauges.
• Continuity tester.
• Screwdrivers - flat blade 1/8 in., 3/16 in. and 1/4 in. blades.
• Tweezers flat-nosed, or magnetic retrieving tool.
• Leadscrew securing tool (75472760).
Engineer’s Reference Guide 6700887000 C-1

Servicing Equipment and Special Tools
• Hearing protectors, (99902379) or equivalent (BS6344 Pt1

7243 DIN ANSI).
• Isopropyl alcohol (99963048).
• Lens cleaning tissues - to be sourced locally.
• Maccurat oil - for the leadscrew.
• Slideway 68 oil - for the V-groove.
• Care Clean L40 (99963262) for cleaning the drum.
• 5 mm ball-ended hexagonal wrench, long-reach 170 mm.
• Densitometer.
• Optics Service tool (75472310)
• Multi-purpose grease (99969196).
• Antistatic cleaning fluid (99963265) - for rollers.
• Lint-free cloth - for general cleaning.
• WD-40 (99962075) - for cleaning and buffing the drum.
• Spare pads (75492590) - for the roller cleaning tool.
• Grid Alignment program (75472370).
• Blanking plugs 75486280 (for laser diode assembly
connectors SK2, SK3 and SK5).
• Loctite 222.
• Low-strength epoxy-type glue.
• Jig Removal tool.
• Input Roller Cleaning tool (75496170) - for cleaning the
rollers.
• Small hand-held mirror and flashlight - for inspecting the
spinner mirror for dirt.
• Latex gloves (99960458) - for cleaning the spinner mirror.
• 3M ScotchBrite (99960453) - used to clean the V-groove.
C-2 Celix 4000 (MkII) Recorder

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Celix 4000 (Mk II)

(ii) Celix 4000 (MkII) Recorder

Engineer’s Reference Guide 6700887000 (iii)

Improper use of controls and switches, failure to comply

(iv) Celix 4000 (MkII) Recorder

Note: This equipment has been tested and found to be

Engineer’s Reference Guide 6700887000 (v)

Electromagnetic Compatibility Information - Europe

(vi) Celix 4000 (MkII) Recorder

73/23/EEC - Low Voltage Directive

Engineer’s Reference Guide 6700887000 (vii)

About this Document

(viii) Celix 4000 (MkII) Recorder

• Chapter 10 - Electronic System Replacements and Setups. Describes how to access,

Engineer’s Reference Guide 6700887000 (ix)

CelebraNT RIP Installation Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67008140

Trademarks and Copyright

Apple, AppleShare, AppleTalk, , System 7, Power Macintosh and Macintosh are

(x) Celix 4000 (MkII) Recorder

Chapter 1 System Overview

1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–1

1.2 Celix 4000 Recorder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–5

1.3 Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–7

1.4 Ancillary Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–10

Chapter 2 Safety Requirements

2.1 Health and Safety at Work . . . . . . . . . . . . . . . . . . . . . . . . 2–1

2.2 Clothing and Jewellery . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–2

2.3 Servicing Equipment and Special Tools . . . . . . . . . . . . . . 2–2

2.4 Site Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–3

2.5 Electrical Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–8

2.6 Mechanical Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–9

2.7 Safety Interlocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–9

Engineer’s Reference Guide 6700887000 (xi)

2.8 Acoustic Noise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–13

2.9 Spinner Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–13

2.10 Laser Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–14

2.11 Antistatic Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–17

Chapter 3 Equipment Physical Description

3.1 Location of PCBs in the Recorder . . . . . . . . . . . . . . . . . . 3–2

3.2 ECU Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–4

3.3 PSU Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–11

3.4 System Data Manager (SDM) Board . . . . . . . . . . . . . . . . 3–16

3.5 Digital Signal Processor (DSP) Board . . . . . . . . . . . . . . . 3–19

(xii) Celix 4000 (MkII) Recorder

3.6 Motion Control Board . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–26

3.7 Power Amplifier Board . . . . . . . . . . . . . . . . . . . . . . . . . . 3–29

3.8 Spinner Controller Board . . . . . . . . . . . . . . . . . . . . . . . . . 3–32

3.9 Media Handling Sensors and Distribution Boards . . . . . . 3–35

Chapter 4 Equipment Functional Description

4.1 System Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–2

Engineer’s Reference Guide 6700887000 (xiii)

4.2 System Electronics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–8

4.3 PSU Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–10

4.4 System Data Manager Board (SDM) . . . . . . . . . . . . . . . . 4–13

(xiv) Celix 4000 (MkII) Recorder

4.5 Digital Signal Processor (DSP) Board . . . . . . . . . . . . . . . 4–22

4.6 Motion Control Board . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–26

4.7 Spinner Controller Board . . . . . . . . . . . . . . . . . . . . . . . . . 4–30

4.8 Power Amplifier Board . . . . . . . . . . . . . . . . . . . . . . . . . . 4–32

4.9 MMI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–34

4.10 Laser Modulator Board . . . . . . . . . . . . . . . . . . . . . . . . . . 4–36

4.11 Media Handling Systems . . . . . . . . . . . . . . . . . . . . . . . . . 4–37