The Avantra 36/44 Service Manual Part Number 580078-0002
AVANTRA 36/44 Service Manual This document discloses subject matter in which Agfa Division, Bayer Corporation has proprietary rights. Neither receipt nor possession thereof confers or transfers any right to reproduce or disclose the document, any part thereof, any information contained therein, or any physical article or device, or to practice any method or process, except by written permission from or written agreement with Agfa Division, Bayer Corporation.
Table of Contents INTRODUCTION About This Manual......................................................................................... xiii Warnings, Cautions, and Notes ..................................................................... xiii Imagesetter Safety Information ..................................................................... xiv Laser Safety ................................................................................................. xiv Labeling...................................
Avantra 36/44 Service Manual Electronics Packaging................................................................................. 2-4 System Architecture.................................................................................... 2-4 Digital Engine Controller (DEC).................................................................... 2-7 Operator Control Panel ................................................................................. 2-8 Micro-controller .....................................
Table of Contents Supply Side Mechanics............................................................................... 2-26 Powered Media Take-up Cassette ............................................................. 2-27 Media Punch/Clamp Assembly .................................................................. 2-28 Take-up Drive Assembly ............................................................................ 2-29 Media Cutter Assembly................................................................
Avantra 36/44 Service Manual Chapter 4: Imagesetter Component Removal/Replacement Procedures Introduction.................................................................................................... 4-1 Covers............................................................................................................. 4-3 Right/Left Side Covers ................................................................................ 4-3 Top, Middle and Bottom Front Panels .....................................
Table of Contents Aperture Wheel Motor ............................................................................... 4-53 Weak Lens Motor ........................................................................................ 4-54 Focus Sensor ............................................................................................... 4-55 Media Transport Removal/Replacement Procedures ................................... 4-57 Supply Drive Servo Motor...................................................
Avantra 36/44 Service Manual Appendix B: Spare Parts Index SECTION II: BRIDGE Chapter 1: Bridge Installation Introduction.................................................................................................... 1-1 Removing the Imagesetter Top Cover .......................................................... 1-2 Attaching the Capture Bar to the Bridge ...................................................... 1-5 Raising and Lowering the Bridge into the Imagesetter ...............................
Table of Contents Bridge Loop Sensor........................................................................................ 4-3 Upper Bridge Servo Motor ............................................................................ 4-4 The Activator Switch...................................................................................... 4-6 The Bridge Up Sensor ................................................................................... 4-7 Bridge Shuttle Motor....................................
Avantra 36/44 Service Manual OLP Unpacking Procedures .......................................................................... 1-3 Tools Required for OLP Unpacking .......................................................... 1-3 OLP Inventory ............................................................................................ 1-3 Opening and Unpacking the Parts Crate .................................................. 1-5 Unpacking and Preparing the OLP Engine........................................
Table of Contents Circulation Pump ........................................................................................... 3-14 Developer or Fixer Replenishment Pumps................................................... 3-15 Heating Element............................................................................................. 3-17 Wet Section Temperature Sensor .................................................................. 3-18 Dryer Section Temperature Sensor ..................................
Avantra 36/44 Service Manual Crane Installation Procedures ....................................................................... 1-3 The Mounting Plate and Boom ................................................................. 1-3 Mounting the Head .................................................................................... 1-7 Chapter 2: Crane Component Removal / Replacement Introduction....................................................................................................
Introduction About This Manual This manual contains all of the information you need to unpack, prepare, and install the Agfa Avantra 36/44 and 36S/44S imagesetter, bridge, buffer, on-line processor, and crane. Warnings, Cautions, and Notes The terms WARNING, CAUTION, and NOTE have specific meanings in this manual. • A WARNING advises against certain actions or situations that could result in personal injury or death.
Avantra 36/44 Service Manual Imagesetter Safety Information Laser Safety WARNING: Looking directly into the laser beam or laser beam reflection can cause permanent eye damage. The Avantra is a class 1 laser radiation device and is harmless during normal operation. However, during certain system alignments and tests, the laser is considered a class 3B device. In this classification, the laser can be harmful to your eyes. The laser presents no danger as long as the protective covers are in place.
Introduction Labeling Various warning and compliance labels are attached to the Avantra 36/44. DANGER LASER RADIATION WHEN OPEN AVOID DIRECT EXPOSURE TO BEAM PELIGRO RADIACION LASER CUANDO SE ABRA EVITE LA EXPOSICION DIRECTA DEL HAZ VORSICHT! LASERSTRAHLUNG TRITT AUS, WENN DECKEL GEOFFNET IST! NICHT DEM STRAHL AUSSETZEN! DANGER RAYONNEMENT LASER A L’OUVERTURE EVITER TOUTE EXPOSITION DIRECTE AU RAYON Multilingual warning label. CLASS 1 LASER LASER KLASSE 1 Laser class label.
Avantra 36/44 Service Manual WARNING: Class 1 lasers are considered safe for operator access in accordance with the Code of Federal Regulation and international standards. Wilmington, MA 01887 Agfa Division certifies that this product conforms to all applicable provisions of 21 CFR Subchapter J in effect as of the date of manufacture. CDRH compliance label. abc Division WILMINGTON, MA 01887 U.S.A. Location MODEL PART NO. SERIAL VOLTS AMPERES WATTS Hz MFG.DATE MADE IN U.S.A.
Introduction • To protect against the hazard of electric shock, do not allow water to run or spill into the electical compartment or components. • Before servicing, always disconnect the electric power or unplug the power cable at the mains. NOTE: The OLP has six built-in safety switches, which disconnect all power whenever the top lids are opened. • The processor contains a lithium battery. WARNING: The battery may explode if mistreated. Do not recharge or disassemble.
Avantra 36/44 Service Manual Chapter 3: Imagesetter Diagnostics Describes the tools used to diagnose and troubleshoot the Avantra. Chapter 4: Imagesetter Component Removal/Replacement Procedures Provides the procedures for removing and replacing components within the Avantra imagesetter. Chapter 5: Imagesetter Alignment Procedures Provides the procedures for aligning and adjusting the Avantra 36/44 imagesetter.
Introduction Chapter 2: Buffer Functional Analysis Provides an operational and functional overview of the Avantra’s buffer. Chapter 3: Buffer Component Removal/Replacement Provides the procedures for removing components within the Avantra buffer. and replacing defective Chapter 4: Buffer Preventive Maintenance Describes the procedures for inspecting and cleaning the Avantra buffer.
Avantra 36/44 Service Manual Product Description The Avantra 36 and 44 are members of the Avantra family of high-end laser based PostScript image recorders. They build upon the Avantra 20/25 advanced capabilities and add new features. The Avantra 36/44 line is especially designed for users requiring large format output, such as packaging and posters. Both systems support the high quality imaging requirements needed for CristalRaster.
Introduction The following illustrations show the imagesetter with all the OLP options installed and attached. 2 1 3 4 The Avantra 36/44 imagesetter, buffer, and crane. ➀–Imagesetter. ➁–Crane. ➂–Buffer ➃–On-line Processor (OLP). 1 2 3 The bridge. ➀–Top cover. ➁–Bridge. ➂–Light shield.
Glossary of Acronyms Introduction This glossary contains acronyms used in the Avantra 36/44 Imagesetter Service Manual and in scanning environments in general. For more information about an acronym, see the index in this manual.
Avantra 36/44 Service Manual xxiv Glossary PCB Printed Circuit Board PLL Phase Lock Loop PWM Pulse Width Modulation RAM Read Access Memory RIP Raster Image Processor ROM Read Only Memory SDM Sensor Driver Module SGM Spot Generation Modules SPI Serial Peripheral Interface TSDM Take-up Side Media Transport T/U Take-Up
Section I: Imagesetter
Chapter 1: Imagesetter Installation Procedures 1.1 Introduction This chapter describes the requirements and procedures necessary for installing the Avantra 36/44 imagesetter. Included in this chapter are: • Customer Pre-site Checklist • Service Engineer Installation Procedure • Pre-installation Checks • Upacking the Imagesetter • Unlocking the Imagesetter • Checking the System • Customer Application Training 1.
Avantra 36/44 Service Manual If the customer is setting up the optional on-line processor (OLP)/buffer as well, the OLP electrical specifications are: • Volts: 230 Amp: 30 Rec.: NEMA L6-30P Phases: 1, 2 or 3 phases + (neutral) + ground Load: Maximum 7.0 kW Environment The system should be located in a clean, static free work area for best operation. The system must not be placed near heating or air conditioning equipment.
Section I: Imagesetter If the customer is setting up the optional on-line processor (OLP)/buffer as well, their physical specifications are: Buffer Width: 61" (154.94 cm) Height: 54" (137.16 cm) Depth: 15" (38.10 cm) Weight: 200 lbs. (90.72 kg) On-line Processor (OLP) • Width: 61" (154.94 cm) Height: 54" (137.16 cm) Length: 66" (167.64 cm) excluding receiver tray 98" ( cm) including receiver tray, roll mat. 120" ( cm) including recevier tray, sheet mat. Weight: 937 lbs. dry (425.
Avantra 36/44 Service Manual 1.3 • Cables–the system must be located so that the Agfa Print Engine Interface Standard (APIS) cable between the Avantra and the RIP is of sufficient length. Verify that all network and interface cables are of correct length for other equipment to be installed (e.g., scanners and frontends). • Densitometer–a required tool for producing high quality film separations.
Section I: Imagesetter 1.3.2 Unpacking the Imagesetter Tools Required: A tool kit is packed inside the imagesetter crate. Remove the kit at Step 5 below and check it against Figure 1-1. 1 2 3 4 5 6 Figure 1-1 The imagesetter tool kit. ➀–Ratchet. ➁–Ratchet extensions. ➂–Sockets. ➃–Jack Screw. ➄–Jack screw (dimpled) plate. ➅–Breaker bar. NOTE: A 5/8" deep socket wrench is also required. Steps: 1. Position the crate in the location that the system will be installed.
Avantra 36/44 Service Manual 1 3 4 5 2 1 Figure 1-2 Removing the outer shipping crate. ➀–Shipping straps. ➁–Top pad. ➂–Spring clips or bolts. ➃–Shipping bolts (2 on each side). ➄–Two crossbars. 6. Remove the parts list and accessory box. Refer to Figure 1-3. Put the accesory box aside for the unlocking and installing procedures. 7. Remove the three (3) bolts at each corner of the end supports. Refer to Figure 1-3. The end supports hold the end plates in place. 8.
Section I: Imagesetter 1 2 3 7 6 5 4 Figure 1-3 Preparing to remove the plates, diapers and skis. ➀–Parts list package. ➁–Shipping straps. ➂–Accessory box. ➃–End support bolts with washers. ➄–Tool kit. ➅–End plate. ➆–Diaper. 9. Cut the two (2) large tie wraps at the center channel, front and back. Refer to Figure 1-4. The bottom diaper should fall to the ground. 10. Remove the bottom diaper by sliding it out from either side of the pallet. Refer to Figure 1-4.
Avantra 36/44 Service Manual 1 3 4 2 Figure 1-4 Removing the diaper and end plates. ➀–One of two tie wraps. ➁–End bolts (3 at each corner). ➂–Diaper (removed). ➃–End plate, 1 at each end (removed). 11. Loosen the two (2) outer channel bolts on either end. Refer to Figure 1-5. Allow only a small gap of 1/8" between the bolt heads and the beams. WARNING: Do not remove the outer channel bolts. Doing so may result in the imagesetter falling off the jack screw (see succeeding steps).
Section I: Imagesetter 1 5 2 3 4 6 6 Figure 1-5 Removing the channel bolts. ➀–Outer channel bolts (3 per skid). Loosen the two bolts at each end first, leaving the center bolt in place. ➁–Inner channel bolts (4 per end channel) connecting the end channels to the imagesetter frame. ➂–Imagesetter frame. ➃–End channel (1 of 2). ➄–Outer channel bolt. ➅–End channel. 12. Loosen the four (4) inner channel bolts, left and right, on the bottom of the end channels. Refer to Figure 1-5.
Avantra 36/44 Service Manual 15. Cut the two (2) packing straps around the unit to remove the cardboard and plastic covers. Refer to Figure 1-6. 1 2 3 Figure 1-6 Removing packing materials from the imagesetter. ➀–Cardboard covering. ➁–Packing straps. ➂–Plastic cover. 16. Open the imagesetter door on the left side. See Chapter 4, Section 4.2.2, Top, Middle, and Bottom Front Panels. 17.
Section I: Imagesetter 5 4 1 2 3 6 Figure 1-7 Using the jack screw and plate for raising the imagesetter (left side). ➀–End plate. ➁–Jack screw. ➂–Jack screw (dimpled) plate. ➃–Outer bolt (1 of 2). ➄–Spring clip. ➅–Skid. 19. Turn the jack screw until the unit begins to lift on the plate. Raise the unit only an inch from the ground. 20. Release the unit from the pallet by removing the two (2) outer bolts and their spring clips. Refer to Figure 1-7.
Avantra 36/44 Service Manual 22. Remove the end cap and jack screw from under the unit. WARNING: Block the wheels on the left side of the unit to keep the unit from rolling during the next steps. 23. Open the right side cover on the unit. See Chapter 4, Section 4.2.2, Top, Middle, and Bottom Panels. 24. Position the jack screw in the access hole between the vacuum pump and the electrical box. Refer to Figure 1-8.
Section I: Imagesetter 1.3.3 Unlocking and Installing the Imagesetter 1.3.3.1 Imagesetter and Imagesetter to Buffer Accessories Kit The imagesetter comes with an accessory kit. against the hardware illustrated in Figure 1-9. Check the contents of this box 2 1 5 3 4 Figure 1-9 Accessories for installing the imagesetter and for attaching the imagesetter to the buffer. ➀–Chafe tray. ➁–Extension platen. ➂–Nuts for attaching the side plates to the platen and the brackets to the imagesetter frame.
Avantra 36/44 Service Manual 1 2 Figure 1-10 Removing the packing materials from the front of the imagesetter. ➀–Cardboard packing strips. ➁–Foam packing strips. 3. Remove the cardboard packing and the two (2) plastic inserts near the top of the imagesetter’s back panel. Refer to Figure 1-11.
Section I: Imagesetter 2 1 Figure 1-11 Removing the packing materials from the rear of the imagesetter. ➀–One of 2 plastic inserts. ➁–Cardboard packing. 4. With the top cover open, remove the four (4) screws in the bridge tie down bracket (red) in the lower left and lower right corners of the bridge foot. Refer to Figure 1-12. Reinsert the screws into the bridge holes once the bracket is removed.
Avantra 36/44 Service Manual 1 2 Figure 1-12 Removing the tie down bracket. ➀–Bridge tie down bracket. ➁–Four hex screws. ➂—Supply tray. WARNING: Do not lift the bridge unless the system has been put in ‘light mode.’ To initiate light mode, the imagesetter must first be turned on. 5. Lift the bridge and the upper light shield. 6. Remove the front top panel. See Chapter 4, Section 4.2.2, Top, Middle, and Bottom Front Panels, for removing the front panels. 7.
Section I: Imagesetter 3 1 2 Figure 1-13 Removing the lower media transport retainer bracket. ➀–Transport retainer bracket. ➁–Two bracket hex screws. ➂–Supply tray. 8. Locate the two upper media transport Retainer Brackets (gray) in the upper right and left of the exposed unit. Refer to Figure 1-14. Remove the shipping screw at the center of the bracket.
Avantra 36/44 Service Manual 1 2 Figure 1-14 Preparing the media transport retainer bracket. ➀–Media transport retainer bracket (one of two). ➁–Shipping screw (one of two),between two lockdown screws. 9. Locate the take-up light shield in the center of the unit. Refer to Figure 1-15. Remove the shield by unscrewing the three (3) locking knobs and pulling the shield straight out. 1 2 Figure 1-15 Removing the take-up light shield. ➀–Take-up light shield. ➁–Three shield locking knobs.
Section I: Imagesetter 10. Insert the chafe tray provided (see Figure 1-9) by hooking the ends into the slots at the bottom and to each side of the exposed area. Refer to Figure 116. 1 2 Figure 1-16 Inserting the chafe tray. ➀–Chafe tray. ➁–Chafe tray hook. 11. Replace the take-up light shield. Unlocking the Vacuum Pump 1. Open the right-side door 2. Loosen the four hex screws on the orange tie-down bracket that secures the vacuum pump. 3. Remove the orange tie-down bracket.
Avantra 36/44 Service Manual Unlocking the Carriage 1. Open the left and right side covers. See Chapter 4, Section 4.2.1, Right/Left Side Covers. 2. Remove the light shields, left and right, by pulling each of the five (5) latch knobs out and twisting them so that they rest outside of the lock slot. Refer to Figure 1-17. The light shield on the left requires a twist toward the door to remove. Pull the light shield on the right straight out.
Section I: Imagesetter 3. Remove the 3/8¨ hex bolt in the end stops at each side, left and right, of the carriage. Refer to Figure 1-18. 2 1 3 Figure 1-18 Unlocking the carriage. ➀–One of 2 end stops (1 on each carriage end). ➁–Center stop. ➂–Foam pad. 4. Remove the 3/8¨ screw in the center stop. 5. Power up the imagesetter, which makes the flappers lift. Remove the foam pads from the right hand side of the imagesetter. Refer to Figure 118. 6.
Avantra 36/44 Service Manual 1.4 Checking the System The following procedures describe how to verify correct system operation and connect properly to the Image Control System (ICS). Steps: 1. Power the the system on and monitor the progress of the power-up boot diagnostics on the control panel. Ensure that no errors occur during the boot sequence and that the system completely loads the application firmware. If errors do occur during the boot cycle, refer to Section 3: Diagnostics. 2.
Section I: Imagesetter • Power cycle the system. As the system boots, an icon appears on the control panel as shown in Figure 1-19. Press the icon. This initiates an automatic dial-out sequence to the Remote Diagnostic Center. SelectSet Avantra Diagnostics Startup V.1.01 O2@@@@@@@@@@@@@@@@@@@@@@@@@6K?he O20Mhe@?hf?I46K?h W2(Mhf@? ?I'6X?g 7(Y?e?/X?g@?gW.hV'1?g ?J(Yf?V/? .Yh?V'=g ?7H? N@6Xf J5 ?3@1f 7HfW2@@@@@@@@@@@@@@@@@@@@6Xh?N@@L?e @?e?W.M I/X?h@@1?e @?eW.Y? ?V/Xh@@@Le @??W.
Avantra 36/44 Service Manual 8. After the density has been checked/adjusted for each resolution, run the Avantra Installation files. Run the following list of files: • 50% @ 1200, 1800, 2400, 3600 • m 100/85% @ 2400, 3600 • m Scale/Fid @ 240 Run the focus test file and adjust as necessary. Refer to Chapter 5: Alignment Procedures. 9. Run the pulse width modulation (PWM) test and adjust as necessary. Refer to Chapter 5: Alignment Procedures. 10. Turn the system off.
Section I: Imagesetter The training should include the following instructions: • Daily/weekly system maintenance routines • Functionality of the control panel • Daily operating procedures • Defining cassette parameters • Determining proper exposure settings • Setting system defaults • System error reporting and brief descriptions of possible solutions to error conditions, which results in reduced numbers of unnecessary service calls Installation 1-25
Chapter 2: Imagesetter Functional Analysis 2.1 Introduction This chapter presents an overview of the Avantra 36/44 imagesetter. Described here are the functions of all major subsystems, modules and submodules within the system. This chapter covers both electrical and opto-mechanical subsystems, showing the major functional block diagrams for each.
Avantra 36/44 Service Manual • Power Supply • Additional Voltages • Power Distribution • Power Good • Optical System Overview • Spot Generation Module • Laser Diode Mount • Polarizer • Spot Size Changer • Spot Forming Lens • Weak Lens • Beam Compressor • Spin Motor Module • Spin Motor • Mirror • Encoder • Linear Carriage Transport Overview • • • Carriage Assembly • Linear Bearing Guideway • Carriage Home Position Sensor • Inner Shrouds • Vacuum System Media Trans
Section I: Imagesetter 2.2 • Software • PC Board: LED Descriptions • Warnings and Indications System Overview The Avantra is a floor-standing unit. It has a simple, language independent control panel, utilizing icons and a touch screen display. The system is designed to interface via the Agfa Print Engine Interface Standard (APIS) to a single Image Control System (ICS), which is packaged separately from the imagesetter.
Avantra 36/44 Service Manual The OCP module, which contains a dedicated micro-controller, is the main controller of the system. User commands originating from the RIP and/or the operator are verified, parsed and either acted upon by the OCP or passed to the DEC. The parsing process includes breaking the macro language of the user into a micro language that is more easily implemented within the engine controller.
Section I: Imagesetter 2.3.2.1 DIAG Micro-controller • System initialization at reset • Power-up tests • System diagnostics • Handling SPI communication primitives • Loading correction tables • Debugging monitor mode • Monitoring SPI communications 2.3.2.
Avantra 36/44 Service Manual 2.3.2.5 • DEC K-1 FLASHROM Main DEC software 2.3.2.6 DSP FLASHROM • DSP main program • Correction tables 2.3.2.
Section I: Imagesetter DEC K1 Micro-controller DEC Machine Parameters DSP FLASHROM DSP Main Program 1. Image/Focus Parameters 2. Media Parameters 3. DSP/PLATE FLASHROM 1. DEC K1 Software OCP EEPROM Correction Tables OCP FLASHROM Micro-controller 1. OCP User Parameters 2. Cassette Parameters 3. Operational Statistics 1. OCP Main Program 2. Control Panel Icons Figure 2-1 Avantra Micro-controller/FLASHROM map. 2.
Avantra 36/44 Service Manual APIS Data Buffer and Control Laser Driver Position Sensors Media Sensors Safety Sensors APIS Commands OCP User Commands Engine MicroController On Line Processor DC Motors Stepper Motors Solenoids Servo MicroController (D.S.P.) Modem Interface Spinner Servo Carriage Servo Media Feed Servo Diagnostics MicroController Figure 2-2 OCP to DEC to sensor/motor/servo flowchart. Commands received at the DEC’s u-controller direct operations to a code segment.
Section I: Imagesetter The OCP module consists of the following submodules and is shown in the OCP block diagram in Figure 2-3.
Avantra 36/44 Service Manual The OCP micro-controller reads the program directly from the FLASHROM via one of its I/O ports. The display portion of the ROM can also be read by the micro-controller and fed directly into the Liquid Crystal Display interface. 2.5.3 Liquid Crystal Display (LCD) The display used on the Avantra is a 320 x 240 bit LCD. The display includes a character generator for a 6 x 12 bit character as well as a graphical interface for the icons stored in FLASHROM.
Section I: Imagesetter The Laser Diode Drive, (LDD), connects to the CSDM. All controlling signals pass from the DEC, through the Flex-Band, and through the CSDM to the LDD. Also see Figure 2-4.
Avantra 36/44 Service Manual • Connects directly to all sensors (except several that connect to the CSDM) and gathers them into matrices of 2 x 6. This allows for a simpler and more orderly system cabling scheme. 2.7.1 SDM to DEC Interface Each SDM has one header connection from the DEC, providing power and two 8bit data lines for reading sensors and controlling motors. The control signals for the servo motors also pass through this header to the appropriate servo motor. 2.7.1.
Section I: Imagesetter ➀ ➁ ➂ ➃ ➄ ➅ ➆ ➇ Figure 2-5 Sensor grid. ➀–Row 0. ➁–Row 1. ➂–Column 0. ➃–Column 1. ➄–Column 2. ➅–Column 3. ➆–Column 4. ➇–Column 5. 2.8 Laser Driver Module (LDM) The LDM controls the laser diode current so that the laser diode light output waveform corresponds to that of the clocked data from the image buffer. The light output intensity on an image basis is programmable via the control panel by varying the laser diode power and polarizer setting.
Avantra 36/44 Service Manual 2.9 Power Supply The power supply is a low voltage switching supply, with non-adjustable outputs. A switch mounted to the side of the power supply configures the input voltages of 110 or 220 volts. The 300 watt power supply generates the following voltages: + 5.0 volts 20.0 amps +24.0 volts 8.0 amps +12.0 volts 1.0 amp -12.0 volts 1.5 amps 2.9.1 Additional Voltages Two other voltages necessary to the system are generated locally with converters on the DEC PCB: - 5.
Section I: Imagesetter 2.10 Optical System Overview The optical system divides into two basic sections: • Spot generation module (SGM) • Spin motor module Several components, which all locate on a sub-base that mounts on the carriage assembly, make up the SGM. The spin motor module also directly mounts to the carriage assembly, which translates through the center of the drum. A laser diode generates a modulated beam of red light under the control of the laser diode driver electronics.
Avantra 36/44 Service Manual 2.11 Spot Generation Module The Spot Generation Module (SGM) is a field replaceable unit that mounts to the carriage assembly. Figure 2-7 illustrates the SGM. The SGM produces a focused laser spot of the proper size, shape and position.
Section I: Imagesetter 2.11.1 Laser Diode Mount The laser diode mount provides the mechanical interface to mount the laser diode driver module PCB, as well as the laser diodes. Refer to Figure 2-7. This submodule also provides precision x and y translations for module-level bow corrections, an angle reference in the z direction of the laser diode for beam ellipticity, and adjustment in the y direction for beam pointing. This component is factory adjusted and is not field replaceable or adjustable.
Avantra 36/44 Service Manual 2.11.5 Weak Lens The weak lens, which is a long focal length lens, moves along the optical axis of the SGM to provide for a system level focus adjustment. It mounts between the polarizer and the spot forming lens. A small motor and screw mechanism translates the lens to provide the proper focal length over the entire range of media thicknesses (4 - 12 mils) as well as a system level fine focus adjustment. A motion of 20 mils.
Section I: Imagesetter 2.12.1 Spin Motor The spin motor is a precision hydrostatic (air bearing) spindle DC servo motor. Refer to Figure 2-8. It runs at a constant velocity of 13,500 RPMs for Avantra 36/44 systems and 20,000 RPMs for Avantra 36S/44S systems. 2.12.2 Mirror The 42.5 degree spin mirror deflector attaches directly to one end of the spin motor shaft. Refer to Figure 2-8. The mirror reflects the converging beam from the spot generation module 95.
Avantra 36/44 Service Manual Figure 2-9 Carriage assembly. The carriage assembly consists of: • Carriage housing with precision mounting interfaces for the bearing components • Optical system • Friction wheel drive components The carriage assembly uses a friction drive system with recirculating ball bearings that ride on two rails mounted to the upper structure. This type of system makes the carriage self contained. 2.13.1.
Section I: Imagesetter Both encoders are high count precision rotary encoders. One of the encoders (analog) couples directly to the friction wheel shaft and is used to feed back carriage velocity errors. The other encoder (digital) mounts inside the carriage housing and is preloaded to make direct contact with the guide rail. This encoder feeds back carriage position errors.
Avantra 36/44 Service Manual 1 2 3 Figure 2-10 Inner shroud. ➀–Solenoids. ➁–Brushes. ➂–Outrigger. 2.13.4.1 Outriggers An outrigger attaches to each inner shroud. The outriggers prevent smaller sized media from curling during a load. 2.13.4.2 Brushes Three sets of brushes attach to each inner shroud. An individual solenoid controls each brush. During imaging and certain feed sequences, the brushes position either up or down.
Section I: Imagesetter 2.13.4.3 Flappers Because the shrouds are not as wide as the drum, the system requires two flappers to hold the media against the drum. The flappers assist the media through the takeup side during the loading process. During the loading sequence, the media stops feeding at a point a few inches short of the take-up punch. The two flappers come down and hold the media against the drum. This is called the flappers’ load position.
Avantra 36/44 Service Manual 2.13.5.2 Vacuum Valves The pump vacuum lines attach to valves, which are controlled by the system software in accordance with the width of the media. Any width below 26 inches causes one of the valves to open. Any width over 26 inches causes both valves to open. 2 1 3 Figure 2-12 The vacuum valves. ➀–Two valves. ➁–Indicators. ➂–Vacuum pump. 2.13.5.3 Vacuum Board The vacuum board controls the vacuum pump and the vacuum valves. Refer to Figure 2-12.
Section I: Imagesetter 2 1 Figure 2-13 The vacuum board and sensor relay. ➀–Vacuum board. ➁–Sensor relay. 2.13.5.4 Vacuum Voltage Sensor Relay This relay senses the voltage when powering on the imagesetter. Refer to Figure 2-13. If the relay senses 220 volts, it configures the transformer for a 115 volt output to the vacuum pump. The green light on top of the relay sensor should come on at 220 volts. If the light is off, then 220 volts can be output to the vacuum pump. 2.
Avantra 36/44 Service Manual The media transport system handles: • Web fed form • Red sensitive paper • Film • Plate The media feeds through the transport system by means of a nip and one of two rollers on the supply side (one for each supply cassette). The nip and roller push the media through an entrance platen into the supply punch module then down onto the drum surface.
Section I: Imagesetter 2.14.1.4 Drive Rollers The drive rollers load and unload media from either spindle A or B. They are nipped by the spindle A/B gear motor, which is controlled by the spindle A/B sensors. 2.14.1.5 Spindle A/B Sensors These two sensors shut off the spindle A/B gear motor when the drive roller is nipped to either A/B drive roller. 2.14.1.6 Supply Jam Sensor The supply jam sensor detects media jams on the supply side.
Avantra 36/44 Service Manual 2 1 3 4 Figure 2-14 Take-up cassette. ➀–Take-up cassette. ➁–Six cover screws. ➂–Core. ➃–Clutch adjustment screw. In order to accept media, the core is driven enough to open the counter-weight gap. A reflective optical sensor is located in the take-up area. This sensor operates during the drive sequence and signals the exact point that aligns the core gap to the entrance chute.
Section I: Imagesetter 2 1 3 Figure 2-15 Media punch/clamp assembly. ➀–Punch assembly. ➁–Sensor. ➂–Punch assembly motor. All punches operate the same way. A gear motor turns a shaft that actuates a pressure plate (clamp) and a rocker mechanism. The rocker assures punch engagement regardless of punch location. Optical switches indicate positions for home, clamp and punch. All punched holes are completed with a single actuation of the punch assembly. 2.14.
Avantra 36/44 Service Manual 1 2 3 4 Figure 2-16 Inner nip drive system. ➀–Inner nip drive system. ➁–Inner nip motor. ➂–Sensor. ➃–Roller. 2.14.4.2 Outer Nip Drive System The outer nip drive system contains the cutter interlock switch, which, when disabled, shuts off the cutter. Refer to Figure 2-17. The outer nip releases the pressure between the rollers to allow media to pass through on an initial media load.
Section I: Imagesetter The solenoid plunger attaches around the drive roller via a bushing arm. To open (release) the take-up rollers, the solenoids are energized for a pre-determined number of seconds. The solenoid stroke opens a .02" gap between the rollers to disengage the take-up drive, but not enough to disengage the drive gear mesh. 1 2 3 Figure 2-18 The take-up drive assembly. ➀–Outer nip drive system. ➁–Inner nip drive system. ➂–Aligned rollers. 2.14.
Avantra 36/44 Service Manual 1 2 Figure 2-19 Media cutter assembly. ➀–Cutter home switch. ➁–Cutter motor. NOTE: The DC gear motor and the home switch can also be replaced separately. The cutter assembly consists of: • Media platens • Cutter bar • Home switch • DC gear motor • Linkage • Take-up media present sensor Internal platens guide the media through the reciprocating cutter mechanism. A DC gear motor, which attaches to the end of the cutter through linkage, drives the cutter.
Section I: Imagesetter The supply cassette consists of: • Cassette housing • Tension roller • Two hub and spindle assemblies Refer to Figure 2-20. 1 2 Figure 2-20 Supply cassette. ➀–Supply cassette. ➁–Spindle bearing. The cassette housing opens in the center to facilitate the loading of media. The tension roller mounts on the upper half of the housing and keeps the media tightly wrapped on its core, while the media is either being pulled out or rewound.
Avantra 36/44 Service Manual 2.15 Humidifier Option Overview This section describes the mechanical, electrical and software characteristics for a field installable humidifier sub-system. 2.15.1 General Description The humidifier creates a 50% (±5%) relative humidity in the drum 15 minutes after the humidifier is turned on. The system maintains an ambient range of 45% to 55% humidity while remaining within the imagesetter’s operating temperature range.
Section I: Imagesetter The humidifier system is closed loop. The inlet port receives drum air, which passes through an air filter. The system then draws the filtered air through a water wick whose bottom section is immersed in water contained in an internal resevoir. Next, through the process of capillary action, the water draws up and saturates the wick. A float switch controls the reservoir’s water level. At a predetermined level of 1.25 inches, the float switch opens.
Avantra 36/44 Service Manual 2.15.3.1 Power The fan power connector (J3) located on the right door supplies the +24 volts used on the board. NOTE: The door fan is not required when the system has a humidifier installed. The (J3) connector supplies power to the wiring harness, which in turn supplies power to the humidifier electronics module. Power from (J3) is in series with the door interlock switches. Power to the humidifier shuts off when either end cap is opened.
Section I: Imagesetter The voltage comparator is structured as an oscillator with the frequency controlled by the sensor. This sensor, a capacitor, varies its capacitance in relation to the amount of moisture in its environment. As the moisture level increases, the sensor capacitance also increases causing the oscillator frequency to decrease. 2.15.5 Interface Connections The controller module connects by cable to the imagesetter through the supply sensor driver module (SSDM) board.
Avantra 36/44 Service Manual 2.16 Humidifier Option: Warnings and Indications The Run and Pause screens display the humidifier enable icon when the humidifier is enabled. 2.16.1 Humidity Low Indicator When switching on the imagesetter, the OCP displays the humidity low icon, if humidity is below the desired level. Once the humidity reaches the desired level, the humidifier enabled icon replaces humidity low. 2.16.
Chapter 3: Imagesetter Diagnostics and Vacuum System Troubleshooting Guide 3.1 Introduction This chapter describes the diagnostic tools necessary for testing and verifying the functionality of the imagesetter. These tools include boot-up diagnostics (in ROM) and the Avantra Diagnostic Program (AVDIAG), which is PC based. This chapter also contains a troubleshooting guide for diagnosing and repairing problems with the vacuum pump system.
Avantra 36/44 Service Manual NOTE: PC Imager software is a tool designed to aid the service engineer when verifying image quality and communication as they relate to a raster image processor (RIP). This software is described in the PC Imager User’s Manual P/N 580024-001. 3.2 Power-up Boot Diagnostics The following section provides a description of the power-up boot diagnostics available on the Avantra system.
Section I: Imagesetter Because the Avantra is a multi-controller system, it provides two levels of tests: • Level One (core tests)–executed by each micro-controller as it is taken out of reset by the DIAG. The test purpose is to verify that each micro-controller and its hardware domain are functional. • Level Two (micro-controller handshake tests)–provides confidence in the inter-micro-controller communication bus and its peripherals.
Avantra 36/44 Service Manual Next, the OCP is taken out of reset. SPI communication tests execute between the DIAG and the OCP. If the tests are successful, the OCP firmware and loader revision levels appear on the control panel, and the DIAG tells the OCP to update the progress bar. A dial-out icon appears in the middle of the display. This icon displays only during the time a manual dial-out can be performed, then it disappears.
Section I: Imagesetter 3.2.3 Error Reporting If any tests fail, the DIAG micro-controller reports the error via the diagnostic serial port on the DEC board or, if possible, on the operator control panel. Also, if a modem is present and enabled, the diagnostics dial a telephone number that has been pre-stored in the modems configuration NVRAM. If all testing completes without errors, the message “Imaging Run Screen” appears on the control panel.
Avantra 36/44 Service Manual 3.2.3.3 LED Error Reporting An LED on the DEC board indicates whether the boot has successfully completed. A red light indicates either that the boot sequence has not been completed or an error condition exists. When the LED goes out, the boot sequence has completed with no errors. 3.2.3.4 DIAG Micro-controller Test Descripions The following describes tests performed on the DIAG micro-controller during the boot sequence. 3.2.3.
Section I: Imagesetter 3.2.3.9 OCP Register Test To test the OCP register, a two byte pattern is written into it. The first byte is the real data, and the second byte is used to retrieve the feedback. 3.2.3.10 FLASHROM Cheksum The flash memory stores the 2400 and 3600 dpi correction table entries and DSP code. As the boot diagnostics progress, they display a checksum of both the 2400 and 3600 dpi correction tables for the checksum of the DSP code.
Avantra 36/44 Service Manual 3.2.3.14 DEC Micro-controller Test Descriptions The following list describes the tests performed on the DEC micro-controller during the boot sequence. • Internal ROM Checksum–performs a rotate and add checksum. Bytes are added to a 16-bit sum, after the sum has been rotated right one position. Bit 0 is rotated into bit 15. The resulting checksum is compared to the checksum stored in ROM.
Section I: Imagesetter • Supply Motors Test–to test the motors, the supply DAC is set to 500 millivolts and one of the motors under test is selected by addressing it via port C. The supply motor DAC controls four motors: • Supply punch • Supply spindle A and B • Supply cassette The test verifies that the MOTORON bit gets asserted low, by reading the sensors. If MOTORON is not asserted within 20 milliseconds, an error is reported. The motor is then de-selected.
Avantra 36/44 Service Manual 3.2.3.15 DSP Micro-controller Test Descriptions The following list describes the tests performed on the DSP micro-controller during the boot sequence: • RAM Test–since the DSP runs out of RAM, it is not useful to run a checksum on the code. If the DSP runs, the ROM is OK. If the external RAM is included, the software runs a march test and an address as data memory test on the external memory.
Section I: Imagesetter 3.2.3.16 OCP Micro-controller Test Descriptions The following list describes the tests performed on the OCP micro-controller during the boot sequence: • External ROM Checksum–performs a rotate and add checksum on the entire FLASHROM. Bytes are added to a 16-bit sum, after the sum has been rotated right one position. Bit 0 is rotated into bit 15. The resulting checksum is compared to the checksum stored in ROM at location 0. The ROM size is stored in location 2; 1=128K, 2=256K.
Avantra 36/44 Service Manual 2. Modem Dial-out After the initialization string has been responded to, the modem dials out the pre-stored telephone number in the modem’s configuration profile. The modem stores up to four telephone numbers in non-volatile memory, 0 - 3. The telephone number must be stored in location 1. The firmware issues the dial command ATDS=1 to the modem. Once the command is sent, the firmware waits for a response string.
Section I: Imagesetter 3.2.5 Boot Error Codes Table 3-1 lists the Avantra boot error codes. Table 3-1 Boot error codes.
Avantra 36/44 Service Manual Error Code Description 167 Cannot command DSP to move carriage in reverse 168 No times 4 carriage encoder pulses 169 Missing (not enough) times 4 encoder pulses 170 Supply sensor/cable not connected 171 Supply punch motor on failed 172 Supply punch motor off failed 173 Supply spindle 1 motor on failed 174 Supply spindle 1 motor off failed 175 Supply spindle 2 motor on failed 176 Supply spindle 2 motor off failed 177 Supply cassette select motor on failed
Section I: Imagesetter 3.2.
Avantra 36/44 Service Manual Error Code Description 51 Bridge Comm Error 52 Bridge Jam Before Center Sensor 53 Bridge Jam at Processor 54 Bridge Jam Before Clear 55 Bridge Motor Jam 56 Bridge Has No Media at Input 57 Processor Off-Line: Fatal 58 Processor Not Communicating 59 Processor Top Cover Open 60 Processor Garbled Communication 61 No Carriage Encoder Mix 62 Possible Out of Media (or Jam) 63 Beam Compressor Jam 64 Falpper Jam 65 Media Warranty Met (Exceeded) 66 Media
Section I: Imagesetter Error Code Description 88-98 Unused 99 Multiple Code Error * * On Error Code 99, keep pressing + key to display all errors. 3.3 Avantra Diagnostic Program (PC) The Avantra Diagnostic Program (AVDIAG) software tool was designed to help diagnose and debug hardware problems. The program also helps when querying for parameters, firmware revisions, error logs, etc. and downloads new firmware into FLASHROMs.
Avantra 36/44 Service Manual Direct Connect: • Avantra diagnostic software 700594-1003* • 9-pin female connector (PC end) 78448-015 • 25-pin male connector (imagesetter end) 78448-016 • Cable 78448-008 * This may not be the latest revision of software. Refer to OMNI Bulletin Board for latest revision of AVDIAG Program. Remote: Refer to Section 3.4, for a detailed list of requirements. 3.3.
Section I: Imagesetter 3.3.3 Starting the Program The following procedure describes how to load, initialize, and start the Avantra Diagnostic Program (AVDIAG): 1. Insure that the Avantra diagnostic software has been properly loaded onto the PC as described in Section 3.3.2. 2. Connect the serial cable from one of the serial ports of the PC (must be com 1 or 2) to the Avantra's diagnostic serial port located on the inside of the system on the DEC I/O panel. 3.
Avantra 36/44 Service Manual 3.3.3.1 User Interface The top bar menu contains the following groups of sub-menus: • TEST • ALIGN • UTILITIES • FLASHROM • EXIT Test Menu Test menu items are: • Selectable Tests • Download CMD File • Functions Selectable Tests Displays a dialog box with the following tests: Test Function DEC. Tests DEC. - K4 Module Test DAC.
Section I: Imagesetter DEC Tests Test Function Register Test Test SPI registers (offgate, ongate, vacuum, vacuum 2) DSP Echo Test Verify DEC - DSP communications Carriage Test Verify encoder feedback from carriage movement Supply Motor Test Supply Motor on/off bit tests at 0 current Take-up Motor Test Take-up motor on/off bit tests at 0 current Video 1 Int Test Image buffer test with 0x55 pattern Video 2 Int Test Image buffer test with 0xAA pattern Video 3 Int Test Image buffer test with i
Avantra 36/44 Service Manual DAC RAMPS NOTE: These tests can only be performed in manufacturing during board test. Running these tests on the PC will post an error. • All Ramps On • All Ramps Off • Density DAC • Mag DAC • Linearity DAC • PWM DAC • DSP DAC CARRIAGE TESTS Test Function Carriage Slew Carriage over max. travel distance Focuser Move Focuser over max. travel distance Spot Changer Move Spot Changer to each resolution setting Polarizer Move Polarizer over max.
Section I: Imagesetter MEDIA TESTS NOTE: To actually see the motors moving, you need to run these tests in continuous mode with a pass count of 10. Test Function Cutter Executes a Media take-up Punch Take-up Punch Execute a Head Clamp-Punch-Home sequence Supply Punch Execute a Tail Clamp-Punch-Home sequence Nip Solenoid Open-Close Nips Spd. Selector Moves from one spindle to the other Spd. Motor A Turns Spindle Motor A On/Off Spd.
Avantra 36/44 Service Manual BOOT TESTS Test Function Diag-Ocp Hadshk Test Verify Diag-Ocp communications in Master Mode Offgate Reg Test Test SPI Offgate Register Ongate Reg Test Test SPI Ongate Register Vacuum 1 Reg Test Test SPI Ongate Register Vacuum 2 Reg Test Test SPI Ongate Register Cor3600 Checksum Display 3600dpi Correction Table FlashRom Checksum Cor2400 Checksum Display 2400dpi Correction Table FlashRom Checksum DSP FlashRom Checksum Display DSP Code FlashRom Checksum Diag-DSP
Section I: Imagesetter CLOSE LOG FILE This closes the opened log file above. Download File • Command Files This program allows the creation of ASCII command files containing a sequence of commands to be sent to the imagesetter's remote diagnostic port. This is a description of the command files supplied with the program and the text of typical command files. CAUTION: Running some of the command files below could cause system problems. Refer to table footnotes for details.
Avantra 36/44 Service Manual Command File Format The following is the format of a typical command file. # a comment not to be executed # This file will first Home the carriage and then # slew the carriage between 8000 and 30000, repeating 10 times SPI CARR_HOME CMD_REPEAT 10 SPI SLEW 8000 SPI SLEW 30000 INC_PASS CMD_ENDREPEAT Functions • Send APIS Message Allows the user to send a raw APIS message to the remote diagnostics port.
Section I: Imagesetter ALIGN MENU Imagesetter Configuration This menu item displays a window containing the currently set options and changes any option setting and saves the configuration to the imagesetter. This setting stores as a machine parameter in DEC EEPROM. The currently settable options are: Machine Type............
Avantra 36/44 Service Manual SGM-A/B Mod Align This menu item controls the alignment of the SGM parameters. The SGM-A/B Mod Align Menu appears as follows: Spinner......................... ON/OFF Beam............................. ON/OFF (BM) Resolution............ 3600 (BM) Gate Start.............. 0 (BM) BOL Position........ 0 (BM) Gate Length.......... 25 Focus............................ Home/In/Out 36/44 Focus Mot. Rt........15300 Focus Steps...................0 Polar. Motor Rate...........
Section I: Imagesetter Defaults: Resolution will be set to 3600 Gate Start to 0 Gate Length to 25 Aperture to 3600. The resolution will automatically change to the aperture's value. Carriage Alignment This menu item allows the alignment of the carriage encoders. This function executes a test on the DSP, reads in the values resulting from that test, displays the values, and calculates new encoder constants and writes the new encoder constants to DEC EEPROM.
Avantra 36/44 Service Manual DEC (Image/Focus/Bridge) Parameter Value Parameter Value Parameter Value BOL Offset.......... * Polarizer Home.... * Brdg Max. Torque Carriage Home..... * Focus Position..... * Buffer Med Spd..... 11421 PWM @1200....... * Focus Steps/Mil... 22 Bridge On Delay.... 1 PWM @1800....... * Focus Motor Rate 15300 Ubr FastSp Thin... 4500 PWM @2400....... * Polarizer Rate...... 1600 Ubr SlowSp Thin.. 6500 PWM @3600....... * Spot Motor Rate...
Section I: Imagesetter Write new values to the imagesetter by typing in the appropriate parameter. Listed below are the parameters and defaults. Bridge Max Torque The maximum torque of the upper bridge motor. Defaullt is 250. Increasing the calue increases the torque. Buffer Med Spd The buffer medium speed, which controls how fast the media is delivered from the buffer to the first set of input rollers on the processor. Default is 11421. Increasing this value decreases the speed.
Avantra 36/44 Service Manual Variable Media Parameter Film (3-5) Narr Film (3-5) Med Film (3-5) Wide Film (6-8) Narr Film (6-8) Med Film (6-8) Wide Film (9-12) Narr Film (9-12) Wide Paper Paper Narr Wide S-Feed Current 24 24 24 40 46 50 50 32 2 34 T-Compress Curr 24 24 24 36 40 60 60 28 24 24 6 6 6 12 12 12 12 6 6 6 T-Compress Speed Midpoints (.01”) M4..............2400 M8...............2400 W4.............3000 W8..............
Section I: Imagesetter 2. The “T-Compress Speed” is really the compression speed for both supply and take-up servo motors. The supply servo uses a percentage of the “TCompress Curr” value. The percentage amount is specified in the “S Cmp Curr Rtio” field, which has a default of 50 (50%). So if: T-Compress Curr = 24 T-Compress Speed = 6 S Cmp Curr Rtio = 50 Then the take-up servo runs at a speed of 6 and a current of 24. The supply servo runs at a speed of 6 and a current of 12.
Avantra 36/44 Service Manual Media Parameter Range Definitions T/U Cassette Align Current (0 - 255) Current for takeup cassette motor to move core to home position. T/U Cassette Wind Current (0 - 255) Torque of takeup cassette motor (Forward Direction). Nips Op Ely Time** The amount of time the nips are opened prior to stopping the feed servos at the end of the feed, which aids in preventing buckles and lifting of media on the drum. Default is 1 (one). Increasing this value increases the time.
Section I: Imagesetter DSP/Plate Selecting DSP displays a dialog box that shows the current Plate/DSP parameters stored in the imagesetter. These parameters are in DEC EEPROM. The software retrieves them from EEPROM upon entering this menu selection. New values are written to the imagesetter by typing in a new value in the appropriate parameter. The DSP values are achieved after running the carriage align test. .
Avantra 36/44 Service Manual NOTE: DSP numbers 0, 1, 2, and 3 are set after executing the Avdiag “Carriage Align” test. DSP numbers 4 and 5 are set after executing the Avdiag “Feed Motor Cal” test. OCP User Parameters User Parameters NOTE: To view the following parameters you must first down load the OCP user parameters. Refer to Section 3.3.4.3 Selecting User Params displays a dialog box that shows the current user parameter settings stored in the imagesetter. The parameters reside in OCP EEPROM.
Section I: Imagesetter Plate Overlap PL-12 Rewind Lev Feed High Res Interpage High Res Feedcut High Res Plate Mode (108) (109) (63) (64) (65) (67) 1080 Cassette Parameters The cassette parameters contain the customer settings for the five cassettes. Write new values to the imagesetter by simply typing in a new value in the appropriate parameter.
Avantra 36/44 Service Manual Firmware Revisions Selecting Firmware Revs displays a dialog box that lists the firmware revision levels installed in the imagesetter currently connected. Avantra Firmware Revisions DEC Firmware (K4/K1 FlashROM : * DSP Firmware (DEC FlashROM) : * OCP Firmware (OCP FlashROM : * OCP Download (OCP EEPROM) : * Diagnostic Firmware (C9) : * Correction Table Version-Type : * Bridge/OLP (OLP FlashROM) : * * The revision levels change from release to release.
Section I: Imagesetter Display Sensors The Display Sensors menu item actively monitors the state of all sensors and switches in the imagesetter. With this menu, the user activates or deactivates a sensor and monitors the state of the sensor on the display (e.g., moving a jam wheel causes the state of the sensor to display on and then off as the wheel moves through the sensor). This utility aids in troubleshooting sensor problems in the system. Below is a typical Engine (imagesetter) Sensor Display screen.
Avantra 36/44 Service Manual Row 4 40 41 42 43 44 45 Row 3 30 31 32 33 34 35 Row 2 20 21 22 23 24 25 Row 1 10 11 12 13 14 15 Row 0 00 01 02 03 04 05 Col 0 Col 1 Col 2 Col 3 Col 4 Col 5 Figure 3-1 Avantra sensor grid.
Section I: Imagesetter Carriage Motion This item moves the carriage in the same manner as it operates during imaging. The Carriage Motion Menu appears as follows: Spinner On Carr. Home Pos. (EEPROM) Home Carriage Carr. Slew to Position Image Start Image End (EOT) Carr. Image to Position Abort Carriage Movement Video Mode Resolution (Image Speed) Gate Start (Pixels) Gate Length (IN.) Spinner Off 863 0 0 0 0 3600 0 25 These are the carriage motion menu functions.
Avantra 36/44 Service Manual Menu Item APIS Command Get Status {MXSS} Abort {MXDS0180} Shut Down Media {MXDS0181} Supply Feed {MXDS0184} Image Feed {MXDS0185} Reverse Feed {MXDS019F} Supply Torque ON {MXDS0196} Supply Torque OFF {MXDS0197} Takeup Cut {MXDS0189} Open Nips {MXDS018E} Close Nips {MXDS018F} Get Sensors {MXDS0199} Head Punch HOME {MXDS01A9} Head Punch CLAMP {MXDS01AA} Head Punch PUNCH {MXDS01AB} Tail Punch HOME {MXDS01A6} Tail Punch CLAMP {MXDS01A7} Tail Punc
Section I: Imagesetter Bridge Primitives Used to test the bridge. The user must turn the bridge on before running any of the tests below. These tests were not designed to test the complete functionality of the bridge. The two sensors (entrance and exit) are not tested during any of the primitive tests. .
Avantra 36/44 Service Manual Utilities Menu The utility menu contains various utility commands and functions used by the AVDIAG, such as reset commands, imagesetter configuration, port configuration, and modem utilities. The following describes each menu selection. New Engine/Restart This menu selection prepares an imagesetter to respond to diagnostic commands.
Section I: Imagesetter Config Comm. Port This menu selection selects which communication port on the PC to use when communicating to the imagesetter. The choices are: COM1-NONE, COM1-XON/XOFF COM2-NONE COM2-XON/XOFF or the internal CGEN Serial Port ATMSCC Other communication ports are not supported (i.e., com3 or com4). Modem Functions This menu selection brings up a dialog box with a list of modem functions performed by the AVDIAG: Dial-out This item initiates a dial-out sequence.
Avantra 36/44 Service Manual Edit Phone File This item enters a new phone number or modifies an existing number located in the AVDIAGs phone file. The phone file is a small database of names and phone numbers used by the AVDIAG when dialing out. NOTE: After entering the customer’s name, you must space over (not tab over) to the fortieth character position and enter the # symbol before entering the phone number.
Section I: Imagesetter Edit File Selecting Edit File allows a text file to be edited using the DOS editor without exiting the AVDIAG program. When edit file is selected, a dialog box appears with prompts for entering a filename to edit. Type in the desired filename and press ENTER. Note that the entire path must be specified as shown in the following example: Filename? cmd\imgfeed.cmd The DOS editor starts and loads the file selected.
Avantra 36/44 Service Manual Set Real-Time Clock Month Date Year Hour Minute FLASHROM The download files should reside in a common subdirectory such as Download. Prog DSP/CORR Programs the DEC FLASHROM. Prior to programming the FLASHROM, the DEC DSP and the DEC CORR must be saved. Prog OCP Programs the OCP FLASHROM. Prog DEC K1 Programs the DEC K1 FLASHROM. Prog Bridge Programs the bridge FLASHROM. Get Blank ID List Blank FLASHROMS. Save DSP Code Saves the DSP code section of the FLASHROM.
Section I: Imagesetter 3.3.4 Save and Restore System Parameters 3.3.4.1 Save/Restore DEC Machine Parameters Use this procedure to save DEC machine parameters to the PC or to restore DEC parameters from a PC back to the system. The parameters saved/restored reside in the DEC micro-controller’s EEPROM and include: • Image/Focus Parameters • Media Parameters • DSP Parameters To Save: 1. Connect the PC to the diagnostic serial port of the system. 2.
Avantra 36/44 Service Manual To Restore: 1. Connect the PC to the diagnostic serial port of the system. 2. Turn the system on and allow the boot cycle to complete. 3. Launch the AVDIAG Program from the PC. 4. Under the ALIGN menu, select DEC Machine Parameters and press ENTER. If AVDIAG was relaunched, the following dialog appears: Loading Dec. EEPROM Machine Parameters into memory. 5. Select N in the dialog box and press ENTER. 6. Select Restore to Engine and press ENTER. 7.
Section I: Imagesetter 3.3.4.2 Save/Restore DEC DSP and DEC Correction Tables (DEC FLASHROM) Use this procedure to save DEC DSP and DEC correction tables or to restore them to the DEC FLASHROM. To Save: 1. Connect the PC to the diagnostic serial port of the system. 2. Turn the system on and allow the boot cycle to complete. 3. Launch the AVDIAG Program from your PC. 4. Select FLASHROM and then Save CORR table. 5. A dialog box appears for Pathname/Filename. Press ENTER. 6.
Avantra 36/44 Service Manual To Restore: 1. Select FLASHROM and then Prog DSP/CORR. 2. Select RAW. 3. Select the filename saved in Step 9. This was the DSP file saved in the save procedures above. 4. Select the correction table for this system that was saved in Step 6 above. A dialog box appears with the two files previously selected to be downloaded to the DEC FLASHROM. 5. If the files are the correct ones for this system, press ENTER.
Section I: Imagesetter 4. Under the ALIGN menu, select OCP User Parameters and press ENTER. A dialog box appears: Loading OCP EEPROM User Parameters and OCP EEPROM Cassette Parameters into memory. Select Y in the dialog box. The OCP parameters load up to the PC. 5. When the load completes, select Save to File. A dialog box appears: OCP EEPROM User and Cassette Parameters to be saved to a file. Select Y in the dialog box. 6. A dialog box appears for Pathname/Filename. Press ENTER. 7.
Avantra 36/44 Service Manual 3.3.4.4 Program OCP FLASHROM Use this procedure to load the OCP software from a PC into the OCP’s FLASHROM. The software to be loaded must reside in the Download directory in the PC. NOTE: Prior to programming, the FLASHROM is automatically erased. 1. Connect your PC to the diagnostic serial port of the system. 2. Turn the system on and allow the boot cycle to complete. 3. Next, launch the AVDIAG Program from your PC. 4.
Section I: Imagesetter 3.3.4.5 Program K1 FLASHROM Use this procedure to load the DEC. K1 firmware from a PC into the DEC. K1 FLASHROM. The software to be loaded must reside in the Download directory in the PC. NOTE: Prior to programming, the FLASHROM is automatically erased. 1. Connect your PC to the diagnostic serial port of the system. 2. Turn the system on and allow the boot cycle to complete. 3. Launch the AVDIAG Program from your PC. 4. Under the FLASHROM menu, select Prog DEC.
Avantra 36/44 Service Manual 3.3.4.6 Program Bridge FLASHROM Use this procedure to program the Bridge FLASHROM firmware from a PC into the bridge’s FLASHROM. The software to be loaded must reside in the Download directory in the PC. NOTE: Prior to programming, the Bridge FLASHROM is automatically erased. 1. Connect your PC to the diagnostic serial port of the system. 2. Turn the system on and allow the boot cycle to complete. 3. Next, launch the AVDIAG Program from your PC. 4.
Section I: Imagesetter These Default Correction Tables, with the Density Variation and Linearity files, contain all the information to make up the Correction Table for each of the Avantra systems. Manufacturing runs two files (a “Density Variation” file and a “Scale” file) which merge with the “Default Correction Table” file to create the unique “Correction Table” for that system. To merge the “DQ” and “L” files to the Default Correction Table, use a program in the “Correction Utility” disk.
Avantra 36/44 Service Manual 1. Insert the floppy disk with the new “DQ” and “L” files into your PC floppy drive. Once you launch the program you will be asked three questions: 1. Serial number of the system. 2. Supported Engine Type. (What engine are you creating this correction table for?) 3. Version Number of the Correction Table. 2. To create the new Correction Table type the Avdiag directory name that you installed the software in your PC. Do not launch the program from Avdiag.
Section I: Imagesetter 5. Type “Y” NOTE: This will only appear if there are “D” files on the floppy disk. The new “DQ” files will create new “D” files). This information will appear on the PC: Processing input file a:\dqxxxxxh.001 Largest fit error is x.xxxxxx. Created output file a:\dxxxxxh.001 Processing input file a:\dqxxxxxl.001 Largest fit error is x.xxxxxx. Created output file a:\dxxxxxl.001 Processing input file a:\dqxxxxxh.007 Largest fit error is x.xxxxxx. Created output file a:\dxxxxxh.
Avantra 36/44 Service Manual NOTE: This writes a new Correction Table to your Avantra directory. The PC displays: Copy COR_HEX to a:? (Y/N) 6. Type “Y”. (This copies the new Correction Table to the “A” floppy drive in the PC). NOTE: Please wait until the PC is finished coping the Correction Table to the floppy disk. The PC displays: Correction Table Completed. Press any key to exit . . .
Section I: Imagesetter 3.4 Remote Diagnostics This section describes the equipment requirements, modem configuration and procedures involved in making a remote connection to an Avantra. 3.4.1 Equipment Requirements A remote connection to an Avantra requires the following equipment. CAUTION: If equipment used to make the remote connection is other than that recommended, unpredictable results may occur.
Avantra 36/44 Service Manual Avantra Modem Specifications Data Rate: 2400 BPS or faster Data Compression: CCITT V.42BIS, MNP Class 5 Data Correction: CCITT V.42, MNP Class 2-4 Compatibility: CCITT V.42BIS/V.42/V.22BIS/V.22/V.21/ V.29/V.
Section I: Imagesetter 3.4.2 Hardware Configuration This section describes the configuration for both the remote and local modems, as well as the interconnection of all necessary hardware. Imagesetter Modem Configuration: The remote modem recommended is a GVC 2400BPS Fax/Modem, Model # FMM9696/24V. This unit has been extensively tested for correct operation in the Avantra. Other modems can be used, but correct operation cannot be guaranteed.
Avantra 36/44 Service Manual NOTE: Remote configuration of this modem is not supported. Configuration must be done at the time of installation. Other modems may support this feature. Refer to manufacturer's documentation. After the modem has been configured, store the settings in the active configuration profile (usually 0) with the following command: AT&W0 The remote diagnostic center's telephone number (for the auto dial-out feature) should now be entered into the modem's non-volatile RAM.
Section I: Imagesetter Local Modem Configuration: The recommended local modem connected to the PC is also a GVC 2400BPS Fax/Modem. If the remote and local modems are the same, command compatibility, data compression, and data correction features should operate properly. Other modems can be used but they must meet the requirements in Table 3-5 and Table 3-6.
Avantra 36/44 Service Manual 3. Plug the telephone line into the modem jack marked LINE. If desired, plug the telephone into the modem jack marked PHONE. 4. Plug the power connector into the modem and plug the AC/DC adapter into an AC outlet. 5. Depress the power switch on the modem to turn it on. Ensure that the Power On/Ready LED on the modem illuminates. The modem should now be ready for remote communication. 3.4.2.
Section I: Imagesetter 9. Use the program to perform diagnostics, retrieve machine parameters, error logs, download new firmware etc. 3.4.2.2 Exiting the Remote Connection After completing the diagnostic session, the remote connection must be terminated. Follow these procedures: 1. Complete or abort any operation currently under way. 2. Under EXIT, select the appropriate method of exiting. Unless otherwise specified, always exit with a soft reset. Click on the Exit with Reset button.
Avantra 36/44 Service Manual 4. If the pump still fails to operate, check the vacuum pump fuse: a. Turn the system off, unplug it. b. Locate the fuse holder on the outside of the electronics box (see Section 4.8, Vacuum in Chapter 4, Imagesetter Component Removal/ Replacement Procedure). Refer to Figure 3-3. c. Check the fuse with an Ohm meter and replace the fuse, if necessary. d. Plug the system in and turn the power on. e. If the new fuse blows, turn off and unplug the system. f.
Section I: Imagesetter 1 A Turn Vacuum ON Yes No Problem Check Input Side of SSR Is Vacuum Pump ON No 8 Yes Is Voltage OK No 9 Replace Solid State Relay 2 Check Volt Sensing Relay Adjustment Yes 11 Check Output of Transformer Is Voltage OK No 10 Check DEC Signal/ Replace Vac. Mod.
Avantra 36/44 Service Manual 24VDC Turns AC ON to Vacuum Pump 24VDC Turns Outer Vacuum Solenoid ON From DEC Bd. Digital signal to turn Punp ON 24VDC Turns Inner Vacuum Solenoid ON FUSE 3A. VACUUM MODULE PCB. 24VDC From Vacuum Module to turn AC ON to Vacuum Pump B A Green LED 110v. - OFF 220v.
Section I: Imagesetter 6. If the voltage reading is wrong, check the voltage coming into the solid state relay (SSR). See Figure 3-3. a. Using a DVM, measure the AC voltage across the following two points: Pin 2 (solid state relay) At 110 V ⇒ 110 V Pin 1 (volt sensing relay) At 220 V ⇒ 110 V If the voltage reading is wrong, skip to Step 7. b. If the voltage reading is good, check the input side of the SSR. Using a DVM, measure the DC voltage across the following two points: c.
Avantra 36/44 Service Manual 3. Locate the volt sensing relay. See Figure 3-3. Locate the green LED and two adjustment screws on top marked: PICK UP and DROP OUT. 4. Turn each adjustment counterclockwise to the MIN setting. 5. Plug in the system and, while monitoring the green LED on top of the volt sensing relay, turn the system on. If the operating line voltage is 110V, the LED will be off. If the line voltage is 220V, the LED will be on. 6.
Chapter 4: Imagesetter Component Removal/Replacement Procedures 4.1 Introduction This chapter describes the procedures for removing and replacing components in the Avantra 36/44 imagesetter.
Avantra 36/44 Service Manual • • • • • Intake Fan Carriage Drive Removal/Replacement Procedures • Carriage Transfer Tool Installation • Carriage Assembly Opto-mechanical Removal/Replacement Procedures • Light Shields (Right and Left) • Spin Motor Module (SMM) • Spot Generation Module (SGM) • Spot Size Sensor • Polarizer Sensor • Beam Compressor Motor • Aperture Wheel Motor • Weak Lens Motor • Focus Sensor Media Transport Removal/Replacement Procedures • Supply Drive Servo Motor
Section I: Imagesetter 4.2 Covers The following describes how to remove the covers and panels. 4.2.1 Right/Left Side Covers Tools Required: None Remove: 1. Open the top cover at the front of the imagesetter. Figure 4-1 Imagesetter with front top cover open.
Avantra 36/44 Service Manual 2. Loosen the thumb screw located on the inside of the imagesetter. Refer to Figure 4-2. 1 2 Figure 4-2 Thumb screw location. ➀–Side Cover. ➁–Thumb screw. 3. Swing the left or right side cover out at a right angle from the system. Replace: 1. Reverse the above procedure.
Section I: Imagesetter 4.2.2 Top, Middle and Bottom Front Panels Tools Required: None NOTE: The bottom panel is not normally removed. Remove: 1. Lift the bottom segment of the top cover. Refer to Figure 4-3. 2 3 1 Figure 4-3 Front of imagesetter. ➀–Front cover. ➁–Bottom segment. ➂–Top segment.
Avantra 36/44 Service Manual 2. Lift the top panel up, releasing it from the lock slots on either side, and pull straight out. Refer to Figure 4-4. . 1 2 Figure 4-4 Top panel lock slots. ➀–Top panel. ➁–Top lock slots.
Section I: Imagesetter 3. Do the same for the middle panel, being careful to clear it from its lock slots on the sides. Refer to Figure 4-5. 2 3 1 4 Figure 4-5 Middle panel lock slots. ➀–Front panels (top and middle). ➁–Top panel lock slots. ➂–Middle panel lock slots. ➃–Bottom panel. 4. To remove the bottom panel, grasp it at the bottom center, lift straight up and pull forward. Replace: 1. Reverse the above procedures.
Avantra 36/44 Service Manual 4.2.3 Electronic Enclosure Cover Tools Required: 1/4" nut driver Remove: NOTE: The electronics enclosure is located inside the right side cover. 1. Open the right side cover. See Section 4.2.1, Right/Left Side Covers. 2. Remove the three (3) 1/4" hex screws at the bottom of the electronics enclosure. Refer to Figure 4-6. 3. While holding the electronics enclosure cover with one hand, loosen one (1) 1/4" hex screw located at the top right side. Refer to Figure 4-6.
Section I: Imagesetter 4.3 Media Transport Removal/Replacement Procedures The following describes the media transport removal/replacement procedures. 4.3.1 Take-up Light Shield 1. Raise the front top cover. 2. Remove the top and middle panels. See Section 4.2.2, Top, Middle and Bottom Front Panels. 3. Loosen the three thumb screws at the bottom of the light shield. Refer to Figure 4-7. 4. Grab the shield by the handles. Refer to Figure 4-7. Pull out, then up.
Avantra 36/44 Service Manual 4.3.2 Outer Take-up Drive (Nip) Assembly Tools Required: Flathead screwdriver Remove: 1. Unload the media and turn the system off. 2. Open the top cover. 3. Remove the top and middle front panels. See Section 4.2.1, Right/Left Side Covers. 4. Remove the take-up light shield. See Section 4.3.1, Take-up Light Shield. 5. Remove the foam on either side of the outer take-up (nip) drive. 6. Disconnect the nip solenoid connector. Refer to Figure 4-8. 7.
Section I: Imagesetter Replace: 1. Reverse the above instructions to re-install the outer take-up drive assembly. 2. The take-up drive assembly should be checked for proper operation before the outer covers are installed. 3. After installing the outer take-up drive assembly and light shield, turn the system on and launch the AVDIAG program from your PC. 4. Select ALIGN and select Engine Primitives. Test the nip solenoids by choosing Open Nips and Close Nips. 5.
Avantra 36/44 Service Manual 6. Disconnect the power plugs from the motor. Refer to Figure 4-9. NOTE: For purposes of replacement, the power sockets are marked: 1 = red wire; 2 = brown wire. Refer to Figure 4-9. 3 4 5 1 2 Figure 4-9 Inner take-up drive (nip) assembly. ➀–Inner take-up drive (nip) assembly. ➁–4 3/16" allen screws securing the drive to the system. ➂–Motor. ➃–2 power cables; 1=red, 2=brown. ➄–Encoder cable. 7. Disconnect the encoder plug from the motor. Refer to Figure 4-9.
Section I: Imagesetter 10. Follow the sensor cable up to the take-up SDM board on the right side of the imagesetter. Unplug the sensor cable at its connector (J6) on the board. Refer to Figure 4-10. 11. Using a 3/16" allen wrench, remove the four (4) bolts, two (2) on each side of the inner take-up (nip) assembly. Refer to Figure 4-9. 12. Pull the assembly out, rocking it gently. 1 2 Figure 4-10 Take-up SDM board. ➀–Take-up SDM board. ➁–Sensor cable. Replace: 1.
Avantra 36/44 Service Manual 5. Enter Display Sensors from the Align menu and check the operation of the take-up jam sensor. The take-up jam sensor can be checked by inserting a piece of film down the right side of the take-up cassette platform until the sensor wheels move, which causes a change in status. 6. Load the media to check the complete feed function. 4.3.4 Inner Take-up Drive (Nip) Motor Tools Required: 3/16" allen wrench, 1/4" and 5/16" nut driver Remove: 1.
Section I: Imagesetter 8. Cut the tie wraps on the motor. Refer to Figure 4-11. 3 4 1 6 2 5 Figure 4-11 Inner take-up drive (nip) motor assembly ➀–Inner take-up drive motor assembly. ➁–Two 1/4" hex screws. ➂–Bracket. ➃–Tie-wrap. ➄–Motor gear. ➅–Allen screw. 9. Disconnect the power plugs from the motor. Refer to Figure 4-9. NOTE: For purposes of replacement, the power sockets are marked: 1 = red wire; 2 = brown wire. 10. Disconnect the encoder plug from the motor. Refer to Figure 4-9. 11.
Avantra 36/44 Service Manual Replace: 1. Install the take-up drive motor using the two (2) 1/4" bracket screws removed in Step 11 in the removal procedure above. Refer to Figure 4-11. 2. Install the motor gear. Refer to Figure 4-11. 3. Check the backlash prior to tightening the bracket screws. 4. Turn the take-up drive roller to make sure that it turns smoothly and does not bind. If it does, the backlash needs to be re-adjusted. 5.
Section I: Imagesetter 1 2 5 4 6 Figure 4-12 Inner take-up (nip) jam sensor. ➀–Inner take-up drive (nip) assembly. ➁–Take-up jam sensor. ➂–1/4" hex head screw in tie clamp. ➃–Two 1/4" hex head screws on bracket. ➄–1/4" hex nut on sensor. 4. Using a 1/4" nut driver, remove the 1/4" hex head screw holding the tie clamp. Refer to Figure 4-12. 5. Using a 1/4" nut driver, remove the two (2) 1/4" hex head screws securing the sensor bracket to the take-up drive (nip) assembly.
Avantra 36/44 Service Manual Replace: 1. Install the new jam sensor to the Jam Sensor bracket. Do not tighten the screw. Refer to Figure 4-12. 2. Install the jam sensor bracket into the inner take-up drive assembly. Refer to Figure 4-12. 3. Adjust the jam sensor so that it does not interfere with the jam sensor wheel. 4. Tighten the jam sensor screw. Refer to Figure 4-12. 5. Install the jam sensor plug into the main shell connector. Refer to Figure 4-10. 6.
Section I: Imagesetter 8 7 6 1 5 4 3 2 3 Figure 4-13 Take-up punch assembly. ➀–Take-up punch assembly. ➁–Take-up punch chafe pan. ➂–Three chafe pan standoffs. ➃–Scribe marks (left and right). ➄–Three vacuum tubes. ➅–Two 3/16" hex bolts. ➆–Sensor motor connector. ➇–Punch shoe (DO NOT REMOVE). 4. Remove the three (3) standoffs securing the chafe direction shield attached to the front of the punch assembly. Remove the chafe direction shield from the system. Refer to Figure 4-13. 5.
Avantra 36/44 Service Manual 7. Remove the two (2) 3/16" hex bolts securing the take-up punch assembly to the outer drum surface. Refer to Figure 4-13. 8. Remove the punch assembly from the system. Replace: 1. Install the punch assembly to the scribe marks. Refer to Figure 4-13. 2. Move the take-up punch assembly completely to the right until it touches the punch shoe. Tighten the two (2) 3/16" allen screws. 3. Reverse the above removal procedures starting with Step 10. 4.
Section I: Imagesetter 3 4 2 1 Figure 4-14 Cutter assembly and SDM board. ➀–Cutter assembly. ➁–Two of four 3/16 " hex bolts. ➂–SDM board. ➃–Switch/sensor connector (J4). 5. Remove the rubber foam from the sides of the cutter assembly. WARNING: Use two people to remove the cutter assembly. CAUTION: The media entrance and exit guides on the cutter assembly can be easily bent if they come into contact with a hard surface.
Avantra 36/44 Service Manual 4.3.8 Cutter Motor Tools Required: Phillips screwdriver, 5/64" allen wrench Remove: 1. Remove the cutter assembly. See Section 4.3.7, Cutter Assembly. 2. Cut the tie wrap around the motor holding the wires in place. 10 2 11 5 1 4 8 6 7 9 Figure 4-15 Cutter motor. ➀–Cutter assembly. ➁–Cutter motor. ➃–Motor cam. ➄–Two 5/64" allen screws. ➅–Shaft. ➆–Coupler. ➇–Two 5/64" allen screws. ➈–Four phillips screws. ➉–Cutter Home Sensor. 11–Two phillips screws. 3.
Section I: Imagesetter 4. Select Test and then Selectable Test. 5. Select Media Test and then Cutter. The cutter should make one revolution and pass the test. 4.3.9 Take-up Media Present Detector Tools Required: 3/4" nut driver, small screwdriver, 3/16" wrench Remove: 1. Remove the cutter assembly. See Section 4.3.7, Cutter Assembly. 2.
Avantra 36/44 Service Manual Replace: 1. Reverse the above removal procedure. 2. Before installing the light shields and panels, turn the system on and launch the AVDIAG program from your PC. 3. Select Align, then Display Sensors. 4. Check the take-up media present sensor by inserting a piece of film down the left side of the take-up cassette platform until the sensor is covered. This should cause a change in status for the take-up media present sensor on the PC. 4.3.
Section I: Imagesetter The following describes the electrical removal/replacement procedures. 4.4.1 Digital Engine Controller (DEC) PCB Tools Required: 1/4" nut driver, small screwdriver. NOTE: Prior to removing the DEC PCB, ensure that the DEC machine parameters, the DSP FLASHROM software and the DEC correction tables are saved. Also, ensure that a copy of the DEC K1 FLASHROM and DSP FLASHROM software are loaded in the PC. Remove: 1. Turn the system off and unplug the power cord from the outlet. 2.
Avantra 36/44 Service Manual 1 3 2 4 5 7 6 9 8 Figure 4-17 Digital Engine Controller PCB (DEC) (cable locations). ➀–SDMs (2). ➁–CSDM cable (behind SDM cable). ➂–Power supply. ➃–OCP. ➄–Vacuum. ➅–Apis. ➆–Bridge. ➇–Modem. ➈–Modem power 6. Remove the six (6) hex screws from the bottom of the electronics enclosure securing the DEC plate to the enclosure. Refer to Figure 4-18. 7. Remove the three (3) hex screws securing the DEC PCB in the enclosure and remove the board. Refer to Figure 4-18.
Section I: Imagesetter 1 2 Figure 4-18 Digital Engine Controller PCB (DEC) screw locations. ➀–Three screws (located in three corners of the DEC board). ➁–Six screws located underneath electrical enclosure. Replace: 1. Install the new DEC board by reversing the above steps. 2. Download and restore all DEC machine parameters. 3. Download the DEC DSP and correction tables. 4. If necessary, program the DEC K1 FLASHROM. 5.
Avantra 36/44 Service Manual 4.4.2 Carriage Sensor Driver (CSDM) PCB Tools Required: 3/16" nut driver, small screwdriver Remove: 1. Turn the system off and unplug the power cord from the outlet. 2. Open the left and right side covers. See Section 4.2.1, Right/Left Side Covers. 3. Remove the inner light shields on the right side of the system, then the light shield on the left side of the system. See Section 4.6.1, Light Shields (Right and Left). This accesses both sides of the carriage assembly. 4.
Section I: Imagesetter 5. 1 On the left side of the system, disconnect the spin motor cable, spin motor encoder cable, carriage motor cable and analog encoder cable from the CSDM PCB. Refer to Figure 4-20. 6 5 4 3 2 Figure 4-20 Carriage sensor driver module PCB (CSDM) (left side). ➀–CSDM PCB. ➁–3/16" hex screws and retaining clip. ➂–Spin motor cable connector. ➃–Spin motor encoder cable connector. ➄–Carriage motor cable connector. ➅–Analog encoder cable connector. 6.
Avantra 36/44 Service Manual Replace: 1. Slide the new CSDM into the carriage assembly and secure with the retaining clip. 2. Install the cabling at both ends of the PCB as removed in previous steps. 3. Turn the system on and launch the AVDIAG program from your PC. Select Test and then Selectable Test. Select Carriage Test and then Carriage. The carriage should move and pass the test. 4.
Section I: Imagesetter 1 3 5 2 4 7 6 Figure 4-21 Operator control panel (OCP). ➀–Power cord clamp. ➁–Removable mounting bracket’s 1/4" hex screw. ➂–1/4" hex screws (2) securing OCP ribbon cable bracket. ➃–Power supply connector. ➄–AC power connector. ➅–OCP ribbon cable. ➆–Removable mounting bracket’s 5/16" hex screw. 4. Remove the hex screw securing the power cord clamp to the electronics enclosure. Refer to Figure 4-21. 5. Remove the power connector located below the control panel. 6.
Avantra 36/44 Service Manual 9. Slide the mounting bracket out from the back of the OCP assembly. Pull the assembly out through the front of the system and rest it on the top cover. 10. Remove the two (2) 1/4" hex screws securing the control panel ribbon cable to the electronics enclosure. Refer to Figure 4-21. 11. Feed the ribbon cable through this hole to complete the removal of the control panel. Replace: 1. Install the new OCP assembly by reversing the steps in the removal procedure. 2.
Section I: Imagesetter 6. Gently squeeze the side of the remaining two (2) plastic stand-offs while pulling the board(s) free from each stand-off. 1 4 5 2 3 Figure 4-22 The take-up and supply sensor driver modules (SDMs). ➀–SDM modules. ➁–Three 3/16" hex screws. ➂–Plastic shield. ➃–Two 1/4" hex screws. ➄–Two plastic standoffs. Replace: 1. Push the SDM(s) back onto the two (2) stand-offs and secure with the two (2) 1/4" hex screws. 2. Connect all cables removed in previous steps. 3.
Avantra 36/44 Service Manual 4.4.5 Power Supply Tools Required: 1/4" nut driver. Remove: 1. Turn the system off and unplug the power cord from the AC outlet. 2. Open the right side cover. See Section 4.2.1, Right/Left Side Covers. 3. Remove the electronics enclosure cover. See Section 4.2.3, Electronic Enclosure Cover. 4. Remove the screw securing the ground wire located behind the intake fan assembly. Refer to Figure 4-23. 5. Remove the two (2) wires going to the intake fan.
Section I: Imagesetter 4 2 5 7 6 1 3 Figure 4-23 Power supply. ➀–Intake fan. ➁–Exhaust fan. ➂–Power connector to control panel. ➃–Power supply. ➄–AC power connector. ➅–Power connector to DEC Board. ➆–Three hex screws under shelf. 6. Remove the cable clamp on the intake fan securing the cable wires. Refer to Figure 4-23. 7. Disconnect the connector going to the exhaust fan. Refer to Figure 4-23. 8.
Avantra 36/44 Service Manual 11. Disconnect the power connector from the control panel to the power supply. Refer to Figure 4-23. 12. Remove the three (3) hex screws that secure the power supply to the electronic enclosure shelf. Refer to Figure 4-23. 13. Slide the power supply out of the electronics enclosure while passing the power connector and fan wires through the holes provided in the electronics enclosure. Replace: 1. Reverse the removal procedure to re-install the power supply. 2.
Section I: Imagesetter 2. Loosen the 1/4" hex screw securing the plate over the power-on switch. Refer to Figure 4-24. 1 Figure 4-24 Main power switch and plug locations. ➀–Main power switch and plugs. 3. Slide the plate down and out of the OCP. 4. Remove the brown and blue wires going to the power switch. Refer to Figure 4-24. Note the wiring orientation for re-installation. 5.
Avantra 36/44 Service Manual 4.4.7 Exhaust Fan Tools Required: 1/4" nut driver. Remove: 1. Open the right side covers. See Section 4.2.1, Right/Left Side Covers. 2. Remove the screw securing the wire clamp on the top left corner of the intake fan assembly (below the exhaust fan). Refer to Figure 4-26. 3. Disconnect the wire connector from the exhaust fan. Refer to Figure 4-25. 1 Figure 4-25 Exhaust fan location. ➀–Exhaust fan. 4. Cut the tie wraps. 5.
Section I: Imagesetter 4.4.8 Intake Fan Tools Required: 3/4" nut driver, screwdriver Remove: 1. Open the right side cover. See Section 4.2.1, Right/Left Side Covers. 2. Remove the two wires going to the intake fan. Note the wire color orientation for re-installation. 3. Snap out the plastic removable guide and remove the fan filter. 4. Remove the four (4) hex screws securing the fan to the mount. 1 Figure 4-26 Intake fan location. ➀–Intake fan. Replace: 1.
Avantra 36/44 Service Manual 4.5 Carriage Drive Removal/Replacement Procedures The following describes the carriage drive removal/replacement procedures. 4.5.1 Carriage Transfer Tool Installation Tools Required: phillips screwdriver NOTE: It is recommended that you remove the left side cover before you install the carriage transfer tool. Remove: 1. Open the right and left side covers. See Section 4.2.1, Right/Left Side Covers. 2. Remove the right and left inner light shields. See Section 4.6.
Section I: Imagesetter 5. Make sure that both the bearing and magnet retaining brackets are in the up position and that the screws are tightened on the transfer tool. Refer to Figure 4-27. 6. Make sure that the carriage locking pins are in the retract position (out) on the transfer tool. Refer to Figure 4-27. 7. Insert the carriage transfer alignment pin into the hole on the engine upper structure frame. Refer to Figure 4-28.
Avantra 36/44 Service Manual 4.5.2 Carriage Assembly Tools Required: Carriage transfer tool Carriage Removal to Transfer Tool: 1. Refer to the carriage transfer tool installation in Section 4.5.1, Carriage Transfer Tool Installation. 2. On the right side of the drum, remove the flex cable going to the carriage board. 3. Move the carriage gently to the left side of the drum. 4. Remove the two (2) power cable connectors going to the brushes on the inner shrouds. 5.
Section I: Imagesetter 4 1 3 2 Figure 4-29 Carriage assembly. ➀–Carriage board. ➁–Spin motor assembly. ➂–Analog encoder. ➃–Analog encoder coupler. 8. Push the carriage to the transfer tool carriage stop. 9. Engage the locking pins on the side of the transfer tool. Refer to Figure 4-27. 10. Loosen the two (2) retaining bracket screws that hold the bearing retainer bracket in the up position on the transfer tool. Refer to Figure 4-27.
Avantra 36/44 Service Manual 1 3 2 Figure 4-30 Transfer tool and carriage assembly. ➀–Transfer tool. ➁–Carriage assembly. ➂–Magnetic transfer bracket. 13. The magnet retainer bracket moves down to secure the carriage magnets. 14. Tighten both retainer screws. Refer to Figure 4-27. 15. Holding the carriage transfer tool by its handle, unscrew the transfer tool from the system and put it on a flat surface with the transfer tool down.
Section I: Imagesetter Carriage Installation from Transfer Tool: 1. Insert the carriage transfer tool pin into the hole on the engine upper structure frame and line up the pin on the transfer tool left rail with the hole in the carriage left rail. Refer to Figure 4-27. 2. As you tighten the transfer tool screw, make sure that the alignment lip on the bottom of the transfer tool right rail is up against the bottom of the carriage right rail. 3.
Avantra 36/44 Service Manual 3. Pull each of the five (5) latch knobs out and twist them so that they rest outside of the lock slot. Refer to Figure 4-31. 2 3 4 3 1 Figure 4-31 Light shield. ➀–Light shield. ➁–Five latch knobs. ➂–Interlock switch. ➃–Latch knob lock slot.
Section I: Imagesetter 4. The light shield on the left requires a twist toward the door to remove. Pull the light shield on the right straight out. NOTE: When removing the light shield, the interlock switch, located above the shield, automatically shuts off the laser and spin motor. Replace: 1. Reverse the above removal procedure. 4.6.2 Spin Motor Module (SMM) Tools Required: 5/32" allen wrench Remove: 1. Open the left side cover. See Section 4.2.1, Right/Left Side Covers. 2.
Avantra 36/44 Service Manual 4 2 3 1 5 Figure 4-32 Spin motor module (SMM). . ➀–Spin motor module. ➁–Mounting bracket. ➂–Three allen screws ➃–Spin motor cable. ➄–Spin motor encoder cable. 4. Cut the tie clamps. 5. Loosen the three (3) allen screws that secure the spin motor mounting bracket to the carriage casting. Refer to Figure 4-32. 6. Slide the spin motor out of the mounting bracket. Refer to Figure 4-32. Replace: 1.
Section I: Imagesetter 4. Reverse the removal procedure starting from Step 4 to complete spin motor installation. 5. Turn the system on and launch the AVDIAG program from your PC. 4.6.3 Spot Generation Module (SGM) Tools Required: Allen wrenches Remove: WARNING: Never hold the SGM module by the laser diode assembly. Doing this could cause misalignment of the laser. NOTE: Each new SGM comes with a sheet of paper that contains the new polarizer, focus home positions, and beam compressor number.
Avantra 36/44 Service Manual 2 1 3 4 5 7 8 6 9 10 11 12 Figure 4-33 Spot generation module (SGM). ➀–Polarizer sensor. ➁–Beam compressor motor. ➂–Beam compression sensor. ➃–Weak lens motor. ➄–Spot size changer. ➅–Spot forming lens. ➆–Laser diode mount . ➇–Polarizer wheel and motor. ➈–Focus sensor. ➉–Spot size sensor. 11–Aperture wheel motor. 12–SGM base. Replace: 1. Reverse the above removal procedure. 4.6.4 Spot Size Sensor Tools Required: Small flathead screwdriver, cutters Remove: 1.
Section I: Imagesetter 1 2 Figure 4-34 Spot size sensor location. ➀–Spot size sensor. ➁–Aperture wheel motor. 4. Remove the hex screw securing the sensor to the SGM casting. Refer to Figure 4-34. 5. Remove the sensor cable plug from the shell connector removed in Step 2. Replace: 1. Reverse the above removal procedure. 4.6.5 Polarizer Sensor Tools Required: Small flathead screwdriver, cutters Remove: 1. Remove the carriage assembly from the system. See Section 4.
Avantra 36/44 Service Manual 4. Remove the two (2) hex screws securing the polarizer sensor to the bracket. Refer to Figure 4-35. 1 Figure 4-35 Polarizer sensor location. ➀–Polarizer sensor. 5. Remove the sensor cable plug from the shell connector removed in Step 2. Replace: 1. Reverse the removal procedure above. 4.6.6 Beam Compressor Motor Tools Required: Small flathead screwdriver, cutters Remove: 1. Remove the carriage assembly from the system. See Section 4.
Section I: Imagesetter 4. Remove the two (2) hex screws securing the compressor motor to the SGM casting. Refer to Figure 4-36. 2 1 Figure 4-36 Compressor motor location. ➀–Beam compressor motor. ➁–Beam compressor sensor. 5. Remove the compressor plug from the shell connector removed in Step 3. Replace: 1. Reverse the removal procedure above. 4.6.7 Aperture Wheel Motor Tools Required: Small flathead screwdriver, cutters Remove: 1. Remove the carriage assembly from the system. See Section 4.
Avantra 36/44 Service Manual 4. Remove the hex screws securing the aperture wheel motor to the SGM casting. Refer to Figure 4-37. 1 Figure 4-37 Aperture wheel motor location. ➀–Aperture wheel motor. 5. Remove the aperture wheel plug from the shell connector removed in Step 3. Replace: 1. Reverse the removal procedure above. 4.6.8 Weak Lens Motor Tools Required: Small flathead screwdriver, cutters Remove: 1. Remove the carriage assembly from the system. See Section 4.
Section I: Imagesetter 4. Loosen the allen screw securing the lead screw of the motor to the casting. 5. Remove the hex screws securing the weak lens motor to the SGM casting. Refer to Figure 4-38. 4 Figure 4-38 Weak lens motor location. ➀–Weak lens motor. 6. Remove the plug from the shell connector removed in Step 3. Replace: 1. Reverse the removal procedure above. 2. Run the FOCUS.FIL file from the PC imager to check the focus adjustment. 4.6.
Avantra 36/44 Service Manual 4. Remove the hex screw securing the focus sensor to the bracket. Refer to Figure 4-39. 1 Figure 4-39 Focus sensor location. ➀–Focus sensor. 5. Remove the sensor cable plug from the shell connector removed in Step 2. Replace: 1. Reverse the removal procedure above. 2. Run the FOCUS.FIL file from the PC imager to check the focus adjustment.
Section I: Imagesetter 4.7 Media Transport Removal/Replacement Procedures The following describes the media transport removal/replacement procedures. Refer to Figure 4-40 for media transport motor and sensor locations. 3 4 5 2 1 Figure 4-40 Supply motor and sensor locations. ➀–Supply cassette A/B rewind motors. ➁–Supply drive motor. ➂–Spindle A/B position sensors. ➃–Flag bracket. ➄–Supply spindle select motor.
Avantra 36/44 Service Manual 4.7.1 Supply Drive Servo Motor Tools Required: Allen wrenches, 1/4" nut driver, 5/16" nut driver Remove: 1. Unload the media from the system. 2. Open the top cover. Refer to Figure 4-41. 3. If the bridge is installed, put the system in light mode and lift the bridge to the up position. Shut the system off before the bridge goes back to heavy mode. 4. Lift up the light shield cover. 1 2 3 Figure 4-41 Imagesetter outer and inner covers. ➀–Top cover. ➁–Bridge.
Section I: Imagesetter 8. Release the tie clamps and bracket on the inner light shield (shell surrounding the motors and sensors) that secure the ribbon cables coming from the supply SDM and carriage board. Refer to Figure 4-42. 1 3 2 4 Figure 4-42 Opening the cable clamps and removing the cables to gain access to the supply motors and sensors. ➀–Two ribbon cable clamps. ➁–Ribbon cables. ➂–Lower cable clamp. ➃–Bracket.
Avantra 36/44 Service Manual 9. Remove the encoder connector from the supply drive servo motor. Refer to Figure 4-43. Note the orientation of the connector for proper replacement. 2 5 6 1 3 4 Figure 4-43 Removing the supply drive servo motor. ➀–Encoder connector. ➁–Red connector. ➂–Brown connector. ➃–Two 7/64" allen screws. ➄–Two hex screws. ➅–Flag bracket. 10. Remove the red wire from Pin 1 and the brown wire from Pin 2 on the motor. Refer to Figure 4-43. 11.
Section I: Imagesetter Replace: 1. Reverse the removal procedures to re-install the supply drive motor. NOTE: Ensure that the supply drive motor gear is positioned in the center of the supply drive roller gear. 2. Turn the system on and launch the AVDIAG program from your PC. 3. Test spindle swap and supply motor. 4.7.2 Supply Cassette A or B Rewind Motors Tools Required: 3/16" and 1/16" allen wrenches Remove: 1. Follow the first eight steps in Section 4.7.1, Supply Drive Servo Motor above. 2.
Avantra 36/44 Service Manual 3. Remove the two (2) 1/4" hex screws securing the motor to the engine side casting. 4. Loosen the two (2) 1/16" allen screws securing the gear to the motor shaft. Refer to Figure 4-44. 5. Remove the gear from the motor shaft. Refer to Figure 4-44. 6. Using a 3/16" nut driver, remove the three hex screws securing the motor bracket to the motor. Refer to Figure 4-44. Replace: 1. Reverse the removal procedure to re-install either the supply cassette motor A or B. 2.
Section I: Imagesetter 1 2 3 5 6 4 Figure 4-45 Removing the light shield to access the supply spindle select motor coupler screws. ➀–Imagesetter.➁–Light shield. ➂–SDM board. ➃–Three light shield hex screws. ➄–Two mounting screws. ➅–Supply spindle select motor. 1 2 3 4 5 6 Figure 4-46 Removing the select motor coupler. ➀–Coupler housing.➁–Coupler. ➂–Supply spindle select motor. ➃–Two coupler allen screws on motor shaft side. ➄–Motor shaft. ➅–Two housing screws.
Avantra 36/44 Service Manual Replace: 1. Reverse the above removal procedure to re-install the spindle position motor. NOTE: Loctite should be added to the two allen screws on the coupling before they are tightened. NOTE: Perform the following procedure to make sure that the supply spindle select motor has been installed properly. 2. Open the supply A or B roller. Place a 1 mil shim between the A or B and drive roller disks. 3. Nip the rollers so that the disks touch.
Section I: Imagesetter 2 1 Figure 4-47 Supply cassette spindle A/B position sensors. ➀–Two sensor securing screws. ➁–Two sensor connectors. Replace: 1. Reverse the above removal procedure to re-install the sensor. 2. Turn the system on and launch the AVDIAG program from your PC. 3. Select motor A or B to test the sensor. NOTE: The sensor flags may need adjustment.
Avantra 36/44 Service Manual 4.7.5 Supply Roller Removal and Installation To Remove the Supply Rollers: 1. Move the nip supply drive roller to the spindle “A” roller. 2. If the system has a bridge, put the bridge in light mode and lift it up. You do not have to disconnect the system from the buffer. 3. Turn the system off. 4. Remove the back supply cassette light shield. 5. Open top supply cassette cover. To Remove the Bottom Roller: 1.
Section I: Imagesetter 3. Move the shuttle motor rod slightly backwards on the left side while removing the top roller from the left side. To Remove the Center Roller: 1. Remove the supply drive motor with the gear and sensor flag assembly. Caution should be taken not to lose the standoffs for the flag assembly. NOTE: In new systems the supply motor gear is covered with Loctite, and is difficult to remove from the motor shaft. This is why the entire motor must be removed. 2.
Avantra 36/44 Service Manual 4.8 The Vacuum System The following describes the vacuum system removal/replacement procedures. Refer to Figure 4-40 for component locations. 3 2 1 Figure 4-48 The vacuum system components. ➀–Vacuum pump.➁–Valves. ➂–Electronics box.
Section I: Imagesetter 4.8.1 Vacuum Pump Tools Required: Flathead and phillips screwdrivers Remove: 1. Open the right side cover. See Section 4.2.1, Right/Left Side Covers. 2. Remove the two (2) tubing fittings from the pump. Refer to Figure 4-49. 3. Using a flathead screwdriver, remove the two (2) mounting plate screws. Refer to Figure 4-49. Remove the plate with the pump on it. 4. Using a phillips screwdriver, remove the screw holding the grounding wire in place. Refer to Figure 4-49. 5.
Avantra 36/44 Service Manual 6. Using a phillips screwdriver, remove the two (2) screws holding the rubber mounts in place. 1 2 Figure 4-50 Vacuum pump rubber mounts. ➀–Rubber mount. ➁–Four rubber mount screws. Replace: 1. Reverse the above removal procedure. 4.8.2 Vacuum Valves Tools Required: Phillips screwdriver Remove: 1. Open the right side cover. See Section 4.2.1, Right/Left Side Covers. 2. Using a phillips screwdriver, remove the screw (one each) in the valve tops. Refer to Figure 4-51.
Section I: Imagesetter 2 1 3 Figure 4-51 Vacuum valves. ➀–Valves.➁–Screws. ➂–Vacuum pump. Replace: 1. Reverse the above removal procedure. 4.8.3 Vacuum Board Tools Required: 11/32" socket wrench, needle nose pliars, flathead screwdriver Remove: 1. Open the right side cover. See Section 4.2.1, Right/Left Side Covers. 2. Remove the three (3) hex nuts, two at the top and one at the bottom, holding the electronics box in place. The electronics box is located to the right of the vacuum pump and valves.
Avantra 36/44 Service Manual 2 1 Figure 4-52 Electronics box. ➀–Electronics box.➁–Three hex nuts. 3. Remove the three (3) connectors from the vacuum board, which is located inside the electronics box on the left hand side. Refer to Figure 4-53. 2 1 Figure 4-53 Vacuum board. ➀–Vacuum board.➁–Sensor relay.
Section I: Imagesetter 4. Using needle nose pliars, squeeze the standoffs in the upper left, lower left, and lower right corners of the vacuum board. 5. Using a flathead screwdriver, remove the screw in the upper right corner of the board. 6. Pull the board free. Replace: 1. Reverse the above removal procedure.
Chapter 5: Imagesetter Alignment 5.1 Introduction This section describes the alignment and adjustment procedures for the Avantra image setter.
Avantra 36/44 Service Manual 5.2 Beginning of Line (BOL) Alignment Procedure Use the BOL Alignment Procedure to set the correct starting position of the laser beam on the drum surface in the fast scan direction. Position the beam by entering an encoder offset value in the AVDIAG Program. This value determines the distance between the encoder's zero reference signal and the actual start of the BOL. The value is stored in EEPROM on the DEC. Tools Required: 18" Scale, eye loupe Coarse Alignment: 1.
Section I: Imagesetter 8. Continue to enter new BOL position values until the scan line centers between the supply and take-up punches on the drum surfaces. NOTE: A BOL position value change of 1000 represents an (approximately) one (1) inch movement on the drum's surface. Lowering the BOL position value moves the scan line counter-clockwise. 9. The BOL position value is temporary. After determining the correct value, it must be stored in the DEC's EEPROM (DEC Machine Parameters). 10.
Avantra 36/44 Service Manual 4. Enter the Image menu. 5. Select the Test Files sub menu. 6. Select the SCALEFID.CON file and press ENTER. The test file should now image. 7. Press the Feed/Cut icon on the Avantra's operator’s control panel (OCP). 8. Remove the take-up cassette and develop. 9. Measure the distance from the first line imaged to the center of the middle round hole punched in the fast scan direction. The distance should be 0.48" +/- 0.01".
Section I: Imagesetter 5. Enter the following Information: Resolution: 3600 Density Start (Enter Starting Density): Inc. 5 Resolution: 2400 Density Start (Enter Starting Density): Inc. 5 Resolution: 1800 Density Start (Enter Starting Density): Inc. 5 Resolution: 1200 Density Start (Enter Starting Density): Inc. 5 6. Press ESC to exit out of this menu. 7. Select Image and then Test Files. 8. In the test file menu select EXP4RES.FIL and press ENTER.
Avantra 36/44 Service Manual 3. Start the PC Imager utility from the PC. NOTE: Refer to the PC Imager User's Manual (P/N 580024-001) for detailed information on running this utility. 4. Enter the Image menu. Select the Test Files sub menu. Select the Scale.fil file and press ENTER. The test file should now be imaging. 5. Press the Feed/Cut Icon on the Avantra's OCP. 6. Remove the take-up cassette and develop. 7.
Section I: Imagesetter 5.5 Focus Alignment Use the Focus Alignment Procedure to establish the correct position of the weak lens (focus lens), which properly focuses the laser beam on the drum surfaces. Position the weak lens by entering a focus home position value in the AVDIAG program. This value is based on 4 mil thick media. Other media thickness focus values derive from this base value automatically when selected from the control panel. The focus home value is stored in EEPROM on the DEC.
Avantra 36/44 Service Manual The output copy consists of two focus patterns (vertical and horizontal) divided by five horizontal black bars. The top pattern is the vertical focus and the bottom pattern is the horizontal focus. See Figure 5-1. The header tells you the starting point, which is defaulted to -280 for each focus pattern. The increment is defaulted to 40. These can be changed in the Special Arrays menu in PC Imager; however, these values should work for most systems. Do not change the 120 value.
Section I: Imagesetter Figure 5-1 Vertical and horizontal focus. (These patterns are only a simulation. They are meant to be used as a guide in selecting a correct value.
Avantra 36/44 Service Manual 5.6 System Leveling Procedure Whenever installing or moving a system to a new location, perform the following procedure to ensure that the system is level. CAUTION: An out-of-level system can cause imaging artifacts in output copy. Tools Required: Adjustable wrench, level Steps: 1. Open the top cover. 2. Open the supply cassette compartment door. 3. Lower the four (4) leveling feet so that they all make contact with the floor. 4.
Section I: Imagesetter 5.7 Voltage Check Procedure Use the Voltage Check Procedure to insure that the correct voltages are being supplied to the electronics of the system. Tools Required: Digital voltmeter Steps: 1. Open the right side doors. Refer to Section 5.2 on page 5-3 in Section 5: Component Removal/ Replacement Procedures. 2. Remove the electronics enclosure cover. Refer to Section 5.3 on page 5-5 in Section 5: Component Removal/Replacement Procedures. 3.
Avantra 36/44 Service Manual 4. Select Image and then Test Files. NOTE: On new releases of the PC Imager software you can run all four resolutions of PWM files at the same time by running the PWM4UP30.FIL file. 5. Select PWM@12.FIL. The system images the 1200 DPI PWM file. 6. When the above file finishes, run: PWM@18.FIL PWM@24.FIL PWM@36.FIL. 7. When the above three files finish, press the Feed/Cut Icon on the Avantra control panel. 8. Remove the take-up cassette and develop the film. 9.
Section I: Imagesetter 11. Check the other three PWM files. When completed you should have four values, one for each resolution. NOTE: Some of the text, especially the PWM@18.FIL, does not line up correctly with the patterns. Look at one of the other PWM files for correct positioning of text. 12. Exit the PC Imager program and launch the AVDIAG program from thePC. 13. Select Align and then DEC Machine Parameters. The following dialog appears: Loading Dec. Machine Parameters. 14.
Avantra 36/44 Service Manual 5.9 Carriage Encoder Alignment Procedure Use the Carriage Encoder Alignment Procedure to normalize the A and B encoder signals from the analog (velocity) encoder. Normalizing the A and B encoder signals reduces the velocity error signal injected into the carriage from the encoder, improving imaging performance. Perform the alignment by executing the Carriage Align Test contained in the AVDIAG Program.
Section I: Imagesetter 2. Remove all supply cassettes. NOTE: It does not matter which way the spindle selector is left; toward A or B works equally as well. 3. Connect the serial cable from the imagesetter to the PC, and launch the AVDIAG Program from your PC. 4. Select Align and then DEC Machine Parameters. The following dialog appears: Loading Dec Machine Parameters into memory. 5. Select Y in the dialog box. 6. When loading completes, select DEC (Media). 7.
Avantra 36/44 Service Manual 14. Once this is complete, go back into the Machine Parameters and restore the S-Feed Current setting in the second column, (for Film/Plate, M4-max). 15. Exit AVDIAG with a Soft Reset from the PC. The supply current offset is complete. 5.11 Take-up Cassette Clutch Adjustment Procedure The following procedure details how to check and adjust the Avantra’s take-up cassette clutch.
Section I: Imagesetter 4. After completing the adjustment, reassemble the cassette core into the takeup cassette. Leave the top cover off at this time. 5. Enter the utility menu on the system control panel. Do a feed and watch the take-up cassette core. Make sure that the cassette finds its home position and that the media wraps around the core. 6. Install the take-up cassette top cover. 5.
Avantra 36/44 Service Manual 1 Figure 5-4 Supply spindle disks. ➀–Supply spindle disks. To check the supply spindle disks: 1. Open the spindle under test and place a 1 mil shim between the disks and then close the spindle. You should not be able to remove the 1 mil shim easily. If you can then the supply rollers need to be adjusted first before adjusting the sensors. Only the top and middle rollers can be adjusted. 2.
Section I: Imagesetter 3. Replace and tighten the screws and perform the 1 mil test again. Even after this procedure is done it’s possible that the disks may still fail the 1 mil test. In this case you need to adjust the left and right side disks of the same spindle so that they have equal (error) space. 4. To adjust the right side disks loosen the two screws securing the spindle select motor to it’s motor housing bracket.
Avantra 36/44 Service Manual 2 3 1 Figure 5-5 Sensor adjustment screws. ➀—Two 5/16 inch screws. ➁—Two 3/16 inch screws. ➂—One of two spindle select motor screws. Once this adjustment is completed test both spindle A and B disks using the 1 mil shim test to make sure that all six disks touch when that spindle is selected.
Section I: Imagesetter 5.14 Slack Loop Test Procedure NOTE: The slack loop test works only for thin media (4 mil and under). It is disabled for thick media (over 4 mil). The slack loop test is used to determine the adjustment setting of the slack loop flag as well as the speed of the bridge and take-up motors, based on the number of times the slack loop is formed during a feed of a given length. The test is performed as follows: 1.
Avantra 36/44 Service Manual 1 2 3 4 5 6 B Errors are On 1 Look 2 Cass 1 Cass 1 Cass 1 P 0 = P 1 = P 2 = 00000000h 00000000h 00000000h Feed is On ROW 3 Cass 1 Cass 1 Cass 1 P 3 = P 4 = P 5 = 00000000h 00000000h 00000000h Buffer On/not in use Slack Loop On 4 Cass 1 Cass 1 Cass 1 P 6 = P 7 = P 8 = 00000000h 00000000h 00000000h Proc On/not in use OCP DEC Off Fix Save A 5 A) Press button 6, 3 to toggle Test ON/Off first B) Press button 6, 1 to Exit Figure 5-7 Exiting the Secret Scr
Section I: Imagesetter c. 6. After adjusting the parameters, reboot the system and check the slack loop number as in Step 4. If the slack loop number is still low, perform steps “a” thru “c” again until required number is reached. If the number of loops formed is less than four and the bridge speed parameters are at nominal values, an adjustment to the slack loop flag is needed. a. Remove the lower bridge front cover and inspect the slack loop bracket/flag and sensor.
Chapter 6: Preventive Maintenance 6.1 Introduction Regular preventive maintenance (PM) extends the reliable and trouble-free operation of the Avantra. The following section details the inspection procedures necessary to keep the system running at top performance. The service engineer should perform the PM inspection every 3 months. This section covers the following: • 6.
Avantra 36/44 Service Manual 6.2.1.1 General Inspection Inspection consists of the following procedures: 1. Disconnect the AC power cord from the wall receptacle. 2. Remove the front cover. Remove the rear cover, if the system is not attached to a buffer. 3. Swing open the side doors on both ends of the system. 4. Inspect the system for the following conditions: 5.
Section I: Imagesetter 6.2.1.3 Spin Motor Mirror Cleaning Procedure The following procedure insures that the spin motor mirror is clean. This prevents a reduction in the amout of laser light that exposes the media on the drum surface. Perform this procedure at each preventative maintenance call. Tools Required: Optic Pads (P/N 78047-002), allen wrench 1. With the system’s power off, open the left side and remove the drum light shield. 2.
Avantra 36/44 Service Manual 4. Open the right side cover and remove the rear access panel by pushing up on the three white buttons. Remove the access panel. 5. Remove the two screws securing the back supply light shield located behind the supply compartment. Pull the light shield up between the supply compartment and the bridge. 6. Lift the panel covering the supply punch and the punch container. 7. Vacuum out punch chaffs from the punch container pan from the right. 8.
Section I: Imagesetter 8. Run the focus alignment procedure. Refer to Chapter 5, Alignment Procedures. 9. Run the pulse width modulation procedure (PWM). Refer to Chapter 5, Alignment Procedures. 10. Run the supply motor offset alignment procedure. Refer to Chapter 5, Alignment Procedures. 11. Save to system Diskette - DEC Machine Parameters, DEC Correction Tables, and OCP User Parameters. Refer to Chapter 3, Diagnostics. 12. Check the top cover shocks for proper operation. Replace if necessary. 13.
Avantra 36/44 Service Manual 2. Remove the black, input fan filter. 3. Hard vacuum the black filter. 4. Soft vacuum fan area. 5. Replace the black, input filter with a new one, if necessary. 6. Check the condition of the drum filter (Orange/White/Black) located on the right drum light shield. This filter cannot be vacuumed. 7. Replace the drum filter with a new one, if necessary. 6.2.3.2 Supply/Take-up Cassette Area To Clean: 1. Open the top cover and lift up the bridge, if installed. 2.
Section I: Imagesetter NOTE: When cleaning the nip drive rollers, do NOT substitute any other tape (i.e. , masking, duct tape, etc.) for clear tape. Substitutes may leave a sticky residue on the roller, and any residue could cause PERMANENT DAMAGE to the rollers. 5. Install the outer take-up nip assembly. 6. Install the take-up light shield cover. 7. Install the bottom front covers. 6.2.3.4 Lower Interior Area To Clean: 1. Open the two (2) side panels. 2. Soft vacuum. 3.
Avantra 36/44 Service Manual 6.2.3.6 Bridge Cleaning If the optional bridge is installed, it should be cleaned during every preventive maintenance. To Clean: 1. Open the top cover and remove the three bridge covers by lifting the two latches on each side. 2. Soft vacuum the: • Three top covers (both sides) • Bridge rollers • Platen between the bridge rollers 3. Lift the bridge to the up position and vacuum the labyrinth opening. 4. Lower the bridge and install the three top covers. 6.2.3.
Appendix A: Specifications A.1 Introduction This section details pertinent technical equipment specifications for the Avantra 36/44 imagesetter. A.2 Avantra 36/44 Imagesetter Specifications This section includes the following imagesetter specifications: • Physical • Electrical • Environmental • Functional Physical Specifications Width: 73" (185.42 cm) Height: 48" (121.92 cm) Depth: 35" (88.90 cm) Weight: 1700 lbs. (771.11 kg) Electrical Specifications Volts: 115/230 Amp: 5 / 2.
Section I: Imagesetter Functional Specifications Format Size: 36" x 44.5" (91.44 cm x 113.03 cm) Maximum Image Area: 35.7" x 44.5" (90.68 cm x 91.44 cm) Resolution/Spot Size: 1200/20 1800/15 2400/9.5 3600/8.0 Repeatability: +/- 0.5 mils Punches +/- 1 mil Accuracy (Duplo): +/- 1.25 mils (Avantra 36S/44S) +/- 1.75 mils (Avantra 36/44) Density Range: 4.2D to 4.6D Density Variation: .
Appendix B Spare Parts Imagesetter The following lists spare parts for the 36/44 and 36S/44S imagesetters.
Avantra 36/44 Service Manual 209287-503 Sensor Driver Module (SDM) AV36S/44S 209287-502/503 *Sensor Driver Module (SDM) AV36/44 209323-501 Vacuum module AV36/44/36S/44S 002525-555 Power supply AV36/44/36S/44S 064404-001 Power cord AV36/44/36S/44S 064466-001 Power cord (international) AV36/44/36S/44S * Depends on the software loaded in the system. Refer to OMNI document (50.
Section I: Imagesetter 066390-121 Take-up media jam sensor AV36/44/36S/44S 002637-563 Take-up cutter assembly AV36/44/36S/44S 002637-562 Take-up drive assembly AV36/44/36S/44S 067334-003 Cutter home switch AV36/44/36S/44S 209973-501 Brush solenoid (3 per) AV36/44/36S/44S 066486-002 Flapper motor AV36/44/36S/44S 002637-524 Flapper assembly (L & R) AV36/44/36S/44S Opto-Mechanical 067253-008 Polarizer home sensor AV36/44/36S/44S 066390-108 Spot changer home sensor AV36/44/36S/44S 06
Avantra 36/44 Service Manual Supply Cassette 002637-537 Supply cassette assembly AV36/44/36S/44S 002935-501 Left spindle assembly (gear) AV36/44/36S/44S 002935-502 Right spindle assembly (thumb wheel) AV36/44/36S/44S 002935-503 Spindle assembly (both) AV36/44/36S/44S Take-up Cassette 002637-522 Take-up cassette assembly AV36/44/36S/44S Vacuum System 067328-001 Volt sensing relay AV36/44/36S/44S 065979-001 Solid state relay AV36/44/36S/44S 067339-001 Vacuum pump transformer AV36/44/36
Index A A/B Roller and Sensor Adjustment 5-17 Aantra serial peripheral interface (SPI) bus 2-3 Accessories for Attaching Imagesetter to Buffer 1-13 Accessories for Installing the Imagesetter 1-13 Accessory Box 1-6, 1-7 Adjustment Procedure, Exposure 5-4 Adjustment Procedure, Pulse Width Modulation 5-11 Agfa Print Engine Interface Specification (APIS) 3-17 Align Menu 3-27 Align Menu Items carriage alignment 3-29 DEC machine parameters 3-29 image/focus 3-29 imagesetter configuration 3-27 media 3-31 SGM-A/B m
Avantra 36/44 Service Manual Board carriage 4-49 DEC 4-35 digital engine controller 4-25 SDM 4-13, 4-20 Boards carriage 4-50 carriage sensor driver (CSDM) 4-28 BOL 5-2 Boot Error Codes 3-13 Boot Tests 3-24 Bottom Front Panel 4-5 Bottom Panel location 4-7 BrdgeOffEly Time definition 3-31 Bridge 6-5, 6-8 Bridge Cleaning 6-8 Bridge Maintenance 6-5 Bridge Max.
Section I: Imagesetter Command Files 3-25 Commands Batch 3-26 Diagnostic 3-44 Enter Service Mode 1 3-44 Hang-up 3-67 New Engine/Restart 3-44 Reset 3-44 Soft Reset 3-44 SPI 3-26 Communication Port 3-45 Component Removal/Replacement Procedures 4-1 Config Comm.
Avantra 36/44 Service Manual Diagnostics, Remote 3-61 Dial-out Feature, Automatic 3-11 Dial-out Icon 3-4 Diaper location 1-8 Digital Encoder Connector location 4-28 Digital Engine Controller 2-7 Digital Engine Controller (DEC) 3-3 Digital Engine Controller PCB (DEC) 4-26, 427 cable locations 4-26 remove and replace 4-25 screw locations 4-27 Disabling error reporting 3-47 film feeding 3-47 Display Controller Test 3-11 Display Error Log 3-38 Display RAM Test 3-11 Display Sensors 3-39 Dolch 386 3-17 DOS Edito
Section I: Imagesetter Firmware Revision Levels displaying 3-19 Firmware Revisions 3-38, 3-44 Firmware, Downloading 3-17 Flag Bracket location 4-57, 4-60 FLASHROM 2-10, 3-2, 3-48 FLASHROM Cheksum 3-7 Foam Packing Strips 1-14 Focus Alignment 5-7 Focus Changer Stepper Motor 2-11 Focus Home Sensor 2-11 Focus Lens 5-7 Focus Sensor 2-16, 4-50 location 4-56 remove and replace 4-55 Friction Wheel 2-28 Front Cover location 4-5 Front Panels 4-5 location 4-7 Functional Analysis 2-1 G Gain Values 5-14 Gear Motor, Sup
Avantra 36/44 Service Manual Lens, Weak 5-7 Level One (Core Tests) 3-3 Level Two (micro-controller handshake tests) 3-3 Leveling 5-10 Leveling Feet 5-10 Light Shield 1-20 location 4-46 Light Shield Cover (lift) location 4-58 Light Shield, Take-up 4-9 Light Shields latch knobs 4-46 lock slot 4-46 remove and replace 4-45 Light Table 1-4 Linear Bearing Guideway 2-21 Linear Carriage Transport carriage assembly 2-19 friction wheel drive subsystem 2-20 Linear Carriage Transport Overview 2-19 Link Test, DEC to DS
Section I: Imagesetter Motor, Beam Compressor 4-52 Motor, DC Spindle A/B Gear 2-26 Motor, Focus Changer Stepper 2-11 Motor, Supply Drive Servo 4-58 Motor, Weak Lens 4-54 Motors aperture wheel 2-16, 4-50, 4-51, 4-53, 4-54 beam compressor 2-16, 4-50, 4-52, 4-53 polarizer 2-16, 4-50 spin 4-47 supply cassette A and B 4-61 supply drive servo 4-58 weak lens 2-16, 4-50, 4-54 Motors, Rewind 2-26 N New Engine/Restart 3-44 New Engine/Restart Command 3-44 Nip Delay definition 3-33 range 3-33 Nip Solenoid Connector lo
Avantra 36/44 Service Manual Power Supply Fuse 2-14 Powered Media Take-up Cassette 2-27 Power-up Boot Diagnostics 3-2 confidence checks 3-2 debug monitor mode 3-2 initializing 3-2 main functions 3-2 modem/auto-dial-out feature 3-2 overview 3-2 Power-up Boot Sequence 3-3 Pre-installation Checks 1-4 Preparing Media Transport Retainer Bracket 118 Preventive Maintenance 6-1 Procedure, System Leveling 5-10 Procedure, Voltage Check 5-11 Procedures, Local Modem Connection 3-65 Prog DEC/DUPLO (defined) 3-48 Prog O
Section I: Imagesetter polarizer 2-16, 4-50 take-up media present 4-23 Sensor Driver Module (SDM) 2-11 Sensor Problems, Troubleshooting 3-39 Sensor, Focus Home 2-11 Sensor, Polarizer Home 2-11 Sensor, Polarizer Rotation 4-51, 4-55 Sensor, Spot Changer 4-50 Sensor, Spot Changer Home 2-11 Sensor, Supply Cassette Spindle A/B Position 4-64 Sensor, Supply Jam 2-27 Sensor, Supply Media Present 2-27 Sensor, Take-up Jam 4-16 Sensors 2-12 beam compression 2-16, 4-50 beam compressor 4-53 focus 2-16, 4-50, 4-55 polar
Avantra 36/44 Service Manual Supply and Take-Up Sensor Driver Modules PCB (SDMs) remove and replace 4-32 Supply Cassette 2-32 Supply Cassette A or B Rewind Motors location 4-61 Supply Cassette A/b Rewind Motors location 4-57 Supply Cassette Motors remove and replace 4-61 Supply Cassette Spindle A/B Position Sensor connector location 4-65 Supply Cassette Spindle A/B Position Sensors remove and replace 4-64 Supply Drive DC Gear Motor 2-26 Supply Drive Motor location 4-57 Supply Drive Servo Motor connector lo
Section I: Imagesetter remove/replace 4-32 Telephone Numbers, Remote Diagnostic Center 3-64 Telephone Requirements 1-3 Temperature operating 1-2 shipping 1-2 Test BOOT 3-24 carriage 3-8, 3-22 DEC 3-21 DEC micro-controller descriptions 3-8 DEC offgate register 3-8 DEC ongate register 3-8 DEC to DSP SPI link 3-8 DEC vacuum register 3-8 display controller 3-11 display RAM 3-11 media 3-23 menu 3-20 OCP 3-23 OCP register 3-7 offgate register 3-6 ongate register 3-6 selectable 3-20 supply motors 3-9 vacuum regis
Avantra 36/44 Service Manual Vacuum Register Test 3-6 Vacuum Tubes location 4-19 Vacuuming bridge 6-8 exterior 6-5 hard defined 6-5 inner System 6-7 intake fan filter 6-4 lower interior area 6-7 soft defined 6-5 supply cassettes 6-4 supply/take-up cassette area 6-6 take-up module area 6-6 Velocity Error Signal 5-14 Verification, Phase Lock Loop 3-10 Video Data Path Test 3-9 Voltage Check Procedure 5-11 W Wall Condition 3-8 Weak Lens 2-18, 5-7 Weak Lens Motor location 2-16, 4-50, 4-55 remove and replace 4-5
Section II: Bridge
Chapter 1: Bridge Installation 1.1 Introduction This chapter describes the steps necessary for installing the internal bridge and for insuring that it functions properly.
Avantra 36/44 Service Manual 1.2 Removing the Imagesetter Top Cover Before the bridge can be installed into the imagesetter, the top cover must be removed. Steps Tools required: Screwdriver 1. At the rear of the imagesetter, remove the allen screws attaching the top back panel. Refer to Figure 1-1. 2. Raise the top cover. 1 1 2 2 1 Figure 1-1 Rear of the imagesetter. ➀–Top cover. ➁–Hinge stop. ➂–Hinge stop bolt. ➃–Gas shock retaining bolt. ➄–Top back panel allen screws.
Section II: Bridge 3. Standing in front of the imagesetter, remove the three (3) shoulder screws (top, bottom and side) on the cover hinge. Refer to Figure 1-2. 1 4 2 5 3 Figure 1-2 The gas shock shoulder screws. ➀–Hinge. ➁–Gas shock retaining bolt. ➂–Gas shock. ➃–Top and bottom shoulder screws (remove). ➄–Side shoulder screw (remove). 4. Drop the top cover down. 5. Standing at the rear of the imagesetter, loosen the two (2) hex head screws from the hinge assemblies, left and right.
Avantra 36/44 Service Manual 7. Pull the bottom segment up on the top cover. Refer to Figure 1-3. 2 3 1 Figure 1-4 Top cover bottom segment. ➀–Front panel. ➁–Bottom segment. ➂–Top segment. CAUTION: Use at least two people when performing the next step; i.e., lifting the top cover. 8. 1-4 With a strong person (or persons) on each end, lift the top cover straight up from the imagesetter.
Section II: Bridge Figure 1-5 Lifting the cover from the imagesetter. 1.3 Attaching the Capture Bar to the Bridge This section tells you how to safely secure the crane’s capture bar to the bridge. Tools required: 1/4" allen wrench In addition to the tools, you will need the bridge accessories kit, which came with the imagesetter. Open the accessories box and check its contents. Steps 1. Place the bridge, top up, on a raised surface near the on-line processor crane.
Avantra 36/44 Service Manual 2 1 3 Figure 1-6 Attaching the capture bar and brackets to the bridge. ➀–Bridge. ➁–Capture bar. ➂–Two capture bar brackets. 4. Using the bridge screws, attach the left bracket to the bridge. Refer to Figure 1-6. The left bracket is for the roll pin side of the capture bar. 5. Using one of the two (2) 9/16" bolts and washers provided, secure the bracket to the side of the bridge. Refer to Figure 1-6. 6. Insert the roll pin side of the bar into the bracket. 7.
Section II: Bridge 1.4 Raising and Lowering the Bridge into the Imagesetter Tools required: 9/16" hex wrench Steps 1. Swing the crane boom around so that the cable clip is over the capture bar eyelet. Lower the cable clip to the eyelet. 2. Clip the cable to the eyelet and raise the bridge slowly. 3. When the bridge height exceeds the height of the imagesetter, swing the boom around. Suspend the bridge over the imagesetter. 4.
Avantra 36/44 Service Manual 5. With the rear of the bridge tilted downward and the bridge aligned over the mounting bracket holes in the imagesetter, slowly lower the bridge into place. Refer to Figure 1-8. 6. Hand tighten the three (3) allen cap screws, in the bearing blocks, left and right (see Figure 1-11). 7. Unclip the cable from the capture bar eyelet. Push the boom and cable out of the way. 8. Remove the 9/16" bolt and washer from the capture bar bracket, left and right (see Figure 1-6).
Section II: Bridge 9. Remove the two (2) screws from the capture bar bracket, left and right (see Figure 1-6). Remove the side brackets and return the screws to the sides of the bridge. 10. Replace the light shields at the top of the bridge. 1.
Avantra 36/44 Service Manual 1 2 3 Figure 1-9 Attaching the foot to the bridge using the foot thumb screws. ➀–Bridge. ➁–Bridge foot. ➂–Foot thumb screw (one of two). 3. Using a flashlight, look to the left and right of the bridge to make sure that the guide blocks are not hitting the take-up platform opening. Refer to Figure 1-10. If a guide block is hitting, move the bridge left or right to compensate. 4. Check to make certain that the bridge foot lies flat on the take-up platform.
Section II: Bridge 1 Figure 1-10 Aligning the bridge using the guide blocks. ➀–Guide block (one of two). 5. Also make certain that the bridge bearing blocks (top left and right) are straight. If they are, secure to the lower casting by tightening the three (3) allen screws. Refer to Figure 1-11. 1 2 3 4 Figure 1-11 Securing the bearing blocks. ➀–Bearing block. ➁–Sensor reflector. ➂–Three allen screws.➃–Lower casting.
Avantra 36/44 Service Manual 1.5.2 Attaching the Gas Shocks Tools required: Screwdriver Steps: 1 2 Figure 1-12 Gas shock and bolts. ➀–Gas shock (one of two). ➁–Spring bolts (two of four) 1. Screw the threaded end of the gas shock into the bridge mount casting at the top rear of the bridge. Refer to Figure 1-13. If necessary, lift the bridge to align the ear with the hole in the bridge mount casting. 2.
Section II: Bridge 1 2 3 Figure 1-13 Attaching the gas shock. ➀–Bridge mount casting. ➁–Lower mount casting. ➂–Gas shock. 3. Lower the bridge slowly to make sure that the shocks work. 4. Lift the bridge and check the guide block for scuffing (see Figure 1-10). Lower the bridge and, with a flashlight, check again that the guides are not hitting the plate.
Avantra 36/44 Service Manual 5. Pop in the button plugs at the top of the bridge, left and right side. Refer to Figure 1-14. 1 2 Figure 1-14 Placing the button plugs. ➀–Bridge. ➁–Button plug (one of two). 1.5.3 Adjusting the Detent Plate Tools required: Screwdriver Steps 1. Open both side doors on the imagesetter by loosening the thumb screws on the inside. Refer to Figure 1-15. 2. Remove the two (2) plastic access panels at the top of the imagesetter. This gives easier access to the detent plates.
Section II: Bridge 1 2 Figure 1-15 Opening the imagesetter side doors. ➀–Side door. ➁–Thumb screw. 4. Install the spring plungers loosely, left and right. Refer to Figure 1-16. Thread the plungers with the ball facing in. 1 2 Figure 1-16 Installing the spring plunger. ➀–Spring plunger. ➁–Gas shock.
Avantra 36/44 Service Manual 5. Make certain that the detent plate adjustment allen screws are loose on the detent plate. Refer to Figure 1-17. 6. Screw the spring plungers in until the spring loaded ball centers within the front V-groove of the detent plate. Refer to Figure 1-17. Make certain that the detent just touches the ball. 1 2 3 Figure 1-17 Adjusting the detent plate. ➀–Detent plate. ➁–V-groove. ➂–Adjustment allen screws. 7. Back the screw out 1/2 turn. 8.
Section II: Bridge 1.5.4 Aligning the Solid Stops Tools required: Loctite, 9/16" wrench Steps NOTE: If the take-up platform in your system does not have the solid stop pad areas (see Figure 1-18), then you must install a newer platform. 1. Put Loctite on the knurl of the solid stop pad. Refer to Figure 1-18. 2. Put the solid stop pad in the hole in the imagesetter take-up platform. Refer to Figure 1-18. 2 3 1 Figure 1-18 Aligning the solid stops. ➀–Solid stop pad.
Avantra 36/44 Service Manual 1.5.5 Setting up the DEC to Bridge/Buffer Interface Tools required: Screwdriver Steps 1. Using the four standoffs and nylon washers, install the Bridge/buffer interface board on the right wall of the imagesetter. Refer to Figure 1-19. 1 3 2 4 Figure 1-19 Attaching the bridge/buffer interface board. ➀–Bridge/buffer interface board. ➁–Standoff and nylon washer. ➂–Interface board cover (attach after connectors are in place). ➃–Four hex screws.
Section II: Bridge 2. Connect the interface board cable to the bottom of the interface board. Refer to Figure 1-20. 3. Pass the interface board cable through the left side of the fan housing and connect the cable with the DEC board on the right door. Refer to Figure 1-20. 3 2 4 1 Figure 1-20 Routing and connecting the interface board cable. ➀–DEC. ➁–Interface board cable (bridge/buffer board to DEC). ➂–Interface board. ➃–Fan housing.
Avantra 36/44 Service Manual 4. Beginning directly under the shuttle motor and working downward, tie wrap the bridge cables (include the interface platen cable). 5. Feed the cable bundle through the rubber grommet in the access hole. The access hole is located in the imagesetter frame below the access plate. 6. Wrap the wires under the shuttle motor into a P-clamp. Using a hex screw and two (2) star lock washers, secure the clamp to the bridge support casting. 7.
Section II: Bridge 10. Using a P-clamp, secure the wires coming from the bridge/buffer interface board on the right. Secure the P-clamp to the frame using a sems screw. 11. Using a P-clamp, secure the wires coming coming from the bridge/buffer interface board on the left. Secure the P-clamp to the frame using a sems screw. 1.5.6 Attaching the Ground Wires Tools required: Screwdriver 1. Remove the sems screw in the P-clamp located under the shuttle motor. 2.
Avantra 36/44 Service Manual 1 3 4 2 Figure 1-22 Attaching the ground cables. ➀–Two ground cables. ➁–Two star washers. ➂–P-clamp. ➃–Sems screw. 3.
Chapter 2: Bridge Functional Analysis 2.1 Introduction The internal bridge option integrates the Avantra and an on-line processor into one complete imaging system. Because the bridge is internal to the imagesetter, the usual long media transport path associated with bridges/on-line processors is greatly reduced. This provides better performance and more reliable operation. It also reduces the required floor space by approximately 30%.
Chapter 3: Bridge Debugger Diagnostic Tool 3.1 Introduction The bridge debugger software is a diagnostic tool built into the bridge/buffer module PCB. This tool has several features that aid in the debugging of bridge and buffer problems on the Avantra 36/44. The debugger port software monitors the flow of bridge and buffer commands to and from the DEC. Monitoring takes place while the system runs in normal operation mode (not service mode).
Avantra 36/44 Service Manual 3.2 Setting Up the Debugger Port Access the bridge debugger port software using a terminal or PC running terminal emulation software (Procomm). The bridge/buffer module uses a 15-pin D-type connector requiring a special adapter cable to interface to the standard serial cable. Refer to Figure 3-1. 15 PIN MALE 25 PIN FEMALE D-TYPE D-TYPE TX 2 3 6 2 RX 3 GND 7 To Buffer/Bridge Module To Terminal Serial Cable Figure 3-1 Avantra 36/44 Bridge Diagnostic Adapter Cable.
Section II: Bridge 3.3 Bridge Debugger User Interface This section describes the debugger user interface including: • Terminal code identifiers • Bridge states • Error codes • Bridge commands • Sensor status information • Parameters • Bridge/buffer commands 3.1.
Avantra 36/44 Service Manual 3.1.3 Bridge States Bridge states display on the terminal when entering or changing an internal state. An “i” precedes a bridge state. A list of valid bridge states follows.
Section II: Bridge 3.1.4 Bridge State Responses Bridge state responses display on the terminal when entering or changing an internal state. An “r” precedes a bridge state. Valid bridge states follow. r01 Error r02 Ready r03 Busy r40 Command Acknowledge r41 Invalid Mode r42 Parameter Out Of Range r43 Invalid Command r44 Command Abort 3.1.5 Bridge Error Codes Bridge error codes display on the terminal when an error condition occurs. An “e” precedes an error code.
Avantra 36/44 Service Manual 3.1.6 Bridge Sensor Status The bridge sensor status displays on the terminal when a Sensor Request command (^F) is issued from the terminal. An “s” precedes the sensor status. The sensor status is returned as a WORD value (two bytes). Each row of sensors (2 rows) are located in a separate byte. Row 1 (5 bits) is located in the lower byte; row 2 (5 bits) is located on the upper byte.
Section II: Bridge 3.1.7 Bridge Parameters Use the bridge parameters with the Set/Get Parameters command. NOTE: These comand/parameters are not normally used for troubleshooting. 0 Nominal speed 1 Max Torque 2 Steps to Processor 3 DC Motor Speed 4 Stepper Import Speed 5 Stepper Length 6 Nominal Slow Speed 7 Stepper Export Speed 3.1.
Avantra 36/44 Service Manual 3-8 Diagnostics ^@ 00 Null Command ^a 01 Status Request ^b 02 Servo1 ON (fast) ^c 03 Servo1 OFF ^d 04 Abort Operation ^e 05 Cut /Transport ^f 06 Sensor Request ^g 07 Clear Error ^h 08 Front Processor ON ^i 09 Front Processor OFF ^j 0A Back Processor ON ^k 0B Back Processor OFF ^l 0C Bridge Slow Speed ^m 0D Bridge Fast Speed ^n 0E Buffer Roller Fast Speed ^o 0F Buffer Roller Slow Speed ^p 10 Set Parameter ^q 11 Short Feed ^r
Chapter 4: Bridge Component Removal/Replacement Procedures 4.1 Introduction This section describes the procedures used when removing and replacing components in the bridge.
Avantra 36/44 Service Manual 4.2 Removing and Replacing the Bridge Foot Tools: None Remove: 1. Put the bridge in the down position and in heavy mode. 2. Unscrew the two (2) thumb screws, one on each side of the foot. Refer to Figure 4-1. 2 1 2 4 3 5 Figure 4-1 Bridge foot. ➀–Foot face plate. ➁–Six (three each side) face plate screws. ➂–Two thumb screws. ➃–Media purchase sensor connector. ➄–Loop sensor connector. 3. Lift the bridge and pull the foot out. Replace: 1. Reverse the procedures above.
Section II: Bridge 4.3 Media Purchase Sensor Tools: Phillips screwdriver, 3/16" allen wrench Remove: 1. Remove the six (6) screws, three (3) on each side, of the bridge foot face plate. Refer to Figure 4-1. 2. Remove the media purchase sensor connector. Refer to Figure 4-1. 3. Using a 3/16" allen wrench, remove the holding screw. Replace: 1. 4.4 Reverse the procedure above. Bridge Loop Sensor Tools: Phillips screwdriver, 5/16" open end wrench Remove: 1.
Avantra 36/44 Service Manual 4.5 Upper Bridge Servo Motor Tools: Phillips head screwdriver, flathead screwdriver, allen head wrench Remove: 1. If the bridge foot is on, put the system in light mode and turn the system off. 2. Using a phillips head screwdriver, remove the six (6) screws from the bridge side cover on the right. Refer to Figure 4-2. 4 1 2 3 5 Figure 4-2 Bridge side cover. ➀–Bridge. ➁–Side cover. ➂–Electrical connector. ➃–Six side cover screws. ➄–Upper bridge servo motor. 3.
Section II: Bridge 7. Using a large flathead screwdriver, remove the two (2) servo motor mounting screws. Refer to Figure 4-3. 8. Using an allen head wrench, remove the two set screws from the servo motor gear. Refer to Figure 4-3. 9. Remove the gear from the motor. Refer to Figure 4-3. 1 2 9 3 8 7 4 5 6 Figure 4-3 Bridge side cover exposed view. ➀–Drive belt. ➁–Tensioner assembly. ➂–Upper bridge servo motor. ➃–Motor power connectors (red and brown). ➄–Servo motor gear with allen screws.
Avantra 36/44 Service Manual 4.6 The Activator Switch Tools: Phillips head screwdriver, flathead screwdriver Remove: 1. Using a phillips head screwdriver, remove the three (3) cover screws. Refer to Figure 4-4. 2. Disconnect the switch connectors. Refer to Figure 4-4. 3. Using a flathead screwdriver, remove the two switch mounting screws. Refer to Figure 4-4. 1 3 4 5 2 Figure 4-4 Activator switch. ➀–Cover. ➁–Three cover screws. ➂–Switch connectors. ➃–Two switch mounting screws.
Section II: Bridge 4.7 The Bridge Up Sensor Tools: Phillips head screwdriver Remove: 1. If the bridge foot is on, put the system in light mode and turn the system off. 2. Using a phillips head screwdriver, remove the six (6) holding screws from the bridge side cover on the right. Refer to Figure 4-2. 3. Remove the connector from the bridge up sensor. Refer to Figure 4-5. 4. Remove the sensor connector. Refer to Figure 4-5. 5.
Avantra 36/44 Service Manual 4.8 Bridge Shuttle Motor Tools: Allen head wrench, flathead screwdriver Remove: 1. Put the bridge in the up position. 2. Remove the allen head screw from the motor cover on the left. Refer to Figure 4-6. 3. Put the bridge in the down position to remove the two (2) remaining allen head screws on the front of the cover. Refer to Figure 4-6. 4. Remove the two (2) power connectors from the bottom of the motor. Note the wire positions for replacement. Refer to Figure 4-6.
Section II: Bridge 5. Using a flathead screwdriver, remove the two (2) motor mounting screws. Refer to Figure 4-7. 2 3 1 4 5 Figure 4-7 Motor mounting screws and coupling. ➀–Anti-static cable. ➁–Shaft. ➂–Cover. ➃–Coupling. ➄–Two mounting screws. Replace: 1. Reverse the above procedure. 2. Put the system through a practice run to make certain that the motor runs properly.
Avantra 36/44 Service Manual 4.9 Shuttle Light and Heavy Sensors Tools: Flathead screwdriver Remove: 1. Using a flathead screwdriver, remove the two (2) mounting screws. Refer to Figure 4-8. 2 3 4 1 5 Figure 4-8 Shuttle light and heavy sensor assembly. ➀–Bridge shuttle motor. ➁–Cover. ➂–Shuttle light and heavy sensor assembly. ➃–Two mounting screws. ➄–Two sensor assembly connectors. 2. Remove the two (2) sensor connectors. Refer to Figure 4-8. 3.
Appendix A Spare Parts Bridge 209686-503 Bridge/Buffer driver module AV36S/44S 209686-501/503 *Bridge/Buffer driver module AV36/44 209684-501 Bridge foot interlock boards AV36/44/36S/44S 067324-001 Bridge gas shocks AV36/44/36S/44S 066481-004 Bridge driver servo motor AV36/44/36S/44S 066481-005 Bridge shuttle DC gear motor AV36/44/36S/44S 066719-001 Slack loop sensor AV36/44/36S/44S 066719-001 Shuttle position sensors AV36/44/36S/44S 066721-002 Bridge foot purchase sensor AV36/44
Index A Access Panels 1-14 Activator Switch 4-6 Adjusting the Detent Plate 1-14 Aligning the Bridge 1-11 Aligning the Solid Stops 1-17 Assembly, Hinge 1-3 Attach the Bridge/Buffer Housing Cover 1-20 Attaching the Bridge Foot 1-9 Attaching the Bridge to the Imagesetter 1-9 Attaching the Capture Bar 1-5 Attaching the Gas Shock 1-13 Attaching the Gas Shocks 1-12 Attaching the ground cables 1-22 Attaching the Ground Wires 1-21 B Bearing Blocks 1-8, 1-11 Bridge debugger port 3-2 diagnostic adapter cable 3-2 err
Avantra 36/44 Service Manual E Error Codes, Bridge 3-5 F Fan Housing.
Section III: Buffer
Chapter 1: Buffer Installation 1.1 Introduction This chapter provides information for unpacking, unlocking and installing the Avantra 36/44 buffer.
Avantra 36/44 Service Manual 1.2 Buffer Installation Procedures 1.2.1 Unpacking the Buffer The buffer ships in a single cardboard box attached to a wooden pallet (see Figure 1-1). Tools: Strap cutters, 7/16¨ hex wrench, 9/16¨ hex wrench Steps: 1. Cut the two (2) straps around the cardboard sleeve and remove the top cardboard cover. Refer to Figure 1-1. 1 2 3 Figure 1-1 The buffer shipping box. ➀–Box cover. ➁–Shipping straps (2). ➂–Shipping box.
Section III: Buffer 2. Remove the two (2) foam spacers at the top. Refer to Figure 1-2. 3. Lift the cardboard sleeve straight off the pallet. 4. Cut the shipping straps going around the unit frame. Refer to Figure 1-2. These straps hold the unit’s top cover in place. 1 2 3 Figure 1-2 Removing the box, spacers and straps. ➀–Foam spacers (2). ➁–Box cover. ➂–Shipping straps (2).
Avantra 36/44 Service Manual 5. Using a 7/16¨ hex wrench, remove the two (2) bolts in each of the outriggers at the bottom rear of the unit. Refer to Figure 1-3. NOTE: Remove the outriggers at the rear of the unit only. 6. Using a 9/16¨ hex wrench, remove the two (2) bolts from the bottom left and two (2) bolts from the bottom right of the pallet. Refer to Figure 1-3. 7. Remove the anti-static bag covering the unit. 3 1 2 4 4 Figure 1-3 Removing the rear outriggers and pallet bolts.
Section III: Buffer 8. Remove the unit’s bottom side panels (left and right) by pulling them straight out. Refer to Figure 1-4. CAUTION: The side panels attach to the unit by means of a lock pin at each of the four corners. Do not tilt the side panels, or the lock pins could bend or snap. WARNING: Four persons must be used for lifting the unit. 1 2 Figure 1-4 Removing the side panels. ➀–Top cover. ➁–Side panels.
Avantra 36/44 Service Manual 9. Each person must grip the unit at the top of the side panel opening. Refer to Figure 1-4. Lift the unit free of the pallet, and set the unit on the floor. WARNING: Do not try to lift the buffer unit from the top, nor should it be tilted. The top cover on the unit is not attached and will come off. 10. Replace the side panels at the bottom of the unit frame. Refer to Figure 1-4. CAUTION: Do not force the side panels back into place.
Section III: Buffer Steps: 1. To unlock the buffer carriage, remove the two (2) shipping screws from the top rear of the buffer. Refer to Figure 1-6. 1 Figure 1-6 Unlocking the carriage lock bolts. ➀–Buffer carriage lock bolt (1 of 2, left and right).
Avantra 36/44 Service Manual 2. Insert the plastic plugs (see Figure 1-5) in the two (2) shipping screw holes. Refer to Figure 1-7. 1 Figure 1-7 Placing the plastic plugs and foam pads. ➀–Plastic plug (1 of 2).
Section III: Buffer 3. To unlock the buffer input platen, remove the two (2) lockdown bolts. The lockdown bolts are located on the left and right portion of the platen near the hinge screws. Refer to Figure 1-8. 1 2 Figure 1-8 Removing the platen lockdown bolts. ➀–Platen. ➁–Platen lockdown bolt (1 of 2).
Avantra 36/44 Service Manual 1.2.3 Installing the Buffer to the Imagesetter The imagesetter comes with an accessories kit, which contains the necessary parts for connection the buffer to the imagesetter. Check the contents of the accessories box with the hardware illustrated in Figure 1-9. 2 1 5 3 Figure 1-9 4 Accessories for attaching the imagesetter to the buffer (and for imagesetter installation). ➀–Chafe tray. ➁–Extension platen.
Section III: Buffer Steps: 1. Remove the back panel from the Imagesetter. Refer to Figure 1-10. 2. Raise the imagesetter front cover, light shield and bridge. 3. Attach the left and right side plates to the extension platen using the four (4) nuts and bolts provided. Refer to Figure 1-10 and Figure 1-11. 1 2 3 Figure 1-10 Inserting the extension platen at the rear of the imagesetter. ➀–Exit platen opening. ➁–Imagesetter rear with back panel removed. ➂–Extension platen assembly. 4.
Avantra 36/44 Service Manual 6. Connect the cable to the sensor on the extension platen prior to installing the extension platen. 7. Insert the extension platen through the opening and position the platen at the inside rear of the imagesetter. Refer to Figure 1-10 and Figure 1-11. 8. Hang the platen brackets on the studs jutting from the imagesetter frame. 9. Remove the imagesetter plastic access panels (left and right) to get at the studs and brackets.
Section III: Buffer 10. Slide the extension platen toward the rear of the imagesetter. CAUTION: Before proceeding to the next step make certain that no interference exists between the bridge (when it is lowered) and the edge of the extension platen. 11. Lower the bridge. 12. Slide the extension platen toward the bridge. Using the two (2) platen alignment pins provided, align the holes on the bottom of the bridge platen (left and right) with the holes in the extension platen. Refer to Figure 1-12.
Avantra 36/44 Service Manual 13. Leaving the platen alignment pins in place, tighten the four (4) nuts (each end) on the brackets attached to the extension platen. Refer to Figure 1-11. CAUTION: With the bracket tightly secured against the extension platen, check that the set of alignment holes in the bridge still line up with the set in the extension platen. If the holes do not align, loosen the nuts and repeat Steps 11 and 12. 14.
Section III: Buffer 5 1 2 3 4 Figure 1-13 The buffer’s adjustable legs. ➀–OLP. ➁–Adjustable leg. ➂–Buffer. ➃–Imagesetter. ➄–leg adjustment screws. 17. Secure the buffer to the imagesetter using the two (2) #10-32 x 1/4¨ sems screws, one at each end of the buffer platen at the top corners. The screws pass through the buffer platen from the inside and into the threaded inserts at the back of the imagesetter. Refer to Figure 1-14.
Avantra 36/44 Service Manual 2 1 3 Figure 1-14 Securing the buffer to the imagesetter. ➀–Buffer. ➁–Imagesetter. ➂–Hex bolt (1 of 2). 18. Open the right side door on the imagesetter. See the Avantra 36/44 Imagesetter Service Manual, Chapter 4, Section 4.2.1 Right/Left Side Covers. 19. Remove the black plastic plug located at the bottom and inside rear of the imagesetter. 20. Open the lower right panel on the buffer by pulling the panel straight out (see Figure 1-4).
Section III: Buffer 21. Press the gasket membrane provided (see Figure 1-5) onto the buffer at the harness hole. Refer to Figure 1-15. The harness hole is located on the right hand side of the buffer at the front and near the bottom. 1 Figure 1-15 Routing the buffer harness cable through hole (right, bottom, inside front). ➀–Wire bundle. 22. Route the wire bundle through the rubber gasket and into the imagesetter. Refer to Figure 1-15.
Avantra 36/44 Service Manual 23. Plug the wires into the buffer/imagesetter interface board at the four points shown in Figure 1-16. 1 6 2 4 3 5 Figure 1-16 Attaching the buffer wires to the buffer/imagesetter interface board. ➀–Buffer to Imagesetter harness opening. ➁–Connector. ➂–Connector. ➃–Connector. ➄–Connector. ➅–Interface board. NOTE: See the Avantra 36/44 OLP Service Manual, for the OLP attachment procedures and for attaching the anti-static wire.
Section III: Buffer 1.2.4 Aligning the Buffer Carriage This procedure is performed after the buffer is attached to the imagesetter. 1. Remove the buffer top cover. 2. Bring the carriage to the front (toward the imagesetter) of the buffer. Hold the carriage tightly against the frame. If both ends of the carriage are flush against the frame, nothing else is required. If the carriage is not flush, go to Step 3. 3. For older buffers: a.
Avantra 36/44 Service Manual For newer buffers: b. The braces will have access holes and will not need to be removed. Refer to Figure 1-18. 1 2 Figure 1-18 Newer buffer brace. ➀–End brace. ➁–Access holes to alignment screws.
Section III: Buffer 4. Loosen the eight (8) adjustment screws, four (4) on each side, at the top of the rail bearing block. Refer to Figure 1-19. 2 3 1 Figure 1-19 Buffer carriage adjustment screws. ➀–Access holes in braces. ➁–Adjustment screws, four on each end. ➂–Buffer carriage (move to the front for adjustment). 5. Straighten the carriage so that it is flush with the frame and tighten the adjustment screws.
Chapter 2: Buffer Component Removal/ Replacement 2.1 Introduction This chapter describes the procedures for removing and replacing components in the Avantra 36/44 buffer.
Avantra 36/44 Service Manual 2.2 Buffer Home and Buffer Processor Sensors The following describes how to remove and replace the home and/or buffer processor sensors. Tools Required: 1/4" open end wrench Remove: 1. Remove the top cover from the buffer. 2. Disconnect the connector(s) from the sensor(s). Refer to Figure 2-1 for identification. 3. Remove the 1/4" hex nuts securing the sensors. 1 2 3 Figure 2-1 Buffer sensors and flags. ➀–Sensor flags.
Section III: Buffer Replace: 1. Reverse the procedures above. CAUTION: When replacing the sensors, make sure that the flags enter the sensors at the correct point. Refer to Figure 2-2. 2.3 Buffer Purchase Sensor The following describes how to remove and replace the purchase sensor. Tools Required: 1/4" open end wrench Remove: 1. Remove the top cover from the buffer. 2. Disconnect the connector from the sensor. Refer to Figure 2-2. 3. Remove the two (2) 1/4" hex nuts securing the sensor.
Avantra 36/44 Service Manual 2.4 Buffer Carriage Drive Motor The following describes how to remove and replace the buffer carriage drive motor. Tools Required: 1/4" open end wrench Remove: 1. Remove the top cover from the buffer. 2. Remove the four (4) screws from the brace located in the top center of the buffer. Refer to Figure 2-3. 1 2 3 4 1 Figure 2-3 Carriage drive motor cover. ➀–Four cover mounting screws. ➁–Carriage drive motor cover. ➂–Carriage drive motor. ➃–Lead screw. 3.
Section III: Buffer 2 1 3 4 5 Figure 2-4 Buffer carriage drive motor. ➀–Motor mounting screws. ➁–Lead screw. ➂–Buffer carriage drive motor. ➃–Electrical connector. ➄–Electrical wiring P-clips. Replace: 1. 2.5 Reverse the procedures above. Buffer Roller Driver Motor The following describes how to remove and replace the buffer roller driver motor. Tools Required: 1/4" open end wrench Remove: 1. Remove the top cover from the buffer. 2. Remove the top side panels. 3.
Avantra 36/44 Service Manual 1 2 3 4 5 6 Figure 2-5 Buffer roller drive motor. ➀–Buffer carriage. ➁–Buffer roller drive motor. ➂–Screws securing motor (two each side). ➃–Three motor mounting screws. ➄–Drive motor allen screw. ➅–Drive gear. 4. Pull the encoder plug from the motor. 5. Remove the four (4) 1/4" screws, two (2) on each side, securing the motor. Refer to Figure 2-5. 6. Cut the tie wrap holding the wires to the motor. 7.
Section III: Buffer Replace: 1. Reverse the removal procedures above. 2. When re-attaching the motor gear, make sure that it matches up correctly with the roller gear. Using your fingers, spin the roller to check that the two gears mesh.
Appendix A Spare Parts Buffer 066486-005 Motor, servo 067338-001 Motor, stepper & shaft 066721-002 Sensor, buffer entrance 066271-002 Sensor, buffer purchase 066719-001 Sensor, buffer home/proc.
Index A Access Panels, Imagesetter 1-12 Accessory Kit, Imagesetter 1-10 Aligning Bridge and Extension Platen 1-13 Aligning the Buffer Carriage 1-19 Alignment Holes bridge 1-14 imagesetter 1-13 labels 1-14 light leakage 1-14 Alignment Pins 1-13 Alignment Pins, Platen 1-13 B Bridge alignment holes 1-14 Buffer adjustable leg 1-15 gasket 1-17 installation procedures 1-2 leg adjustment screws 1-15 outriggers 1-4 pallet bolts 1-4 platen 1-9 side panels 1-5 unlocking 1-6 unlocking kit 1-6 unpacking 1-2 Buffer Car
Avantra 36/44 Service Manual buffer processor 2-2 buffer purchase 2-3 Side Panels 1-5 U Unlocking buffer carriage 1-7 buffer input platen 1-9 carriage lock bolts 1-7 plastic plugs 1-8 Unlocking Kit, Buffer 1-6 Unlocking the Buffer 1-6 Unpacking the Buffer 1-2 I-2 Index
Section IV: On-line Processor
Chapter 1: OLP Installation 1.1 Introduction This chapter provides information for unpacking, assembling and installing the Avantra 36/44 On-Line Processor (OLP). Also described here are the electrical, plumbing, and other physical requirements.
Avantra 36/44 Service Manual 1.2 OLP Work Space Requirements 1.2.1 Space OLP Dimensions Width: 61" (154.94 cm) Height: 54" (137.16 cm) with stand Length: 66" (167.64 cm) excluding receiver tray 98" (248.92 cm) including receiver tray, roll mat. 120" (304.80 cm) including receiver tray, sheet mat Buffer Dimensions Width: 61" (24 cm) Height: 54" (21.25 cm) Length: 15" (6 cm) Imagesetter Dimensions Width: 73" (29 cm) Height: 48" (19 cm) Length: 35" (14 cm) 1.2.
Section IV: On-line Processor Imagesetter Electrical Volts: 115/230 Amp: 5 / 2.5 Rec: NEMA 5-20R Power: 575 Watts 1.2.4 Operational OLP Water Requirements Water connection: 3/4" BSP (0.3-10 bar, max. temp. 110˚ /43˚C) Drain: 5.3 US Gal. (3 x Ø25 mm, 3 x 20 L/min) Water consumption: 0.5 US Gal. (0-2 L/min) 1.3 OLP Unpacking Procedures 1.3.1 Tools Required for OLP Unpacking • Crowbar • Claw hammer • Strap cutters 1.3.2 OLP Inventory The Avantra 36/44 OLP arrives in two crates.
Avantra 36/44 Service Manual 11. Left lower door 12. Legs 13. Cover for entrance rack 14. Lower front cover for entrance rack (1 of 2) 15. Lower front cover for entrance rack (2 of 2) 16. Inner cover for entrance rack (under top cover) 17. Panel between imagesetter and OLP 18. Top cover (rear) 19. Chemistry trolley 20. Drip tray (1 of 2) 21. Rack drip tray 22. Filter parts, chemical bottle covers, etc 23. Fixer rack 24. Developer rack 25. Wash rack 26. Developer/fixer crossover guide 27.
Section IV: On-line Processor 1 2 1 2 Parts Container Engine Container Figure 1-1 OLP shipping crates. ➀–Parts crate (open first). ➁–Engine crate. 1.3.3 Opening and Unpacking the Parts Crate Steps: 1. Take the pallet with both crates to the site where the OLP is to be installed. If this is not possible, unpack, remove, and transport the parts according to the followings steps. 2. Using strap cutters, cut the straps from around the wooden crate. 3. Using a crowbar and claw hammer, open the crate.
Avantra 36/44 Service Manual 2 1 4 3 6 5 8 7 10 9 12 11 14 16 13 15 17 18 19 20 22 21 29 28 26 23 30 24 25 27 Figure 1-2 OLP parts inventory. ➀–➁–Receiver basket (two parts). ➂–Rear exit panel (bottom). ➃–Middle top cover. ➄–rear exit panel (top). ➅–rear lower panel. ➆–rear top side panel. ➇–Front top side panel (control). ➈–Evaporation cover. ➉–Right lower door. 11–Left lower door. 12–Legs. 13–Forward top cover.14– 15–Lower front covers for entrance rack (2).
Section IV: On-line Processor CAUTION: The rack assemblies and legs are heavy and should be transported through mechanical means. 5. Load the three (3) cardboard boxes containing the racks onto a separate pallet. Cover the boxes with cardboard. Figure 1-3 Rack boxes. 6. Load the legs on top of the cardboard and with a forklift take the pallet to the installation site. Figure 1-4 OLP legs.
Avantra 36/44 Service Manual 1.3.4 Unpacking and Preparing the OLP Engine 1. Take the pallet with the engine crate to the site where the OLP is to be installed. If this is not possible, unpack, remove, and transport the OLP engine according to the followings steps. 2. Using strap cutters, cut the straps from around the wooden crate. 3. Using a crowbar and claw hammer, open the crate. 4. Remove the cardboard cover and the plastic cover. 1 2 Figure 1-5 Engine crate. ➀–Bottom shipping crate.
Section IV: On-line Processor 5. At the front of the engine, remove the roller and bearing on top. Refer to Figure 1-6. 6. At the rear of the engine tape the door securely to the frame. Refer to Figure 1-6. 1 2 Figure 1-6 Engine lid and roller. ➀–Lid (tape before moving engine). ➁–Roller (remove before moving).
Avantra 36/44 Service Manual 7. Using a phillips head screwdriver, remove the two (2) open-door sensors located on the side of the engine and tape them to the inside of the frame. Refer to Figure 1-7. 8. Using a phillips head screwdriver, remove the chimney (with fan attached) and tape them to the inside of the frame. Refer to Figure 1-7. 1 2 Figure 1-7 Open-door sensors and fan. ➀–Sensor (1 of 2) with screws. ➁–Fan attached to chimney.
Section IV: On-line Processor 9. Using an open ended wrench, remove the four (4) shipping standoffs securing the OLP engine frame to the bottom of the crate. The standoffs are located at the four corners of the frame. Refer to Figure 1-8. 1 2 Figure 1-8 Standoffs. ➀–Bottom of crate. ➁–Shipping standoff (1 of 4).
Avantra 36/44 Service Manual 10. Position two (2) dollies against the bottom of the crate. Block the wheels then tip the OLP engine onto its side and lift onto the dollies. Refer to Figure 1-9. WARNING: Always use proper back support belts when lifting heavy weights (see Figure 1-10). 1 2 Figure 1-9 Engine assembly loaded on dollies. ➀–Engine assembly. ➁–Transport dollies. 11. Bring the engine to the installation site.
Section IV: On-line Processor 1.4 Installation Procedures 1.5 Tools and Equipment Required for Installation The following tools and equipment are required to perform installation, set-up, and checkout of the processor. • Digital Voltmeter (DVM) • Phillips and slotted-head screwdrivers • Level • Darkroom thermometer (long barrel, non-mercury type) • Adjustable open-end wrench • 500 ml graduate 1.5.
Avantra 36/44 Service Manual 3. Attach the leveler feet to the top two (2) legs only. Refer to Figure 1-10 and Figure 1-11. WARNING: Use two people for tipping the engine (next step). 4. Tip the OLP engine right side up. Rest the legs on a block and install the remaining two (2) leveler feet. Refer to Figure 1-10 and Figure 1-11. WARNING: Always use proper back support belts when lifting heavy weights (see Figure 1-10). 5. Reattach the sensors to the side of the frame (see Figure 1-7). 6.
Section IV: On-line Processor 1 2 3 4 Figure 1-11 Assembling the legs, brace and leveler feet. ➀–Support leg. ➁–Two hex screws. ➂–Stabilizer brace. ➃–Rear leveler feet (block legs and attach these last). 1.5.2 Connecting the Water Supply and Drainage CAUTION: To ensure sufficient rinsing of the media after developing and fixing, the processor must be connected to temperate wash water. The water temperature must not exceed 110°F (43°C), and the water pressure must be 0.3 bar to 10 bar.
Avantra 36/44 Service Manual Water Connection 3/4" BSP (0.3-10 bar, max. temp. 43°C/110°F) Drain 3 x Ø25 mm, 3 x 20 L/min. (5.3 US Gal.) Water Consumption 0-2 L/min. (1/2 US Gal.) Tank Capacity, developer 14.3 L (3.8 US Gal.) Tank Capacity, fixer 13 L (3.5 US Gal.) Tank Capacity, water 11.5 L (3 US Gal.
Section IV: On-line Processor ➀ Figure 1-12 Interface cable. ➀–Interface cable. 5. Connect the RJ45 satin cable to the closest port in the OCP. 6. Connect the two cables together, using the RJ45 to DB9 adapter. 7. Check that the cable does not interfere with other components when closing the cabinet doors. 1.5.3 Connecting The Electrical Supply CAUTION: Electrical connections and sources must comply with local electrical codes.
Avantra 36/44 Service Manual Before connecting the processor to the local electrical power source, determine whether the unit requires any internal wiring modifications. Processor input wiring connections are located in the electronics compartment beneath the dryer section. Power Transformer Primary Tap Connections The power transformer, located near the power triacs, has three alternate primary tap connections to accomodate variations in the ac supply voltage. Refer to Figure 1-13.
Section IV: On-line Processor 400±415V 3 N FUSE AMP 6.3 13.0/ L3 13.0 10 10 3 400±415 VAC 2.2/ L2 6.4 0/ 9.9 2 15 F6 F106 F5 F4 F104 F3 F103 1 F2 F102 F1 F101 230±240 VAC N 2 F105 400±415 VAC L1 50/60HZ 101 102 103 104 105 106 N3 4 N2 N1 N4 208±240V SINGLE PH FUSE AMP L2 50/60HZ 101 102 103 104 105 106 10 10 15.2/ 29.3 15 10 15 10 L1 F3 F103 15.2/ 29.3 F2 F102 1 230±240V N L1 10 15.2/ 29.
Avantra 36/44 Service Manual 1.5.4 Leveling and Attaching the OLP to the Buffer 1. For side-to-side leveling, use a spirit level across the top of the divider walls of the developer and fixer tank. 2. For front to back leveling, use the spirit level along the top of the tank side walls. 3. Attach the front panel. Refer to Figure 1-15. 1 3 5 4 2 Figure 1-15 Attaching covers and panels to the OLP. ➀–Front left vent cover. ➁– Front right vent cover. ➂–Lower rear panel. ➃–Left side panel.
Section IV: On-line Processor 5. Remove the upper entry platen from the entrance rack. Refer to Figure 1-16. 6. Roll the imagesetter with the buffer attached to the OLP. The buffer and OLP must interface as shown in Figure 1-16. 2 1 4 3 Figure 1-16 The buffer and OLP interface. ➀–Buffer interface. ➁– OLP front plate. ➂–Lower platen of entry rack. ➃–Upper platen (removed during the interface alignment).
Avantra 36/44 Service Manual 7. If the interface is off, follow these steps. With the imagesetter/buffer and OLP in close proximity, measure the distance from the floor to the buffer exit platen and the floor to the OLP entrance platen. Refer to Figure 1-17. 1 Figure 1-17 2 Measuring from the floor to the platen for correct OLP To Buffer Alignment. ➀–OLP entrance platen. ➁–Buffer exit platen.
Section IV: On-line Processor 8. Raise or lower the OLP and/or buffer leveling feet at the bottom until the platens align. Refer to Figure 1-18. 9. Push the buffer (attached to the imagesetter) flush against the OLP. 10. Lower the feet at the front of the imagesetter to hold the imagesetter/buffer assembly tightly against the OLP. 5 1 2 4 3 Figure 1-18 Adjusting the buffer legs for buffer to OLP alignment. ➀–OLP ➁– Adjustable leg. ➂–Buffer. ➃–Imagesetter ➄–Leg adjustment screw.
Avantra 36/44 Service Manual 1.5.5 Attaching the Panels and Covers 1. Using phillips head screws and washers, attach the side covers (one [1] on each side) to the front of the OLP engine. Refer to Figure 1-19. 2. Attach the lower rear panel. Refer to Figure 1-19. 3. Attach the left side panel (bottom). Refer to Figure 1-19. 1 3 4 2 Figure 1-19 Front, rear and side panels. ➀–Front left side cover. ➁–Front right side cover. ➂–Lower rear panel. ➃–Left side panel (bottom). 4.
Section IV: On-line Processor 5. Attach the top side panel to the left side of the frame. Refer to Figure 1-20. 6. Attach the striker plate to the right side of the frame. Refer to Figure 1-20. 7. Attach the left lower door (hinged) to the right side of the frame. Refer to Figure 1-20. 8. Attach the right lower door (hinged) to the right side of the frame. Refer to Figure 1-20. 1 3 2 4 Figure 1-20 Side covers, striker plate, doors for right side. ➀–Top left side panel. ➁–Bottom left side panel.
Avantra 36/44 Service Manual 9. Remove the tape from the door at the top of the engine (see Figure 1-6). Remove the foam from the dryer section. 10. Place the drip tray, trolley and fluid containers under the OLP. Refer to Figure 1-21. 3 2 1 Figure 1-21 Placing the drip tray, chemistry trolley and fluid containers. ➀–Drip tray. ➁–Chemistry trolley. ➂–Fluid containers. 11.
Section IV: On-line Processor 12. Inspect each of the three roller rack assemblies. Check that the gears mesh properly and operate smoothly when turned manually. CAUTION: Installing the racks (in the next step) requires two people unless the crane is installed. If two people are not available at this step in the installation, see The Avantra 36/44 Crane Service Manual, Chapter 1, Installing the Crane. 13. Put the racks in in the following order: a. developer b. fixer c. wash Refer to Figure 1-22.
Avantra 36/44 Service Manual 4. Replace the roller and bearing at the top front of the engine. Refer to Figure 1-23. 5. Check for a proper mesh between the main drive worm gears and the corresponding gears on each rack. 2 1 Figure 1-23 Replacing the roller. ➀–Right side cover. ➁–Roller (replace). 6. Plug in the power cord at the rear of the engine. 7. Attach the back panel.
Section IV: On-line Processor 8. Attach the basket (2 parts) at the rear. Refer to Figure 1-24. 1 2 Figure 1-24 Rear panel and media basket. ➀–Rear panel. ➁–Media basket assembly. 26. Put in the two (2) crossovers.
Avantra 36/44 Service Manual 27. Install the filter housing for the developer without the cartridge installed. Rinse each tank thoroughly with water. Put in the color coded overflow tubes in each tank, as follows: • Red for developer • Blue for fixer • Grey for water Refer to Figure 1-25. 1 2 Figure 1-25 Overflow supports and tubes. ➀–Overflow supports. ➁–Overflow tubes. 28. Check that the overflow tubes are secure by tightening with a T-wrench. 29. Re-tighten all hose clamps. 30.
Section IV: On-line Processor 32. Partially fill the replenishment containers with water and insert the replenishment hoses and level sensors. 33. Set the main power switch to on. 34. Turn on the main water supply valve. 35. Turn on the processor. 36. Check that the circulation pumps operate and that all air is expelled from the pumps and hoses. CAUTION: Do not allow circulation or replenishment pumps to run dry at any time or pumps may be damaged. 37.
Avantra 36/44 Service Manual 46. Drain and remove the developer filter housing. 47. Install the Millipore Filter Cartridge supplied and re-install the housing. 48. Empty the replenishment containers. 49. Replace the overflow tubes, racks, crossover guides, and lids. 50. Put in the two (2) anti-evaporation covers (stainless steel) inside the racks. Next place the front cover and the two (2) anti-oxidation covers. Refer to Figure 1-26.
Section IV: On-line Processor 51. Put in the middle and rear anti-oxidation covers (plastic) over the racks. Refer to Figure 1-27. 1 2 Figure 1-27 Evaporation covers over racks. ➀–Middle evaporation cover (over fixer). ➁–Developer.
Avantra 36/44 Service Manual 52. Put the Top Covers on in the following order: • middle • forward (front) • rear Refer to Figure 1-28. 1 2 2 Figure 1-28 Top covers. ➀–Forward (front) top cover. ➁–Middle top cover. ➂–Rear top cover.
Chapter 2: OLP Functional Analysis 2.1 Introduction This chapter describes the OLP’s boot-up procedures (including the system modes), OLP electronics (including the boards and sensors), OLP racks (including the methods of replenishment).
Avantra 36/44 Service Manual 2.2 Description of OLP Boot-up Procedures Immediately after the main switch has been turned on and the OLP has power, an internal communication takes place between the individual circuit boards and various code signals display on the OCP. When information ceases to be displayed, the OLP automatically switches to standby mode. 2.2.1 OLP Standby Mode While in standby mode, the OLP will be in the following modes: 1. Jog 2. Standby replenishment 3. Topping-up 2.2.
Section IV: On-line Processor When material passes through the OLP, or when Man Start is deactivated the OLP switches to: • Ready Mode--if all preset parameters are met • Idle Mode--if the developer temperature is incorrect • Low Level Mode--if the solution level is low When the level is too low in either or both the developer and fixer tank, a halt message goes to the imagesetter, no media transports.
Avantra 36/44 Service Manual 2.3.1.1 LCB Inputs and Outputs Inputs and outputs include: • Digital input and output • Analog input Description of LCB Inputs and Outputs • X501, Input sensors, safety switches (only for OLP input and output sensors and cassette sensor). Digital input. (active state = high).
Section IV: On-line Processor • X600–Power supply input 10V AC and 18V AC from the secd. of the transformer. • X400, RS-232 ATB–Data communication link between the LCB pcb and the Agfa Terminal Board (ATB) power supply. Connections: -1/2 connected to the ATB L3-1 and L3-2 serial data codes -3 connected to the ATB L3-3 12V DC -4 connected to the ATB L3-4 ground -5 connected to the ATB L3-5 18V AC • X402, RS-232 OLP Com.
Avantra 36/44 Service Manual • X1, X2–Input to trigger circuit (plug-in unit) of Triac channels and coils of power relays. • X3 pins 1 and 2–10 VAC input for 12 VDC unregulated power supply. • X3 pins 3 to 4–DC output (12 V) to electrical and condensation fans. • X2–Safety switches connection. Open=> no power to trigger circuit and relay coils. • F, N (Phase, Neutral) Same as L1/L2–See the electrical diagram Triac/Relay PCB. Main power input terminals.
Section IV: On-line Processor • X1, X2, X3 and X7 input to trigger the circuit of the triac channels and coils of power relays and 12V supply. See below. • X1: -l 12V DC connected to the LCB pcb X200 -212/22 -2 from X200-10 input to K11 (circ. pumps) -3 from X200-11 input to K10 (Aqua stop sol) -4 from X200-1 input to K9 (fix, repl. pump) -5 from X200-2 input to K8 (dev, repl. pump) -6 from X200-3 input to K7 (dryer, fan, basic heat) -7 (not used) -8 from X200-5 input to Q3 (1500W fix.
Avantra 36/44 Service Manual 2.3.3 The LUTH Motor Board (LMB) The Luth Motor Board (LMB): • Amplifies the motor preset value to the corresponding high voltage to drive the main motor. • Senses and limits the armature current. • Receives and converts I/R pulse preset values. Description of Inputs and Outputs (P/N 52024000100) • X102 1, 2–24V AC input. • X102 5, 6–0-24 DC output. • X1 1, 2, 3–Optical interrupter. • X3 1, 2–Tacho feedback to CPU. • U201–Infrared receiver.
Section IV: On-line Processor 2.4 OLP Racks Transport takes place through seperate sections called racks. They are the: • Developer • Fixer • Wash and dryer The racks are the most important parts of the processor. Each rack consists of side plates with rollers driven by worms and gears to ensure an even and stable transport. 2.4.1 Temperature Control The temperature of the developer and fixer baths are controlled electronically to obtain optimum developing results.
Avantra 36/44 Service Manual Since the amount of chemicals pumped into the tanks is always 100 cc, the system automatically calculates the time interval between each pulse as 100 cc x 24 hours divided by the preset value: Interval Time = 100 cc x 24 hours Preset oxy stdb replenishment value = hours All calculations base on a 50% density. Consequently, the basis of all values displayed is 50% density. 2.4.2.
Chapter 3: OLP Component Removal/ Replacement 3.1 Introduction This chapter provides instruction for removing and replacing components in the Avantra 36/44 On-Line Processor (OLP).
Avantra 36/44 Service Manual 3.2 Drive Motor The following describes how to remove and replace the drive motor. Tools Required: Phillips screwdriver, 13mm socket and ratchet wrench Remove: 1. Turn off and unplug the OLP. 2. Remove the side panel at the top left. 3. Using a phillips screwdriver, remove the bracket with the encoder sensor/ sensor connector attached. Refer to Figure 3-1. 1 2 8 3 4 5 9 6 7 Figure 3-1 The drive motor. ➀– Drive wheel set screw. ➁–Drive wheel. ➂–Drive belt. ➃–Idler.
Section IV: On-line Processor 4. Disconnect the two (2) power connectors (M1 and M2). Refer to Figure 3-1. NOTE: Note the position of the power connectors for replacement. 5. Using a phillips screwdriver, remove the encoder disk at the end of the shaft. Refer to Figure 3-1. 6. Remove the set screw from the belt wheel. 7. Loosen the three (3) mounting bolts (near the encoder disk). Refer to Figure 3-1. 8. Lift the belt from the idler and remove the idler’s securing bolt. Refer to Figure 3-1. 9.
Avantra 36/44 Service Manual 3.3 CPU-OLP The following describes how to remove and replace the OLP central processing unit (CPU). Tools Required: Phillips screwdriver, 1/4" nut driver Remove: 1. Turn off and unplug the OLP. 2. Remove the top covers. 3. Remove the top back panel. 4. Pull the electronics box straight out on its rollers. 5. Remove the seven cable plugs at the rear of the box. Refer to Figure 3-2. 6. Remove all fourteen (14) standoffs at the rear of the box. Refer to Figure 3-2.
Section IV: On-line Processor 7. Using a phillips screwdriver, remove the four (4) hinge screws at the rear of the box. Remove the four central screws only. Refer to Figure 3-3. 1 2 Figure 3-3 Electronics box rear screws. ➀– Electronics box. ➁–Four rear screws.
Avantra 36/44 Service Manual 8. Using a phillips screwdriver, remove the four (4) screws on the top and the two (2) screws on each side of the box. Refer to Figure 3-4. 9. Open the top of the box and disconnect the: a. Low voltage CPU power connector b. Power board cable Refer to Figure 3-4. 1 2 1 3 Figure 3-4 Electronics box side/top screws and power cables. ➀–Side screws. ➁–Four top screws. ➂–Low voltage and CPU power cables.
Section IV: On-line Processor 10. Remove the three (3) phillips screws securing the inner cover. Refer to Figure 3-5. 11. Remove the six (6) standoffs at the rear. Refer to Figure 3-5. Remove the cover. 3 1 2 Figure 3-5 CPU cover screws and standoffs. ➀–Three CPU cover screws. ➁–CPU cover. ➂–Six standoffs.
Avantra 36/44 Service Manual 12. Remove the CPU fuse connectors from the PCB. Refer to Figure 3-6. NOTE: The fuse connectors can be replaced in any order. 13. Remove the three (3) mounting screws. Refer to Figure 3-6. 1 2 3 4 5 6 7 Figure 3-6 The CPU board with fuse connectors and mounting screws. ➀–Low voltage connector. ➁–Power cable connector. ➂–Lithium battery. ➃–Fahrenheit/Centigrade jumper. ➄–EEPROM. ➅–CPU fuse connectors. ➆–Three mounting screws. Replace: 1.
Section IV: On-line Processor 3.4 LUTH Motor Control Board The following describes how to remove and replace the motor control board. Tools Required: Phillips screwdriver, needle-nose pliars Remove: 1. See the removal procedures in Section 3.3, CPU-OLP for exposing the board. 2. Remove the connectors at X5 and X7. Refer to Figure 3-7. 3. Remove the connectors at X6 and X2. Refer to Figure 3-7. NOTE: Note the position of the power connectors for replacement. 4.
Avantra 36/44 Service Manual Replace: 1. Do not clean the silicon off the back of the chassis. 2. Reverse the order of the removal steps above, being careful to reattach the connectors into their proper plugs. 3. When the board is in place, make sure that the LED is in proper alignment with the CPU LED. Refer to Figure 3-7. 4. Check the jumper settings. Refer to Chapter 4, OLP Maintenance. 5. Perform the motor speed calibration. Refer to Chapter 4, OLP Maintenance. 3.
Section IV: On-line Processor 1 2 3 4 5 Figure 3-8 LUTH rectifier board (LRB). ➀–Four nylon standoffs. ➁–Terminal block. ➂–LRB board. ➃–Terminal block. ➄–Fuse. Replace: 1. Reverse the steps in the removal procedure above. CAUTION: Be careful to return the wires to their proper places in the terminal blocks. 3.6 Power Board The following describes how to remove and replace the power board. Tools Required: Phillips screwdriver, small flathead screwdriver Remove: 1.
Avantra 36/44 Service Manual 2. Remove the plastic cover plate. Refer to Figure 3-9. 2 3 1 4 Figure 3-9 Electronics box with power board. ➀–Terminal blocks. ➁–Plastic cover. ➂–Electronics box. ➃–Power board. 3. Remove the connectors at: a. X3 (red, brown) b. X7 (pink, gray) c. X1 (main connector) d. X2 (red/brown, white) Refer to Figure 3-10. Note the wire colors for proper replacement.
Section IV: On-line Processor 2 1 3 4 5 6 7 Figure 3-10 Power board. ➀–Terminal strips. ➁–Power board. ➂–Mounting screws. ➃–X3 connector. ➄–X7 connector. ➅–X1 connector. ➆–X2 connector. 4. Using a small flathead screwdriver, remove the high voltage connectors from the terminal blocks. Refer to Figure 3-10. Note the wire labeling for proper replacement. 5. Using a phillips screwdriver, remove the four (4) mounting screws, one at each corner. Refer to Figure 3-10. Remove the board. Replace: 1.
Avantra 36/44 Service Manual 3.7 Circulation Pump The following describes how to remove and replace the circulation pump. Tools Required: Flathead screwdriver, open end wrench Remove: 1. Turn off and unplug the OLP. 2. Remove the top and side covers. 3. Drain the tank. CAUTION: Even with the tanks drained, chemistry will remain in the hose connections. Wear rubber gloves and have rags ready for spillage before proceeding to the next step. 4.
Section IV: On-line Processor 6. Using an open end wrench, remove the nuts in the mounting plate. Refer to Figure 3-11. Replace: 1. 3.8 Reverse the steps in the removal procedure above. Developer or Fixer Replenishment Pumps The following describes how to remove and replace the replenishment pumps. Tools Required: Socket wrench (7 mm) Remove: 1. Turn off and unplug the OLP. 2. Remove the top and side covers. CAUTION: Even with the tanks drained, chemistry will remain in the hose connections.
Avantra 36/44 Service Manual 1 2 3 Figure 3-12 The fixer pump. ➀–Fixer replenishment pump. ➁–Electrical connection. ➂–Mounting block. 1 2 3 Figure 3-13 The Developer Pump. ➀–Developer pump. ➁–Power wires. ➂–Mounting block.
Section IV: On-line Processor 3.9 Heating Element The following describes how to remove and replace the heating element. Tools Required: Adjustable open end wrench Remove: 1. Turn off and unplug the OLP. 2. Remove the top and side covers. 3. Drain the tank. 4. Follow the red, white, green/yellow power wires (electrical connection) to the terminal block and disconnect. Refer to Figure 3-14. Note the wire positioning for proper replacement. 5. Loosen the PVC nut on the outside of the tank.
Avantra 36/44 Service Manual Replace: 1. Insert the element and make certain that the O-ring is flush with the PVC nut before tightening. . CAUTION: Do not over tighten the PVC nut. 2. Reconnect the wires in their proper positions in the terminal block. 3. Refill the tank with water and check for leaks. 4. Reverse Steps 2 and 1 in the removal procedure above. 3.10 Wet Section Temperature Sensor The following describes how to remove and replace the temperature sensor.
Section IV: On-line Processor 6. Pull the cover from the chamber harness and disconnect the connector. Replace: 1. Reverse the removal procedure above being careful that the distance between the tank wall and the tip of the sensor does not exceed 1". Refer to Figure 3-15. 3.11 Dryer Section Temperature Sensor 1. Turn off and unplug the OLP. 2. Remove the top covers. 3. Remove the top back panel. 4. Pull the electronics box straight out on its rollers (see Figure 3-2). 5.
Avantra 36/44 Service Manual Replace: 1. Reverse the removal procedure above. NOTE: Unlike the wet section temperature sensor, the depth of insertion in not important. 3.12 Dryer Blower Motor Assembly 3.12.1 Dryer Heater Element The following describes how to remove and replace the dryer heater element. Tools Required: Tie cutters, phillips screwdriver Remove: 1. Turn off and unplug the OLP. 2. Remove the top covers and left side panel. 3.
Section IV: On-line Processor 1 2 3 2 Figure 3-17 Dryer heater element front plate. ➀–Tie wrap/mounting screw fixture. ➁–Dryer element mounting screws. ➂–Grounding wire.
Avantra 36/44 Service Manual 1 2 4 3 Figure 3-18 Dryer assembly (from the rear). ➀–Dryer assembly. ➁–Element mounting screws. ➂–Rear element mounting bolts. ➃–Dryer element. 7. From the rear, remove the two (2) element mounting bolts. Refer to Figure 3-18. 8. From the front, remove the two (2) element mounting screws. Refer to Figure 3-18. 9. Using a small flathead screwdriver, remove the three (3) corresponding wires from the terminal block at the front of the plate. Refer to Figure 3-17.
Section IV: On-line Processor 3.12.2 Dryer Blower The following describes how to remove and replace the dryer blower. Tools Required: Tie cutters, phillips screwdriver Remove: 1. Turn off and unplug the OLP. 2. Remove the top covers and left side panel. 3. Open up the upper half of the dryer section. 4. Remove the heating elements. See the removal procedure in Section 3.12, Dryer Blower Motor Assembly above. 5. Remove the two (2) screws at the top of the dryer/blower unit. Refer to Figure 3-19.
Avantra 36/44 Service Manual 2 1 3 4 5 6 7 Figure 3-19 Dryer blower. ➀–Sensor. ➁–Top screws. ➂–Dryer/blower unit. ➃–Dryer heating elements. ➄–Left side screws/electrical connections. ➅–Terminal block. ➆–Right side screws.
Section IV: On-line Processor 8. Remove the wires in the terminal block located on the left side of the housing: a. #1 b. #3 c. #2 d. #4 (green/yellow ground wire) Refer to Figure 3-20. CAUTION: Note the numbering of the wires for proper replacement. Remove the two (2) screws in the terminal block. Refer to Figure 3-20. 9. Remove the two (2) blower mount screws and pull the housing out. 1 1 3 2 4 2 3 Figure 3-20 Dryer blower assembly. ➀–Blower/dryer assembly. ➁–Terminal block.
Avantra 36/44 Service Manual Replace: 1. Detach the duct from the old blower and attach it to the new blower. 2. Reverse the order of the removal procedures above being careful to seat the wires in their proper places. 3.13 Entry Rack Assembly 3.13.1 Drive Belt The following describes how to remove and replace the entry rack drive belt. Tools Required: Tie cutters, phillips screwdriver, 10mm wrench Remove: 1. Turn off and unplug the OLP. 2. Remove the top covers. 3. Remove the side covers. 4.
Section IV: On-line Processor Replace: 1. Loosen the entry drive idler. 2. Place the new belt over the belt wheel. 3. Reverse Steps 4 and 5 above. 4. Replace the tension belt with idler and tighten. CAUTION: Do not over tighten the belt. 3.13.2 Drive Shaft 1. Remove the entry rack drive belt. See Section 3.13.1, Drive Belt above. 2. Remove the allen set screw from the belt wheel. 3. Remove all three racks. 4. Loosen the three drive motor mounting bolts to loosen the belt.
Avantra 36/44 Service Manual 5. Remove the allen set screw from the belt wheel. Refer to Figure 3-22. 6. Remove the three (3) J-hooks (two at the center, one at the rear). Refer to Figure 3-23 and Figure 3-24. 7. Using a 10mm wrench, remove the bolts from the three (3) bearing brackets (located at the front, center and rear). Lift the drive shaft back and out. Refer to Figure 3-22, Figure 3-23, and Figure 3-24. 1 2 Figure 3-23 Bearing bracket and J-hooks. ➀–Bearing bracket (center).
Section IV: On-line Processor 1 2 Figure 3-24 Bearing block and J-hook. ➀–Bearing bracket (rear). ➁–J-hook (rear). Replace: 1. Reattach the three (3) bearing brackets. Do not tighten the bolts. 2. Replace the racks. 3. Raise the drive at the back and front until the worm gears and drive gears are properly meshed. 4. Check that the fix worm gear is not deflecting the shaft. Adjust as required. 5. Tighten all three bearing bracket bolts. CAUTION: Do not over tighten bolts.
Chapter 4: OLP Maintenance 4.1 Introduction This chapter provides instructions for maintaining the Avantra 36/44 On-Line Processor (OLP).
Avantra 36/44 Service Manual 4.2 Servicing 4.2.1 Checking Sensor Operation When reading the following procedures, refer to the low voltage wiring diagram. 4.2.1.1 1. Optical Interrupter Check the +5 V supply. Connect the DVM between P31,4 (common) and P31,2 (+). Reading should be 4.75 to 5.25 V DC. 2. Check the supply to the transmitter. Connect the DVM between P31,4 (common) and P 31,3 (supply) of the optical interrupter. Reading should be 1.7 to 1.9 DC. 3.
Section IV: On-line Processor Checking Temperatures Below are some examples of the correlation between temperature and resistance: 21°F (-6.1°C) = 540.4 ohm 30°F (-1.1°C) = 557.8 ohm 32°F (0.0°C) = 561.6 ohm 34°F (1.1°C) = 566.5 ohm 35°F (1.7°C) = 569.3 ohm 38°F (3.3°C) = 573.2 ohm 40°F (4.4°C) = 577.0 ohm 42°F (5.6°C) = 580.9 ohm 45°F (7.2°C) = 586.6 ohm 50°F (10.0°C) = 596.3 ohm 55°F (12.8°C) = 605.9 ohm 60°F (15.6°C) = 615.5 ohm NOTE: If temperatures in the bath are incorrect, no adjustment is possible.
Avantra 36/44 Service Manual b. Disconnect the X503 plug (level and feedback). c. i. Measure the voltage between pins 1 and 9. The nominal value is 10 VAC. ii. Reconnect the X503 plug. Disconnect the X500 plug (temperature sensors). i. Measure the voltage between pins 1 and 6. The nominal value is 5 VDC. ii. Reconnect the X500 plug. 4.2.3 Checking the Battery 1. Remove the EMC shield of the LCB before checking the battery. 2. Connect a DVM across the battery terminals. The reading should be 3.
Section IV: On-line Processor 4.2.
Avantra 36/44 Service Manual J3 A Trigger circuit for Q5 powered from return line N4 B Trigger circuit for Q5 powered from return line N3 * Factory installed positions. CAUTION: Closing both S3 and S4 will short circuit the 12V power supply. 4.3 Calibrating/Jumper Settings The procedures in Sections 4.3 and 4.4 require the use of Control Panel keys on the OLP. The examples below detail the two types of keypads. Older Control Panels use Alphabetical keys (Figure 4-1).
Section IV: On-line Processor 2 1 3 4 5 6 7 8 9 10 11 12 13 Dev Fix H2O Dev 15% 50% 85% P1-P9 28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 Figure 4-2 New Control Panel with icon key pad (Descriptions of keys on next page) OLP Control Panel Icons (for Figure 4-2) 1– Low Dev. or Fix. 2–Display 3–Low Repl. 4–Waste Full 5–Fix. 6–Dev. 7–Time 8–Temp. 9–Stdby Repl. 10–Repl. 11–Up 12–Preset 13–Down 14–On/Off 15–Enter 16–Man. Start 17–Man. Repl.
Avantra 36/44 Service Manual 2. Slide the control panel up and remove. 3. Disconnect the control panel cable and take it to the back of the processor. 4. Connect the control panel to the X400 with the remote cable. WARNING: The PCB has high voltage terminals. Use caution when handling. CAUTION: Never connect or disconnect the cable when the processor is plugged in, or the CPU fuse will fail. NOTE: Potentiometer P102, N Min on the LUTH motor board, is not used with infrared pulse transmission.
Section IV: On-line Processor 4. When the motor is turning in the wrong direction, switch the motor off immediately by pressing the 50% button on the control panel. Exchange the motor wires M1 and M2. 5. Set the speed to 20 seconds and adjust P203 (N-max.) until 20 ±1 seconds is obtained. To increase the speed, turn P203 clockwise. 6. Set the speed to 50 seconds and adjust P219 (N-min.) until 50 ±2 seconds is obtained. To increase the speed, turn P219 clockwise.
Avantra 36/44 Service Manual Potentiometers: N-MIN : Adjustment of minimum speed (R219) N-MAX. : Adjustment of maximum speed (R203) I-OFFSET : Adjustment of offset in current amplifier circuit. Factory adjusted and sealed; do not adjust. ➀ ➁ ➂ ➃ X102 24VAC ➄ ➅ ➆ ➇ X4 X4 X1 X2 M– M+ X3 – 0,5A Fuse R219 R203 N-Min N-Max – 5A Current Select P102 I-offset Motor Board LMB.02 ➈ ➉ CPU Board Figure 4-3 LUTH Motor Board (LMB). ➀–To secondary transformer (6/5). ➁–Not used. ➂–To motor.
Section IV: On-line Processor The following table shows switch settings. Check the position accuracy of these switches. X201 A S201 OPEN 4-circuit optical interrupter u CLOSED 3-circuit optical interrupter B A u S202 AB Digital tacho + armature feedback OPEN Analog input 5V u CLOSED A S203 B u Analog input 10V A u Armature voltage feedback B Analog preset signal Infrared PWM preset signal = normal; i.e., factory setting 4.3.
Avantra 36/44 Service Manual CAUTION: Never connect or disconnect the cable when the processor is plugged in, or the CPU fuse will fail. 5. Switch on the mains (i.e., restore power to the processor). 4.3.3 Replenishment Pumps Calibration To Calibrate the Replenishment Pumps: 1. Adjust the replenishment pumps: a. Remove the replenishment J hook from the side of the tank (Dev/Fix), and place it in a 1000 ml graduated beaker. b.
Section IV: On-line Processor c. To adjust the developer, use program 321. To select the program, press: WAT H2O FIX Fix DEV Dev Note: DEV Dev = 1 FIX Fix = 2 WAT H2O = 3 The display shows a preset value from 0 to 200%. Average values range from 95% to 105%. d. Press the 15% key to increase the percentage value and the 85% key to decrease the percentage value. Adjust the value so that the amount of replenisher released will be 100 ml. e. To adjust the fixer, use program 322.
Avantra 36/44 Service Manual 4.4 Troubleshooting 4.4.1 The Service Program Among the features of the electronics is a service program containing a number of codes. These codes are listed on succeeding pages, along with the adjustments they control. Each code tests relay output and digital input. To Run the Service Program: 1. Switch the processor off. 2. Press the following keys in the sequence shown: AUTO DRYER SAVER + TIME The display should read: Service Code ___.
Section IV: On-line Processor 6. To end the service program session, press the ON/OFF key. When code 321 and 322 (repl. pump adjustment) are selected, the display shows the present percentage (Adjustment Range: 0-200%). 7. Press 15% to increase percentage. Press 85% to decrease percentage. NOTE: The service program allows more than one test to run at a time. The LED displays only the last code entered. WARNING: PK7 is always activated with code 232/233.
Avantra 36/44 Service Manual 4.5 Service Program Codes Code Function 111 Main motor Switch Element K 12 15% Key Start 85% Key Stop 112 Main motor Speed adjust Increase Decrease Circ. pumps K 11 Start Stop 123 Solenoid, water K 10 Open Close 131 Dev. repl. K8 On Off 132 Fixer repl. K9 On Off 211 Dev. heat LO Q1 On Off 212 Fixer heat LO Q3 On Off 213 Dev. heat HI Q5 On Off 221 Dev.
Section IV: On-line Processor 4.5.1 How to Use the Repair Method Tables The three tables on the following pages help locate and fix problems that may occur. The following procedure explains how to use these tables: 1. Look for the problem in Table 4-2 below and note the code number. 2. Find the same problem code number in Table 4-3 below and make a note of the numbers listed to the right. These refer to the repair steps in Table 44 below. 3.
Avantra 36/44 Service Manual 4.5.1.1 Problem Codes 1.0 When Switching On Main Power 1.1 No display information. 1.2 No LED indicators turned on. 1.3 No fan motor. (After switching on at the control panel.) 2.0 developer Bath 2.1 Temperature in bath too high compared to preset. 2.2 Temperature in bath too low compared to preset. 2.3 Temperature increases too slowly. 2.4 Temperature correct but displayed temperature does not correspond to thermometer reading. 2.
Section IV: On-line Processor 7.0 Water Solenoid Valve 7.1 Water solenoid valve is activated constantly. 7.2 Water solenoid valve is never activated. 7.3 Incorrect water flow. 8.0 Circulation Pumps 8.1 Circulation pumps are constantly active. 8.2 Pumps are never active. 9.0 Film Input 9.1 Film input constantly active and film input LED lights constantly. 9.2 Film input sensor activated, LEDs on, but main motor/rollers are okay. 10.0 Low Level 10.
Avantra 36/44 Service Manual 4.5.1.2 Problem Code 1.1 1.2 1.3 2.1 2.2 2.3 2.4 2.5 3.1 3.2 3.3 4.1 4.2 4.3 4.4 4.5 5.1 5.2 5.3 5.4 6.1 6.2 6.3 6.4 6.5 7.1 7.2 7.3 8.1 8.2 9.1 9.2 10.1 10.2 10.3 11.1 11.2 12.1 13.1 13.2 13.3 13.4 13.
Section IV: On-line Processor 4.5.1.3 Repair Steps 01. Measure 220/240 V. AC to GND. If voltage is not 220/240 V., check fuse F1 on LPB. Replace defective fuses. 02. Measure 12 V. DC voltage at X3,3(+) and X3,4(-) of LPB. If voltage is not 12 V., check that there is 10 V. AC at X3,1 and 3,2 of LPB. 03. Measure 18 V. AC voltage at X400 plug between pins 4 and 5. If voltage is not 18 V., check fuse F1 on LCB. Replace defective fuses. 04. Check response of temperature sensor.
Avantra 36/44 Service Manual 28. Check internal wiring between X501 plug and input sensors. 29. Check that circulation pumps are running during heating. 30. Verify operation of electronic system with service code 111. 31. Verify operation of electronic system with service code 121. 32. Verify operation of electronic system with service code 123. 33. Verify operation of electronic system with service code 131. 34. Verify operation of electronic system with service code 132. 35.
Section IV: On-line Processor 58. Check water inlet all the way from water tap to the wash section. 59. Check alignment of suspension for input sensors and sufficient room for wiring. 60. Agfa Light Diode Board (ALB) is not in proper position. 61. Clean area around low level sensors for chemistry. 62. Adjust racks as described in the Installation Checkout Procedure in Chapter 1. 63. Adjust LMB as described in the LMB calibration procedure Section 4.3 on page 4-6. 64. Blank. 65.
4-24 Maintenance Figure 4-4 Switches and sensors.
Section IV: On-line Processor 4.5.1.5 OLP Status and Error Messages The following status and error messages are displayed at the OLP control panel. Job in Process Meaning: Media is currently in the processor and no new job has started imaging since the last piece of media entered the processor. Action: No action required. Status message only. Input Jam Meaning: Media activated the input sensors of the processor, but did not reach the input out sensors in the given amount of time.
Appendix A: Specifications A.1 Introduction This section details pertinent technical equipment specifications for the Avantra 36/44 on-line processor (OLP) A.2 On-line Processor (OLP) Specifications This section includes the following OLP specifications: • Physical • Electrical • Operational Physical Specifications Length: 66" (167.64 cm) excluding receiver tray 98" (248.92 cm) including receiver tray, roll mat. 120" (304.80 cm) including receiver tray, sheet mat. Width: 61" (154.
Avantra 36/44 Service Manual Electrical Volts: 208-240 VAC Hertz: 50/60 Hz Phases: 1, 2 or 3 phases + (neutral) + ground Load: Maximum 7.0 kW Operational Specifications Water connection: 3/4" BSP (0.3-10 bar, max. temp. 110˚ [43˚C]) Drain: 5.3 US Gal. (3 x Ø25 mm, 3 x 20 L/min) Water consumption: 0.5 US Gal. (0-2 L/min) Tank capacity: Developer: Fixer: Water: 8 US Gal. (30.3L) 8 US Gal. (30.3L) 8 US Gal. (30.
Section IV: On-line Processor Material length: Min 7" (17.78 cm) Transport length: Developer: Fixer: Wash: Dryer: 16.5" (41.91 cm) 16.5" (41.91 cm) 16.5" (41.91 cm) 19" (48.26 cm) Developing time range: 15-60 sec Speed range: 66-16.5" Dry to dry time: (at 20 sec dev time) 83 sec Developer repl rate: 50-500cc/m2 Fixer repl rate: 50-500cc/m2 Max dryer blower capacity: 21894 Ft3 (620 m3/hour) Max anti-cond.
Appendix B Spare Parts On-Line Processor (OLP) The following lists and illustrates spare parts for the 36/44 P and OLP.
Avantra 36/44 Service Manual Avantra 36/44 OLP Parts B-2 Spare Parts
Section IV: On-line Processor Avantra 36/44 OLP Parts List 1 LU+0510Y013100 LU+0507Y013101 Control panel complete (P version) Control panel complete (OLP version) 2 LU+2621Y001001 LU+2621Y001006 Keyboard cable 2.75 m (P version) Keyboard cable 3.
Avantra 36/44 Service Manual Avantra 36/44 OLP Parts B-4 Spare Parts
Section IV: On-line Processor Avantra 36/44 OLP Parts List 1 LU+6203X000800 Magnetic lock 2 LU+3611E291842 LU+3611E291942 LU+3611E290342 Top cover, rear Top cover, middle Top cover, front 3 LU+3611E290244 LU+3611E290540 LU+3611E290640 LU+3611E290740 Side plate, right, upper Side plate, right, front, lower Side plate, right, middle, lower Side plate, right, rear, lower 4 LU+3611E290144 LU+3611E290840 LU+3611E290940 Side plate, left, upper Side plate, front, left lower Side plate, rear, left, lowe
Avantra 36/44 Service Manual Avantra 36/44 OLP Cassette Parts B-6 Spare Parts
Section IV: On-line Processor Avantra 36/44 OLP Cassette Parts List 1 LU+3621E300242 Cassette cover 2 LU+3621E300742 Feed table upper 3 LU+3621E300602 Feed table lower 4 LU+3621E301134 Stop bar 5 LU+3621E300834 Bottom plate for cassette 6 LU+6221X000203 Gas damper for cassette cover 7 LU+6221X000102 Gas damper for feed table 8 LU+1351Z060401 Slide bearing Ø6/Ø4 x 4 9 LU+1201Z201505 Gear wheel 10 LU+3621E300142 Cassette bottom Spare Parts B-7
Avantra 36/44 Service Manual Avantra 36/44 OLP Feed Rack Parts B-8 Spare Parts
Section IV: On-line Processor Avantra 36/44 OLP Feed Rack Parts List 1 LU+3611E300234 Cover for frontbox 2 LU+1451X000100 Paper path sensor 3 LU+3022Z000701 Side plate (left and right) 4 LU+1351Z000501 Bearing for roller PBTP (upper) 5 LU+1351Z000101 Bearing reamed to 10.2mm 6 LU+1410Z041404 Rubber roller Ø25.0 15/35 (lower) 7 LU+1414Z241404 Heavy roller Ø25.0 15/35 8 LU+1282Z161501 Gear M = 1.
Avantra 36/44 Service Manual Avantra 36/44 OLP Tank Parts B-10 Spare Parts
Section IV: On-line Processor Avantra 36/44 OLP Tank Parts List 1 LU+3219Z000101 Key for overflow pipes 2 LU+3201Z321901 Overflow pipe, dev. 3 LU+8181X000800 O-ring 19.2 x 3.0 4 LU+3202Z321901 Overflow pipe, fixer 5 LU+3203Z321901 Overflow pipe, wash 6 LU+3601E120100 Tank with fittings 7 LU+3041Z000101 Fixation block for heater element dev + fix tank 8 LU+2201Y000201 Heater element 1000/500 W 230 V dev + fix tank 9 LU+3230Z000401 Union nut Ø16.
Avantra 36/44 Service Manual Avantra 36/44 OLP Right Side View Parts B-12 Spare Parts
Section IV: On-line Processor Avantra 36/44 OLP Right Side View Parts List 1 LU+6900X000500 Filter housing complete 2 LU+8181X001600 O-ring 98.02 x 3.
Avantra 36/44 Service Manual Avantra 36/44 OLP Control Panel Parts B-14 Spare Parts
Section IV: On-line Processor Avantra 36/44 OLP Control Panel Parts List LU+0510Y013100 Control panel (P version) Keyboard (LU+2621X001700) (P version) LU+6205Y010200 LU+6205Y010000 Board, control panel EPROM LU+0507Y013100 Control panel (OLP version) Keyboard (LU+2621X001600) (OLP version) LU+6205Y010300 Board, control panel LU+6205Y010000 EPROM LU+2631Y001201 Internal keyboard cable Spare Parts B-15
Avantra 36/44 Service Manual Avantra 36/44 OLP Rack Spare Parts B-16 Spare Parts
Section IV: On-line Processor Avantra 36/44 OLP Rack Spare Parts List 1 LU+3601E210000 Developer rack 2 LU+3601E222000 Fixer rack 3 LU+3601E230000 Wash rack 4 LU+3601E210100 Side plate, right dev. 5 LU+3601E210200 Side plate, left dev. 6 LU+1351Z000104 Bearing, upper, reamed to 10.5mm 7 LU+1351Z000102 Bearing, lower, reamed to 10.
Avantra 36/44 Service Manual Avantra 36/44 OLP Dryer Spare Parts 18 B-18 Spare Parts
Section IV: On-line Processor Avantra 36/44 OLP Dryer Parts List 1 LU+0401X000100 W Heating element 220 V, 2 x 750 2 LU+0301X001000 Dryer fan 3 LU+2101Y000401 Temperature sensor PT500 4 LU+1410Z041404 Rubber roller Ø25.0 15/35 5 LU+1414Z241404 Heavy rubber Ø25.0 15/35 6 LU+1450Z041404 PUR/teflon roller Ø25/ 15/35 7 LU+1351Z000601 Thrust bearing, square 8 LU+1282Z161501 Gear, M = 1.
Avantra 36/44 Service Manual Electronics (upper) Spare Parts B-20 Spare Parts
Section IV: On-line Processor Electronics (upper) Spare Parts List 1 LU+2415X100000 Fuse, 10AT, 5 x 20mm 2 LU+5202Y000100 LUTH motor board, LMB 02 3 LU+2416X006000 Fuse, 600 mAF, 5 x 20mm 4 LU+1311X000100 Lithium cell, 3 Volt 5 LU+6301Y840000 LU+6305Y010000 EPROM 36F44V02R02 (P version) EPROM 36A44V02R03 (OLP version) 6 LU+6301Y000501 LUTH computer board, LCB 01 with antiloop 7 LU+2304Y000301 Fan, 12V 8 LU+4121Z000501 Bracket for plugs 9 LU+4121Z000401 Shield for electronics 10 L
Avantra 36/44 Service Manual Electronics (lower) Spare Parts B-22 Spare Parts
Section IV: On-line Processor Electronics (lower) Spare Parts List 1 LU+5111Y000200 LUTH power board, LPB 01 2 LU+2621Y003201 Interconnection cable 3 LU+2415X003200 Fuse, 315 mAT, 5 x 20mm 4 LU+3111X000800 Terminal strip, 5 circuit 5 LU+4121Z000201 Protective plastic shield (NOT SHOWN) 6 LU+2401X000100 Fuse holder, complete 7 LU+3848 Power triac, 25 A 8 LU+1501X000300 Transformer 9 LU+2121X000400 Motor capacitor 10 LU+3847 Trigger Board 11 LU+2501Y003801 Molex, 2-wire 12 LU+4
Appendix C Wiring Diagrams C-1
Index A Adjust the Replenishment Pump 4-12 Adjusting the Buffer Legs 1-23 Adjusting the buffer legs 1-23 Agfa Terminal Board 2-5, 2-8 functions 2-8 Agfa Terminal Board (ATB) description of inputs and outputs 2-8 Align OLP to Buffer 1-22 Anti-evaporation Cover Location 1-32 Anti-evaporation Covers 1-32 Anti-oxidation Cover Locations 1-32 Anti-oxidation Covers 1-32 Armature Current 2-8 ATB 2-5, 2-8 ATB Inputs and Outputs Described 2-8 Attaching Covers and Panels to the Olp 1-20 Attaching the Legs and Feet 1-
Avantra 36/44 Service Manual Crystallization 2-3 D Data Communication Link between LCB and ATB 2-5 between LCB and imagesetter 2-5 Default Replenishment Amount, Developer 210 Default Replenishment Amount, Fixer 2-10 Default wiring 1-18 Description of Inputs and Outputs (P/N 52024000100) 2-8 Description of Inputs and Outputs, ATB 2-8 Description of LCB Inputs and Outputs 2-4 Description of OLP Boot-up Procedures 2-2 Developer 1-27, 1-33 Developer Anti-oxidation Cover 1-6 Developer Default Replenishment Amou
Section IV: On-Line Processor Inserting the Replenishment Hoses 1-31 Installation Procedures on-line processor 1-13 Installation Tools and Equipment 500 ml graduate 1-13 darkroom thermometer 1-13 digital voltmeter 1-13 level 1-13 Installing Filter Housing 1-30 Installing Level Sensors 1-31 Installing Overflow Tubes 1-30 Installing, Millipore Filter Cartridge 1-32 Internal Wiring Modifications 1-18 Inventory, OLP 1-3 LRB Board 3-11 LUTH Computer Board functions 2-3 Luth Computer Board 2-3 LUTH Motor Board
Avantra 36/44 Service Manual OLP Entrance Platen 1-22 Olp Entrance Platen 1-22 Olp Front Plate 1-21 OLP Inventory 1-3 OLP Jog Function 2-3 OLP Legs 1-7 OLP Operational Specifications A-2 OLP Parts Inventory 1-6 OLP Racks 2-9 Olp Shipping Crates 1-5 OLP Standby Mode 2-2 OLP To Buffer Alignment 1-22 OLP Unpacking Procedures 1-3 OLP Unpacking Tools 1-3 OLP Water Requirements 1-3 OLP Weight 1-2 OLP Work Space Requirements 1-2 On-line Processor battery 4-4 checking operation of LCB 4-3 checking the battery 4-4
Section IV: On-Line Processor Racks, OLP 2-9 Ready Mode 2-2, 2-3 Rear exit panel 1-6 Rear Exit Panel (Top) 1-6 Rear Leveler Feet 1-15 Rear Lower Panel 1-6 Rear Top Cover 1-6 Rear Top Side Panel 1-6 Receiver basket 1-6 Red (Developer) Hose 1-26 Removing Foam from Dryer Section 1-26 Removing Tape from Door 1-26 Repair Method Tables how to use 4-17 Repair Steps 4-21 Replacing the Roller 1-28 Replenishment 2-9 topping-up 2-10 Replenishment Hoses, Installing 1-31 Replenishment Pumps adjust 4-12 Replenishment Pu
Avantra 36/44 Service Manual Toplid Safety Switches 2-4 Topping-up Replenishment 2-10 Transport Dollies 1-12 Transport Speed, Checking 1-31 Trolley, Placing 1-26 Troubleshooting on-line processor 4-14 Troubleshooting Diagram 4-20 U Unpacking Procedures, OLP 1-3 Unpacking the OLP Engine 1-8 Unpacking the Parts Crate 1-5 Upper Entry Platen 1-21 Upper Platen 1-21 Using the Repair Method Tables 4-17 V Variations in AC Supply Voltage 1-18 W Wash 1-27 Wash Rack 1-6 Wash Recirculator 1-16 Water consumption 1-16 W
Section V: Crane
Chapter 1: Crane Mounting Instructions 1.1 Introduction This chapter explains how to unpack and install the Avantra 36/44 crane, which attaches to the on-line processor (OLP).
Avantra 36/44 Service Manual 1.2 Unpacking the Crane The crane ships in a single cardboard box attached to a wooden pallet. Tools: Strap cutters Steps: 1. Move the packing box to the imagesetter site and place it on the right hand side of the OLP. 2. Cut the ties around the box. Lift off the top and remove the packing. 3. Lay out and check the contents against the items shown in Figure 1-1. 1 4 3 Figure 1-1 Crane inventory. ➀–Boom (arm/mast assembly).➁–Cassette cable. ➂–Capture bar.
Section V: Crane 1.3 Crane Installation Procedures 1.3.1 The Mounting Plate and Boom Tools required: Hex driver, 17mm socket wrench Steps 1. Power down the OLP and disconnect its power plug. 2. Remove the four (4) hex screws (top) and three (3) hex screws (bottom) in the top side panel on the right side of the OLP. Refer to Figure 1-2. NOTE: Later OLP models should have the mounting plate assembly already in place. 3.
Avantra 36/44 Service Manual 4. Insert the adapter into the mount and secure with the two (2) set screws and locking nuts. Refer to Figure 1-3. 2 1 3 Figure 1-3 Inserting the adapter into the mount. ➀–Boom. ➁–Adapter (fit into mount). ➂–Mount. NOTE: Later OLP models should not require the following procedure. 5. Replace the top side panel to the OLP and verify that the panel cut-out for the crane has an acceptable fit. Refer to Figure 1-2 and Figure 1-3.
Section V: Crane 6. Lift the base of the boom into the adapter/mount. Route the power cable exiting the boom base down through the mount center. Refer to Figure 1-4. 7. Lower the boom into position until the boom fits snugly into the adapter/ mount. Refer to Figure 1-4. 8. With the boom/adapter in place in the mount, connect the boom power cable to the matching plug at the OLP. Refer to Figure 1-4. 3 4 5 Figure 1-4 Crane power cable connections. ➂–Mount. ➃–Mounting bracket.
Avantra 36/44 Service Manual 9. Install the stop pin through the base of the boom, which extends below the mount. Refer to Figure 1-5. Make sure that the head of the stop pin is on the same side as the control switches. The locking pin locks the boom in place once the set screws have been tightened against the adapter. Make sure the locking pin is facing straight out as shown before tightening the set screws. Note that the adapter has recesses for the set screws.
Section V: Crane 1.3.2 Mounting the Head Tools required: Flathead screwdriver Steps 1. Using a flathead screwdriver, remove the end stop mounted at the tip of the boom arm. Refer to Figure 1-6. 1 2 Figure 1-6 The boom with side rails and end stop. ➀–Boom rail. ➁–End stop. 2. Remove the plastic end cover from the head at the rear (the end farthest away from the cable exit). Note the power connector behind this cover.
Avantra 36/44 Service Manual 3. Pull the gearbox vent plug found on the head in the boom travel areas. Refer to Figure 1-7. The plug has a tag on the end labeled “Remove Plastic Plug.” CAUTION: Once this plug is removed the head should not be turned over on its sides for any period longer than a few minutes. 1 2 Figure 1-7 The gearbox vent plug. ➀–Head (rack/cassette crane). ➁–Plastic plug.
Section V: Crane 4. Place the head onto the boom arm, power connector end first. Push the first two guiding rollers over the boom rails (see Figure 1-6) and roll approximately halfway onto the boom. Refer to Figure 1-8. 1 2 3 4 Figure 1-8 Mounting the head. ➀–Head. ➁–Rear mounting bracket. ➂–Roller. ➃–Power cable/connector.
Avantra 36/44 Service Manual 5. While holding the head in this position, work the power cable at the bottom of the boom arm past the first set of guide roller mounting blocks on the head. Refer to Figure 1-9. 1 4 2 5 3 Figure 1-9 Routing the power cable. ➀–Roller. ➁–Rear mounting bracket.➂–Power cable/connector. ➃–Head. ➄–Crane boom. 6. Loop the cable around the guide roller mounting block on the left side as viewed from above. Refer to Figure 1-9.
Section V: Crane 7. Maintain the cable routing while moving the head the rest of the way onto the boom. In doing so, the cable should form a loop and exit at the power connector end (rear) of the head. Refer to Figure 1-9. WARNING: Install the end stop at the tip of the boom now! Failure to do so could cause the head to be accidentally pushed from the boom during the steps that follow. 8. Verify that the cable is properly routed. Refer to Figure 1-9. 9.
Chapter 2: Crane Component Removal / Replacement 2.1 Introduction This chapter explains how to remove and replace components within the Avantra 36/44 crane, which attaches to the on-line processor (OLP).
Avantra 36/44 Service Manual 2.2 Crane Removal/Replacement Procedures 2.2.1 Crane On/Off Switch Tools Required: phillips head screwdriver Remove: 1. Power down the OLP and disconnect its power plug. 2. Remove the top covers and, using a phillips head screwdriver, remove the four (4) screws on the top and three (3) screws on the bottom of the right side panel. Refer to Figure 2-1 and 2-2. Lift and remove the side panel. 1 2 3 4 Figure 2-1 OLP cover and panel identification and location.
Section V: Crane 1 2 Figure 2-2 Screw locations OLP top side panel. ➀– Location 4 hex screws top of side panel. ➁–Location 3 hex screws bottom of side panel.
Avantra 36/44 Service Manual 3. Disconnect the power cable coming from the crane assembly to the plug inside the OLP. Figure 1-3. 8 Figure 2-3 The crane power cable. ➀– Power cable/connector.
Section V: Crane 4. Using a phillips head screwdriver, remove the two (2) screws attaching the switch plate to the crane arm. Figure 1-4. 3 1 2 O I Figure 2-4 Screw location on switch plate. ➀– Up/down switch. ➁–On/off switch. ➂– Phillips screws.
Avantra 36/44 Service Manual 5. Pull the plate out gently noting the switch wiring for proper replacement. Figure 1-5. Remove the wires. 3 4 2 5 1 6 8 7 Figure 2-5 Crane switch wire color and location. ➀–Light blue. ➁–Thin black. ➂–Thin brown. ➃–Dark blue/light blue. ➄–Thick white. ➅–Thick brown/thin brown. ➆–Thick black. ➇–Thin brown. Replace: 1. Reverse the removal procedures above.
Section V: Crane 2.2.2 Crane Motor Tools Required: Phillips head screwdriver, flat head screwdriver, 9/64" hex wrench, 5/32" allen wrench Remove: 1. Using the on/off switch, lower the crane cable as far as possible. 2. Using a phillips head screwdriver, remove the four (4) screws on the front and back cover of the head. 3. Disconnect the power cable at the end of the head. 4. Using a flat head screwdriver, remove the three (3) screws in the end stop at the front of the boom. Figure 1-6. 5.
Avantra 36/44 Service Manual 6. Using a 9/64" hex wrench, remove the four (4) hex screws at the top of the head. CAUTION: While removing the screws, support the motor at the cable end. 7. Pull the cable and hook up through the hole in the head. 8. Spread the sides of the head and slide the head assembly free. 9. Cut the wrap to free the motor power cable on the top of the head. Using a pin removal tool, remove the pins in the plug.
Section V: Crane 2.2.3 Crane Slack Safety Switch Tools Required: Phillips head screwdriver, flat head screwdriver, 9/64" hex wrench Remove: 1. Using a phillips head screwdriver, remove the four (4) screws on the front and back cover of the head. 2. Disconnect the power cable at the end of the head. 3. Using a flat head screwdriver, remove the three (3) screws in the end stop at the front of the boom. Figure 1-6. 4. Carefully roll the head off the crane boom.
Avantra 36/44 Service Manual 2.2.4 Crane Cable Tools Required: phillips head screwdriver, flat head screwdriver, 9/64" hex wrench, pliars Remove: 1. Using the up/down switch, lower the crane cable as far as possible. 2. Using a phillips head screwdriver, remove the four (4) screws on the front and back cover of the head. 3. Disconnect the power cable at each end of the head. 4. Using a flat head screwdriver, remove the three (3) screws in the end stop at the front of the boom. Figure 1-6. 5.
Section V: Crane 9. On the motor side, remove the E-clip to detach the cable sheave pin and sheave. Figure 1-7. 4 5 6 3 2 1 Figure 2-7 E-clip, Sheave, and sheave pin. ➀–Cable. ➁–Sheave pin. ➂–Sheave. ➃–Drive assembly. ➄–Drive coupler. ➅–E-clip.
Avantra 36/44 Service Manual 10. Turn the assembly over and remove the four (4) 3/16" allen screws that connect the top plate to the cable drum assembly. Figure 1-8. 5 4 3 6 2 1 Figure 2-8 Top plate. ➀–Two 5/32" allen screws. ➁–Cable drum assembly. ➂–Two 3/16" allen screws (long). ➃–Top plate. ➄–Two 3/16" allen screws (short). ➅–Motor power cable.
Section V: Crane 11. Remove the E-clip from the guiding bar and slide the bar out. Figure 1-9. 12. By hand, turn the drive coupler clockwise to unwind the cable. Figure 1-9. 13. Using a 5/32" hex wrench, remove the screw from the cable guiding block. Figure 1-9. 2 3 4 5 6 7 1 Figure 2-9 Cable drum with guiding bar and block. ➀–Cable drum. ➁–Slack safety switch wires. ➂–Two phillips screws for safety switch. ➃–Slack safety switch. ➄–Guiding bar. ➅–Guiding block. ➆–One 5/32" hex screw. 14.
Avantra 36/44 Service Manual 1 2 3 Figure 2-10 Set screw, cable hole. ➀–Set screw (1/16" allen). ➁–Cable hole. ➂–Cable. 15. Slide the cable out of the drum. Replace: 1. Take about an inch of new cable and bend it at a 90 degree angle using a pliars. 2. Insert the bent cable end into the cable hole in the Drum. Figure 1-10. 3. Tighten the set screw. Figure 1-10. 4. Turn the drive coupler counterclockwise while maintaining tension on the cable. Figure 1-7.
Appendix A Spare Parts OLP Crane 067246-012 Capture bar 067246-003 Motor/Carriage assembly 067246-004 “Up/Down” rocker switch 067246-005 Circuit breaker/On-Off switch 067246-006 Cable assembly 067246-011 Cassette chain 067246-016 Carriage cover 067246-017 Cable slack switch w/ actuator 067246-018 Cable slack switch w/o actuator 067246-019 Hoist limit switch A-1
Index Symbols (Rack/cassette Crane 1-8 A Adapter 1-4 location 1-4, 1-6 Adapter, Crane 1-6 Aligning the Motor Coupler 2-8 Arm, Boom 1-10 Arm/mast Assembly 1-2 B Boom 1-2, 1-3 end stop 1-7 location 1-4, 1-6 locking pin 1-6 side rails 1-7 Boom Arm 1-7, 1-9, 1-10 end stop 1-7 Boom Power Cable 1-5 Boom Rail 1-7 location 1-7 Boom Rails 2-10 location 2-7 Boom, Crane 1-5 C Cable location 2-14 Cable Connections, Crane 1-5 Cable Connector boom 1-10 head 1-10 Cable Crane removing and replacing 2-10 Cable Drum 2-13 lo
Avantra 36/44 Service Manual location 2-11 Electrical Cable with Connector location 1-5 End Stop 1-7, 1-11 location 1-7, 2-7 screws 2-9, 2-10 warning 1-11 F Forming a Loop with Cable in Crane Head 111 Forward Top Cover location 2-2 G Gearbox Vent Plug 1-8 location 1-8 Guide Roller Mounting Block 1-10 Guide Roller Mounting Blocks 1-10 Guiding Bar 2-13 location 2-13 Guiding Block 2-14 location 2-13 Guiding Rollers 1-9 H Head 1-2, 1-8 cable routing 1-11 cover screws 2-9 location 1-9 power cable 2-9 power cabl
Section V: Crane location 2-11 Side Panel screw locations 2-3 Side Rails location 1-7 Slack Safety Switch 2-9, 2-13 removing and replacing 2-9 Slack Safety Switch Wires location 2-13 Stop Pin 1-6 Switch crane slack safety 2-9 On/off 2-5 plate 2-5 screws 2-5 slack safety 2-13 Up/down 2-5 wire colors 2-6 wire locations 2-6 wiring 2-6 Switch Block screws 2-9 Switch Plate 2-5 T Top Plate 2-12 Top Side Panel location 2-2 screw locations 2-3 Top Side Panel, Removing 1-3 U Unpacking the Crane 1-2 Up/down Switch l
Avantra 36/44 Service Manual I-4 Index
