AGFA d-lab.3 Digital Compact Lab

TECHNICAL DOCUMENTATION 

DD+18060022D0 

dlabr000 

AGFA d-lab.3 

Digital Compact Lab 

Printer 

Paper Processor 

Type 8060/100 (CE/UL) 

Type 8060/200 (CE/UL) 

Repair 

Edition 2001-01-02 /PN 9009_01

© 2001 Agfa-Gevaert AG. All rights reserved. 

No part of this documentation is allowed to be copied or transferred by any means or 

for any purpose without prior written autorisation by Agfa-Gevaert AG. 

All rights of design 

modifications and alterations of designations or 

indications of the scope of delivery reserved. 

Printed in Germany on 

paper made without chlorine.

List of Registers 

Edition 

Register 

Introduction...................................................................... 2001-01-02.................. 1 

Basic Machine ................................................................. 2001-01-02.................. 2 

Diagnosis / Troubleshooting ............................................ 2001-01-02.................. 3 

Scanner ........................................................................... 2001-01-02.................. 4 

Main-PC........................................................................... 2001-01-02.................. 5 

Printer .............................................................................. 2001-01-02.................. 6 

Paper Processor .............................................................. 2001-01-02.................. 7 

Software........................................................................... 2001-01-02.................. 8 

Maintenance .................................................................... 2001-01-02.................. 9 

General Data and Information.......................................... 2001-01-02................ 10 

Index................................................................................ 2001-01-02................ 11 

Preinstallation / Installation .............................................. 2001-02-15................ 12

leere Seite 

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Repair 

Introduction 

Contents 

Use of the Technical Documentation ....................................................................................................... 1.1 

Structure................................................................................................................................................ 1.1 

Symbols................................................................................................................................................. 1.2 

Text Styles............................................................................................................................................. 1.2 

Safety Instructions................................................................................................................................. 1.2 

Legal Situation............................................................................................................................................ 1.3 

Copyright ............................................................................................................................................... 1.3 

Safety Prescriptions .............................................................................................................................. 1.3 

General ....................................................................................................................................... 1.3 

For the Operation........................................................................................................................ 1.4 

For Service / Repair Work .......................................................................................................... 1.4 

For the Disposal of the machine .................................................................................................1.4 

Handling Photochemicals ......................................................................................................................... 1.5 

Legal Regulations.................................................................................................................................. 1.5 

Disposal................................................................................................................................................. 1.5 

Spent Processing Solutions ........................................................................................................ 1.5 

Liquid Residues........................................................................................................................... 1.6 

Chemical Containers................................................................................................................... 1.6 

Safety Precautions ................................................................................................................................ 1.6 

Use of the Laser Beam............................................................................................................................... 1.8 

Storage ........................................................................................................................................................ 1.9 

Chemicals ............................................................................................................................................. 1.9 

Photographic Paper............................................................................................................................... 1.9 

AGFA d-lab.3 2001-01-02 /PN 9009 1.i

Introduction 

Repair 

■ 

1.ii 2001-01-02 /PN 9009 AGFA d-lab.3

Repair 

Introduction 

Use of the Technical Documentation 

Structure 

The complete documentation is included in the 

scope of delivery of the machine 

Folder Customer Operator Technician Information 

Operation Use of the documentation 

✘ 

Safety precautions 

Machine settings 

Production 

Maintenance (regular jobs to maintain the 

operation and keep the machine in good 

working order) 

Repair Diagnosis and repair of electronic / 

✘ 

mechanical parts and complete 

assemblies 

Removal, installation, adjustment of 

single parts / complete assemblies 

Maintenance carried out by technicians 

(yearly, every two years) 

Circuit and reference diagrams: Signal 

tracing 

Spare parts list 

✘ ✘ 

Finding a machine part and its part 

number 

Preinstallation 

(booklet) 

Installation 

(booklet) 

✘ 

✘ 

Preinstallation actions 

Installation performed by an Agfa 

technician 

AGFA d-lab.3 2001-01-02 /PN 9009 1.1

Introduction 

Repair 

Symbols 

The symbols that are used have the following 

meaning: 

− General description 

− Operating steps 

− Prerequisite 

− Note 

− Safety instructions 

− Reference to another chapter 

− Tools and measuring means 

Text Styles 

The following text parts are highlighted in bold 

letters / italic letters in the technical 

documentation: 

1. Screen designations, e.g.: 

Example: Pressing OK will validate the 

displayed text and the Input screen is 

closed. 

2. Designations of buttons, e.g.: 

Strike Reorder to handle reorders 

3. Reference to other text parts in the technical 

documentation is indicated in italic letters, 

e.g.: 

See also the section Menu overview and 

Screen structure on the following pages. 

Safety Instructions 

The words Caution and Warning in the 

documentation and on the machine labels 

indicate the following risks: 

Caution! 

Low risk. 

Potentially dangerous situation. May cause 

minor injuries to persons or damage to property. 

Warning! 

Average risk. 

Possible danger. May cause severe injuries to 

persons and death. 

1.2 2001-01-02 /PN 9009 AGFA d-lab.3

Repair 

Introduction 

Legal Situation 

The operation of the machines is ruled by the 

appropriate regulations for the place of installation 

in force in the country concerned. 

This technical documentation includes a EU 

conformity explanation (CE) about the 

harmonised standards that apply. 

Caution! 

The following safety regulations, warnings and 

instructions on machine labels must be 

observed by all means. 

The non-observance may be dangerous for 

persons, equipment and buildings: injuries, 

electric shocks, fire. 

The manufacturer and the service will not 

assume any responsibilities for accidents and 

damages resulting from incorrect operation. 

Copyright 

Copies of photographs, negatives and other 

pictures must not be made without the 

permission of the author. Under normal 

conditions, the Copyright is the property of the 

photographer. The one who orders the copy is 

not always the author of the material. 

Safety Prescriptions 

General 

Warning and instructions on machine stickers 

must be strictly observed. 

Safety devices: 

− Do not bypass or make inoperative built-in 

safety devices. 

− Do not modify presettings on safety 

components. 

− Replace fuses that have blown only by the 

same type of fuse: Value, switch-off 

characteristics. 

− Never modify the electrical switching circuit. 


Introduction 

Repair 

For the Operation 

Do not operate the machine without the covers 

and panels. Persons who open or remove 

covers expose themselves to dangerous 

voltages or run other risks. 

Do not cover or block the venting openings in 

the housing: This may lead to overheating of 

single components. 

No objects or liquids should get into the 

machine through the venting openings: This 

may cause fire or electric shocks. 

Do not squeeze the power cable and install it in 

such a way that no one can step on the cable. 

Avoid excessive generation of dust as this may 

damage the components in the machine. 

For Service / Repair Work 

− Please respect the local safety precautions 

− Be sure to switch off the machine before 

service and repair jobs are performed 

− The machine is equipped with high-voltage 

carrying and fragile components. For this 

reason, the following jobs must only be 

performed by authorised service technicians: 

− Repairs on electrical components 

− Maintenance jobs / removal of parts and 

covers not described in this documentation 

− Use original Agfa spare parts: Only these parts 

have been tested for their safety and usability 

− When replacing electrical components: 

Observe the data given in the circuit and wiring 

diagrams. 

− At the end of all service / maintenance jobs: 

Check the general function of the machine as 

well as the correct condition of the safety 

devices. 

Disposal 

The machine must be disposed of as industrial 

waste. 


Repair 

Introduction 

Handling Photochemicals 

Legal Regulations 

The machine is subject to the legal regulations 

about water: 

− Photochemicals are not allowed to be drained 

off into the public sewage system. 

− It must be checked whether residual 

substances can be avoided, reduced or 

recycled. 

− All photographic solutions as well as plastic 

containers holding harmful residues are 

considered to be special waste. 

− When storing spent processing solutions, it 

must be made sure that no waters are polluted, 

e.g. by unintentional leakage. 

The regulations about the handling and correct 

disposal of chemistry are different in each country. 

Information about the regulations in force can be 

obtained from: 

− The country’s authorities in charge 

− The nearest Agfa subsidiary 

Disposal 

Spent Processing Solutions 

The processing solutions used are usually only 

slightly water endangering (Water endangering 

class 1). For this reason, these solutions can be 

stored in commercial containers for 

photochemicals until their final disposal. 

For larger tanks, a conformity certificate is 

usually required. 


Introduction 

Repair 

Liquid Residues 

All solutions that cannot be reused or that do not 

contain recyclable substances (film developer) are 

to be disposed of as special waste. 

Argentiferous solutions, in contrast, are liquid 

residual substances that can be used for silver 

recovery. For this reason, they should be 

collected separately from the other solutions. 

The disposal of argentiferous solutions should be 

ensured by fixing bath recycling firms that are 

normally also authorised to dispose of nonargentiferous 

solutions. 

For tank cleaning, cleaning agents based on 

peroxides are recommended. If these substances 

are used as prescribed, the local regulations 

about the draining of waste water are kept. This 

means that the cleaning and rinsing water of the 

tank cleaning can be drained into the public 

sewage system. 

Chemical Containers 

Rinse them with water used for the preparation 

of the solutions and provide for their recycling. 

Safety Precautions for the Handling of Chemicals 

Caution! 

The work with the machine involves the handling 

of slightly poisonous, irritating and etching 

substances. The user (employer) 

− has to elaborate operation instructions for the 

handling of dangerous substances and 

− provide for the instruction of his staff at least 

once a year. 

− Apart from this, the user must ensure sufficient 

aeration. The air in industrial workrooms should 

be exchanged at least eight to ten times per 

hour. 


Repair 

Introduction 

All photographic developers contain substances 

which may irritate the skin, the mucous membrane 

and the eyes and which may cause allergic skin 

reactions affecting very sensitive persons. For this 

reason, avoid long or repeated skin contact, 

especially with developer solutions. 

For all jobs where photographic processing 

solutions may splash, e.g. preparing and filling in 

chemical solutions, cleaning processing racks 

etc.: 

− Wear protective gloves and change them every 

day, if possible; rinse all solutions that get on 

the skin with plenty of running water 

− Wear industrial glasses: If in spite of this, 

splashes do get into your eyes, wash them 

immediately with plenty of water, pulling apart 

the eyelids. Consult an oculist! 

Store chemicals and processing solutions in a 

safe place. 


Introduction 

Repair 

Use of the Laser Beam 

The d-lab.3 is equipped with an Argon ion laser of 

class 3B. 

In order to prevent damages caused by the laser 

beam, the latter is capsulated in the machine so 

that the whole machine can be classified Laser 

class 1. 

The laser beam cannot hit the operator when the 

d-lab.3 is operated normally, even not when the 

machine doors are open. 

The laser and the laser module are identified by 

appropriate machine stickers. 

Warning! 

A laser beam of class 3B may be accessible after 

the removal of covers. 

Be sure to keep the mechanical laser shutter on 

the fibre coupling closed when working on the 

laser. 

Looking directly into lasers of class 3B is 

dangerous and can always hurt the eyes. 

Make sure during maintenance and repair work 

that the laser beam is not reflected by parts or 

tools and gets into the eyes. 


Repair 

Introduction 

Storage 

Chemicals 

The chemicals should be stored and prepared 

according to the manufacturer’s information and 

advice. 

Photographic Paper 

All Color papers must always be stored in a cool 

and dry place. 

The best storage temperature is between +2 ºC 

and +10 ºC. 

Opened packages have to be stored at a 

relative humidity of 50-60%. 

Storage at 20 ºC over several days is possible 

without problems. 

Storage temperatures above 30 ºC should be 

avoided because they will cause visible 

alterations after only a few days. 


Introduction 

Repair 

■ 


Repair 

Basic Machine 

Contents 

Major Assembly Groups ............................................................................................................................ 2.1 

Mechanical Structure............................................................................................................................. 2.2 

Electrical Structure ................................................................................................................................ 2.3 

Additional Air / Exhaust Air.................................................................................................................... 2.4 

Description.................................................................................................................................................. 2.5 

Allocation of Assembly Groups and Parts Functions ............................................................................ 2.5 

Scanner, PC, Printer ................................................................................................................... 2.5 

Paper Processor ......................................................................................................................... 2.6 

Names of Assembly Groups and Shortcuts ..........................................................................................2.7 

Parts Functions ................................................................................................................................... 2.11 

Signals....................................................................................................................................................... 2.12 

Circuit Diagrams - Scanner ..................................................................................................................... 2.13 

Connections Print Engine PE (1).... 2.1.8061.3003.0.......................................................................... 2.13 

Connection Print Engine PE (2) ..... 2.1.8061.3003.0.......................................................................... 2.14 

Connection Print Engine PE (3) ..... 2.1.8061.3003.0.......................................................................... 2.15 

Connections Film Feeder, Negative Carrier, Mirror Box FF-NC-MB.... 2.1.8061.3003.0.................... 2.16 

Circuit Diagrams - Printer........................................................................................................................ 2.17 

Printer Mainboard PF ..................... 2.1.8060.5003.0.......................................................................... 2.17 

RH Magazine Drive MR.................. 2.1.8060.5003.0..........................................................................2.18 

LH Magazine Drive ML................... 2.1.8060.5003.0..........................................................................2.19 

Sheet Gear SG............................... 2.1.8060.5003.0.......................................................................... 2.20 

Print Engine PE .............................. 2.1.8060.5003.0.......................................................................... 2.21 

Lane Distributor LD ........................ 2.1.8060.5003.0.......................................................................... 2.22 

Transport Unit TU........................... 2.1.8060.5003.0.......................................................................... 2.23 

Mains Connection and Power Supply.................................................................................................. 2.24 


Basic Machine 

Repair 

Circuit Diagrams - Paper Processor .......................................................................................................2.25 

General Circuit Diagram ......................................................................................................................2.25 

Connections.........................................................................................................................................2.26 

Power Supply (AC) ..............................................................................................................................2.27 

Power Supply (DC) ..............................................................................................................................2.28 

55A-PWD (1/5) ....................................................................................................................................2.29 

55A-PWD (2/5) ....................................................................................................................................2.30 

55A-PWD (3/5) ....................................................................................................................................2.31 

55A-PWD (4/5) ....................................................................................................................................2.32 

55A-PWD (5/5) ....................................................................................................................................2.33 

55P-CNR .............................................................................................................................................2.34 

55P-CPU .............................................................................................................................................2.35 

55P-IRC (1/2) ......................................................................................................................................2.36 

55P-IRC (2/2) ......................................................................................................................................2.37 

55P-MDV (1/4).....................................................................................................................................2.38 

55P-MDV (2/4).....................................................................................................................................2.39 

55P-MDV (3/4).....................................................................................................................................2.40 

55P-MDV (4/4).....................................................................................................................................2.41 

55P-SSR..............................................................................................................................................2.42 

■ 


Repair 

Basic Machine 

Major Assembly Groups 

dlabr003 

A 

Scanner 

B 

Main-PC 

C 

Printer 

D 


- Light 

- Image processing 

- Paper cutting 

- Paper development 

- Filtering 

- General control 

- Paper transport 

- Paper drying 

- Mirror Box 

- Timer function 

- Paper exposure 

- Order sorting 

- Film transport 

- Prescanner 

- Lens + CCD 

- Electronic 


Basic Machine 

Repair 

Mechanical Structure 

dlabr218 

1 Print engine PE (exposure unit) 

2 Touch screen 

3 Processing racks 

4 Shifter (print chuter) 

5 Densitometer measuring head 

6 Sorter 

7 Infra-red predryer + dryer 

8 Replenisher tanks 

9 Drain cocks 

10 Lane distributor LD 

11 Cutter units CA + paper turnaround 

12 Paper transport TU 

13 Paper magazines 


Repair 

Basic Machine 

Electrical Structure 

dlabr001 

1 Main-PC 

2 Driver sensor board 

3 Scanner motherboard with 6 plug-in boards 

4 Prescanner electronic 

5 Densitometer electronic 

6 Motor driver board 

7 Paper Processor control 

8 Paper Processor power supply unit 

9 Lane distributor control 

10 Back printer control 

11 CCD and Zoom electronic 

12 Paper magazine control 

13 Control Switching Gear + Paper Cutter Units CA 

14 Paper transport control 

15 Printer Mainboard 

16 Printer power supply unit + Power Monitor PCB 

17 Laser power supply unit 

18 Blue-Green Laser (beam generation) 

19 Control Print Engine PE 

20 Laser module (beam processing) 

21 Monitor (Touch Screen) 

22 Laser electronic 

23 Red Laser diode 


Basic Machine 

Repair 

Additional Air / Exhaust Air 

The wet section of the Paper Processor is 

encapsulated; for this reason, warm air is only 

produced in the Printer part; see exhaust air of the 

laser (5). 

An adapter pipe end (hose dia. 125 mm) is available 

for the connection to an air exhaust system: 

Type 8060/370, ABC-Code 5GVP2 

dlabr154 

1 Additional air: Printer power supply unit 

2 Exhaust air: Laser and Printer power supply unit 

3 Additional air: Laser 

4 Additional air: Printer 

5 Exhaust Air: Laser 

6 Exhaust Air: Printer 


Repair 

Basic Machine 

Description 

Allocation of Assembly Groups and Parts Functions 

Scanner, PC, Printer 

Sensors / loads; e.g.: TU_LS07 

− 1 st and 2 nd pos.: Assembly group 

− 3 rd pos.: Underline 

− 4 th and 5 th pos.: Function of the part 

− Current number in the assembly group 

Printed circuits; e.g.: MD_GS35 

− 1 st and 2 nd pos.: Assembly group 

− 3 rd pos.: Underline 

− 4 th and 5 th pos.: Function of the part 

− Current number in the assembly group 

See also the two following lists: 

1. Name of assembly groups and shortcuts 

2. Parts functions 

Cables, e.g.: 

KAXX 

8.8060.XXXX.X 

LD_GSXX:STXX 

Cable designation 

Cable reference number 

Address consisting of: 

- Functional assembly group 

- Function of the part 

- Connector designation 

The designations of the printed circuits on the 

board are not concerned by these agreements: 

8.8060.XXXX.X Part number of the board 

STXX 

Connector 


Basic Machine 

Repair 


The usual designations are kept in the Paper 

Processor, e.g.: 

MO1PRP 

− 1st and 2 nd pos.: Function of the part 

− 3 rd pos.: Current number in the assembly group 

− 4 th position: Always P for Paper Processor 

− 5th and 6 th position: designation of the 

assembly group in which the part is located 

See the following lists: 

1. Names of assembly groups and shortcuts 

2. Parts functions 


Repair 

Basic Machine 

Names of Assembly Groups and Shortcuts 

Shortcut 

BK 

CA 

CF 

CG 

CL 

CT 

CU 

DH 

DR 

DS 

EK 

ET 

FE 

FF 

FT 

FW 

IR 

LA 

LD 

LG 

LH 

LS 

LU 

MB 

MD 

MF 

MK 

ML 

MR 

NC 

NM 

PC 

PD 

PE 

PF 

Assembly group (English) 

Block assy 

Paper Cutter + Switching Gear 

Cartridge Feeder 

CCD-Group 

Cleaner 

Chemical Temperature 

Paper Cutter 

Dryer Heater 

Dryer 

Dust Shutter 

External Keyboard 

Effluent Tank 

Film Exit 

Film Feeder 

Film Take Up 

Filter Wheel 

Infra Red Heater 

Laser Module 

Lane Distributor 

Lens Group 

Lamp House 

Lane Shifter 

Laser Unit 

Mirror Box 

Magazine Drive 

Main Frame 

Magazine Lock 

Paper Magazine, left 

Paper Magazine, right 

Negative Carrier 

Negative Mask 

PC 

Processor Drive 

Print Engine 

Printer Frame 


Basic Machine 

Repair 

Shortcut 

PO 

PO 

PP 

PP 

PR 

1) 

1) 

1) 

1) 


Power Module 

(Power Monitor + Printer Power Supply) 

Paper Outlet 

Printer Parts 


Printer 

PW 

RD 

RD 

RP 

RT 

RW 

SB 

SC 

SF 

SG 

SH 

SL 

SM 

SO 

SP 

SR 

ST 

SU 

SX 

TD 

TK 

TU 

ZH 

1) 

1) 

Power Supply Unit 

Back Printer 

Replenishment Mixer 

Replenishment Pump 

Replenisher Tank 

Replenishment Water 

Sheet Bridge 

Scanner 

Scanner Frame 

Switching Gear 

Shutter 

Single Lens 

Slide Mask 

Sorter 

Scanner Parts 

Sheet Stocker 

Sheet Transfer 

Shutter 

Strip Box 

Twin Drum Engine 

Tank 

Transport Unit 

Zoom Holder 

1) 

The shortcuts PO, PP and RD exist twice. But 

this should not cause confusion, owing to the 

different functions of these assembly groups. 


Repair 

Basic Machine 

Assembly groups, position in d-lab.3 

PO 

LS 

CG 

MD 

IC 

FL 

ET 

FD 

LD 

TK 

PD 

CT 

IR 

DH 

DR 

LH 

CT 

CT 

PP 

PP 

HP 

SO 

MB 

SL 

PP 

FF 

LG 

CC 

CF 

SC 

NM 

NC 

ST 

LD 

RP 

RD 

RD 

RW 

RD 

RT 

RT 

RT 

LA 

TU 

RD 

PE 

SB 

LU 

HP 

SR 

SG 

MR 

VO 

LU 

PO 

ML 

dlabr244.eps 


Repair 

Basic Machine 

Parts 

Shortcut 

FA 

FS 

HT 

HS 

LS 

MS 

MO 

TH 


Fan 

Float Sensor 

Heater 

Heat Sensor 

Light Sensor 

MicroSwitch 

Motor 

Thermostat 

Certain positions in the descriptions of the sensors 

and loads indicate the function of a part: 

− 4 th and 5 th position for Scanner, PC, Printer 

− 1 st and 2 nd position for Paper Processor 

The lists of the loads and sensors are connected 

to the major assembly groups: See Signal lists in 

the sub-registers: 

− 4.2 Scanner 

− 6.2 Printer 

− 7.2 Paper Processor 


Basic Machine 

Repair 

Signals 

dlab132e 


Repair 

Basic Machine 

Circuit Diagrams - Scanner 

Connections Print Engine PE (1) 1.8061.3003.0 


Repair 

Basic Machine 

Connection Print Engine PE (2) 1.8061.3003.0 


Repair 

Basic Machine 

Connection Print Engine PE (3) 1.8061.3003.0 


Repair 

Basic Machine 

Connections Film Feeder, Negative Carrier, Mirror Box FF-NC-MB 1.8061.3003.0 


Repair 

Basic Machine 

Circuit Diagrams - Printer 

Printer Mainboard PF 1.8060.5003.0 


Repair 

Basic Machine 

RH Magazine Drive MR 1.8060.5003.0 


Repair 

Basic Machine 

LH Magazine Drive ML 1.8060.5003.0 


Repair 

Basic Machine 

Sheet Gear SG 1.8060.5003.0 


Repair 

Basic Machine 

Print Engine PE 1.8060.5003.0 


Repair 

Basic Machine 

Lane Distributor LD 1.8060.5003.0 


Repair 

Basic Machine 

Transport Unit TU 1.8060.5003.0 


Repair 

Basic Machine 

Mains Connection and Power Supply 

dlabr136d 


Repair 

Basic Machine 

Circuit Diagrams - Paper Processor 

General Circuit Diagram 


Repair 

Basic Machine 

Connections 


Repair 

Basic Machine 

Power Supply (AC) 


Repair 

Basic Machine 

Power Supply (DC) 


Repair 

Basic Machine 

55A-PWD (1/5) 


Basic Machine 

Repair 

55A-PWD (2/5) 


Repair 

Basic Machine 

55A-PWD (3/5) 


Basic Machine 

Repair 

55A-PWD (4/5) 


Repair 

Basic Machine 

55A-PWD (5/5) 


Basic Machine 

Repair 

55P-CNR 


Repair 

Basic Machine 

55P-CPU 


Basic Machine 

Repair 

55P-IRC (1/2) 


Repair 

Basic Machine 

55P-IRC (2/2) 


Basic Machine 

Repair 

55P-MDV (1/4) 


Repair 

Basic Machine 

55P-MDV (2/4) 


Basic Machine 

Repair 

55P-MDV (3/4) 


Repair 

Basic Machine 

55P-MDV (4/4) 


Basic Machine 

Repair 

55P-SSR 

• 


Repair 

Diagnosis / Troubleshooting 

Contents 

Service Functions ...................................................................................................................................... 3.1 

Access................................................................................................................................................... 3.1 

Log Files................................................................................................................................................ 3.2 

Scripts ................................................................................................................................................... 3.3 

Commands............................................................................................................................................ 3.3 

Remote Diagnosis with the RDS System................................................................................................. 3.4 

Script Language Daisy............................................................................................................................... 3.5 

Conversions .......................................................................................................................................... 3.6 

Key Words............................................................................................................................................. 3.6 

Grammar............................................................................................................................................... 3.6 

Commands.......................................................................................................................................... 3.10 

msgbox ..................................................................................................................................... 3.10 

wait............................................................................................................................................ 3.10 

include....................................................................................................................................... 3.10 

trace .......................................................................................................................................... 3.10 

cmd, answer, comment, var_read, var_ask_int........................................................................ 3.11 

var_ask_string........................................................................................................................... 3.11 

MiniCalc - calc........................................................................................................................... 3.12 

String Allocation – var_set ........................................................................................................ 3.12 

Example of a Script................................................................................................................... 3.13 

Exiting the Service Mode......................................................................................................................... 3.15 



Repair 

■ 


Repair 


Service Functions 

Access 

The Service Functions are only accessible when the 

user logging in has the right of access. 

All menus and functions are accessible in the 

service mode (unlimited right of access). 

− Call-up of the main menu line: 

Test 

Service 

The service operator interface is displayed 

(language: English). 

Service functions: 

− Configuration 

− Software Information 

− Firmware Download 

− Firmware Version 

− Logfiles 

− Scripts 

− Commands 

− Film Drive 

− Paper Processor 

− Printer 

− Image Processor 

− Timer board 

− Software 

A touch screen, a mouse and a keyboard are 

used for the input and output of all servicerelevant 

data. 



Repair 

Log Files 

Command and data strings can be recorded during 

the operation and saved in Log files for the analysis 

of malfunctions. They are saved on the hard disk or 

on external storage media and can be called up on 

the machine or transmitted via remote data 

transmission. 

Logbooks: 

− Communication: 

Communication between Main and Subs 

− Error: 

Error and time span between errors 

− Service call: 

The technician has to confirm his service call 

(repair and preventive maintenance) in this 

Logbook. The time elapsed since the last service 

call is calculated automatically. 

− Modifications: 

− Repairs are entered in this Logbook by the 

technician. 

− PCBs with version number coding and new 

Software versions are entered automatically. 

− Extensive conversion kits are entered 

automatically from a diskette. 

− Single exchange parts and small conversion 

kits are entered by the technician. 

− Versions: 

New Software and version numbers of boards 

are entered in addition in this Logbook. 

− Laser: 

Check of the beam capacity and entry in this 

Logbook. If the limit value is reached, an 

message to replace will appear. 


Repair 


Scripts 

The Script language daisy developed for the d-lab.3 

will be used to create test routines. The directory 

Scripts contains ready test routines to activate and 

check sensors and loads. For this reason, the 

modification / recreation of scripts should only be 

necessary in exceptional cases. 

See Script language daisy in this register. 

Commands 

For the analysis of the Log files, i.e. the command 

execution recorded there, an overall knowledge of 

the commands is required. 

The transmission of commands and replies 

requires a special protocol based on telegrams. 



Repair 

Remote Diagnosis with the RDS System 

The RDS functions (Remote Diagnose Service) 

integrated in the machine shortens service calls or 

eliminates them altogether: 

Defective Hardware and operating errors can be 

recognised by means of the RDS. 

For this reason, the d-lab.3 can be linked with the 

PC of a service organisation via a network, remote 

data transmission or the Internet. This PC can be 

used to monitor, analyse, call up and edit data: 

Data can be checked in remote Offline mode: 

− Production statistics 

− Customer and machine data 

− MBL and PBL values 

− Measuring values of the chemical test strips 

− Configuration files 

− Software versions 

− Indices of the installed Hardware 

− Log files 

− Monitoring of the machine functions 

The remote control of the machine is possible in 

remote Online mode (activation of production 

procedures). 

Defective Hardware and operating errors can be 

recognised by means of the RDS. 


Repair 


Script Language Daisy 

The script language daisy can be used to program 

own test routines (scripts) in addition to the existing 

scripts. 

service_gui1 

service_gui2 



Repair 

Conversions 

− italics 

for non-terminal symbols 

− Non-proportional fond bold 

for key words and characters 

− Comments begin with a // and are valid up to the 

end of the line 

Key Words 

Letter fonts: 

Capital and small letters are not checked (case 

insensitive). 

answer ask_int ask_string calc 

dump end_loop include loop msgbox 

parameter_file set timeout trace 

trace_file trace_var 

Grammar 

daisy 

: EOF 

| expr_list EOF 

expr_list 

: expression NL 

| expression NL expr_list 

expression 

: answer 

| cmd 

| comment 

| dump 

| include 

| loop_head expr_list loop_tail 

| msgbox var 

| parameter_file file 

| timeout int 

| trace 

| trace_file file 

| wait 

| var_ask 

| var_calc 

| var_read 

| var_set 


Repair 


loop_head : loop int NL 

| 4 int NL 

loop_tail 

: end_loop 

| 5 

wait 

: wait int 

| 6 int 

include 

: include file 

| 9 file 

trace 

: trace rest_of_line 

| trace_var var 

| 8 rest_of_line 

cmd 

: cmd string reg_string 

| 1 string reg_string 

answer 

: answer reg_string 

| answer reg_string int 

comment 

: # rest_of_line 

| 0 rest_of_line 

var_read 

: read_int var 

| read_string var 

var_set 

: set var assignop 

var_set_expr 

var_set_expr 

: var_set_expr addop var_st 

| var_st 

var_st 

: q_string 

| string 

| var 

| var vs int 



Repair 

var_ask 

: ask_string var var 

| ask_string var var int 

| ask_int var var 

| ask_int var var int 

| ask_int var var int int int 

var_calc 

: calc var assignop expr 

expr 

: expr addsubop term 

| term 

term 

: term mulop factor 

| factor 

factor 

: po expr pc 

| int 

| var 

int 

: digit 

| digit int 

reg_string 

: string 

| reg_expr 

| reg_expr reg_string 

| string reg_string 

reg_expr 

: var vs int vs 

| wildcard 

q_string 

: q char_seq q 

| string 

string 

: daisy_char 

| daisy_char string 

char_seq 

: char 

| char char_seq 

var 

: vid int 


Repair 


// 

// terminal symbols 

// 

addop : + 

addsubop : addop 

| subop 

assignop : = 

char 

: each element of the character 

string except NL and " 

daisy_char 

digit 

EOF 

file 

mulop 

: ASCII characters ranging 

0x2b (+) – 0x5f(_) 

: one of 

0 1 2 3 4 5 6 7 8 9 

: End of file 

: A valid file name 

: one of 

* / 

NL 

: Line separator, 

\n and \r\n are accepted 

pc : ) 

po : ( 

q : " 

subop : - 

vid : $ 

vs : ! 

wildcard : % 



Repair 

Commands 

msgbox 

Msgbox var 

Creation of a message box with the text of variables. 

The message box comprises two push buttons: Ok and Cancel. 

After pressing Cancel, the Script is terminated, otherwise it is continued. 

Example: 

calc $1 = 4 * 5 

set $2 = "PP Result: " + OK + " " + $1 

msgbox $2 

wait 

wait int 

The program run is stopped for ms. 

Example: 

Wait 1000 

include 

Include file 

The indicated file is included in the Script, recursive including being trapped. 

Example: 

include q:\dlabscripts\a.txt 

trace 

trace rest_of_line 

trace var 

8 rest_of_line 

The variable or the String are output in the Trace window and the Tracefile is 

output 

Example: 

trace_var $1 

trace hello world, it is 11:20 now 


Repair 


cmd, answer, comment, var_read, var_ask_int 

ask_int var text len min max 

User input, a dialogue appears for the entry of numeric values. 

var and text are variables, len, min and max are optional 

Integers. 

Example: 

set $1 = "Please enter a digit number:" 

ask_int $3 $1 2 10 80 

set $1 = "The variable $3 has the value: " + $3 

msgbox $1 

var_ask_string 

ask_string var text len 

User input, a dialogue appears for the entry of the character string 

value. 

var and text are variables, len, min and max are optional 

Integers. 

Example: 

set $1 = "Please enter a character string:" 

ask_string $3 $1 6 

set $1 = "The variable $3 has the value: " + $3 

msgbox $1 



Repair 

MiniCalc - calc 

MiniCalc is an Interpreter to calculate numeric 

expressions. The basic calculation operations (+ - 

* /), the allocation (=) and the setting into brackets 

((4+7)*8) of expressions are supported. The result 

must be allocated to a variable, variables and 

Integers are admissible as operands. 

Syntax: 

calc var = expr 

Example: 

calc $1 = 10 

calc $2 = 90 

calc $3= ($1 * $2 + 100 - 200) / 2 

set $4 = "($1 * $2 + 100 - 200) / 2 = " + $3 

msgbox $4 

String Allocation – var_set 

Example: 

calc $1 = 4 * 10 

set $2 = "ipv" + $1 

msgbox $2 

# variable are indicated with leading zeros 

set $2 = "ipv" + $1!6 

msgbox $2 


Repair 


Example of a Script 

# 

# timeout for scriptfile 

# 

#timeout 50000 

# send command to IP 

# 

cmd IP IASCAN3072204801 

# 

# wait max. 1 second for the answer and extract the last 8 

# characters in the variable $3 

# 

answer IASCAN$3!8! 1000 

# 

# shows the last 8 characters 

# 

set $2 = "the last 8 characters of the answer: " + $3 

set $2 = $2 + ". Is this answer ok ?" 

#msgbox $2 

set $2 = "Please enter a two-digit number:" 

ask_int $2 $2 1 1 4 

msgbox $2 

cmd IP IASCAN30722048$2!2! 

calc $1 = 0 

loop 10 

# loopcounter 

calc $1 = $1 + 1 

# send command to IP 

# 

cmd IP IASCAN3072204801 

# 

# wait max. 1 second for the answer and extract the last 8 

# characters in the variable $3 3000 

# 

answer IASCAN$3!8! 



Repair 

# build trace string 

set $2 = "loop " + $1 + "answer: " + $3 

# write trace message 

trace_var $2 

# wait 3 seconds 

wait 3000 

end_loop 

set $4 = "release frame, command: IFSCAN " + $3!8 

trace_var $4 

cmd IP IFSCAN$3!8! 

wait 3000 


Repair 


Exiting the Service Mode 

After the service mode has been exited, a Reset is 

performed for all assembly groups. 

The start screen of the d-lab.3 user interface is 

displayed. 

Caution! 

The service technician has to make sure that the 

assembly groups are not in error conditions which 

cannot be recognised by the Software during the 

Reset. 

002 



Repair 

■ 


Repair 

Scanner 

Contents 

General Overview .................................................................................................................................... 4.1.1 

Sensors / Loads in the Scanner ......................................................................................................... 4.1.1 

Block Circuit Diagrams........................................................................................................................... 4.1.3 

Scanner, Data / Signals...................................................................................................................... 4.1.3 

General Scanner Control.................................................................................................................... 4.1.4 

Image Recording................................................................................................................................ 4.1.5 

Scanner Motherboard......................................................................................................................... 4.1.6 

Driver Sensor Board........................................................................................................................... 4.1.9 

LH Output Stage............................................................................................................................... 4.1.12 

FD/SD Output Stage ........................................................................................................................ 4.1.13 

FL Controller..................................................................................................................................... 4.1.14 

Algorithm/Interface Board ................................................................................................................ 4.1.16 

APS Magnetic Decoder .................................................................................................................... 4.1.18 

CG Controller ................................................................................................................................... 4.1.19 

CCD Board....................................................................................................................................... 4.1.21 

Image Data....................................................................................................................................... 4.1.22 

Prescanner....................................................................................................................................... 4.1.23 

Signal Lists .............................................................................................................................................. 4.2.1 

Description / Abbreviations of Assembly Groups ............................................................................... 4.2.1 

Scanner SC / Scanner Parts SP ........................................................................................................ 4.2.2 

Lamphouse LH................................................................................................................................... 4.2.2 

Mirror Box MB .................................................................................................................................... 4.2.3 

Lens Group LG................................................................................................................................... 4.2.3 

Film Feeder FF................................................................................................................................... 4.2.3 

Negative Carrier NC........................................................................................................................... 4.2.4 

Prescanner SC................................................................................................................................... 4.2.4 

CCD Group CG .................................................................................................................................. 4.2.4 

Other Sensors .................................................................................................................................... 4.2.4 

Activation of Motors and Loads............................................................................................................. 4.2.5 

Stepper Motor Data............................................................................................................................ 4.2.5 


Scanner 

Repair 

Functional Description............................................................................................................................4.3.1 

Mechanical Structure / Electrical Structure.........................................................................................4.3.1 

Components .......................................................................................................................................4.3.2 

ON and Film Stop Key........................................................................................................................4.3.2 

Scanner Optic.....................................................................................................................................4.3.3 

Functional Description............................................................................................................................4.3.4 

After the Insertion of a Film ................................................................................................................4.3.4 

Exposure Path ....................................................................................................................................4.3.4 

Main Scan Cycle.................................................................................................................................4.3.5 

Functions and Properties of the Components in the Exposure Path ................................................4.3.6 

Lamphouse.........................................................................................................................................4.3.6 

Halogen Lamp ....................................................................................................................................4.3.6 

Filters..................................................................................................................................................4.3.6 

Light Shutter LH_MO03 / CG_MO03..................................................................................................4.3.9 

Mirror Box .........................................................................................................................................4.3.10 

Auxiliary Shutter (Dust shutter / frosted glass) .................................................................................4.3.11 

Negative Mask..................................................................................................................................4.3.12 

Prescanner / Scanner.......................................................................................................................4.3.14 

Lenses ..............................................................................................................................................4.3.17 

CCD (Main Scan) .............................................................................................................................4.3.18 

Functions and Properties of the Components of the Film Drive ......................................................4.3.19 

Position of the Feeders FF_MO01 ...................................................................................................4.3.19 

Film Transport in the Feeder FF_MO02...........................................................................................4.3.20 

Position of the Film Drive Roller FF_MO04......................................................................................4.3.20 

Position of the Gear FF_MO03.........................................................................................................4.3.20 

Film Drive NC_MO01 .......................................................................................................................4.3.21 

Magnet Negative Pressure NC_MG01 .............................................................................................4.3.21 

Scanner Carriage SC_MO01............................................................................................................4.3.21 


Repair 

Scanner 

Control.................................................................................................................................................... 4.3.23 

Scanner Motherboard....................................................................................................................... 4.3.23 

LH Output Stage............................................................................................................................... 4.3.24 

FD/SD Output Stage (Film drive / Scanner drive) ............................................................................ 4.3.25 

FL Controller..................................................................................................................................... 4.3.25 

Algorithm/Interface Controller .......................................................................................................... 4.3.28 

APS Magnetic Decoder .................................................................................................................... 4.3.30 

CG Controller (CCD Group Controller) ............................................................................................ 4.3.31 

CG_GS01 - CCD Board ................................................................................................................... 4.3.32 

Driver Sensor Board......................................................................................................................... 4.3.33 

Bus Systems and Interfaces................................................................................................................. 4.3.34 

CAN Bus........................................................................................................................................... 4.3.34 

LVDS ................................................................................................................................................ 4.3.34 

RS232 .............................................................................................................................................. 4.3.34 

Ethernet............................................................................................................................................ 4.3.34 

I 2 C Bus ............................................................................................................................................. 4.3.35 

Repair / Adjustments............................................................................................................................... 4.4.1 

KG Segment....................................................................................................................................... 4.4.1 

Shutter................................................................................................................................................ 4.4.3 

Filter Wheel ........................................................................................................................................ 4.4.4 

Dust Shutter ....................................................................................................................................... 4.4.6 

2-Film Feeder..................................................................................................................................... 4.4.7 

Negative Carrier ............................................................................................................................... 4.4.14 

Replacing the Zoom / Fixed Focus Lens..........................................................................................4.4.21 

Replacing the Boards ....................................................................................................................... 4.4.22 

Precanner Adjustment...................................................................................................................... 4.4.23 

Prescanner Adjustment with Film..................................................................................................... 4.4.24 

Scanner Calibration.......................................................................................................................... 4.4.27 

Prescanner Calibration..................................................................................................................... 4.4.30 

AGFA d-lab.3 2001-01-02 /PN 9009 4.iii

Scanner 

Repair 

■ 

4.iv 2001-01-02 /PN 9009 AGFA d-lab.3

Repair 

Scanner 

General Overview 

Sensors / Loads in the Scanner 

Lamphouse (LH) 

LH_LS01 Initialisation filter wheel 

LH_LS02 Initialisation KG filter paddles 

LH_LS03 Initialisation light shutter CLOSED 

LH_MO01 Filter wheel drive 

LH_MO02 KG filter paddles 

LH_MO03 Wheel light shutter drive 

LH_MS01 Monitoring lamphouse opening 

LH_FA01 Cooling of the filter group 

LH_FA02 Cooling of the el. rack 

LH_LA01 Scanner light 250W / 24V 

LH_GS01 Flow sensor 

Mirror Box (MB) 

MB_MO01 Mirror box motor (frosted glass flap) 

MB_LS01 Position monitoring of the mirror box motor 

Film Feeder (FF) 

FF_LS01 Feeder zero position monitoring 

FF_LS02 Detection: Film in Feeder 

FF_LS04 Detection: Film in front of rocker 

FF_LS05 Detection: Rocker up 

FF_LS06 Detection: Rocker down 

FF_LS07 Detection: Film driver roller up 

FF_LS08 Detection: Film driver roller down 

FF_MO01 Feeder motor (film width adjustment) 

FF_MO02 Film transport in Feeder 

FF_MO03 Rocker movement 

FF_MO04 Film driver roller position 

Film Feeder (FF) 

NC_LS01 - 

NC_LS06 Film mask coding 

NC_LS07 Position monitoring auxiliary drive LHS 

NC_LS08 Position monitoring auxiliary drive RHS 

NC_MO01 Film drive 

NC_MO02 Position motor auxiliary drive LHS 

NC_MO03 Position motor auxiliary drive RHS 

NC_MG01 Negative pressure solenoid 

Prescanner (SC) 

SC_LS01 Scanner sledge zero position monitoring 

SC_MO01 Scanner sledge motor 

Dust Shutter (DS) (prototypes) 

DS_LS01 Initialisation auxiliary shutter 

DS_MO01 Auxiliary shutter motor 

CCD Group (CG) 

CG_MO01 Zoom: Rotation of the chip through 90° 

CG_FA01 Cooling CCD 

dlabr188 

AGFA d-lab.3 2001-01-02 /PN 9009 4.1.1

Repair 

Scanner 

Block Circuit Diagrams 

Scanner, Data / Signals 

dlabr090 

AGFAd-lab.3 2001-01-02 /PN 9009 4.1.3

Scanner 

Repair 

General Scanner Control 

dlabr044 

1 Scanner lamp 9 Film pressure 

2 Shutter + LS-Signal for T interrupt 10 Lens + CCD image recording (Zoom + Controller / fixed focus lens) 

3 Filter wheel colour 11 Dust shutter 

4 Filter wheel brightness / shutter 12 Video preamplifier (on CCD) 

5 Frosted glass of mirror box 13 CCD fan 

6 Film Feeder 14 Prescanner, SC-Controller 

7 Negative carrier 15 Lamphouse fan 

8 Film 16 Video A/D converter (on CG-Controller) 

4.1.4 2001-01-02 /PN 9009 AGFA d-lab.3

Repair 

Scanner 

Image Recording 

dlabr042 


Scanner 

Repair 

Scanner Motherboard 

LH 

FD/SD 

FL 

A/I 

APS 

CG 

LH Output stage 

FD/SD Output stage 

FL Controller 

Algorithm/Interface Board 

APS Magnetic decoder 

CG Controller 

dlab045e 


Repair 

Scanner 

Scanner Motherboard: LEDs 

LED Sensor Function ON when 

D1 LH_LS01 Light sensor for Zero Positioning Filter wheel Light sensor open 

D2 LH_LS02 Light sensor for Zero Positioning KG-Filter Light sensor open 

D3 LH_LS03 Light sensor for Zero Positioning Shutter Light sensor open 

D4 LH_LS04 (not used) — 

D7 DS_LS01 Light sensor for Zero Positioning Dust Shutter Light sensor open 

LH_LS05 

D8 — Service PC Timer (not used) — 

D9 — Sensor Service switch on (S3) 


Scanner 

Repair 

Scanner Motherboard: Connection of the Loads, Sensors, Boards 

dlab080e 


Repair 

Scanner 

Driver Sensor Board 

dlabr047 


Scanner 

Repair 

Driver Sensor Board: LEDs 

LED Sensor Function ON when 

D4 MB_LS01 Light sensor for mirror box Mirror box pushed in 

D8 FF_LS05 Light sensor for gear position Gear up 

D9 FF_LS06 Light sensor for gear position Gear down 

D11 FF-LS01 Zero position feeder width Light sensor open 

D12 FF_LS07 Position Feeder auxiliary drive Feeder auxiliary drive up 

D13 FF_LS08 Position Feeder auxiliary drive Feeder auxiliary drive down 

D14 NC_LS07 Left auxiliary drive Light sensor open 

D15 NC_LS08 Right auxiliary drive Light sensor open 

D16 NC_LS01 

D17 NC_LS02 

D18 NC_LS03 Negative carrier Light sensor open 

D19 NC_LS04 

D20 NC_LS05 

D21 NC_LS06 

D25 FF_LS04 Film detection Film in front of gear 

D26 FF_LS02 Film detection Film in Feeder 

D27 SC_LS01 Zero position prescanner carriage Light sensor open 

D30 MB_MO01 Frosted glass Frosted glass up 

D31 FF_MO04 

D32 FF_MO03 

D33 NC_MO03 

D34 NC_MO02 

D35 NC_MG01 

D37 FF_MO01_DIR 

D38 FF_MO01_CLK 

D39 FF_MO02_DIR 

D40 FF_MO02_CLK 

D41 FF_MO01_ENA 

D42 FF_MO02_ENA 


Repair 

Scanner 

Driver Sensor Board: Connection of the Loads, Sensors 

dlabr043 


Scanner 

Repair 

LH Output Stage 

dlabr067 

LH Output Stage: LEDs 

LED Sensor LED Sensor LED Sensor 

D10 LH_MO01_IO D17 LH_MO03_I1 D24 LH_MO04_IO 

D11 LH_MO01_I1 D18 LH_MO02_IO D25 MS2_OUT 

D12 LH_MO01_DIR D19 LH_MO02_I1 D26 MS2_IN 

D13 LH_MO01_CLK D20 LH_MO02_DIR D27 CG_MO01_DIR 

D14 LH_MO03_CLK D21 LH_MO02_CLK D28 LH_MO04_I1 

D15 LH_MO03_DIR D22 LH_MO04_CLK D29 CG_MO01_BUSY 

D16 LH_MO03_IO D23 LH_MO04_DIR 


Repair 

Scanner 

FD/SD Output Stage 

dlabr085 

LED FD/SD Output Stage 

D1 

TEMP_ERR 

LED Film Advance Master 

D9 

Reset 


Scanner 

Repair 

FL Controller 

dlab081e 


Repair 

Scanner 

FL Controller: LEDs 

LED 

D1 

D2 

D3 

D4 

D5 

D6 

D7 

D8 

D9/STATUS 

D38/TX 

D39/TX 

D40/RX 

D40/RX 

Function 

Software internal 


without function 



flashes, when a stepper motor runs in PWM mode 

flashes, when a stepper motor runs in CC mode 

flashes, when film advance is active; 

if LED does not flash, the software has crashed 

on, when film advance not in Reset 

CAN 

RS232 

CAN 

RS232 


Scanner 

Repair 

Algorithm/Interface Board 

dlab082e 


Repair 

Scanner 

Algorithm/Interface Board: LEDs 

LED 

D1 

D2 

D3 

D4 

D5 

D6 

D7 

D8 

D9/STATUS 

D10/TX 

D11/RX 

D12/LNK 

D13/SEL 

D14/RX 

D15/TX 

Function 

Software internal (Watchdog) 


flashes while motor moves during film positioning 

flashes during interrupt, when prescanner can receive data 

flashes when controller active; 

if LED does not flash, the software has crashed 

ON when controller not in Reset 

Ethernet 

Ethernet 

Ethernet Link = cable connected 

Ethernet 

CAN 

CAN 


Scanner 

Repair 

APS Magnetic Decoder 

ST1 

I²C 

EEPROM 

I²C Bus 

CAN 

PCA82C250 

CAN Bus 

A 

D 

8 

Microcontroller 

SAB 163CS 

FIFO 

SM_CLK 


SAB 167CS 

FILM_IN 

PERFO 

A 

D 

8 


SAB 163CS 

FIFO 

ST6 

Bootstrap 

Logic 

Reset 

Logic 

APS-Magnetic decoder: LEDs 

LED Function 

D11 Fast flashing: Slow running light: 

D12 Magnetic data being processed Waiting for data 

D13 

D14 Flashes for successful evaluation of the 

magnetic data (per frame) 

D7 Fast flashing: Slow running light: 

D8 Magnetic data being processed verarbeitet Waiting for data 

D9 

D10 

D31 

D32 

D33 

D34 

D40 

D29 

D27 

D35 

D36 

D37 

Flashes for successful evaluation of the 

magnetic data (per frame) 

Heartbeat 

Fifo 

CAN 

CAN 

CAN 

hw_spec_007 


Repair 

Scanner 

CG Controller 

dlab083e 


Scanner 

Repair 

CG-Controller: LEDs 

LED 

D1 

D2 

D3 

D4 

D5 

D6 

D7 

D8 

D9 

D10 

D11 

D12 

D13 

D14 

D15 

D16 

D17 

D18 

D19/RxD 

D20/TxD 

D21 

D22/+3.3 

D23/+5A 

Function 

Heartbeat: flashes (approx. every second), when film advance is active. 

If LED does not flash, the software has crashed 


on when FPGA not in Reset 

on when Controller not in Reset 

CAN 

CAN 

3.3 V 

5 V 


Repair 

Scanner 

CCD Board 

dlabr084e 


Scanner 

Repair 

Image Data 

CCD resolution: 

2 K x 3 K = 6.000.000 pixel 

The image data is transmitted analogue to the CG 

board and are digitised there by means of 

Correlated Double Sampling: 

Each pixel is digitised twice (dark and bright value). 

The dark value is subtracted from the bright value. 

The CCD is output from 4 quadrants, allowing a 

higher speed. 

Resolution of the AD converter: 

12 Bit = 4.096 steps 

Speed of the AD converter: 

The output of a complete image takes about 

180 ms. 

dlab121e 

The lens and the CCD are adjusted fixedly with 

respect to each other: 

Always replace the two units together in the field! 


Repair 

Scanner 

Prescanner 

dlab091e 


Scanner 

Repair 

■ 


Repair 

Scanner 

Signal Lists 

Description / Abbreviations of Assembly Groups 

Abbreviation 

BK 

CF 

CG 

CL 

CU 

DS 

EK 

FE 

FF 

FT 

FW 

LG 

LH 

MB 

NC 

NM 

SC 

SF 

SH 

SL 

SM 

SP 

ZH 

Assembly Groups 

Block assy 

Cartridge Feeder 

CCD-Group 

Cleaner 

Paper Cutter 

Dust Shutter 

External Keyboard 

Film Exit 

Film Feeder 

Film Take Up 

Filter Wheel 

Lens Group 

Lamp House 

Mirror Box 


Negative Mask 

Scanner 

Scanner Frame 

Shutter 

Single Lens 

Slide Mask 

Scanner Parts 

Zoom Holder 

The abbreviations of sensors and loads indicate 

their assembly group, e.g.: 

MB_MO01 = Mirror box motor 

See Allocation of Assembly Groups and Parts 

Functions, register 2 


Scanner 

Repair 

Scanner SC / Scanner Parts SP 

No. Designation Task Control 

SC_LS01 Light sensor Zero position Scanner carriage FL-Controller 

SC_MO01 Stepper motor 5 Ph. Motor scanner carriage, 

FL-Controller 

U = 24V, Iph = 0,75A 

SP_FA02 Fan Cooling E-Insertion, U = 24V (not switched) — 

Lamphouse LH 

Mechanically split up into the modules LA (Lamphouse) and FG (Filter group) 


LH_LS01 Fork light sensor Filter wheel initialisation FL-Controller 

LH_LS02 Fork light sensor Initialisation KG filter paddle FL-Controller 

LH_LS03 Fork light sensor Light shutter initialisation – CLOSED CG- Controller 

LH_LS05 Fork light sensor Initialisation wheel auxiliary shutter FL- Controller 

LH_MO01 2PH-Stepper 1,8° Filter wheel drive => 

FL-Controller 

fmax = 3,5 kHz, Iph = 3,4 A, U = 36V 

Half step 

LH_MO02 2PH-Stepper 1,8° KG Filter paddle => 

FL-Controller 

fmax = 3,5 kHz, Iph = ?, U = 36V 

Half step values 

LH_MO03 2PH-Stepper 1,8° Wheel light shutter drive => 

FL-Controller 

fmax = 4,0 kHz, Iph = 3,5A, 

Half step 

U = 36V 

LH_MS01 Interlock switch Lamphouse opening control for lamp change — 

(risk of glare) 

LH_MS02 Interlock switch Filter wheel motor, switch off the segment motor — 

to clean the filter ! 

LH_FA01 Fan Filter group cooling 

— 

U = 24V (not switched) 

LH_LA01 Halogen lamp Scanner light 250W / 24V — 

DS_MO01 2PH-Stepper 1,8° Wheel auxiliary shutter (located above lens, but FL-Controller 

functionally belonging here) corresponds to PIKO 

frosted glass! 

U = 36V , Iph = 1,7 Amax. 

DS_LS01 Fork light sensor Initialisation wheel auxiliary shutter (functionally 

belonging here) 

— 


Repair 

Scanner 

Mirror Box MB 


MB_MO01 DC motor Mirror box motor (frosted glass flap), 

FL-Controller 

U = 12V 

MB_LS01 Fork light sensor Position monitoring of mirror box motor (frosted FL-Controller 

glass flap) 

MB_COD — Mirror box coding Driver Sensor 

MB_DONE — Signal from Hardware that the motor was stopped Driver Sensor 

MB_OK — Signal that the mirror box has been pushed in Driver Sensor 

Lens Group LG 


LG_HS01 Temperature Temp. compensation for fixed focus lens sensor CG-Controller 

sensor 

on CCD Controller 

Film Feeder FF 


FF_LS01 Fork light sensor Feeder zero position monitoring (Init. Feeder FL-Controller 

motor) 

FF_LS02 Reflex-LS3 Detection whether film in Feeder FL-Controller 

FF_LS04 Reflex-LS3 Detection whether film in front of gear FL-Controller 

FF_LS05 Fork light sensor Detection gear up FL-Controller 

FF_LS06 Fork light sensor Detection gear down FL-Controller 

FF_LS07 Fork light sensor Detection film drive roller up FL-Controller 

FF_LS08 Fork light sensor Detection film drive roller down FL-Controller 

FF_MO01 2PH-Stepper 1,8° Feeder motor (film width adjustment) 

FL-Controller 

U = 24V, Iph= 0,9A 

FF_MO02 2PH-Stepper 1,8° Film transport into Feeder, U = 24V, Iph= 0,9A FL-Controller 

FF_MO03 DC motor Movement / Position of gear, Un = 12V FL-Controller 

FF_MO04 DC motor Position of film drive roller, Un = 12V FL-Controller 


Scanner 

Repair 

Negative Carrier NC 


NC_LS01- Fork light sensor Negative carrier coding FL-Controller 

NC_LS06 

NC_LS07 Fork light sensor Position monitoring auxiliary drive LHS FL-Controller 

NC_LS08 Fork light sensor Position monitoring auxiliary drive RHS FL-Controller 

NC_MG01 Lifting magnet Magnet negative pressure FL-Contr, U = 24V FL-Controller 

NC_MO01 Stepper motor 5 Ph. Film drive, U = 24V, Iph = 0,95A FL-Controller 

NC_MO02 DC motor Position motor auxiliary drive LHS, U = 12V FL-Controller 

NC_MO02_ 

DONE 

— Signal from hardware that motor has been 

stopped 

NC_MO03 DC motor Position motor auxiliary drive RHS, U = 12V FL-Controller 

NC_MO03_ 

DONE 

— Signal from hardware that motor has been 

stopped 

Prescanner SC 


SC_LS01 Fork light sensor Zero position monitoring Scanner carriage FL-Controller 

SC_MO01 Stepper motor 5 Ph. Scanner carriage motor, U = 24V, Iph = 0,75A FL-Controller 

CCD Group CG 


CG_MO01 Motor Zoom: Chip rotation 90° CG-Controller 

CG_FA01 Fan Cooling CCD (not switched) CG-Controller 

Other Sensors 

No. Designation Task 

FILM_NOTAUS 

FILM_FWD 

FILM_REW 

general keys Emergecy OFF switch 

Film transport (advance) 

Film transport (backward) 

TEMP_ERR — Temperature control of the drivers for the stepper motors for film 

advance and scanner on FD/SD output stage 


Repair 

Scanner 

Activation of Motors and Loads 

Stepper Motor Data 

Name Designation Motor type, 

angle 

Operating 

mode 

Rated 

voltage 

[V] 

Starting/ 

breaking 

current 

[A] 

Running 

current 

[A] 

DS_MO01 Auxiliary shutter 2PH, 1.8° Half step 24 1,7 1,4 0,3 

0,9° 

FF_MO01 Feeder motor 2PH, 1.8° Full step 24 0,9 

FF_MO02 Film transport in 2PH, 1.8° Full step 24 0,9 

Feeder 

LH_MO01 Filter wheel 2PH, 1,8° Half step 32 – 40 3,4 3,2 0,3 

0,9° (24) 

LH_MO02 KG filter 2PH, 1.8° Half step 32 – 40 2,0 2,0 1,0 

0,9° (24) 

LH_MO03 Light shutter 2PH, 1,8° Half step 32 – 40 3,9 3,0 1,0 

0,9° (24) 

NC_MO01 Film drive 5PH, 0.72° Full step 0,95 

SC_MO01 Scanner carriage 5PH, 0.72° Full step 0,75 

Stop 

current 

[A] 

Direction of rotation / transport (cw turning) (3) 

Name Control, output Direction of rotation 

stage (1) 

with DIR=High (2) 

DS_MO01 FL, LH LHS OPEN-CLOSED frosted glass 

FF_MO01 FL, DS — Feeder closes 

FF_MO02 FL, DS — Film moving out of the Feeder 

LH_MO01 FL, LH LHS R-Neg, R-Dia, G-Neg, G-Dia, .... 

LH_MO02 FL, LH LHS Filter is turned out 

LH_MO03 CG, LH LHS See separate description 

NC_MO01 FL, FD/SD RHS Film transported to the right 

SC_MO01 FL, FD/SD RHS Scanner pushed into the light path 

(1) FL FL Controller 

GG GC Controller 

LH LH Output Stage 

DS Driver/Sensor-Board 

FD/SD FD/SD Output Stage 

(2) The direction for DIR=High is defined when looking 

on the turning motor shaft. 

(3) The direction of rotation / transport refers to a cw 

turning motor. 


Scanner 

Repair 

■ 


Repair 

Scanner 

Functional Description 

Mechanical Structure / Electrical Structure 

The Scanner assembly groups are exchangeable 

thanks to clearly defined mechanical and electrical 

interfaces. 

1 

SK01 LH 

SK02 FD/SD 

SK03 FL 

SK04 A/I 

SK05 APS 

SK06 CG 

Mechanical structure: 

1 Film Feeder 

2 Lamphouse 

3 Filter 

4 Mirror box 

5 Film Take Up 

6 Negative carrier 

7 Prescanner 

8 Fan for film advance electronic 

9 CCD fan 

10 CCD 

11 Print chuter 

12 Zoom / fixed focus lens 

dlab143 

Electrical structure: 

1 Motherboard with 


FD/SD Output Stage 

FL Controller 

A/I Board 


CG Controller 

2 Driver Sensor Board 

3 SC_GS01 Prescanner Board 

4 ZO_GS01 Zoom Board 

5 CG_GS01 CCD Board 

4 

5 

2 

3 

dlabr144 


Scanner 

Repair 

Components 

− Control (motherboard with PCBs) and 

light source / lamphouse (1) 

− Exposure filter (2) 

− Mirror box (3) 

− Film advance 

− Film Feeder (4) 

− Negative carrier (5) 

− Prescanner (6) 

− Film advance electronic 

− CCD fan (7) and CCD (8): 

The air is sucked in through the film chuter (9) 

and guided to the electronic through the fan. 

− Zoom (10) 

− Fan (11) for film advance electronic 

Film advance: see also Functions and Properties of 

the Components of the Film Drive in this register 

dlabr018 

ON and Film Stop Key 

− ON key (1) 

− TIMER lamp (2) 

− Film stop key (3) 

dlabr1778 


Repair 

Scanner 

Scanner Optic 

dlab149e 


Scanner 

Repair 


After the Insertion of a Film 

− The film is caught by the transport roller TR3 in 

the Film Feeder. 

− The Prescanner moves into the negative mask 

and performs the calibration: 

Brightness and colour measurement of the 

printing lamp light 

− The Prescanner scans the film; the TFS and the 

exposure parameters are defined. 

− The film is scanned after the CCD calibration: 

The exposure data is calculated and exposed by 

the exposure unit. 

Exposure Path 

− Prescan to define the APL (automatic 

positioning logic) and TFS values 

− Infrared scan to define the film grain, 

scratches and fluffs (on CCD area) 

− The adjustment of the negative size to the 

CCD chip size is done by the Zoom or fixed 

focus lens. 

− Main scan by means of CDD with a resolution 

of 2.048x3.064 pixels 

dalbr133 

1 Lamp 

2 Exposure filters 

3 Mirror box 

4 Film advance 

5 Lens 

6 CCD area 


Repair 

Scanner 

Main Scan Cycle 

Filter 

wheel in R 

Scan pos. 

Fully close light shutter 

Slip 

correction 

Close negative 

pressure 

Open 

dust 

shutter 

Red scan 

Exposure 

red at 70 ms 

pixel exposure 

time 

Filter wheel in 

G Scan position 

Output 

red image 

Green scan 

Exposure 

green at 100 ms 


time 


B Scan pos. 

Output 

green 

image 

Blue scan 

Exposure 

blue at 220 ms 


time 


IR Scan pos. 

Move out 

KG filter 

Output 

blue 

image 


Prescan pos. 

Move in 

KG filter 

Output 

IR image 

IR Scan 

Exposure 

IR at 60 ms 


time 

Close 

dust 

shutter 

Terminate Scan 

Open negative 

pressure 

Fully open 

light shutter 

Film transport 

next frame 

dlabfe11 


Scanner 

Repair 

Functions and Properties of the Components in the Exposure Path 

Lamphouse 

− KG5+IR-UV: Cold glass and IR absorption for 

heat filtering 

− RG850 for Infrared Scan 

− Light dimmer (Mask filter) 

− Light shutter 

− Exposure filter wheel with 8 positions: 

red, green, blue always for frame and slide, light 

dimmer, free 

Halogen Lamp 

The lamp is subject to warming up and ageing 

effects. The Prescanner is used instead of a 

sensor to measure the lamp brightness 

(calibration measurement of each film). 

Filters 

The lamp drift is compensated by the white 

balance in comparison with the RGB colour filters 

and the calibration of the Prescanner (only 

negative, no slide). 

The RG850 filter for the IR-Scan has also to be 

calibrated. As the KG5 filter is always in the light 

path upon the RGB Scan, it is always calibrated 

automatically as well. 

Colour Filter Wheel: 50% Filter 

For the fast mirror box 135, the 50% filter in the 

colour filter wheel has to be moved in for the 

Prescan; also for the calibration of the Prescanner 

in order to prevent thermal overload of the film 

(Fading). 

The 50% filter itself need not be calibrated. 


Repair 

Scanner 

Filter Wheel LH_MO01 

The filter wheel stepper motor is connected to the 

filter wheel by a toothed belt. The filter wheel can 

hold eight filters (in cw order): 

1. free 

2. RED-Negative 

3. RED-Slide 

4. GREEN-Negative 

5. GREEN-Slide 

6. BLUE-Negative 

7. BLUE-Slide 

8. Light dimmer 

The zero position is reached with light sensor 

LH_LS01. 

The motor is energised by different currents via 

LH_MO01_I0 and LH_MO01_I1: 

A 

B 

Arrow 

dlabr153 

Zero position (position for the 1 st exposure) 

Initialisation position (Position LH_LS01) 

Direction of rotation 

I0 0 1 0 1 

I1 0 0 1 1 

Current 100% 72% 38% 0% 

The motor runs in half step mode: 

− Step angle 1,8° 

− Transmission of 3:1. 

The filter wheel is turned through 0.3° per step. 

150 steps must be performed between the filters. 

− Direction of rotation of the filter with a cw turning 

motor: RED-Negative, RED-Slide, GREEN- 

Negative, etc. 

− Zero position of the light sensor with a cw turning 

motor: 6° before the RED-Negative filter 

− Clock: Indicated by LH_MO01_CLK 

− Direction: Can be selected by LH_MO01_DIR 

− When the lamphouse opens, the stepper motor is 

switched off. 


Scanner 

Repair 

KG Filter Wheel LH_MO02 

The KG filter wheel consists of two paddles: 

− The 1 st paddle (A) is linked rigidly with the motor 

shaft by a toothed belt. 

− The 2 nd paddle (B) is fastened on the motor shaft 

and can be turned. 

Both arms are linked by a spring which presses the 

KG5+IR-IV filter against the stop. 

The paddles can be pushed into the light path up to 

a stop, the light sensor LH_LS02 being covered. 

This is the starting position (KG+IR-UV filter in the 

light path). 

When the paddles are moved out of the light path 

by one filter position, the RG850 filter is in the light 

path. This filter is used for the Infrared Scan. 

When the filter is moved into the light path from the 

initial position, the first paddle moves (with the light 

dimmer) into the light path against the spring 

mechanism. In this position, two filters are in the 

light path: The KG+IR-UV filter and the light dimmer. 

Filter Positions 

When the filter is out of the light path, the light 

sensor is uncovered. When the KG+IR-UV filters is 

moved in, the light sensor (2) is covered. If the 

motor continues to turn, the KG5-IR+UV filter is 

pressed against the stop (1) by a spring, the light 

dimmer is moved in. 

A 1st paddle 

B 2nd paddle 

1 RG850-filter (IR-Scan) 

2 Stop 

3 Motor shaft 

4 Mask filter 

5 KG5+IR-UV filter 

dlabr021 

Filter 

moved out 

RG850 filter 

moved in 

KG5+IR-UV filter 

moved in 

(initial position) 

KG5+IR-UV and light 

dimmer moved in 

dlabr022/dlabr023 


Repair 

Scanner 


LH_MO02_I0 and LH_MO02_I1: 

I0 0 1 0 1 

I1 0 0 1 1 

Current 100% 72% 38% 0% 

The clock for the motor is defined by 

LH_MO02_CLK, the direction is selected via 

LH_MO02_DIR. 

When the lamphouse is opened, the stepper motor 

is switched off. 

Settings 

− KG: KG5 and UV-IR blocking for colour scans 

− RG: RG850 + IR band for IR Scans 

− KG + 20%: Calibration for shutter damping 

Light Shutter LH_MO03 / CG_MO03 

The exposure is executed by a rotating disk (light 

shutter / Shutter). The two wings cover the light 

path. The cutout (72°) releases the light path (2) 

during an exposure. 

The light shutter is driven by stepper motor 

LH_MO03. 

The light sensor LH_LS03 (1) opens just before the 

shutter completely opens the light path from the 

CLOSED position. 


LH_MO03_I0 and LH_MO03_I1. The clock for the 

motor is defined by LH_MO03_CLK and the 

direction is selected by LH_MO03_DIR. 

The motor has a step angle of 1,8°. As the motor is 

operated in half steps, the actual step angle is 0,9°. 

dlabr024 

1 Light sensor LH_LS03 

2 Light path 

Arrow Direction of rotation of a cw turning motor 

(looking on the shaft) 


Scanner 

Repair 

Mirror Box 

The mirror box influences the overall brightness 

and the illumination. 

The two mirror boxes can be changed any 

number of times. When a mirror box is changed, a 

complete initialisation including a calibration is 

performed. 

Mirror Box Versions 

− Fast for size 135 and smaller 

(small light transmission, hence faster) 

− Slow for sizes as of 4.5x6 

(large light transmission, hence slower) 

Mirror Box Motor MB_MO01 

Motor MB_MO01 can be used to fold an additional 

frosted glass in the light path. A control disk is 

fastened to the motor that covers the light sensor 

with varying segments. 

The motor position is defined by the light sensor 

MB_LS01. On the basis of the run times, the 

Software determines in which position the motor 

is. 

The motor stops automatically at a dark-light 

transition of the light sensor (signal MB_DONE). 

When the motor is switched back on, it moves 

automatically to the next position. The position 

can be defined by the varying length of the 

segments. 

It must be observed that the motor continues 

turning up to 30°. 

dlabr020 


Repair 

Scanner 

Auxiliary Shutter (Dust shutter / frosted glass) 

Only in prototype, omitted in mass production 

The shutter consists of a sector disk with 2 sectors. 

One sector is open, the other one comprises a 

pinhole plate with a defined transmission. 

Auxiliary Shutter Motor DS_MO01 

The auxiliary shutter covers the lens and serves as 

additional frosted glass for the pixel correction of the 

CCD. 

The auxiliary shutter consists of a paddle (directly 

linked with the stepper motor) with 2 filter sets. The 

frosted glass is mounted in one of them, the other 

one is fitted with a dark glass. 

The auxiliary shutter is driven by the stepper motor 

DS_MO01. It can take three positions: 

− Open (A) 

− Dark (B), initial position 

(closed, dust protection) 

− Frosted glass (C) 

Light sensor DS_LS01 is used for the zero 

positioning of the shutter in home position (B). This 

means that is opens when the dark field covers the 

light path. 

Stops prevent the auxiliary shutter from moving 

beyond the indicated positions. 

The filters are 28,8° apart. At a step angle of 0,9° 

(half step) this corresponds to 32 steps of the 

stepper motor DS_MO01. 

The motor is operated by different currents via 

DS_MO01_I0 and DS_MO01_I1: 

dlabr026 

1 Light sensor DS_LS01 

2 Frosted glass PIKO 

3 Dark field 

4 Light path 

Arrow Direction of rotation of the cw turning motor 

(looking on the shaft) 

I0 0 1 0 1 

I1 0 0 1 1 

Current 100% 72% 38% 0% 

The motor clock is given via DS_MO01_CLK, the 

direction, via DS_MO01_DIR. 


Scanner 

Repair 

Negative Mask 

Negative Mask Versions 

− 135 frame 

− APS 

− Rollfilm 120 (4,5x6, 6x6, 6x7, 6x9) 

− Slide 135 (small APS slide, no large sizes) 

Negative Masks Coding 

Position of the light sensors when the negative 

carrier is removed and turned: 

NC_LS01 NC_LS02 NC_LS03 NC_LS04 NC_LS05 NC_LS06 

dlabr120 

Negative mask NC_LS01 NC_LS02 NC_LS03 NC_LS04 NC_LS05 NC_LS06 

None 0 0 0 0 0 0 

135 FF (full frame) 1 1 1 1 1 1 

135 P (Panorama) 1 1 1 0 0 1 

135 HF (half frame) 1 1 1 0 0 0 

135 Hi Vision 1 1 1 1 0 1 

135 Fileprint 1 1 1 1 1 0 

135 with glass 1 1 1 0 1 0 

APS without magnetic reader 1 1 0 1 1 0 

APS with magnetic reader 0 1 0 1 1 0 

APS PIE mask 0 1 0 0 1 1 

110 (Pocket) 1 1 1 0 1 1 

120 6*4,5 1 1 0 1 1 1 

120 6*6 1 0 1 1 1 1 

120 6*7 1 0 0 1 1 1 

120 6*8 0 1 1 1 1 1 

120 6*9 0 1 0 1 1 1 

Slide not inserted => slide mask 0 0 0 1 0 1 

Slide inserted => slide mask 0 0 0 1 1 1 


Repair 

Scanner 

Position Auxiliary Drive LHS NC_MO02 / Position Auxiliary Drive RHS NC_MO03 

The auxiliary drives are positioned by DC motors: 

− NC_MO02 Auxiliary drive LHS 

− NC_MO03 Auxiliary drive RHS 

A control disk is used for the positioning of the 

auxiliary drives which activates and deactivates a 

light sensor (1) as a function of the angle: 

− NC_LS07 Auxiliary drive LHS 

− NC_LS08 Auxiliary drive RHS 

Upon the initialisation, the initial position must be 

found by means of the following signals: 

− NC_LS07 / NC_MO02_DONE LHS 

− NC_LS08 / NC_MO03_DONE RHS dlabr027 

The frosted glass turns in the indicated direction. In 

the figure, the auxiliary drive is in the bottom 

position. 

It must be observed that the motor continues turning 

approx. 30° when lowered. When lifted, the motor 

must press against a spring and therefore does not 

afterrun so much. 

The DC motor is switched off automatically by the 

Hardware at the dark/bright transition (DONE signal 

going to High). 

Upon the initialisation, the current position can be 

defined by time measurements on the light 

sensor (1). 


Scanner 

Repair 

Prescanner / Scanner 

− Transport, positioning (APL = automatic 

positioning logic, slip correction) and exposure of 

the inserted film for the Prescan and the main 

scan 

− Definition of the film and negative-specific 

exposure data (TFS) as well as of the exposure 

time for the main scan by the Prescanner 

− Digitising of the frames for the main scan by the 

CCD (exposure of the frame on the CCD) 

− The Prescanner is used to define the specific 

properties of the film prior to the main scan, like 

position and colour / density values of each 

individual frame / slide. 

− On this basis, a digital image of the frame / slide 

is created by the CCD unit (Main-Scan) and sent 

to the Main PC for image processing (image 

processing board). 

Prescanner 

Structure: 

The Prescanner has a density line and three colour 

lines fitted with photodiodes. Each colour line is 

1 mm wide and is 8 mm away from the other colour 

lines. The width of the density line is reduced by a 

shutter in the paper filter (ensures higher optical 

resolution). 

The structure of the lines for RGB is identical: 

They consist of 32 photodiodes, the first four and 

the last four being switched in pairs. This way, there 

are 24 individually addressable photodiodes that can 

be used as a function of the film size. 

The line for the density consists of 32 photodiodes 

switched in groups (as a function of the film size). 

The photodiodes are connected to amplifiers after 

they have been switched together which have the 

following functions: 


Repair 

Scanner 

Amplifiers, functions: 

− Setting the optimum amplification for the check of 

the photodiodes. For optimum utilisation of the 

modulation of the AD converter, the amplification 

factor for the current / voltage conversion can be 

modified. 

− Converting the current of the photodiodes into a 

voltage. 

Only the current of a photodiode is proportional 

to the infalling light. For this reason, the light 

must be measured here. The AD converter 

switched behind can only measure voltages. 

The amplification of the current/voltage converter is 

adjustable by the film drive processor. 

Functions: 

− The Prescanner is used to analyse the frames 

prior to the actual exposure and main scan 

procedure in the d-lab.3: 

For the Prescan, the Prescanner is moved into 

the light path and the film is passed over the 

Prescanner. For single frames, the Prescanner is 

put under the stationary frame. The film is 

digitised at low resolution while the colour and 

density values of the entire film including the 

border are collected. 

− The digitised data is transmitted to the FL 

Controller where the required integration times 

are found for each colour depending on: 

− the density of the individual frame 

− the colour corrections as a function of the film 

mask 

− the colour corrections as a function of a 

general colour cast on the film, e.g. on 

artificial light shots 

− Reading the DX code 

− Detecting the image boundaries for the 

subsequent image positioning 

− Exact image positioning during the film transport 


Scanner 

Repair 

The Prescanner collects the following data: 

− Brightness of the colours RGB 

− Density of the frame 

− Perforation 

− DX coding 

This data is edited and made available for the 

following actions and algorithms: 

− APL (Automatic Position Logic) 

− Slip correction 

− TFS (Total Film Scanning) 

− DX coding 

− Lamp brightness monitoring 


Repair 

Scanner 

Lenses 

− Fixed focal length for film sizes 135 and smaller 

− Zoom for all sizes 

The Zoom lens has a rotating chip structure 

because of the 120 size (4,5x6). The CCD is 

turned when the negative carrier is changed. 

The lens is only changed by the service. 

A lens change implies a complete initialisation as 

is the case upon switch-on. 

Zoom / Fixed Focus Lens and CCD (Main-Scan) 

The lens is used to show the negative image in such 

a way that it can be reproduced on the CCD with a 

slight lack of coverage of the size. 

To reproduce a 120 frame 4,5 x 6, the CCD is 

turned through 90° by a motor. 

The sharp reproduction of the frame on the CCD is 

ensured by the Autofocus function of the Zoom. 

Three colour extracts of the frame are projected on 

the monochrome CCD by means of the exposure 

filters. 

The board on which the CCD is mounted prepares 

the analogue signals for the AD converter of the CG 

Controller (CCD group) on the Motherboard. 

For quicker availability of the image data, the CCD 

is divided into 4 quadrants which are read out 

concurrently. 

The Zoom electronic mounted on the side of the 

Zoom has been matched to the corresponding 

Zoom and cannot be replaced separately. 

The CCD with 2048x3072 pixels (on the CD board) 

used to capture the images is directly connected to 

the Zoom. The Zoom and the CCD form a unit and 

must be replaced together. 


Scanner 

Repair 

CCD (Main Scan) 

CCD Rotation with 4,5x6 Negatives CG_MO01 

This DC motor turns the CCD through 90°. 

The feedback signal CG_MO01_BUSY remains 

active until the motor is switched off. 

If the level is changed by CG_MO01, the motor 

turns in the other direction. 

The motor is automatically switched off when it 

hits a stop and the current rises. A special 

mechanism makes sure that the motor is not 

switched off by the higher starting current when 

it starts running. 


Repair 

Scanner 

Functions and Properties of the Components of the Film Drive 

dlabr142 

1 Film advance incl. Film Feeder + Film mask 8 Fan for film advance electronic 

2 Film Feeder 9 Dust/auxiliary shutter 

3 Lamphouse 10 Zoom / fixed focus lens 

4 Exposure filters 11 CCD fan 

5 Mirror box 12 CCD (Main Scan) 

6 Film mask 13 Film chute 

7 Prescanner 

Position of the Feeders FF_MO01 

The Feeder motor opens the jaws in the Film 

Feeder. The motor has a step angle of 1,8°. 

− The zero position can be defined by the light 

sensor FF_LS01. It turns on when the Feeder is 

closed. The light sensor lights up when the 

Feeder is closed. 

The Feeder closes when the motor is turning cw. 

− The motor is energised by FF_MO01_ENA 

− FF_MO01_DIR indicates the direction 

− FF_MO01_CLK clocks the motor 


Scanner 

Repair 

Film Transport in the Feeder FF_MO02 

The motor FF_MO02 draws the film into the Feeder 

and transports it to the gear. 

The motor has a step angle of 1,8°. The 

transmission to the drive is 1:1. 

When the motor is turning cw, the film is exited from 

the Feeder. 

− Light sensor FF_LS02 recognises whether a film 

has been inserted in the Feeder 

− Light sensor FF_LS04 recognises whether the 

film is in front of the gear 

− FF_MO02_ENA energises the motor 

− FF_MO02_DIR indicates the direction 

− FF_MO02_CLK clocks the motor 

Position of the Film Drive Roller FF_MO04 

This DC motor positions the film drive roller in the 

Feeder. 

The light sensors FF_LS07 and FF_LS08 indicate 

the top and bottom position of the gear. 

The motor remains switched on until the film drive 

roller has reached its end position. 

Position of the Gear FF_MO03 

This DC motor positions the gear. 

The light sensors FF_LS05 and FF_LS06 indicate 

the top and bottom position of the gear. 

The motor remains switched on until the gear has 

reached its end position. 


Repair 

Scanner 

Film Drive NC_MO01 

The stepper motor NC_MO01 transports the film 

from the gear to the negative mask and further on. 

The motor has a step angle of 0,72°. The film is 

advanced 125µm per step. 

The film position is monitored by the Scanner. 

The motor is operated with different currents via 

NC_MO01_I0 and NC_MO01_I1. 


NC_MO01_CLK; the direction is selected by 

NC_MO01_DIR. 

A High level on DIR makes the motor turn cw, 

looking on the shaft. 

Magnet Negative Pressure NC_MG01 

The magnet NC_MG01 holds the frame in the 

negative mask. 

Scanner Carriage SC_MO01 

The stepper motor SC_MO01 moves the 

Prescanner. The motor has a step angle of 0,72°. 

The zero position can be reached by means of 

light sensor SC_LS01. 

The Scanner is in home position when it is not in 

the light path. In this position, the light sensor is 

closed. 

When the motor is turning cw (when looking on 

the motor shaft), the Scanner is moved into the 

light path. 


SC_MO01_I0 and SC_MO01_I1. 


SC_MO01_CLK; the direction is selected by 

SC_MO01_DIR. 

A High level on DIR makes the motor turn cw, 

looking on the shaft. 


Scanner 

Repair 

Concept of the CCD Signal Processing 

In order to improve the noise distance, the so-called 

CDS method (Correlated Double Sampling) is used: 

There is not only the actual pixel value for each 

pixel, but also a dark reference which takes into 

account local differences of the PRNU. PRNU are 

pixel-dependent voltage differences which do not 

depend on the time and the light. 

The two signals are found by a special CDS chip 

which exists separately for each quadrant of the 

CCD chip. The difference between these two signals 

is the output signal. 

The CCD chip comprises 6 additional lines per 

quadrant whose pixels are not active electrically. 

The average value of their contents serves as 

parameter to check the temperature or the dark 

current. 

Frosted Glass for Pixel Correction (Piko) 

A frosted glass is mounted in addition in the mobile 

pallet of the auxiliary shutter (dust shutter for the 

lens). 

− It is used for the calculation of the parameters 

needed for the multiplicative pixel correction. 

− It should ensure an optimum homogeneous and 

dustfree illumination. 


Repair 

Scanner 

Control 

The Motherboard links the various Scanner 

components: It holds a number of single boards 

which are connected to external components. 

Apart from this, the Motherboard provides the 

interfaces for a number of external components. 

The Main-PC controls the Scanner Hardware. The 

commands are sent to an FL Controller via an 

RS232 interface which transmits them via a CAN- 

Bus, or processes them itself, as required. 

Most of the components can output board-specific 

data via an I 2 C-Bus, e.g. version numbers. 

See Block circuit diagram Scanner Hardware in 

Register 4.1. 

Scanner Motherboard 

− The Motherboard can receive other boards. 

− The Motherboard distributes the load and sensor 

signals to the plug-in boards. 

− The power supply for the entire Hardware is 

connected to the Motherboard and filtered before 

it is made available to the boards, sensors and 

loads. 

− The Motherboard ensures the filtering of the 

signals and, if required, also the power supply for 

sensors that are directly connected to the 

Motherboard. 

− The Motherboard has an interface to the Main- 

PC (RS232) and a connection for the CAN-Bus. 

See Motherboard and LEDs in Register 4.1. 


Scanner 

Repair 

Power Supply 

The various components are energised via the 

Motherboard. The current comes from the power 

supply unit of the Printer energies by the power 

connection of the Paper Processor. 

Connecting voltages 

Voltage max. current Remark 

+5V 10A Switching power supply unit 

+15V 3A Linear regulation 

-15V 3A Linear regulation 

+24V 6A, temporarily 10A Switching power supply unit 

+36V 6A, 8A for 200 ms Switching power supply unit 


The LH output stage is located in the lamphouse. 

The motors are driven by the 

LH output stage: 

− LH_MO1 

− LH_MO2 

− LH_MO3 

− LH_MO4 

− CG_MO01 

Stepper motor filter wheel 

Stepper motor filter wheel paddle 

Stepper motor shutter 

Stepper motor auxiliary shutter 

DC motor to turn the CCD 

The signals for the stepper motors LH_MO01 and 

LH_MO02 are switched off in addition via 

LH_MS2_IN. This signal generates the lamphouse 

opening for cleaning / changing a lamp. 

See Driver Sensor Board and LEDs in Register 

4.1. 


Repair 

Scanner 

FD/SD Output Stage (Film drive / Scanner drive) 

The FD/SD output stage is a pure driver board of 

the stepper motors for the film advance and the 

Scanner carriage. The motors are 5-phase 

motors. PLDs are used for the activation that have 

to be programmed. The two connectors ST2 and 

ST3 are provided for the programming. 

The driver board gets the control signals via the 

Motherboard. The motor signals are also 

transmitted via the Motherboard. 

If the output stages get too hot, the driver board 

sends an error signal through the line TEMP_ERR 

that can be processed by the FL Controller. 

See FD/SD Output Stage and LEDs in 

Register 4.1 

FL Controller 

− This is the central control processor for the 

Scanner Hardware with an interface to the Main- 

PC (connection via RS232). 

− The commands received by the Main-PC are 

either transmitted to other components via the 

CAN-Bus, or they are processed by the FL 

Controller itself. 

− Control of motors, loads and sensors of the film 

advance. The status of the motors and the film 

can be checked by means of various sensors, 

mainly light sensors. 

− Control of the Prescanner. The TFS data is 

transmitted to the Main-PC (Ethernet). To ensure 

a clock-synchronous operation of the Prescanner 

and the film advance or Scanner motor, these 

clocks are divided and alternately sent to the 

Prescanner. 

− Monitoring of the voltages (by means of the AD 

converter of C167) and the temperature of the 

Scanner Hardware 

− Master for CAN-Bus and I 2 C-Bus 

See FL Controller and LEDs in Register 4.1. 


Scanner 

Repair 

Properties: 

− SAB 167CR as Microcontroller 

− 1Mbyte Flash to store codes and data (externally 

programmable by means of a Bootstrap logic) 

− 1Mbyte SRAM for data 

− 1Mbyte additional Flash (only equipped as an 

option) for special data 

− Bootstrap logic to program the Microcontroller 

from a PC (via RS232) 

− 1 SIO establishing the connection to the Main-PC 

(2 nd SIO is an option) 

− CAN-interface for the communication with other 

components of the SC Hardware 

− Temperature sensor (approximate measurement) 

− Digital inputs/outputs to control the loads and 

check the sensors 

− Analogue inputs to measure / control external 

voltages / temperature 

− I²C-EEPROM to store board-specific data, e.g. 

board numbers 

MAIN function: 

In the MAIN function, the following actions are 

performed: 

− Updating the status registers for the sensors 

− Execution of State machines for certain 

procedures (initialisation, exposure, etc.) 

− Interpretation of telegrams from the Main-PC 

− Editing telegrams 

− to the Main-PC 

− for the CAN-Bus 

− Transformation of messages from CAN-Bus to 

telegrams on the Main-PC 

− Performance of commands of the Main-PC 

− Check of certain statuses (doors, temperatures) 


Repair 

Scanner 

Functions: 

− Control of stepper motors (film drive, Scanner 

carriage, filter wheel, KG filter, auxiliary shutter, 

Feeder motor, film transport in the Feeder) 

− Control of the DC motors (gear, position of film 

drive roller, mirror box motor, position of the 

auxiliary drive left/right) 

− Control of fans (negative cooling) 

− Control of the magnet for the negative pressure 

− Control of the Feeder 

− Control of the film drive (film pulled in, film 

positioned, APL) 

− Voltage monitoring 

− Temperature monitoring (on the FL Controller 

and the output stages for the stepper motors) 

− Monitoring of the temperature switch 

− Monitoring of the sensors 

− Check of the Film mask coding 

− Control and monitoring of the mirror box (type of 

mirror box, move in frosted glass) 

− Assessment of keys 


Scanner 

Repair 

Algorithm/Interface Controller 

Functions: 

− Activation of the Prescanner and adjustment of 

the stepper motor clocks for the Prescanner 

− Assessment of the data for the APL (Automatic 

positioning logic) and slip correction 

− Calculation / performance of the slip correction 

− Entry of the TFS data from the Prescanner 

− Scanner configuration 

− Interface to the APS magnetic decoder 

(Assessment of the DX coding) 

− Transfer of the TFS data to the Main-PC 

(Ethernet) 

The A/I Controller processes the following data 

flows: 

− Data from the Prescanner via special interface 

and FIFO 

− Data from the APS magnetic decoder via the 

CAN-Bus 

− Data to the Main PC via the Ethernet 

This data is needed for the following functions : 

− Calibration of the Prescanner 

− Entry of the reference data for single frames and 

for a film (brightness adjustment) 

− Monitoring of the lamp light 

− Entry of the Prescan data 

− Normalisation of the Prescan data with the 

reference data (brightness adjustment) 

− Resorting of the Prescan data for the transfer to 

the Main PC 

− Calculation of the APL 

− Slip monitoring 

− Transfer of the APS magnetic data to the Main 

PC via the Ethernet 

− Positioning of the Prescanner 


Repair 

Scanner 

The TFS is not performed on the algorithm board, 

but on the PC (see previous section FL Controller) 

See Algorithm/interface board and LEDs in 

Register 4.1. 

Properties: 



programmable by means of a Bootstrap logic) 


− Bootstrap logic to program the Microcontroller 

from a PC (RS232) 

− CAN-interface for the communication with other 

components of the SC Hardware 


board numbers. 

− LEDs to show the internal statuses 

− Selection of the clocks for the Prescanner. 

By means of a selector logic, the clocks of the 

film advance or Scanner motor can be sent to the 

Prescanner undivided or divided in two. This 

allows the Prescanner to synchronise with the 

film or carriage movement. 

− Ethernet Controller (10 MBit) for fast data 

transfer to the Main-PC 


Scanner 

Repair 


The APS magnetic decoder uses the data of the 

magnetic track of an APS film and processes 

them. The data is transmitted to the 

algorithm/interface board for further assessment. 

Coding on APS films: 

− 2 magnetic tracks on which the operator can 

save data by means of the APS camera 

− 2 magnetic tracks on which the photofinisher can 

alter or add product-specific data 

− Film-specific information can be saved in the film 

tip area 

− Data that only holds for one frame (picture title, 

aspect ratio, exposure data) is recorded in the 

so-called negative data area 

See APS Magnetic Decoder and LEDs in 

Register 4.1. 

Superior data for Photofinishing 

Magnetic image data for Photofinishing 

Optical image data of the manufacturer 

Magnetic camera image data (customer entries, 

e.g. size) 

Optical camera image data (customer entries, e.g. 

size) 

• Panorama 

•• Classic 

__ High Vision 

Superior optical data of the camera (exposure 

conditions, e.g. flash) 

Superior magnetic data of the camera (exposure 

conditions, e.g. flash) 

Superior optical data of the manufacturer 


Repair 

Scanner 

CG Controller (CCD Group Controller) 

− Control of the exposure by way of loads / sensors 

(e.g. turning CCD, shutter motor) 

− Black value corrections (control of the voltage for 

the SW balance for CCD) 

− Dark and light current measurements 

− Preprocessing of the image data of the CCD 

(Digitising of the image data) 

− Transfer of the image data: After the AD 

conversion, the image data is preprocessed in 

the FPGA (Field Programmable Gate Array), 

multiplexed 4:1 and transmitted to the image 

processing card (VIPS) in the Main-PC in the via 

an LVDS interface. 

− Setting the clock phase for the AD conversion 

See CG Controller and LEDs in Register 4.2. 

Properties: 



programmable by means of a Bootstrap logic). 

The Flash also holds the programming of the 

FPGA. 


− CAN-Bus for the communication with other 

components of the SC-Hardware 

− Digital inputs/outputs to control the loads and 

check the sensors 

− FPGA (freely programmable logic): Control of the 

CCD and preprocessing of the image by the CCD 

− Four fast AD converters with a 12 Bit resolution 

for the image signals from the four quadrants of 

the CCD 

− Transmission of the image data to the Main-PC 

via multiplexed LVDS lines 

− Transmission of the control signals to the CCD 

board via differential lines 

− D/A converter for the adjustment of the black 

value on the CCD 


board numbers 


Scanner 

Repair 

CG_GS01 - CCD Board 

− CG_GS01 is linked rigidly with the lens 

− Monochrome CCD chip 

− Processing of the control signals (level 

conversion) for the CCD 

− Adjustment of the image signals 

(preamplification) of the CCD for the AD 

converter on the CG Controller 

− Setting of the voltages for the black value 

balance 

The level of the current supply of the CCD with 

respect to GND is shifted by means of the SW 

balance so that an easy activation of the video 

preamplifiers is possible. The analogue data is 

transmitted to the CG Controller. 

The CCD board gets the following control signals 

from the CG Controller: 

− Clock (10MHz) 

− vertical and horizontal synch signals 

− special signals for the output of the CCD lines 

Differential line pairs ensure an almost troublefree 

transmission. 

The dark current of the CCD can be balanced by 

means of a black value balance of the CG 

Controller. 

To get optimum conditions for the preamplification 

of the image signals, the whole power supply of the 

CCD can be shifted. This is achieved via the input of 

the black value balance. 

See CCD board and LEDs in Register 4.1. 


Repair 

Scanner 

Driver Sensor Board 

The driver sensor board is located above the film 

advance, behind the mirror box. 

All loads and sensors of the film drive are 

connected here (except the Prescanner). 

See Driver Sensor Board and LEDs in Register 

4.1. 


Scanner 

Repair 

Bus Systems and Interfaces 

CAN Bus 

The CAN Bus is used for the internal 

communication of the Scanner Hardware. 

The following units are connected to the CAN Bus: 

− FL Controller as Master 

− Algorithm/interface board 

− CG Controller 

− APS Cartridge Feeder 

− Zoom (Lens Group) 

The ID of the CAN nodes is set in the Software and 

not by way of DIP switches. 

The Software protocol is specified in Register 8 

Software. 

LVDS 

Interface (differential line pairs) between the CG 

Controller and the image processing board in the 

Main PC. 

RS232 

Serial interface between the Motherboard and the 

Main PC. 

Ethernet 

There are 2 network boards with a transmission 

speed of 10 MBit/sec and 100 MBit/sec in the 

Main PC. 

The 10 MBit board is used for the data transfer 

between the algorithm/interface board and the 

image processing board (VIPS) in the Main PC. 

The 100 MBit board connects the d-lab.3 to an 

external network. 


Repair 

Scanner 

I 2 C Bus 

The 2-Bit bus on the Motherboard links all boards 

of the Scanner on which Hardware and Software 

conditions are checked. There is an EEPROM on 

each one of these boards. 

The version number coding of the board is 

checked on the I 2 C-Bus. 

Version Number Coding of the Boards in the Film Advance 

To facilitate the maintenance and troubleshooting, 

the development status of the larger boards is 

recognised while the d-lab.3 is running and is 

reported to the Main-PC. 

− When the Layout / the component equipment is 

changed, an Index is counted up on the board 

concerned so that the current machine 

configuration can be recognised in case of 

problems. 

− The version number is saved in the serial 

EEPROM X24C02. 

− The EPROM’s of all new boards are linked by a 

2-Bit-Bus (I 2 C-Bus) on the Motherboard. 

− The FL Controller can address each EEPROM 

individually and check the version number via this 

Bus during operation. 


Scanner 

Repair 

■ 


Repair 

Scanner 

Repair / Adjustments 

KG Segment 

1 IR filter (golden shining side up) 

2 Belt 

3 Light dimmer 

4 KG5 glass 

5 UV/IR filter, swivelling 

Toothed belt adjustment: 

Belt tension 110 Hz ± 10% 

Meter 

F = 1,2 ± 0,1 N 

with 2 mm deflection 

(see Fig. on the next page) 

The steel core ends of the belt are opposite the 

test point 

Belt tension meter or meter 

Calliper gauge 

− Check the belt tension with a belt tension meter 

dlabr219 

dlabr220 

1 Toothed belt 

2 Steel core cut 

3 Measuring head (frequency measurement on the 

other side of the steel core ends) 


Scanner 

Repair 

− Check the belt deflection 

dlabr221 




Repair 

Scanner 

Shutter 

Toothed belt: 

Visual check: Must not brush 

Toothed belt pulley on the motor: 

Starting torque of the clamp 

1,8 Nm ± 0,1 Nm 

Toothed belt pulleys (visual check) 

In alignment 

Height mismatch ≤ 1 mm 

Toothed belt: 

Belt tension 191 Hz ± 10% 

Alternative F = 1,1 ± 0,1 N 






dlabr222 



3 Markings (must point towards each other) 

4 Measuring head 

dlabr223 





Scanner 

Repair 

Filter Wheel 

Replacing the Filter Wheel 

Screwdriver 

− Unscrew 4 screws (see arrow) 

− Disconnect the cable 

− Remove the filter wheel and mount it again 

Toothed belt: 

Belt tension 

Alternative 

150 - 190 Hz 

F = 3,2 ± 0,3 N 


(= belt thickness) 

dlabr059 







4 Measuring head 

5 Cast cutout 

6 Filter wheel 

dlabr224 


Repair 

Scanner 





4 Cast cutout 

5 Filter wheel 

dlabr225 

Replacing single Exposure Filters 

Caution! 

Be sure to switch off the lamp, otherwise the prism 

glass will burn. 

− Lock the lamp opening mechanism with the 

black lever. 

− Slightly lift the filter cover (1) and pull it off to 

the front (2): The exposure filter wheel is accessible 

− Turn the filter wheel until the desired filter is accessible. 

Confusion is not possible, thanks to 

the fool-proof shape of each individual filter and 

the filter holder. 

− Visual check 

− The spring must jam the filter safely (no gap 

between the spring and the glass filter) 

− The spring ends must rest safely against the 

inner stop (spring locking; the spring is 

slightly pretensioned towards the inside) 

dlabr058 

dlabr060 


Scanner 

Repair 

Replacing the Filter Motor / the Light Sensor 

Toothed belt pulley motor: 

Clamping tool 

Starting torque 1,8 Nm ± 0,1 Nm 

Light sensor: 

Axial distance to filter wheel (visual check) 

> 0,5 mm 

Toothed Belt Pulleys, Adjustment 

Toothed belt pulleys: 

Aligned 

Height mismatch ≤ 1 mm 

The belt must not brush 

Dust Shutter 

Omitted in mass production 

Light sensor: 

− The paddle must not brush: 

A Paddle centred between the base and cover 

plate and parallel 

B Paddle brushes on the sliding foil; parallel 

alignment with the base plate 

C Paddle not at an angle on the motor shaft or 

sagging; unparalleled alignment with respect 

to the base plate; the paddle only brushes 

on the sliding foil at the end of the swivel 

area 

− Light sensor position 

Move the paddle in home position (initialisation) 

Offset adjustment by the Software; no light sensor 

adjustment required. 

1 Paddle 

2 Sliding foil 

3 Cover plate 

4 Base plate 

dlabr226 


Repair 

Scanner 

2-Film Feeder 

Dismounting the 2-Film Feeder 

Short screwdriver 

− Unscrew the screw and 

− Pull out the cover to the front 

− Dismount the 2-Film Feeder: 

It is fastened on the negative carrier with 3 

screws. 

− Remove the screws (1) 

− Lift the Feeder up and off 

1 

dlabr190 

1 

dlabr191 

All units are easily accessible after the Feeder has 

been removed. For this reason, the removal and 

installation are not described in detail here. 


Scanner 

Repair 

Film Guide, coarse Adjustment 

An adjustment becomes necessary when the gear 

position on the shafts changes, e.g. after the replacement 

of the toothed belt. 

− Unscrew the cover plate 

− Remove gear B and turn the stop ring to the 

RH end of shaft B 

− Detach skid A from shaft A (grub screws) 

− Hold shaft A tight and turn gear A until the 

threadless end of the shaft is just reaching 

2 mm out of the associated bush. The shoulder 

of gear A must not slip out of its hole! 

− Push skid A to the middle up to the stop and 

fasten it on shaft A 

− Turn gear A approx. half a ccw turn 

− Detach skid B from shaft B (grub screws) 

− Push skid B out up to the stop 

− Relocate shaft B until the threadless end of the 

shaft is just reaching 2 mm out of the associated 

bush 

1A Skid A 1B Skid B 

2A Shaft A 2B Shaft B 

3A Gear A 3B Gear B 

4 Stop ring 

5 Cover plate 

6 Lug 

dlabr245 

− Fasten skid B again on shaft B so that the shaft 

extends 2 mm and the skid is completely at the 

outer edge 

− Push skid B to skid A, hold them tight 

− Turn the stop ring until skid B starts moving to 

the right 

− Put on gear B 

− Screw on the cover plate 

− Move the Feeder in position 120 and in zero 

position: 

In none of the two positions should the threadless 

end of a shaft reach into the associated 

bush (overtravel 0,5 - 1,8 mm). 

− If necessary, repeat the coarse adjustment 


Repair 

Scanner 

Installing the Feeder 

− Lift the top film transport roller 

− Put the Feeder on the negative carrier on a 

slant from above, inserting the film exit flap 

between the top and bottom film transport 

roller. 

− Screw on the Feeder 

Film Guide, Adjustment 

− Position (alignment) of the Feeder skids with 

respect to the negative mask 135FF: 

Feeder skids adjusted to the film transport 

width in the negative mask; adjustment including 

the slant of the skids 

∆x = 0 ± 0,3 mm (metal gauge 35) 

− Close the driver to the gauge width 

− Detach the Feeder skids from the shaft 

− Push them manually towards the inserted 

metal gauge 135 and jam them 

− Fasten the skids 

∆x is the widest distance between the metal 

gauge and the left or right Feeder skid 

− Open and close the skids several times 

electrically and check the dimension 

1 Negative mask 135F 

2 Feeder 

3 Gauge 

dlabr233 

Film guide widths of the Feeder: 

135 35,15 - 35,65 mm 

110 16,00 - 16,50 mm 

120 62,20 - 62,70 mm 

IX240 24,05 - 24,55 mm 


Scanner 

Repair 

Detection of the Film Transport Width 

Zero position gauge 

− Insert the zero position gauge 

− Turn the toothed belt wheel to close the Feeder 

skids until the gauge 135 is jammed (zero position) 

− Slacken the light sensor actuator and pull it out 

of the light sensor 

− Push the actuator back into the light sensor until 

the latter lights 

− Fasten the actuator again 

− Open the skids to size 120 (Service) 

− Move the skids back into home position 

− The gauge must fit again with a play of 

±0,1 mm, correct if necessary, or repeat the 

adjustment 

In home position, the skids are asymmetric with 

respect to the optical axis. 

1 Light sensor actuator 

dlabr246 

2-Film Feeder, Adjustments 

Meter 

Toothed belt tension, width adjustment: 

Force F = 1,5 - 2,5 N with a 

Path ∆x = 2 mm 

Toothed belt tension, additional drive: 

Force F = 2-3 N with a 

Path ∆x = 2 mm 

dlabr227 


Repair 

Scanner 

Feeder rocker 

Feeler gauge 

− Feeder rocker (visual check) 

Swivel area smooth moving 

Move the rocker up and down in the service 

mode. 

− Position rocker up 

Height between film skid in negative carrier 135 

and bottom rocker edge 

x =≥ 1,5 mm 

− Position rocker down 

Height between film skid in negative carrier 135 

and top rocker edge 

min. 

max. 

x =≥ 1,0 mm 

The bottom rocker edge must not 

be under the stopping slant 

1 Negative mask 

2 Feeder rocker 

dlabr228 

− Rollers in the rocker (visual check): 

− Free moving (not brushing anywhere) 

− Rubber rings not damaged 


2 Negative mask, stopping slant 

dlabr229 


Scanner 

Repair 

Additional drive: 

− Pressure force of the counter roller in closed 

condition, measured under spring load when 

the air gap between the rollers disappears 

(before the rollers are lifted) 

7 - 9 N (meter) 

− Film tractive force; drive active, force to stop 

the film while the drive is running 

F ≥ 2,0 N (test leader, spring balance) 

Light sensors FF_LS02 and FF_ LS04: 

− Height of the light sensors 

Distance between varnished surface on 

Feeder cast part and front surface of reflected 

light sensor 

FF_LS02 and FF_LS04 

x = 8,5 ± 0,5 mm (calliper gauge) 

dlabr231 

Adjustment of the Feeder: 

− x direction: 

Distance between the upper FF rocker and the 

negative carrier 135FF 

∆x = 0,5 ± 0,1 mm (feeler gauge) 

− Operate the rocker manually: 

Dimension at the narrowest point ∆x 

dlabr232 


2 Feeder rocker 


Repair 

Scanner 

− Light sensor actuator: 

15 ± 0,1 mm after the adjustment with the 

metal gauge (15 mm wide) 

Adjust the Feeder and move it into zero position 

(distance 15 mm, move the driver in closed direction 

of the skids) 

− Detach the light sensor actuator and move it 

into the light sensor from the outside until 

the latter responds 

− Fasten the light sensor actuator 

− After opening the skids to size 120 and 

closing them again to zero position, the dimension 

between the skids must be again 

15 ± 0,1 mm. 

− If necessary, correct the light sensor actuator 

1 Light sensor actuator 

2 Gauge 

dlabr234 


Scanner 

Repair 


Removing the Negative Carrier 

Some parts, e.g. the film drive and rocker motors, 

are only accessible after removal of the negative 

carrier. 

Screwdriver 

Caution! 

Do not unscrew the red lacquer-sealed banjo 

bolts. 

− Unscrew the marked screws (arrows) 

− Lift off the negative carrier 

#negcar01 

1 Banjo bolt: Do not touch! 

2 Active film exit 


Repair 

Scanner 

Changing the Lifting Magnet, toothed Belt and auxiliary Drive Shaft 

Allen key 

Screwdriver 

Lifting magnet: 

− Unscrew the marked screws (grub screws) 

− Pull off the magnet 

Belt: 

− Pull off the additional gear incl. the armature 

plate 

− Change the belt 

Auxiliary drive shaft: 

− Unscrew the holder (3 screws) 

− Pull out the shaft; the bearings can be removed 

after the lock washer has been removed 

− Mind the correct position of the holder when 

mounting it again (see Figure) 

dlabr247 

1 Magnet 

2 Armature plate 

3 Gear 

4 Holder 

5 Auxiliary drive shaft 

6 Lock washer 


Scanner 

Repair 

Working on the Rockers 

The removal and installation of the two rocker 

motors and eccentric blocks are identical 

− Unscrew the cover plate incl. the light sensor 

− Pull out the motor 

− Remove the lock washer on the eccentric block 

Caution! 

Do not dismantle the eccentric block, only replace 

it as a complete unit. 

− Pull out the eccentric block: 

The preceding gear need not be removed; only 

rocker shaft A has to be pulled out a little. 

− Dismounting the rocker: 

− Remove the lock washer from the rocker eccentric 

− Pull out rocker shaft B: 

Mind the washers; note down the position 

− Remove the lock washer in the rocker 

Caution! 

Do not try to detach the rocker eccentric from the 

rocker. 

− Pull off the rocker with the eccentric 

See Figure on the next page 


Repair 

Scanner 

1a Cover plate A 1b Cover plate B 

2a Motor A 2b Motor B 

3a Eccentric block A 3b Eccentric block B 

4a Rocker shaft A 4b Rocker shaft B 

5a Rocker 5b Rocker eccentric 

dlabr251 


Scanner 

Repair 

Mounting the rocker: 

− Remove the guide plates 

− Remove the bottom rubber roller: 

− Jam the shaft: Push a pin or a hexagon key 

through the hole in the motor shaft 

− Unscrew the marked screw 

− Pull off the roller 

− Push the rocker with the inserted spring a few 

mm on the shaft; for the spring position see 

Figure below 

− Turn the rocker until it sits on the motor shaft 

(eccentric hangs down) 

− Turn the spring until the long leg is on the 

rocker: The leg moves away from the rubber 

roller towards the motor shaft. 

− Push the rocker incl. spring completely on the 

shaft: The short leg of the spring slides into the 

recess on the shaft. 

− Turn the rocker against the spring tension until 

it rests on the negative carrier (eccentric is also 

in contact) 

− Fasten the bottom rubber roller again on the 

motor shaft 

− Put the lock washer in the rocker 

− Screw the blades on the negative carrier 

1 Blades 

2 Motor shaft 

3 Bottom rubber roller 

4 Rocker 

dlabr252 


Repair 

Scanner 

Changing the Light Sensors for the Negative Carrier Coding 

− Press down the snap locks of the light sensor 

holder a little and push the unit to the back 

− Lift off the light sensor 

dlabr249 

1 Light sensor holder with light sensor 

2 Cover plate 

3 Locking knob 

Changing the Negative Carrier Lock 

Caution! 

Change only the complete lock. 

− Change: 

− Unscrew the cover plate (2 screws) 

− Remove the lock 

− Installation: 

Mind the correct position of the locking knob 

(see Figure above) 


Scanner 

Repair 

Negative Carrier, Adjustments 

Belt tension: 

F = 1 N results in a 

2 - 3 mm deflection or 

160 ± 20 Hz 

1 Tensioning roller 

dlabr235 

Meter or belt tension meter 

Pressure force of the counter rollers in closed 

condition, measured under spring load when the 

air gap between the rollers disappears (before the 

rollers are lifted): 

left (TR4) 7 - 9 N 

right (TR5) 7 -10 N 

Meter 

Film tractive force per drive, always one drive active, 

force to stop the film while the drive is running: 

F ≥ 5,0 N always for TR4 / TR5 

Test leader, spring balance 


Repair 

Scanner 

Replacing the Zoom / Fixed Focus Lens 

Screwdriver 

− Dismount the fan (2 screws) 

− Remove the film chuter (4 screws) 

dlabr113 

− Carefully turn the CCD cw through 90º by hand: 

The connectors are then accessible 

− Remove 2 connectors 

− Remove the Zoom / the fixed focus lens 

(4 screws, see arrows) 

dlabr114 

dlabr189 


Scanner 

Repair 

Replacing the Boards 

− Remove the cover (1) 

For better access, the complete Motherboard 

with the boards can be lifted approx. 10 cm and 

locked: 

− Push in the locking tongue 

− Pull the locking lever in the lamphouse to the 

front 

− Remove the board: 

Hold the board only by the handles provided for 

this. 

dlabr002 

038a 


Repair 

Scanner 

Precanner Adjustment 

The sledge motor is directly accessible, the 

toothed belt and the scanner sledge, after the 

negative carrier has been removed. 

Reference value for the toothed belt tension: 

with approx. 2,5N the deflection is 3 mm 

All measuring cells are located directly on the 

scanner board. The board can be removed without 

problems from the scanner sledge and put back. 

dlabr250 

1 Scanner tray 

2 Sledge motor 


4 Scanner sledge 

5 Scanner board 


Scanner 

Repair 

Prescanner Adjustment with Film 

− Mirror box pushed in 

− Lamp switched on 

− Prescanner adjustment film available 

When the lamp switch is operated and the machine 

is switched on, the lamp holder must not be 

moved out as otherwise the exposure filters will 

burn. 

The adjustment film ETN is used to measure the 

two tracks of the DX code simultaneously. 

Definitions: 

V front near the operator 

H back away from the operator 

XX No. of DX codes read at the front 

YY No. of DX codes read at the back 

Do not cut the adjustment film into pieces as otherwise 

no exact measurement is possible! 

The display does no longer show the measured 

average signal amplitude, but the absolute number 

of DX codes read. 

DX Reading 

Open the LOG file and check the DX values 


Repair 

Scanner 

Remove the following parts / covers: 

1. Negative carrier 

2. Mirror box 

3. Film supply + Film Feeder 

4. Lamphouse lid 

5. Air filter cover 

6. Front cover (grey): 

lift a little at the back (arrow 1) and then pull it 

off to the front (arrow 2), see Figure below 

7. PC cover 

8. Film Take Up 

dlabr174 

Allen key, short 

− Push the scanner sledge to the left: 

Take the paper filter (1) and push it to the left 

up to the stop 

− Slacken 3 scanner tray fastening screws (2) 

with the Allen key 

dlabr058 

dlabr172 


Scanner 

Repair 

− 2 mm Allen key long (approx. 23 cm) 

− Open the front door 

− Adjust the scanner: 

The screw can be reached through the hole (1) 

with the long Allen key 

If the Prescanner can only be set in tolerance 

when the scanner tray is at the back stop, the 

cone shaft unit (single frame positioning) must be 

replaced. 

As this unit is adjusted as a complete unit, it can 

only be replaced completely (part no. on demand). 

dlabr171 

dlabr248 

Adjustment Film, Scope of Delivery 

Pcs. Designation Part no. 

1 Test film with 2 DX tracks CM+9.8506.9931.1 

1 Allen key CM+9.9999.1036.0 

1 Instruction 

The attached Allen key cannot be used for the 

adjustment of the d-lab.3. 


Repair 

Scanner 

Scanner Calibration 

The following calibration procedures are performed 

automatically when required. It is not necessary 

that a technician or the operator intervenes. 

The Scanner contains several optical elements 

which are calibrated automatically. 

− Replacement of the light sensors in the lamphouse: 

The film drive software automatically finds the 

exact positions of the 3 light sensors in the 

lamphouse and the light sensor of the KG segments 

when the corresponding routines are 

called up. The positions are stored internally in 

an EEPROM. 

− White balance: 

Red, green, blue scan without a film to check 

the balance. 

Brightness changes, above all of the lamp 

brightness, are compensated. 

− CCD pixel correction 

Calibration Procedures, Correlations 

Performed upon: 

Calibration 

Pixel 

correction 

White 

balance 

IR adjustment 

Shutter 

damping 

Prescan 

Switch-on X X X X X 

Lamp change X X X X 

Mirror box inserted X X X X 

Negative carrier inserted (X) X X X 

Prescanner calibrated X X 

CCD dark reference defined X X X 

− X: 

The calibrations marked by an X must be performed 

when the corresponding component is 

modified. 

− (X): 

Required when a negative carrier is inserted for 

a different frame size. 


Scanner 

Repair 

Order of Calibration Procedures 

− Pixel correction 

− Dark 

− Bright 

− White balance (filter / lamp calibration) 

− Prescanner 

− RGB 

− IR 

− Shutter damping 

− Zoom lens 

Pixel Correction (Piko) 

This calibration ensures that the CCD chip is 

standardised and supplies the same signals for all 

pixels. Only then can the CCD be used as tool for 

other calibrations, e.g. for the white balance. 

The pixel correction is always performed when 

modifications are carried out on the light path 

which have an impact on the spacial light distribution 

on the CCD (e.g. lamp change, cleaning of 

filters and other optical components) or when the 

electrical properties of the chip themselves change 

(e.g. due to temperature). 

Compulsory pixel correction: 

− At the first switch-over to a larger size 

− After the installation of the mirror box 

− After the lamp has been moved in, even if it 

was not changed. 

− After the change of the negative mask 

Blemish correction: 

Here, defective CCD pixels are found. 


Repair 

Scanner 

White Balance 

A white balance is performed when 

− the light quantity on the CCD absolute and in its 

spectral composition has changed 

− a pixel correction has been performed since the 

last white balance 

The white balance ensures that an image signal of 

4.095 means "white without a film". On this basis, 

an appropriate exposure time can be controlled as 

a function of the film mask and the film density. 

The lamp brightness is monitored for each film by 

the Prescanner. 

The overall calibration of the Prescanner is performed 

by force when the mirror box or the lamp is 

changed. Otherwise for each film when an overdrive 

of a photocell is recognised. 


Scanner 

Repair 

Prescanner Calibration 

Calibration Methods 

No. Calibration Remark 

1 Finding the zero position Position in which the light sensor responds (Prescanner 

moves to the left) 

2 Finding the print position Scanner keeps on moving until the density array is 

exactly under the right perforation (maximum light) 

3 Finding the Scan position Scanner keeps on moving until the density array is 

exactly under the left perforation 

4 Setting the amplification factors for 

the colour arrays for the negative 

scan 

5 Finding the amplification factors for 

the colour arrays to define the lamp 

brightness 

6 Setting the amplification factors for 

density, DX, Perfo 

7 Measuring the light without a film 

(bright alignment) 

The amplification factors are adjusted until no photodiode 

is overdriving. The mask factor is switched off 

(on 1). Illumination with white light (no IR). 

The amplification setting is calculated on the basis of 

the setting of the amplification factors for the colour 

arrays for the negative scan in such a way that the 

photodiodes are driven to half output. This amplification 

setting is kept up to the next white balance of the 

Main Scanner. The measurement of the lamp brightness 

serves to trigger a white balance of the Main 

Scanner. 

The amplification factors are adjusted until no photodiode 

is overdriving. In contrast to the colour arrays, 

the mask factor is adjusted as well. Light adjustment 

as above. 

The resulting values for all photodiodes are used as 

reference for the Scan. 

8 Measuring the lamp brightness No actual calibration of the Prescanner, but described 

here as it is necessary as Trigger for the white balance 

of the Main Scanner. 

Along with the amplification factors defined before 

(half full-scale deflection) the Prescanner moves in 

scanning position without a film with white light (no 

IR). While it is moving, the measuring values are integrated 

for each colour over a fixed path. 

If the deviation from the last measuring value is too 

important (spectral or in terms of brightness), a new 

white balance of the Main Scanner is performed. 

If the deviation is small, the measuring values are 

used for the correction of the integration times. 

Not calibrated 

Mask factor (component tolerance, depending on the 

selected amplification) and dark Offset 


Repair 

Scanner 

Moment of Execution of the Calibration Methods 

Moment 

New start 

Mirror box change 

Negative carrier change 

Insertion of a film strip 

(prior to the Prescan) 

Start of the exposure of 

single frames 

Calibration method 

Finding the zero position 

Finding the print position 

Finding the Scan position 

Setting the amplification factors for the colour arrays: 

Negative scan and determination of the lamp brightness 

Setting the amplification factors for density, DX, Perfo; 

Measurement of the light quantity as reference 















Measuring the lamp brightness 

Setting the amplification factors for the colour arrays for the negative 

scan 

Measuring the light without a film (bright adjustment) 

Measuring the lamp brightness 

Setting the amplification factors for the colour arrays for the negative 

scan 

Measuring the light without a film (bright adjustment) 


Scanner 

Repair 

■ 


Repair 

Main-PC 

Contents 

Overview ..................................................................................................................................................... 5.1 

Main-PC ................................................................................................................................................ 5.1 

Interfaces / Connections ....................................................................................................................... 5.1 

Drives .................................................................................................................................................... 5.3 

Hard Disk .............................................................................................................................................. 5.3 

Graphic Card......................................................................................................................................... 5.3 

Ethernet Boards .................................................................................................................................... 5.3 

PC-Mainboard ....................................................................................................................................... 5.4 

Timer Board .......................................................................................................................................... 5.6 

Image Processing Board (VIPS) ........................................................................................................... 5.6 

BIOS Settings........................................................................................................................................ 5.7 

Jumper Settings of the Drives ............................................................................................................... 5.8 

Operating System.................................................................................................................................. 5.9 

Radio Shielding ..................................................................................................................................... 5.9 

Functional Description ............................................................................................................................ 5.10 

Repair ........................................................................................................................................................ 5.11 

Removal of the PC .............................................................................................................................. 5.11 


Main-PC 

Repair 

■ 


Repair 

Main-PC 

Overview 

Main-PC 

dlabr014 

Interfaces / Connections 

dlabr287 

1 Machine sticker 1 Power supply 8 Network 2 

2 AC Input 9 Network 1 

3 Printer 10 Graphic card 

4 Scanner 11 Parallel Port 

5 PCMCIA Controller 12 Keyboard 

6 Timer board 13 Mouse 

7 Image processing 


Main-PC 

Repair 

Serial Interfaces / 8-port SIO (RS232) 

ST01 

ST02 

ST03 

ST04 

ST05 

ST06 

ST07 

ST08 

ST09 

3 wires 

7 wires 

7 wires 

3 wires 

3 wires 

7 wires 

3 wires 

3 wires 

8-port SIO 

dlabr046 

label_2 

Plug / Cable Port#-COM Port# -board Registry Module 

ST01 / KA204 — — — goes to Scanner Motherboard Bu09 

ST02 COM4 Extern7 MO Modem 

ST03 COM5 Extern6 BC Bar code reader 

ST04 COM6 Extern5 PC Pricing unit (PRU) 

ST05 / KA05 COM7 Extern1 PP Paper Processor 

ST06 COM8 Extern8 Touch Screen 

ST07 / KA41 COM9 Extern2 PR Printer 

ST08 COM10 Extern4 DM External Densitometer 

ST09 — — — goes to PC (8-port SIO, RS232) 

— COM1 PC internal TI Timer board 

— COM3 PC internal FL Film advance 


Repair 

Main-PC 

Drives 

Drives (drive letter): 

1. Hard disk 

− 1. Partition (C) 

− 2. Partition (D) 

2. CD-ROM (E) 

3. ZIP Drive (F) 

4. PCM-CIA rack for memory cards 

− Rack 1 (G *) 

− Rack 2 (H *) 

5. 3,5“ Disk drive (A) 

* Drive letters cannot be allocated permanently. 

The first Slot occupied gets the letter. 

dlabr108 

Hard Disk 

Harddisk with 2 partitions: 

C:\ 2 GB NTFS NT 4.0 / SP6 

D:\ max. GB NTFS 

Graphic Card 

Resolution: 1.024x768 Pixel 

Image recurrence frequency: >75Hz 

Ethernet Boards 

− 10 Mbit/s Internal use 

− 100 Mbit/s Connection for external network 


Main-PC 

Repair 

PC-Mainboard 

Set the Jumpers in accordance with the internal 

speed of the processor (preset for Pentium II, 

450 MHz): 

CPU BUS Frequency Multiple Frequency CPU:PCI 

Intel 

Freq. Mult. BUS F FS0 FS1 FS2 FS3 BF0 BF1 BF2 BF3 MS0 MS1 

CPU Model MHz 

MHz 

Pentium III 733 5,5x 133 [1-2] [1-2] [1-2] [1-2] [1-2] [1-2] [1-2] [2-3] [2-3] [1-2] 

Pentium III 667 5,0x 133 [1-2] [1-2] [1-2] [1-2] [2-3] [1-2] [1-2] [2-3] [2-3] [1-2] 

Pentium III 700 7,0x 100 [1-2] [1-2] [1-2] [2-3] [1-2] [1-2] [1-2] [2-3] [1-2] [2-3] 

Pentium III 650 6,5x 100 [1-2] [1-2] [1-2] [2-3] [1-2] [1-2] [1-2] [2-3] [1-2] [2-3] 

Pentium III 600 6,0x 100 [1-2] [1-2] [1-2] [2-3] [2-3] [1-2] [1-2] [2-3] [1-2] [2-3] 

Pentium III 550 5,5x 100 [1-2] [1-2] [1-2] [2-3] [1-2] [1-2] [1-2] [2-3] [1-2] [2-3] 

Pentium III 500 5,0x 100 [1-2] [1-2] [1-2] [2-3] [2-3] [1-2] [1-2] [2-3] [1-2] [2-3] 

Pentium II / III 450 4,5x 100 [1-2] [1-2] [1-2] [2-3] [1-2] [2-3] [1-2] [2-3] [1-2] [2-3] 

dlab192e 


Repair 

Main-PC 

PC Mainboard Connections 

CPU_FAN 

CHA_FAN 

JTCPU 

Wake on LAN 

Panel Connector 

to CPU – cooling fan 

to front fan 

temperature sensor for the 

sensor for the CPU, 

measuring point (see fig. 

below) 

to Timer board 

ATX Power Switch to 

Timerboard (see fig. right) 

dlabr253 

Temperature sensor on heat sink: Test point (1) 

dlabr281 


Main-PC 

Repair 

Timer Board 

PCI-Slot #3 

The Timer board is connected to the Mainboard by 

2 cables: 

− Cable 1 (A) supplies the Timer board with the 

Standby voltage of +5 V 

− Cable 2 (B) switches on the PC 

The operating voltage of +5 V is sent to the Timer 

board via the ISA or PCI rack, or else via ST08 

(Pin 3 +5 Volt, Pin 4 GND). 

The d-lab.3 is switched on step by step via 

ST01 - ST06. 

dlab285 

Image Processing Board (VIPS) 

− 200 MHz 

− 2 Texas Instruments DSP Processors 

− 512 MByte 

The image processing board is supplied by +5 V via 

a Y cable. 

dlabr286 

1 Printer 

2 Scanner 


Repair 

Main-PC 

BIOS Settings 

AWARD Bios Version 

− ASUS P3V133 BIOS Revision 1002 

Main 

− Supervisor Password 

− Halt on 

on request 

all, but keyboard 

Advanced - Chip Configuration 

Advanced - I/O Device Configuration 

− Serial Port 2 

Disabled 

Advanced - PCI Configuration 

− Slot 1 IRQ 11 



− Slot 4 IRQ 

NA 

Advanced - PCI Configuration - PCI / PNP ISA IRQ Resource Exclusion 

− IRQ 3 Used By ISA No/ICU COM 2 

− IRQ 4 Used By ISA No/ICU COM 1 

− IRQ 5 Used By ISA Yes Multi I/O board 

− IRQ 7 Used By ISA No/ICU Parallel Port 

− IRQ 9 Used By ISA No/ICU Network board 2 

− IRQ 10 Used By ISA Yes VIPS board 

− IRQ 11 Used By ISA No/ICU Network board 1 

− IRQ 12 Used By ISA No/ICU PS/2 Mouse 

− IRQ 14 Used By ISA No/ICU IDE 1 

− IRQ 15 Used By ISA No/ICU IDE 2 

Advanced - Shadow Configuration 

Power 

− Power Savings 

Power - Up Control 

Power - Hardware Monitor 

Boot 

− 1 DIE Hard Drive 

− 2 ATAPI CD-ROM 

− 3 Removable Device 

− 4 Other Boot Device 

Type of hard disc 

CD-ROM drive 

Legacy Floppy 

None 


Main-PC 

Repair 

Jumper Settings of the Drives 

Hard disk: 

Master active, 10 GB 

Jumper settings 

The Jumpers allow the selection of the following 

options (architecture with 16 logic heads): 

MASTER active 

SLAVE active 

Cable select 

SLAVE Present 

Reserved 

Pin designation 

A-B and G-H 

A-B and C-D 

A-B and E-F 

E-F and G-H 

I 

1 Jumper block 

2 AT I/F Connector 

3 Pin 1 (on Power Connector) 

4 Pin A 

dlabr282 

CD-ROM (Master) 

dlabr283 

ZIP Drive (Slave) 

1 Jumper block 

2 Slave (Drive 1, factory setting) 

3 Cable Select 

4 Master (Drive D) 

5 reserved (do not use!) 

dlabr284 


Repair 

Main-PC 

Operating System 

Windows NT 4.0 / SP6 

Radio Shielding 

EN 55022 Class B 


Main-PC 

Repair 


The d-lab.3 is supplied with a quasi industrial PC. It 

is located at the back of the Scanner area. 

The Main-PC 

− functions together with the d-lab.3 Main Software 

as central control unit for the operation and the 

service. 

− controls via the Main Software the interaction of 

the major assembly groups: Scanner, Printer and 

Paper Processor. 

− calculates the images to be exposed by the Laser 

(the image processing card is located in the 

Main-PC). 

− serves as input device for digital files (format: 

jpg) to be printed, from CD, Zip, disk or PCM-CIA 

− controls the monitor (graphic card) 

− has an integrated Timer for the control of the 

machine (Timer card) 

dlabr014 


Repair 

Main-PC 

Repair 

Removal of the PC 

− Remove the cover (1) 

− Upon the first removal: 

Loosen the PC fastening screws (2) and (3) 

− Pull out the PC, disconnect it and take it out 

− Installation in reverse order 

dlabr254 


Main-PC 

Repair 

■ 


Repair 

Printer 

Contents 

General Overview ....................................................................................................................................6.1.1 

Sensors and Loads in the Printer.......................................................................................................6.1.1 

Mechanical Structure .........................................................................................................................6.1.3 

Electrical Structure.............................................................................................................................6.1.4 

Paper Magazine Control ....................................................................................................................6.1.7 

Designations / List of Signals ................................................................................................................6.2.1 

Main Assembly Groups......................................................................................................................6.2.1 

Printer Mainboard PF.........................................................................................................................6.2.2 

Paper Magazine LH ML .....................................................................................................................6.2.3 

Paper Magazine RH MR ....................................................................................................................6.2.4 

Sheet Gear SG...................................................................................................................................6.2.5 

Transport Unit TU / Sheet Bridge SB.................................................................................................6.2.6 

Print Engine PE..................................................................................................................................6.2.7 

Laser Module LA................................................................................................................................6.2.8 

Laser Unit LU .....................................................................................................................................6.2.8 

Lane Distributor LD ............................................................................................................................6.2.9 

Sheet Transfer ST............................................................................................................................6.2.10 

Printer Mainboard (Printer Mainboard L8.8060.2000.B)..................................................................6.2.11 

Printer Mainboard, Connector Allocation .........................................................................................6.2.18 

PE_GS01, Connector Assignment...................................................................................................6.2.22 

Functional Description ...........................................................................................................................6.3.1 

Major Assembly Groups.....................................................................................................................6.3.1 

Paper Transport and Exposure..........................................................................................................6.3.2 

Switch-on and Reset Behaviour of the Printer...................................................................................6.3.3 

Flowcharts, Transport Unit.................................................................................................................6.3.5 

Flowcharts, Lane Distributor / Sheet Transfer .................................................................................6.3.10 

PF_GS01 – Printer Mainboard..............................................................................................................6.3.15 

Functional Description, general .......................................................................................................6.3.15 

Functional Description, Image Processing ......................................................................................6.3.16 

PF_GS01 - Technical Data ..............................................................................................................6.3.24 

Magazine Drive MD................................................................................................................................6.3.26 

ML_GS01_GS – LH Magazine Drive MR_GS01_GS - RH Magazine Drive ..................................6.3.26 

ML_GS02 / MR_GS02 and ML_GS05 /MR_GS05 (Magazine Coding, Locking Detection; 

left / right) .........................................................................................................................................6.3.30 

AGFA d-lab3 2001-01-02 /PN 9009 6.i

Printer 

Repair 

Switching Gear SG ................................................................................................................................6.3.31 

SG_GS01 – Switching Gear Control................................................................................................6.3.31 

Sheet Stocker SR...................................................................................................................................6.3.33 

Sheet Bridge SB.....................................................................................................................................6.3.33 

Transport Unit TU ..................................................................................................................................6.3.34 

Functional Description......................................................................................................................6.3.34 

TU_GS01 (Transport Unit Control)...................................................................................................6.3.35 

Print Engine PE......................................................................................................................................6.3.37 


Laser Module....................................................................................................................................6.3.38 

PE_GS01..........................................................................................................................................6.3.39 

PO_GS01 (L8.8060.2200.) - Power Monitor ....................................................................................6.3.45 

LA_GS01 – Distributor Board...........................................................................................................6.3.49 

LA_GS05 – Red Laser Diode...........................................................................................................6.3.50 

LA_GS07 - Polygonal Drive .............................................................................................................6.3.50 

LA_BE04 – AOM Amplifier, blue LA_BE04 – AOM Amplifier, green ...............................................6.3.51 

Lane Distributor LD / Sheet Transfer ST .............................................................................................6.3.52 


LD Parameters: Paper Widths / Distribution ....................................................................................6.3.53 

LD_GS01 - Lane Distributor Control ................................................................................................6.3.54 

RD_GS01 - Back Printer Control......................................................................................................6.3.56 

Laser Fundamentals..............................................................................................................................6.3.57 

Colour Laser Scanner (Beam generation, Beam processing, Beam deflection) .............................6.3.57 

Laser Module (LA)............................................................................................................................6.3.58 

Setting the Pixel Coverage ...................................................................................................................6.3.61 


Repair 

Printer 

Removal, Installation, Adjustment ........................................................................................................6.4.1 

Mainboard Replacement (PF_GS01), Edition 3 ................................................................................6.4.2 

Replacing the Printer Power Supply Unit.........................................................................................6.4.11 

Replacing / adjusting the Guide Rails of the Paper Magazines, Replacing Light Sensor 

ML/MR_LS08 (locking detection).....................................................................................................6.4.13 

Replacing the Magazine Drive ML/MR ............................................................................................6.4.14 

Replacing the Cutter Unit CU...........................................................................................................6.4.16 

Replacing the Switching Gear SG ...................................................................................................6.4.18 

Sheet Bridge SB, replacing Parts ....................................................................................................6.4.24 

Transport Unit TU, replacing Parts ..................................................................................................6.4.28 

Print Engine PE, replacing Parts......................................................................................................6.4.33 

Replacing the Laser Module / Laser ................................................................................................6.4.45 

Lane Distributor LD, replacing Parts ................................................................................................6.4.54 

Sheet Transfer ST, replacing Parts..................................................................................................6.4.62 

AGFA d-lab3 2001-01-02 /PN 9009 6.iii

Printer 

Repair 

■ 

6.iv 2001-01-02 /PN 9009 AGFA d-lab.3

Repair 


Sensors and Loads in the Printer 

Transport unit 

Loads: 

TU_MO01 Drive takeover section (stepper motor) TU1 

TU_MO02 Drive transfer section (stepper motor) TU1 

TU_MO03 Drive sheet rotation (stepper motor) 

TU_MO04 Drive sheet centring (stepper motor) 

TU_MO05 Drive takeover section (stepper motor) TU2 

TU_MO06 Drive transfer section (stepper motor) TU2 

TU_MO07 Roller lift-off takeover section (linear actuator) TU1 

TU_MO08 Roller lift-off transfer section (linear actuator) TU1 

TU_MO09 Pressure plate lift-off (linear actuator) 

TU_MO10 Roller lift-off takeover section (linear actuator) TU2 

TU_MO11 Roller lift-off transfer section (linear actuator) TU2 

TU_MO12 Roller lift-off transfer section TU2 

TU_MO13 Roller lift-off takeover section TU2 

TU_MO21 Sheet flap drive 

SB_MO01 Stepper motor sheet flap (on steering roller) 

Sensors: 

TU_LS01 to TU_LS06 Transport unit light sensors 

TU_LS07 Fork light sensor for Home position sheet centring 

Sheet transfer ST 

Loads / Sensors: 

ST_MO01 Drive for sheet transfer, two lanes 

ST_LS01/02 free + time constant = ST free 

Printer 

Exposure unit 

Loads: 

PE_MO01 Print roller drive (stepper motor) 

PE_MO02 Inlet and outlet roller drive (geared DC motor) 

PE_MO03 Flap drive (linear drive) 

Sensors: 

PE_LS01 Light sensor in front of print roller 

PE_LS02 Flap control (fork light sensor) 

PE_LS03 Light sensor behind print roller 

PE_LS04 Speed control of PE_MO02 

PE_LS05 Sensor sheet pick-up, BOP sensor 

(transmitter/receiver LS) 

PE_LS06 Sensor exposure start BOL sensor 

(Laser receiver part) 

PE_LS07 Paper detection inlet PE (reflected light sensor) 

PE_LS08 Print roller rotation control (reflected light sensor) 

Paper supply 

Paper detection: 

ML_LS07 / MR_LS07 / SG_LS21 / SG_LS41 / 

SG_LS01 / SG_LS02 /SG_LS03 / SG_LS04 

Splice detection : 

SG_LS22 / SG_LS42 

Lane distributor LD 

Loads: 

LD_MO01 Drive for LD takeover 

LD_MO02 Drive for upright distribution 

LD_MO03 Drive for horizontal distribution 

LD_MO04 Drive for LD exit 

LD_MO05 Drive for back printer 

Sensors: 

LD_LS01 Signal for back printer 

LD_LS02 STOP LD_MO01, parking before distribution 

LD_LS03 Paper width 102 (shift yes/no) 

LD_LS04 Reference distribution 

LD_LS05 STOP LD_MO02, sheet in position 

LD_LS06 Check distribution free yes/no 

LD_LS07/08 Paper supply distribution free (from a length of 176) 

LD_LS10 STOP control strip threading 

LD_LS11 Control strip yes/no 

dlabr122 


Repair 

Printer 


dlabr061 

1 Lamphouse LH 11 Magazine drive MD (ML) 

2 Sheet transfer ST 12 Laser power supply unit 

3 Zoom / CCD 13 Power supply PW 

4 Lane distributor LD 14 Laser (Fibre) 

5 Back printer RD 15 Print engine PE 

6 Control strip box SX 16 Laser module 

7 Sheet bridge SB 17 Paper transport and exposure 

8 Magazine drive MD (MR) 18 Transport unit TU 

9 Cutter unit CU 19 Film chuter 

10 Sheet gear SG 20 Sheet stocker SR 


Printer 

Repair 


dlabr051 

1 Lane distributor control 10 Laser power supply 

2 Back printer control 11 Blue-Green Laser (beam generation) 

3 CCD and Zoom electronic 12 Laser module (beam processing) 

4 Paper magazine drive RHS 13 Laser electronic 

5 Paper transport control 14 Red Laser diode 

6 Printer Mainboard PF_GS01 (complete Printer control) 

7 Paper magazine drive LHS 

8 Printer power supply 

9 Power monitor PO_GS01 


Repair 

Printer 

Voltage Distribution in the Printer 

dlabe148 


Printer 

Repair 

Voltages on the d-lab.3 

24 V switchable measurable Voltage for Printer and Scanner 

(switched together !) 

36 V switchable measurable Voltage for Printer and Scanner 

(switched together!) 

28 V not switchable measurable AOM – voltage 

22,8 

V 

switchable and 

interruptible on 

primary side by 

Interlock switch 

measurable 

Scanner lamp voltage 

5 V not switchable measurable Scanner – Microcontroller voltage 

± 15 

V 

not switchable measurable Scanner and red Laser diode 

(switched together!) 

6,5 V not switchable measurable 5 V Printer – Microcontroller voltage 

± 9 V not switchable measurable Analogue voltage 

Laser Remote 

input 

(switchable) 

Laser Remote 

input 

(switchable) 

can be 

checked via 

SPI Power 

module 

can be 

checked via 

SPI Power 

module 

Unloading circuit on the Laser: 

− after switch-on approx. 20 min until a stable status is 

reached 

− after switch-off approx. 5 min for the fan afterrun 

Circuit of the Standby mode: 

− after activation and switch-back approx. 3 min until a 

stable status is reached 

Available test points result from the descriptions 

of the individual printed circuits. 

see Register 6.3 


Repair 

Printer 

Paper Magazine Control 

dlabe139 

SG 

MK 

SU 

ML 

MR 

Sheet gear SG 

Paper magazine lock MK 

Shutter SU 

Paper magazine drive left ML 

Paper magazine drive right MR 


Printer 

Repair 

■ 


Repair 

Printer 

Designations / List of Signals 

Main Assembly Groups 

BK 

CU 

LD 

LA 

LU 

MD 

MK 

ML 

MR 

PE 

PF 

PO 

PP 

PR 

RD 

SB 

SG 

SR 

ST 

SU 

SX 

TU 

Block assy 

Paper Cutter 

Lane Distributor 

Laser Module 

Laser Unit 

Magazine Drive 

Magazine Lock 

Paper Magazine Left 

Paper Magazine Right 

Print Engine 

Printer Frame 

Power Module 

(Power Monitor + Printer Power Supply) 

Printer Parts 

Printer 

Back Printer 

Sheet Bridge (transfer SG → TU) 

Sheet Gear (transfer ML/MR → SB) 

Sheet Stocker 

Sheet Transfer (transfer ST → Paper Processor) 

Shutter 

Strip box 

Transport unit 

The loads and sensors are allocated to the 

assembly groups by means of shortcuts, e.g.: 

PE_GS01 = printed circuit in the print engine 

For more detailed explanations see Names of 

components / Allocation of assembly groups and 

parts functions in Register 2. 


Printer 

Repair 

Printer Mainboard PF 

Printed circuit Part number Function 

PF_GS01 8.8060.2000. Printer Mainboard; SPI Mainboard for Printer section 

PO_GS01 8.8060.2200. Power Monitor; monitoring and control of the voltage supply (incl. 

laser) 

Motor Part number Function 

PF_MO01 — Fan, printer frame 

Power supply Part number Function 

PF_BE01 7.8060.PWA1. Printer power supply unit 

Microswitch Part number Function 

PF_MS01 — Switch for front door 

PF_MS02 — Switch for Print Engine 


Repair 

Printer 

Paper Magazine LH ML 

Printed circuit Part number Function assigned to 

ML_GS01 8.8060.2150. Magazine control RH / LH Distributor board 

ML_GS02 — Magazine coding ML_LS01 to ML_LS06 

ML_GS03 50A-SN4 Paper detection SU ML_LS07 

ML_GS04 50A-LED Magazine change ML_LA01, ML_LA02 

ML_GS05 — Magazine lock detection ML_LS08 

Light sensor Type Function on Printed Circuit 

ML_LS01 Reflex-LS Sensor 1 magazine coding LH ML_GS02 






ML_LS07 Reflex-LS Sensor paper detection shutter LH ML_GS03 

ML_LS08 Fork light sensor Sensor magazine lock detection LH ML_GS05 

LED Type Function on Printed Circuit 

ML_LA01 LED indication LED magazine control LH ML_GS04 

Motor Type Function 

ML_MO01 Stepper motor Drive paper transport magazine LH 

ML_MO02 Stepper motor Drive magazine core LH 

Magnet Type Function 

ML_MG01 Magnetic coupling Coupling roller set of magazine LH 

ML_MG02 Magnetic coupling Coupling roller set of cutter LH 


Printer 

Repair 

Paper Magazine RH MR 


MR_GS01 8.8060.2150. Magazine control RH / LH Distributor board 

MR_GS02 — Magazine coding MR_LS01 to MR_LS06 

MR_GS03 50A-SN4 Paper detection-SU MR_LS07 

MR_GS04 50A-LED Magazine change MR_LA01, MR_LA02 

MR_GS05 — Magazine lock detection MR_LS08 


MR_LS01 Reflex-LS Sensor 1 magazine coding RH MR_GS02 






MR_LS07 Reflex-LS Sensor paper detection shutter RH MR_GS03 

MR_LS08 Fork light sensor Sensor magazine lock detection RH MR_GS05 

LED Type Function on Printed Circuit 

MR_LA01 LED indication LED magazine control RH MR_GS04 


MR_MO01 Stepper motor Drive paper transport magazine RH 

MR_MO02 Stepper motor Drive magazine core RH 


MR_MG01 Magnetic coupling Coupling roller set of magazine LH 

MR_MG02 Magnetic coupling Coupling roller set of cutter LH 


Repair 

Printer 

Sheet Gear SG 


SG_GS01 8.8060.2070. CU-SG-control SG_LS05, SG_LS06 

SG_GS02 8.8060.2180. SG-distributor Distributor board 

SG_GS03 8.8060.2130. Reflex sensor_3 SG_LS01 




SG_GS07 52A-SN1-B Cutter position LH SG_LS23, SG_LS24 

SG_GS08 50A-SN3 Paper detection cutter LH SG_LS21, SG_LS22 

SG_GS09 52A-SN1-A Cutter position RH SG_LS43, SG_LS44 

SG_GS10 50A-SN3 Paper detection cutter RH SG_LS41, SG_LS42 


SG_LS01 Reflex LS Paper detection magazine RH SG_GS03 

SG_LS02 Reflex LS Paper detection magazine LH SG_GS04 

SG_LS03 Reflex LS Remaining length detection for SG_GS05 

magazine LH 

SG_LS04 Reflex LS Remaining length detection for SG_GS06 

magazine RH 

SG_LS05 — CU-SG-control SG_GS01 

SG_LS06 — CU-SG-control SG_GS01 

SG_LS21 Reflex LS Paper detection cutter LH SG_GS08 

SG_LS22 Reflex LS Splice detection LH SG_GS08 

SG_LS23 Fork light sensor Home position cutter LH SG_GS07 

SG_LS24 Fork light sensor End of cut, cutter LH SG_GS07 

SG_LS41 Reflex LS Paper detection cutter RH SG_GS10 

SG_LS42 Reflex LS Splice detection RH SG_GS10 

SG_LS43 Fork light sensor Home position cutter RH SG_GS09 

SG_LS44 Fork light sensor End of cut, cutter RH SG_GS09 


SG_MO01 Stepper motor Drive paper transport gear 

SG_MO02 Stepper motor Drive gear position 

SG_MO05 Fan Fan paper supply 

SG_MO21 DC motor Drive cutter LH 

SG_MO41 DC motor Drive cutter RH 


Printer 

Repair 

Transport Unit TU / Sheet Bridge SB 

The Sheet Bridge (SB) is a part of the Transport 

Unit (TU), and therefore assigned to it. 


TU_GS01 8.8060.2030. TU-Distributor Distributor board 

TU_GS02 8.8060.2110. Reflex sensor_1 TU_LS01 






TU_LS01 Reflex LS Inlet takeover section TU1: 

TU_GS02 

Paper detection before 1st roller set 

TU_LS02 Reflex LS Exit takeover section TU1: 

TU_GS03 

Paper detection after turntable, before last 

roller set 


TU_GS04 

Paper detection after sheet centring 


TU_GS05 

Paper detection after Print Engine 

TU_LS06 Reflex LS Exit takeover section TU2: 

TU_GS06 

Paper detection at transfer TU to LD after last 

roller set 

TU_LS07 Fork light sensor Home position sheet centring — 


TU_MO01 Stepper motor Drive takeover section TU1 – from SG to TU 

8.8888.8888. 

TU_MO02 Stepper motor Drive transfer section TU1 – from TU to PE 

TU_MO03 Stepper motor Drive sheet rotation 

TU_MO04 Stepper motor Drive sheet centring 

TU_MO05 Stepper motor Drive takeover section TU2 – from PE to TU 

TU_MO06 Stepper motor Drive transfer section TU2 – from TU to LD 

TU_MO07 Linear actuator Roller lift-off takeover section TU1 

TU_MO08 Linear actuator Roller lift-off transfer section TU1 

TU_MO09 Linear actuator Turntable lift-off 





TU_MO21 Stepper motor Drive sheet bridge 

SB_MO01 Stepper motor Drive sheet bridge guide roller (in TU) 


Repair 

Printer 

Print Engine PE 


PE_GS01 8.8060.2170. PE distributor Distributor board 

PE_GS02 8.8060.2050. BOL: Laser detection PE_LS06 

PE_GS03 8.8060.2060. BOP: Sheet detection PE_LS05 

PE_GS04 8.8060.2110. Reflex sensor_1 PE_LS01 




PE_LS01 Reflex LS LS before printing roller PE_GS04 

PE_LS02 Fork light sensor LS for flap control actuator — 

PE_LS03 Reflex LS LS after printing roller PE_GS05 

PE_LS04 Fork light sensor Speed control for PE_MO02 — 

PE_LS05 Transmitter/receiver LS Sensor sheet pick-up (BOP) PE_GS03 

PE_LS06 Laser receiver part Sensor exposure start (BOL) PE_GS02 

PE_LS07 Reflected light LS Paper detection inlet PE PE_GS06 


PE_MO01 Stepper motor 

Drive printing roller 

8.8060.4800. 

PE_MO02 DC motor Drive feed and exit roller PE 

PE_MO03 Linear actuator Flap control on PE 


Printer 

Repair 

Laser Module LA 

Some sensors and loads (see *) cannot be replaced 

individually. In case of a defect, replace Laser 

module (colour laser recorder 4.4150.1000.) 

Printed circuit Part number Function 

LA_GS01 * 8.8060.2090. LFB-distributor (LFB = Laser-Feedback) 

LA_GS02 * 8.8060.2080. LFB, monitor diode red 

LA_GS03 * 8.8060.2080. LFB, monitor diode green 

LA_GS04 * 8.8060.2080. LFB, monitor diode blue 

LA_GS05 * 8.8394.5880. Voltage regulator LD/MOD; 

Voltage regulation laser module 

LA_GS06 * 8.8394.5800. L/D-modulator analogue 

LA_GS07 * — Polygon drive 

LA_GS08 * 8.8060.2080 LFB, monitor diode total 


LA_MO01 * Stepper motor Drive polarisation filter red 

LA_MO02 * Stepper motor Drive polarisation filter green 

LA_MO03 * Stepper motor Drive polarisation filter blue 

LA_MO04 * Stepper motor Polygon drive 


LA_MG01 — Shutter 

AOM Type Function 

LA_BE04 — AOM amplifier, blue 

LA_BE04 — AOM amplifier, green 

Laser Unit LU 

Diverse Part number Function 

LU_BE01 7.8060.LUC1. Laser power supply 

LU_BE02 7.8060.LUD0. Laser 


Repair 

Printer 

Lane Distributor LD 


LD_GS01 8.8060.2100. LD-distributor Distributor board 

LD_GS02 8.8060.2110. Reflex sensor_1 LD_LS08 









LD_LS01 Reflex LS Paper detection back printer LD_GS09 

LD_LS02 Reflex LS Parking position before distribution LD_GS07 

LD_LS03 Reflex LS Check of paper width before distribution LD_GS06 

LD_LS04 Fork light sensor Reference position horizontal distribution — 

LD_LS05 Reflex LS Paper detection after distribution - back LD_GS05 

LD_LS06 Reflex LS Paper detection after distribution - front LD_GS04 

LD_LS07 Reflex LS Paper detection exit LD back LD_GS03 

LD_LS08 Reflex LS Paper detection exit LD front LD_GS02 

LD_LS10 Reflex LS Threading stop control strip LD_GS08 


LD_MO01 Stepper motor Drive takeover section LD 

LD_MO02 Stepper motor Drive distribution vertical 

LD_MO03 Stepper motor Drive distribution horizontal 

LD_MO04 Stepper motor Drive exit station, 2 lanes, separately controllable by magnetic 

coupling 

LD_MO05 Stepper motor Drive back printer 


LD_MG01 Magnetic coupling Magnetic coupling in exit station LD 


Printer 

Repair 

Sheet Transfer ST 


ST_GS01 50A-SN2A Paper detection LD_LS11, LD_LS12 

ST_GS02 — — — 


LD_LS11 Reflex LS Paper detection 

LS before sheet transfer (back) 

LD_LS12 Reflex LS Paper detection > 152 mm; 

LS before sheet transfer (front) 

ST_GS01 

ST_GS01 


Repair 

Printer 

Printer Mainboard (Printer Mainboard L8.8060.2000.B) 

Connector Assignment 

ST 1: SPI – Interface reserve 

PIN Signal name Comment I/O 

1 GND GNB reference potential O 

2 /RESET_SPI Interface RESET O 

3 + 6,5 V Source voltage O 


5 + SDO Data output + O 

6 - SDO Data output - O 

7 + SDI Data input + I 

8 - SDI Data input - I 

9 + CLK Clock signal + O 

10 - CLK Clock signal - O 

11 + SS Chip select + O 

12 - SS Chip select - O 

13 + INT Operator prompting + I 

14 - INT Operator prompting - I 

15 GND Reference potential GND O 


ST 2: SPI – Interface reserve 



















Printer 

Repair 

ST 3: SPI – Interface MR 


















ST 4: SPI – Interface ML 



















Repair 

Printer 

ST 5: SPI – Interface TU 


















ST 6: SPI – Interface PO 



















Printer 

Repair 

ST 7: SPI – Interface SG 


















ST 8: SPI – Interface LD 


















17 CANH CAN – HIGH O 

18 CANL CAN - LOW O 




Repair 

Printer 

ST 9: SPI – Interface PE 


















ST 19: External programming voltage 


1 VPP External programming voltage I 


ST 20: External RESET 


1 /EXT_RESET External RESET I 


ST 23: Control Interface 



2 RXD RS 232 Data input I 

3 TXD RS 232 Data output O 


Printer 

Repair 

ST 26: CAN – Interface 



2 CANH CAN – HIGH I/O 

3 CANL CAN – LOW I/O 


The connectors ST 21, ST 22,ST 24 and ST 28 

have no significance. 

Their use does not make sense at present. 

ST 31: ISP– Programming connector 


1 ISPCLK Programming clock O 

2 MODE Mode line O 

3 ISPDI Prog. data O 

4 ISPSDO Read data O 

5 ISPEN Enable O 

6 ISPRES Reset O 

7 + 5 Operating voltage +5 V I 

8 GND Reference potential GND I 

Jumper Assignment and LED 

D 1 = LED_ROT > 

Lights when an SPI module has logged in an 

Interrupt 

J 1 = nc 

J 2 = nc 

J 4 = nc 

J 5 = nc 

J 6 = plugged in 

ISPEN is passive 

Vacant 

Not plugged in, CPU works in 

normal mode 

All displays are passive 

CAN termination resistance 

active 

Test Points 

MP 3 

MP 4 

MP 23 

= +5 V 

= GND 

= Not used (no significance) 


Repair 

Printer 

Printer Controller, Structure 

XILINX 

progr. 

Decoder 

isp LSI 

1032E-70LT 

LED - Monitor 

D0 - D15 

CS 

D 0 - D15 

P 3.0 - P 3.7 

A 0 - A 11 

SPI 1 

SPI - 

Interface 

SSC 

High - Speed Synchronous Serial Interface 

/RD ; /WR 

/RESET 

SPI 12 

CLK 

CLK1 

CLK2 

CLK3 

/RESET 

/RES 

Taktgenerator 

CLK 39,32 MHz 

CLK 1 19,66 MHz 

CLK 2 9,83 MHz 

CLK 3 4,91 MHz 

RESET 

WDT 

UB-NMI 

CLK 1 

/RESET 

/NMI 

P 3 

P 3 

µC 

C 167 CR 

P 1; P 4 

P 0 

Steuerl. 

Adr. 

Daten 

Adr. 

Daten 

Decoder 

A12 - A19 

CS4 

isp LSI 

1032E-70LT 

A12 - A19 

CS0 - CS3 

CS 

HW_ADR 1 

bis 

HW_ ADR 15 

Steuerl. 

CAN 

CAN-Interface 

P 4.5 - P 4.6 

RS 232/1 

RS 232/2 

RS 232/3 

RS 232 Interface 

P 3.10 - P 3.11 

Steuerl. 

Adr. 

Daten 

CS 

Flash - Memory 

AM 29 F 040 

512 k x 8 


AM 29 F 040 

512 k x 8 


AM 29 F 040 

512 k x 8 


AM 29 F 040 

512 k x 8 

Bank 1 

CS 0 

Bank 3 

CS 2 

INT 0 - 4 

P 2.0 - P 2.7 

PORT 2 

INT 5,6 - SPI 

INT 7 - RS 232 

16 

SRAM 

HM 628512 

128 k x 8 

SRAM 

HM 628512 

128 k x 8 

Bank 2 

CS 1 

P 7.0 - P 7.7 

PORT 7 

8 

SRAM 

HM 628512 

128 k x 8 

SRAM 

HM 628512 

128 k x 8 

Bank 4 

CS 3 

P 5.0 - P 5.15 

INT 1 ( Timer ) 

PORT 5 

nur Input 

P 5.13 

16 

P 6.5 - P 6.7 

PORT 6 

reserviert 

3 

P 8.0 - P 8.7 

PORT 8 

8 

main_con.skd 


Printer 

Repair 

Printer Mainboard, Connector Allocation 

Bu 1 

Middle contact 

Housing 

Bu 2 


Housing 

Bu 3 


Housing 

Video output voltage red channel 

0... 600 mV 

analogue GND 

Video output voltage blue channel 

0... 600 mV 

analogue GND 

Video output voltage green channel 

0... 600 mV 

analogue GND 

Bu 4 

LVDS Interface 

1 GND 

2 GND 

3 n.c. 

4 AFULL+ + differential Output FIFO-Flag almost full 

5 AFULL- – differential Output FIFO-Flag almost full 

6 RXCLKIN+ + differential Input Channel Link Receiver Clock 

7 RXCLKIN- – differential Input Channel Link Receiver Clock 

8 GND 

9 Reserve Output (CM2) 

10 GND 

11 Reserve Input (CM1) 

12 RXIN0+ + differential Input Channel Link Receiver data channel 0 

13 RXIN0- – differential Input Channel Link Receiver data channel 0 

14 B_START+ + differential Output image start (not used) 

15 B_START- – differential Output image start (not used) 

16 n.c. 

17 GND 

18 Reserve Output (CM3) 

19 GND 





24 Reserve Input (CM0) 

25 GND 

26 GND 

ST10 


Housing 

ST11 


Housing 

Input measuring voltage laser energy green channel 

(0...) 1,87... 2,07V 

analogue GND 

Input measuring voltage laser energy blue channel 

(0...) 1,87... 2,07V 

analogue GND 


Repair 

Printer 

ST13 Test plug FIFO Operation: n.c 

1 PIXB0 Pixel data blue data bit 0 











1 PIXG0 Pixel data green data bit 0 






7 FIFOCLR FIFO clear 

8 FIFOCLK FIFO read clock 

9 FIFORD FIFO read enable 

10 DARK Dark signal for the red laser diode control 






5 PIXR0 Pixel data red data bit 0 











5 ZEILENSYNCHRON Line end detection 

6 BILDSYNCHRON Image end detection 

7 FE FIFO empty 

8 FAF FIFO almost full 

9 FF FIFO full 

10 BILDSTART 


Printer 

Repair 

ST17 Trailing cable to the print engine 

1 GND 

2 GND 

3 +BOL + differential Input BOL 

4 -BOL – differential Input BOL 

5 GND 

6 GND 

7 +BOP + differential Input BOP 

8 -BOP – differential Input BOP 

9 +FSS + differential Input Facet sync signal 

10 -FSS + differential Input Facetted sync signal 

11 +DARK + differential Output Dark signal 

12 -DARK – differential Output Dark signal 

13 GND 

14 GND 

ST18 Trailing cable to the LFB distributor 

1 +9PM analogue Source voltage +9V 

2 AGND_PM AGND_K 

3 +DOUTM + differential, serial data output 

4 -DOUTM – differential, serial data output 

5 +9PM analogue Source voltage +9V 


7 +DINM + differential, serial data input ADC 

8 -DINM – differential, serial data input ADC 

9 RGND_PM GND 

10 RGND_PM GND 

11 -/CS-DAC – differential Output Chip select DAC 

12 +/CS-DAC + differential Output Chip select DAC 

13 -/CS-ADC – differential Output Chip select ADC 

14 +/CS-ADC + differential Output Chip select ADC 


16 -9PM analogue Source voltage -9V 

17 +SCLK + differential Output Serial clock 

18 -SCLK – differential Output Serial clock 


20 -9PM analogue Source voltage -9V 

ST25 Analogue Source voltage 

1 +9V 

2 0V_A (analogue GND) 

3 0V_A (analogue GND) 

4 -9V 


Repair 

Printer 

ST29 Logic Source voltage 

1 +6,5V 

2 +6,5V 

3 +6,5V 

4 GND (digital GND) 



ST30 FPGA Boundary Scan Operation: n.c 

1 BSCAN-TDI Test Data Input 

2 BSCAN-TCK Test Clock 

3 BSCAN-TMS Test Mode Select 

4 BSCAN-TDO Test Data Output 

5 /INITX Bi-directional signal, low during the stabilisation of the 

operating voltage and clearing of the configuration 

memory as Input held low FPGA in wait state prior to 

the configuration start 

6 n.c. 

ST32 FPGA Down Load Operation: n.c 

1 +5V 

2 GND 

3 CCLK Clock input 

4 DONE bi-directional signal, as Output shows the status of the 

initialisation, as Input delays the global Logic reset and 

the Output enable 

5 DIN Data input 

6 /PROG initialises the configuration process 

7 /INITX bi-directional signal, low during the stabilisation of the 

operating voltage and clearing of the configuration 

memory as Input held low FPGA in wait state prior to 

the configuration start 

8 RSTX Reset FPGA logic 

ST 33 

ST 34 

Test point for EOL signal 

Test point for Picture work 

ST 35 Read back FPGA Operation: n.c. 

1 GND 

2 TRIG Trigger 

3 RBT Read back trigger 

4 RBD Read back date 

XS 1 Screen LVDS cable Operation: n.c 

XS 2 

Screen cable LFB distributor 


Printer 

Repair 

PE_GS01, Connector Assignment 

ST1 SPI-Interface 

1 GND Logic GND of the Printer 

2 /RESET Reset input for the Controller 

3 +6,5V Logic - Source voltage 

4 +6,5V 

5 +IN SPI-Input 

6 –IN 

7 +OUT SPI-Output 

8 –OUT 

9 +CLK SPI-CLK-Input 

10 –CLK 

11 +SS Slave-Select- Input 

12 –SS 

13 +INT Interrupt request Output 

14 –INT 

15 GND Logic GND of the Printer 

16 GND 

ST2 Programming connector 

1 +5V Programmer power supply 

2 /SS Slave-Select 

3 nc 

4 MOSI SPI-Input 

5 PROG Programming signal 

6 MISO SPI-Output 

7 GND 

8 SCK SPI-PROG clock 

9 GND 

10 RESET 

ST3 RS232- Monitor (test plug) 

1 GND 

2 TXD Output 

3 RXD Input 


Repair 

Printer 

ST5 RS422 – Connection to the Printer Mainboard 

1 GND 

2 GND 

3 +BOL Begin of Line – Signal Output 

4 –BOL 

5 GND 

6 GND 

7 +BOP Begin of Paper – Signal Output 

8 –BOP 

9 +FSS Facet sync – Signal Output 

10 .. 

11 +DARK 

12 –DARK 

13 GND 

14 GND 

ST6 PE_LS6 (Begin of Line-Sensor) 

1 +6,5V Source voltage 

2 +BOL Signal 

3 GND 

4 –BOL Signal 

ST7 2-Ph-Stepper motor polarisation filter red 

1 W1A 

2 W1E 

3 W2A 

4 W2E 

ST8 2-Ph-Stepper motor polarisation filter green 

1 W1A 

2 W1E 

3 W2A 

4 W2E 

ST9 2-Ph-Stepper motor polarisation filter blue 

1 W1A 

2 W1E 

3 W2A 

4 W2E 

ST10 2-Ph-Actuator flap drive 

1 W1A 

2 W1E 

3 W2A 

4 W2E 


Printer 

Repair 

ST11 DC motor supply and exit roller drive 

1 V+ 

2 V- 

ST12 PE-LS7 Reflected light sensor print roller rotation control 

1 +5V 

2 Signal input 

3 GND 

4 GND 

ST13 PE-LS4 Fork light sensor Speed – Sensor supply and exit roller 

1 +5V 

2 GND 


ST14 PE_LS2 Fork light sensor flap (not used) 

1 +5V 

2 GND 


ST15 PE_LS5 BOP sensor 

1 +5V 

2 Signal input (Frequency) 

3 GND 

4 nc 

ST17 PE_LS1 LS in front of print roller 

1 +5V 


3 GND 

4 GND switched to LED switch-off 

ST18 PE_LS3 LS behind print roller 

1 +5V 


3 GND 

4 GND 

ST19 Connection for polygonal drive 

1 +24V supply voltage 

2 PGND 

3 LOCKED Feedback „f_END reached“ 

4 START/STOP ON/OFF of the polygonal drive 

5 PGND 

6 /INDEX Index pulse from the polygonal drive at every rotation 

7 nc 

8 F_POLY Generator frequency for polygonal drive 


Repair 

Printer 

ST20 Operating voltage supply for analogue voltage 

1 +9V 

2 AGND 

3 –9V 

4 AGND 

ST21 Connection to the red laser diode triggering (will be modified) 

1 +9V Supply voltage 

2 AGND 

3 -9V Supply voltage 

4 AGND 

5 nc 

6 LAS_OK Feedback 

ST22 PE_LS7 LS at input PE 

1 +5V 


3 GND 

4 GND switched to LED switch-off 

ST23 2-Ph stepper motor print roller 

1 W1A Winding switched parallel 

2 W2A 

3 W1E 

4 W2E 

5 W3A 

6 W4A 

7 W3E 

8 W4E 

ST24 Power voltage supply 

1 +36V, max. 2A 

2 GND f. 36V 

3 +24V, max. 3A 

4 GND f. 24V 

ST27 Shutter connection (always linked with 24V) 

1 +24V 

2 PGND 

ST28 Spare sensor not mounted 

1 +5V 


3 GND 

4 Nc 


Printer 

Repair 

ST29 Pin connector strip as test pins 

1 +5V 

2 GND 

3 PE_LS2 

4 LASD_OK 

5 PE_LS4 

6 PE_LS3 

7 PE_LS1 

8 PE_LS8 

9 PE_LS7 

10 f_BOP 

ST30 LED heater 

1 +24V, max. 2A 

2 PGND 

■ 


Repair 

Printer 


Major Assembly Groups 

dlabr061 

1 Lamphouse LH 11 Magazine drive MD (ML) 

2 Sheet transfer ST 12 Laser power supply unit 

3 Zoom / CCD 13 Power supply PW 

4 Lane distributor LD 14 Laser (Fibre) 

5 Back printer RD 15 Print engine PE 

6 Control strip box SX 16 Laser module 

7 Sheet bridge SB 17 Paper transport and exposure 

8 Magazine drive MD (MR) 18 Transport unit TU 

9 Cutter unit CU 19 Film chuter 

10 Sheet gear SG 20 Sheet stocker SR 


Printer 

Repair 

Paper Transport and Exposure 

− The print size is cut immediately after the paper 

has been extracted from the magazine (CU). 

− The single prints are advanced by means of a 

sheet gear (SG) which allows free selection of 

access to the magazines. 

− The sheet bridge (SB) feeds the single sheet into 

the transport unit (TU). 

− When the paper is drawn out of the RH 

magazine, the sheet is transported into the sheet 

stocker (SR) by the sheet rocker (SR) after the 

stop. 

When the rocker has changed position, the sheet 

is fed into the TU via the sheet bridge. 

− In the transport unit (TU) the sheet is turned (if 

required), centred and advanced to the print 

roller in the print engine (PE). 

− The paper is exposed in the print engine. The 

complete Laser module (LM) with the guide 

mirror sits on the print engine. 

− The exposed sheets are transmitted to the lane 

distributor (LD) in the exit area of the transport 

unit (TU). In the lane distributor, the following 

operations are performed: 

− Back print (2 lines) 

− Distribution of the exposed single sheets on 

2 lanes or 

− Mismatch compensation for larger sizes 

(required because of the difference between 

the centred advance in the Printer and in the 

Paper Processor) 

− The sheet transfer (ST) advances the sheets in 

pairs or offset to the Paper Processor. 

The Printer frame carrying the above assembly 

groups comprises in addition the Scanner, the 

power supply with all associated printed circuits 

(GS) and the wiring. The frame ensures the 

required light-tightness. 

All assembly groups are accessible from the front 

or from the left side through the doors. 


Repair 

Printer 

Switch-on and Reset Behaviour of the Printer 

Switch-on Behaviour of the Machine 

− Main switch (1) on the Paper Processor ON 

− Mains voltage present on the Main-PC 

− Main-PC in Sleep mode (Timer plug-in unit in 

operation) 

− Printer and Scanner unit dead 

dlabr125 

The Timer switches on the Main-PC in 

accordance with the preset switch-on time 

1 Main switch 

2 RCD device 

The operating and user systems are booted 

The mains voltage for the Paper Processor and 

the power supply unit of the Printer / Scanner (via 

interface RS232) is switched on 

All secondary voltages (except the 24V/36V 

motor, laser, lamp voltage) are switched on 

The booting on the Printer Mainboard is started; 

all registers are initialised 

The FPGA is loaded (freely programmable logic 

circuit) 

Command interface to the Main-PC available 

Initialisation of the SPI interface (prerequisite: 

Reset by the Printer-µC on P4.4 inactive) 

The power voltages are switched on by a 

command of the Main-PC via the Printer 

Mainboard 

Check of the status of the motor voltages by the 

AVR Controller on the SPI interfaces 


Printer 

Repair 

Behaviour upon Printer Shut-down 

− The Main-PC triggers a command to switch off 

the power voltages 

− The AVR Controllers supply a voltage failure 

message 

− The Main-PC switches off the supply voltage of 

the power supply unit 

Reset of the Main PC 

A Reset sent by the Main PC to the Printer µC can 

be generated via a separate line. This Reset also 

resets the AVR Controllers, i.e. all motors are 

stopped. 

The AVR Controller in the power monitor is not 

reset automatically and can thus remain in the old 

switching status. 


Repair 

Printer 

Flowcharts, Transport Unit 

Paper Feed (Magazines, Rocker, Bridge) 

SG_LS02 

free 

yes 

LH magazine 

Which 

magazine? 

RH magazine 

Switch rocker 

Switch rocker 

TU_LS01 

free 

TU_LS01 

free 

Remove paper from magazine 

Cut paper 

Rewind paper 

Remove paper from magazine 

Cut paper 

Rewind paper 

Switch rocker 

Transport up to TU_LS01 

dlabrfe01 


Printer 

Repair 

Sheet Rotation / Sheet Centring 

no 

Sheet

Repair 

Printer 

Roller Feed 

Paper in 

TU_LS04 and 

sheet centring 

ready 

yes 

PE_LS01 

free 

yes 

Transport up to PE_LS01 

Timer 

run down and 

image data 

confirmed 

yes 

Put on sheet 

Open TU_TR02 

Start Timer 

dlabfe03 


Printer 

Repair 

Roller Exit, Part 1 

Paper 

in PE_LS03 

and roller exit 

Part 1 

ready 

yes 

Open TU_TR04 

no 

Sheet

Repair 

Printer 

Roller Exit, Part 2 

TU_LS06 

free and 

roller exit Part 1 

ready 

yes 

Close TU_TR05 

Transport up to TU_LS06 

dlabfe05 


Printer 

Repair 

Flowcharts, Lane Distributor / Sheet Transfer 

Distributor Feed 

LD_LS02 

free 

yes 

Transport up to LD_LS02 

Control of paper width with 

LD_LS03 

dlabfe06 


Repair 

Printer 

Back Print 

Paper in 

LD_LS01 

yes 

Load lead 

Enable step pulses 

Print 

position 

reached 

yes 

Print test 

Disable step pulses 

dlabfe07 


Printer 

Repair 

Sheet Distribution – Two Sheets Side by Side, one Lane 

LD_LS05 

and LD_LS06 

free 

yes 

Move distributor to the right 


left/one lane 

Distributor 

right 

no 

LD_LS07 

and LD_LS08 

free 

yes 

Centre sheet 

Distribute sheet 

Transport up to 

LD_LS07 

LD_LS02 

free 

yes 

Distribute sheet 

LD_LS07 

and LD_LS08 

free 


LD_LS08 

free 

yes 


no 

Sheet

Repair 

Printer 

Sheet Transfer to Paper Processor – Two Sheets Side by Side, one Lane 

Distributor 

ready 

yes 

no 

Transport up to ST_LS01/02 

Paper in 

ST_LS01 or 

ST_LS02 

yes 

Transfer 

ready 

Transport up to Paper Processor 

Transfer to Paper Processor with Vpp 

Vpp = Highest speed 

dlabfe09 


Printer 

Repair 

Sheet Transfer to Paper Processor – Two Sheets offset 

Paper in 

ST_LS01 or 

ST_LS02 

yes 

Transport up to Paper Processor 

Transfer to Paper Processor with Vpp 

Vpp = Highest speed 

dlabfe10 


Repair 

Printer 

PF_GS01 – Printer Mainboard 

Functional Description, general 

PF_GS01 (8.8060.2000) 

Functions: 

1. Image data processing 

2. Printer control 

In detail: 

− Transformation of the serial image data stream 

(input) to the 3 parallel currents RGB: serial clock 

40 MHz 

− Data buffering in the FIFO: 

1,2 pixel lines for an image width of 8,5 Inch 

− Facet correction for each one of the 18 facets for 

RGB: < 1% 

− Correction Laser noise: ± 4% 

− Correction Laser drift 

− LUT calculation 

− Pixel delay: up to 16 pixels 

− Pixel shift in 1/8 pixel steps 

− Definition of the line beginning by means of the 

register value 

− Pixel register for text exposures 

− LUT calculation: Adjustment of the densityproportional 

image data to the sensitivity of the 

paper, taking into account the transfer 

characteristics of AOM, Polygon, corrections 

dlabr135 


Printer 

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Functional Description, Image Processing 

General Task 

This part of the printed circuit has the task to 

transfer the serial image data stream coming from 

the image processing to three parallel data pipelines 

(RGB), include various correction mechanisms in 

the calculation and make available three analogue 

signals whose amplitude and timing are adjusted to 

the output medium of the print engine. The 

description below follows the signal stream. 


The image data coming from the image processing 

unit is transmitted to the Printer Mainboard via the 

LVDS interface by serial transmission. 

1. The LVDS Channel Link Receiver DS 90CR284 

can receive serial data on 5 line pairs (4 data + 

1 clock pair) and convert it to a 28-bit parallel 

data word. Four line pairs on the Printer 

Mainboard (3 data + 1 clock pair) are used for 

the serial transmission and converted to an 

18-bit data word (16 Bit pixel data + 2 Bit control 

data for the Low and High part). A pixel date 

(32 Bit) is composed of two time-multiplex 

transmitted 16-bit data words (Low + High part). 

The serial clock frequency is 40 Mhz. 

2. The differential driver sends the FIFO status 

(FAF) via the LVDS interface. 

Sync FIFO 

The data paralleled by the Channel Link Receiver is 

entered in a FIFO. The FIFO is used to buffer and 

synchronise the image data for the subsequent 

image processing units. It is read with the pixel 

clock under Pipeline control. The FIFO consists of 

four circuits (each one organised 4096 x 9 Bit) which 

are circuited to 4096 x 32 Bit. 

For an image width of 8,5 inch, 1,2 pixel lines can 

be buffered so that the Retrace time can be used for 

the data transfer – reduction of the data rate. 


Repair 

Printer 

FPGA 

FPGA (Field Programmable Gate Array ): After the 

supply voltage has been applied, its function must 

be loaded which is done by the Microcontroller (µC), 

allowing Updates in the field. 

The FPGA represents the central processing unit for 

the data pipeline in which the process control, the 

pixel processing, error corrections, service modes, 

the communication with the µC are implemented. 

Communication of the Microcontroller with the 

modules is via a 

13-bit wide internal data bus. Address, data and 

control signals from the µC are latched with the 

master clock (60,9 MHz). 

FPGA Module: 

1. Address decoder 

It decodes the synchronised controller addresses 

and generates select signals for the individual 

modules. 

2. Address generator 

It minimises the signal lines to the µC (7 instead 

of 18 address lines). When a certain field is 

addressed, the generator is active. The 

addresses for the external LUT red, green, blue 

and the internal RAM and ROM are formed. The 

µC has only one address for each memory bank. 

To address the memory cells of a number n of a 

bank, the µC must call the bank address n times, 

e.g. 2 18 times when reading or writing an LUT 

page of a colour. The address is incremented by 

1 at every computer access. The internal address 

counter must be cleared by a command prior to 

every new memory bank access. 

3. Image detector 

It stores the 8 low order Bits of the first pixel of 

each image in an internal register which can be 

read by the µC during the time until the next 

image is output and which holds an image 

number between 1 and 99. 


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4. Begin Off Line (BOL-Module) 

It is controlled by the Pipeline control. At the end 

of an exposure line, the 4 highest order Bits of 

the red pixel bus are separated from the DAC by 

the module-internal logic and replaced by the 

4 Bit register data and a clock is generated for 

the red DAC. This results in an analogue voltage 

selectable in 16 steps by the Software and used 

to trigger the red laser so that a BOL pulse can 

be generated. Apart from this, the initialisation 

prerequisites for the triggering of the red laser 

diode (Laser off BOL register = 0h, Dark 

active) as well as the laser enable/disable control 

are materialised in this module after the supply 

voltage has been applied. 

5. Facet correction 

The facet correction is used to compensate minor 

colour-dependent differences (

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Printer 

Owing to the freely programmable limits, there 

is a window comparator for each colour whose 

window can be shifted within a certain range 

and whose window width is variable. From the 

counted errors conclusions can be drawn about 

the drift direction which can be compensated by 

readjusting the laser energy between the 

images as well as about the noise amplitude. 

7. LUT address multiplexers 

The LUT address multiplexers (RGB) send the 

pixel data resulting from the calculation (Laser 

enable) or the address generator (Laser disable 

and µC access) to the LUT addresses in 

accordance with the operating mode. For this, 

appropriate control signals are generated for 

the LUTs (Chipselect, Output enable, Write 

enable) and the LUT data multiplexers (Read 

enable, Write enable). 

8. LUT data multiplexers 

The LUT data multiplexers (RGB) control the bidirectional 

Input/Output of the FPGA on the 

LUT data lines for the reading or writing. When 

the µC is writing, the data is sent from the 

internal data bus to the LUT data lines of the 

corresponding colour. When the µC reads a 

LUT, the data of this LUT is switched to the 

internal data bus. 

9. LUT Switch 

The Printer Mainboard holds memories for two 

LUT´s for each colour. The Software switchover 

between the two LUT´s happens in this 

module. Apart from this, the border exposure is 

set until the end of an image. 

10. Mode 

In this module, the various operating modes of 

the data pipeline are set. The Software writes a 

7-bit date into the mode register. A mode is set 

as a function of the Pipeline control and the 

date in the mode register. 


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The following modes are available: 

Printer mode dyn. Laser noise correction on 

Printer mode dyn. Laser noise correction off 

Register mode 1 

Data is taken from the three colour registers and output after the signal 

BOL with the loaded line length until mode 0000 is set. 

Register mode 2 Data is taken from the three colour registers and output at the next BOL 

with the loaded line length until mode 0000 is set, every second pixel 

being blanked. 


with the loaded line length until mode 0000 is set, always two pixels are 

unblanked and two pixels are blanked. 


with the loaded line length until mode 0000 is set, always 256 pixels are 

unblanked and 256 pixels are blanked. 

Register mode 5 Data is taken from the three colour registers and output quasi statically 

without a signal BOL. 

FIFO data read by µC 

Red channel on max. intensity 

Switching of the red laser triggering in the static or dynamic mode 

11. Pipeline control 

Central control for the data pipeline. 

It generates clocks and control signals for the 

internal modules and external units (FIFO, LUT, 

Latch, DAC, ADC). 

It controls the process of a pixel line: 

BOL detection = line start start line exposure 

end line exposure Retrace (EOL, Dark) 

line end, red laser set to BOL value. 

A 16-bit counter linked with comparators 

generates the control signals for the 

corresponding phase. Fixedly programmed 

comparators exist for the Retrace and the line 

end. The comparators for the start and end of 

the line exposure are programmable. They are 

used to define the image width and image 

position. Other modules for the image start and 

end detection, the dark signal generation and a 

logic for the facet address generation and 

synchronisation have been integrated. 

12. Pixel delay 

A pixel delay module has been implemented for 

each of the three colours (RGB). These 

modules are in the data pipeline and allow the 

delay of the pixel data of each colour by entire 

pixel clocks independent of each other. The 

delay can be programmed between 1 and 

16 pixels. 


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Printer 

13. Pixel shift 

In the Pixel shift module, three independent 

clocks are generated for the red, green and 

blue DAC. A Software-programmable shift 

register exists for each colour. The shift 

registers allow the shift of the DAC-Clocks at a 

resolution of 1/8 pixel clock, i.e. an adjustment 

of the pixel coverage of the three colours is 

possible in steps of 1/8 pixels. 

14. Red correction 

The red correction comprises an 8-bit wide 

register that can be loaded by the Software. 

The content of the register is calculated in the 

calculation module in the same way as the 

noise correction of grn/blu. Hence, a fine 

adjustment of the red channel by ± 4% is 

possible. 

15. Service 

In the service module, the 32-bit wide pixel data 

is divided to the three channels (RGB). 

Depending on the selected operation mode and 

the status of the Pipeline control, the pixel data 

is put on the data pipeline or sent to the µC 

data bus by the FIFO or the registers. Three 

implemented 10-bit registers, one for each 

colour, enable the Software to save any pixel 

value for each colour which can be used for the 

internal test image generation or the horizontal 

image border exposure (see 10. Mode). 

16. Status 

In the status module, the different Pipeline 

conditions are assessed and error messages 

are generated. The µC can check the status. 

Some of the signals are indicated in addition by 

LEDs on the Mainboard. 

The following conditions can be checked and 

are indicated: 

Status Display Data bit LED 

FIFO empty FIFO Flag direct D0 none 

FIFO almost full FIFO Flag direct D1 D37 yellow 

FIFO full FIFO Flag direct D2 none 

End Of Line (EOL) Line retrace D3 D33 yellow 

Work Image output D4 D34 yellow 

Image Error Image data line unequal exposure line D5 D4 red 

Facet synch. Facet counter asynchronous D6 D3 red 

Laser status Laser enable/disable D7 none 

FIFO-Empty-Latch Saved FIFO empty during exposure (Error) D8 D36 yellow 

FIFO-Full-Latch Saved FIFO full during exposure (Error) D9 D38 yellow 


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17. Calculation 

The noise correction values for green and blue 

and the value of the red correction are 

calculated with the facet correction values 

separately for each colour. As these are small 

percentage values, the errors are simply added. 

The result is one Byte for each colour that is 

limited to FFh in the addition with carryover. In 

the mode „Noise correction off“ a fixed value 

corresponding to an error of 0 % is added with 

the facet correction values instead of the noise 

data and red correction. The 8-bit correction 

values are used along with the 10-bit pixel data 

to form an 18-bit address for each colour for the 

following LUTs. 

18. Version 

Here, a rereadable version number of the FPGA 

program is stored. 

19. Red laser 

There are two different trigger circuits for the 

red laser diode at present: 

- Only dynamic triggering 

- Dynamic and static triggering (Default) 

The appropriate triggering can be selected by 

the Software. The required control signals for 

the red laser are generated. 

Look Up Table (LUT) 

In the LUTs the density-proportional image data is 

adjusted to the output medium while the 

characteristics of the lasers and the transfer 

characteristics of the actuators are taken into 

account. The Printer Mainboard holds two SRAM 

banks 256k x 16 for each colour. 

It is possible to save LUT data for two paper types 

at the same time. The density-proportional pixel 

data coming from the FPGA and carrying a 

correction value form an 18-bit LUT-address for 

each colour. The addressed memory cell holds the 

12-bit wide result from the transformation of the 

density-proportional pixel data with the paper 

characteristic (conversion into performanceproportional 

data), the following multiplication with 

the reciprocal correction data and subsequent 

transformation of the AOM characteristic. 


Repair 

Printer 

Latch 

The LUTs are topped by a 16-bit Latch for each 

colour. The Latches are used to synchronise and 

buffer the asynchronous LUT data with the pixel 

clock. 

Digital Analogue Converter (DAC) 

The DAC converts the 12-bit wide image date into 

an analogue current between 0 and 20 mA as a 

function of its clock. The Printer Mainboard holds a 

DAC for each colour whose clock can be controlled 

independent of the others (see 4.13. Pixel shift). 

Current/Voltage Conversion & 50 Ohm Line Adjustment 

The output currents are transformed to analogue 

voltages which are amplified by operational 

amplifiers and ride on the cables with 50 ohms 

(RGB). The voltage amplitude is 0... 600mV. 

Level Adjustment & Amplification 

The circuit filters out the noise part of the energy of 

the green and blue laser channels measured by the 

monitor diode and amplifies the total noise 

amplitude by a factor 10. 

High Speed Analogue-Digital Converter (ADC) 

The 2-channel ADC converts the amplified noise 

signals of the green and blue laser channel to one 

Byte each. Digitising is in real time for each colour, 

i.e. at every pixel clock. The digital values are 

validated in the FPGA for the calculation. 


Printer 

Repair 

PF_GS01 - Technical Data 

Layout 

dlabr179 

Voltages PF_GS01 

+ 5V Logic supply 

+ 6,5 V Logic source voltage 

+ 9V Supply voltage 

– 9V Supply voltage 


Repair 

Printer 

Jumpers 

J1 not plugged in 


J3 plugged in Main clock for data pipeline (60,929170 MHz) 


J5 not plugged in The Jumper must not remain plugged in during normal operation! 

Only for the LEDs active, the operating conditions can be checked 

service: plugged in 

J6 plugged in CAN-termination resistor active 

LED Display 

D1 LED red Lights when the Reset line on the SPI Interface is active 

D2 LED red Initialisation FPGA (signal/INITX in the SP) 

D3 LED red Polygon facet not synchronous 

D4 LED red Picture error 

D33 LED yellow End of line (EOL), during Lineretrace 

D34 LED yellow Picture work, lights during the image output 

D35 LED yellow no significance 

D36 LED yellow FIFO empty latch 

lights when a communication error occurs with the LVDS interface 

D37 LED yellow FIFO almost full 

D38 LED yellow FIFO full latch, communication error with the LVDS interface 

Test Points 

MP3 +5V 

MP4 GND GND against +5V 

MP7 +5V (digital) 

MP8 +3,3V(digital) 

MP9 

Video output voltage Red channel 

MP10 

Video analogue GND 

MP11 

Video output voltage Blue channel 

MP12 

Video output voltage Green channel 

MP13 

Measuring voltage laser energy Green channel 

MP14 

DC-compensated amplified noise voltage Green channel (0...1,2...2,4V) 

MP15 

Measuring voltage laser voltage Blue channel 

MP16 

DC-compensated amplified noise voltage Blue channel (0...1,2...2,4V) 

MP23 

Not used 

ST33 

Test point for EOL signal 

ST34 

Test point for Picture Work 

Connector Allocation 

see Printer Mainboard in register 6.2 


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Magazine Drive MD 

ML_GS01_GS – LH Magazine Drive 

MR_GS01_GS - RH Magazine Drive 


MD = Magazine Drive 

ML_GS01_GS – Magazine Drive 8.8060.2150. 

MR_GS01_GS - Magazine Drive 8.8060.2150. 

Drive of the Paper magazines: 

− Paper Magazine (ML) 

− Paper Magazine (MR) 

The central control unit SPI (Serial Peripheral 

Interface) comprises the following functional 

assembly groups: 

− DC/DC converter to supply the +5 V operating 

voltage 

− Voltage monitoring of the +36 V and +24 V power 

voltages 

− RS232 interface to output the test displays of the 

AVR module with the following settings: 

− Transfer rate = 19,2 kBaud 

− Data bits = 8 

− Stop bits = 1 

− Parity = None 

− Protocol = Xon / Xoff 

− RESET generator to link the various RESET 

sources. 

− Clock generator 8 MHz 

− The SPI interface drivers with a transfer rate of 

1Mbit/s. 


Repair 

Printer 

Paper Magazine Coding 

Slide closed 

■ Slide open 

PATTERN 

PAPER SIZE 

1 2 3 4 5 6 

3.25 inch (82 mm) • • 

3.50 inch (89 mm) • • • 

3.75 inch (95 mm) • • • 

4.00 inch (102 mm) • • • 

4.75 inch (120 mm) • • • GLOSSY • 

5.00 inch (127 mm) • • MATTE •• 

6.00 inch (152 mm) • CUSTOM1 • 

6.50 inch (165 mm) • • CUSTOM2 

7.00 inch (178 mm) • • 

8.00 inch (203 mm) • • 

8.25 inch (210 mm) • 

Magazine Drive, Functional Assembly Groups 

− Sensor signal for the measuring length (PSG, 

NSG): It is sent directly by the SPI module sheet 

gear SG_GS01 and defines the 

distances between two sensors for which a step 

number is defined. This step number is made 

available for the calculation of the winding core. 

− Magazine Lock that holds the magazine and 

sends a signal via LS08 when a magazine has 

been put in. 

− The magazine change indication informs the 

operator when to change a magazine. LED_RT 

active = magazine change not allowed! 

− The Shutter assembly group is mechanically 

coupled to the magazine and sends a signal via 

LS07 when paper has been transported out of 

the magazine. 

− The magazine coding encompasses the 

reflected light sensors LS01 to LS06. These 

sensors are used to detect the paper type and 

the format after the magazine has been put in. 

The format is set by the mechanical slides on the 

magazine. 

− Drive of the magazine core: The motor MO02 is 

driven directly by the AVR Controller. It is 

responsible for the formation of a paper loop in 

the magazine. The loop must be large enough so 

that a maximum paper size can be supplied 

quickly and at any time by motor1. 


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− The paper transport drive MO01 and the 

magnetic couplings MG01 and MG02 together 

form a functional assembly group. They advance 

the photographic paper from the paper loop in 

the magazine to the sheet gear assembly group 

for further handling. 

− The assembly groups of the RH paper magazine 

(MR) and the LH paper magazine (ML) only differ 

by their mechanical structure. 

See also PORT allocation in Register 6.2 

Position 

ML_GS01 / MR_GS01 are screwed directly to the 

magazine drive assy left / right (8.8060.MD01. / 

MD02.). 

The assembly group must be dismounted to change 

the GS. 

Layout 

dlabr204 


Repair 

Printer 

Voltages 


+ 6,5V Logic source voltage 


+ 36V Power voltage supply 

Jumper 

J1 

not plugged in 

Only for the service: 

plugged in 

Activation of the display LEDs, operating conditions can be checked 

LED Display 

D12 LED green Lights when logic voltage +5V is present 

D22 LED red Lights when Reset of the GS is active; 

Reset can be triggered manually with S2 

D13 LED yellow Only for development work; is active when the AVR Controller is 

triggered via an external programming unit 

Test Points 

MP1 + 5V 


MP3 not used 

MP4 not used 

MP5 not used 


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ML_GS02 / MR_GS02 and ML_GS05 /MR_GS05 

(Magazine Coding, Locking Detection; left / right) 

Positions 

Two printed circuits per magazine compartment: 

− Mx_GS02 in the support (magazine coding 

detection) 

− Mx_GS05 lateral, turned to the Shutter 

(locking detection) 


Repair 

Printer 

Switching Gear SG 

SG_GS01 – Switching Gear Control 


SG = Switching Gear 

Magazine drive: 

SG_GS01 sends the sensor signal for the 

measuring length (PSG, NSG) that defines the 

distance between two sensors for which a step 

number is found. It is needed for the calculation of 

the winding core. 

Position 

SG_GS01 is located on the fan assembly group 

below the assembly group SG (1). 

1 

The electrical connection is interrupted when the 

fan assembly group is removed. 

dlabr146 


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Layout 

dlabr205 

Voltages 




Jumper 

J1 


Only for service: 

plugged in 


LED Display 

D1 LED red Lights when SPI Controller is Reset 

D12 LED green Lights when +5V supply voltage is applied 


Repair 

Printer 

Sheet Stocker SR 

SR = Sheet Stocker 

Sheet buffer (see Arrow) for paper from the RH 

paper magazine: 

After the cut, the paper is transported into the single 

sheet buffer and then by the sheet gear to the print 

engine on the same path as the paper from the LH 

paper magazine. 

dlabr007 

Sheet Bridge SB 

SB = Sheet Bridge 

The sheet bridge (1) is part of the transport unit 

(TU). It cannot be removed separately. 

dlabr110 


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Transport Unit TU 


TU = Transport Unit 

The transport unit located in the centre of the 

paper drive has the following functions: 

− Sheet transport from the sheet bridge (SB) to the 

print engine (PE) 

− Sheet rotation through 90º for horizontally cut 

sizes 

− Sheet centring in the middle and parallel to the 

paper advance direction 

− Smooth transfer of the sheet to the print engine 

and smooth taking over of the sheet by the print 

engine 

− Advance of the sheet to the lane distributor (LD) 

Prerequisites: 

− Paper widths 3,25" - 12" 

− Shortest sheet length 

− before the rotation 3,25" 

− after the rotation 4,75" 

− Longest length to be handled 18" 

− Largest size to be turned 5x7" (13x18) 

dlabr068 

See also Block circuit diagram of the transport unit 

in Register 6.2 and Flowcharts / Transport unit in 

this Register. 

Parameter TU: Clock Time 

For a productivity of 1.700 prints of the size 

10 cm x 15 cm, a clock time of 1,89 s/sheet results. 


Repair 

Printer 

TU_GS01 (Transport Unit Control) 


Particularity: 

The primary logic and the power electronic are 

electrically separated. 

− Control of the TU assembly group 

− Communication with the Printer Mainboard 

PF_GS01 

Position: Behind the front cover of the TU 

dlabr068 

Layout 

dlabr206 


Printer 

Repair 

Voltages 



Jumper 

ST3 


Only for Service: 

plugged in 


LED Display 

D2 LED green Lights when logic voltage +5V is applied on the microcontroller (is in 

Hardware Reset) switching part 

D51 LED red Lights when logic voltage +5V is applied on the microcontroller (is in 

Hardware Reset) switching part 

Connectors 

ST1 

ST5 

ST24 

ST27 

assigned 

assigned 

assigned 

assigned 


Repair 

Printer 

Print Engine PE 


PE = Print engine 

− Smooth taking over of the single sheets from the 

transport unit TU 

− Exposure transport and exposure control 

− Transfer of the exposed single sheet to the 

transport unit 

Major assembly groups: 

− Supporting frame with oscillation stabilisers (1) 

− Laser module with guide mirror (2) 

− Exposure roller (3) 

− Belt assembly group (4) 

− Flaps (5) 

Laser module: 

− LA_GS01 LFB distributor (1) 

− LA_GS06 Red Laser diode (2) 

− PE_GS01 PE distributor (3) 

− LA_GS07 Polygonal drive (4) 

− LA_BE04 AOM (5) 

− LA_BE04 AOM (6) 

dlabr076 

dlabrx48 


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Laser Module 

Warning 

The cover plate must never ever be opened. 

dlabr158 

1 Laser diode (rot) 

2 Monitor diode (measures beam intensity) 

3 Polygon 

4 Postscan 

5 Image plane 

6 Laserbeam of the Argon ion laser 

7 Polarisation filter 

8 AOM (blue, green) 

9 Laser beam 

dlabr175 


Repair 

Printer 

PE_GS01 


The printed circuit PE_GS01 (L8060.2170.) 

− controls all functions of the print engine assembly 

group (PE) and the Laser module (LM) and 

− reports the corresponding sensor conditions 

For this, the commands on the SPI interface in the 

microcontroller are checked and the corresponding 

actions are initiated. 

The SPI interface implemented in the Controller is 

triggered by differential drivers (RS422). 

Polarisation filter output stages: 

The Controller controls the stepper motor output 

stages on ST7, ST8 and ST9 by applying the 

appropriate winding phases for the half step 

operation to a shift register. The windings are 

switched dead during the sleep phase. 

Flap activation: 

The output stage on ST10 for the flap is triggered by 

an additional Controller with run-up ramps. 

This sub-controller functions with the program of the 

flap control when there is zero potential on the input 

of the Pins 17,18,19. 

Print roller activation: 

The output stage on ST23 for the print roller is 

controlled by the Controller during the startup curve 

and is then switched to a clock defined by the quartz 

oscillator MC7 (2,33472MHz / 2 9 = 4,560 kHz). It 

works in half-step mode. 

1 Printed circuit PE_GS01 

dlabrb48 


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Connection of the polygon control: 

The polygon drive on the Laser module receives 

through ST19: 

− the supply voltage of 24V 

− an On/Off signal and 

− a feedback signal: Required speed reached 

The polygon frequency is provided by the quartz 

oscillator MC6 (1,43332MHz / 2 10 = 1,3997kHz) via 

ST19. 

Feed and exit roller drive (ST11): 

It is controlled by an electronic potentiometer set by 

the Controller. The corresponding actual parameter 

is recorded by the Controller via ST13 as rotation 

period of the roller. The control voltage of the 24V 

motor varies between 8 and 14V. 

Sensor signals: 

The signals of the connected light sensors are 

directly sent to the Controller. They can be traced 

on the male connector strip ST29. 

Sheet tip sensor PE_LS05 (2): 

The sheet tip sensor supplies via ST15 a frequency 

that is proportional to the light reflected by the 

paper. The duration of the period is checked by the 

Controller and serves to generate the signal BOP on 

ST5. 

Exposure start sensor PE_LS06 (1): 

Connection of the Laser diode control: On ST5, a 

differential facet sync signal is applied and a DARK 

signal for the Laser diode triggering is received. The 

generated BOP signal and the beginning-of-line 

signal from ST6 are sent differentially through ST5. 

The activation of the red Laser diode is supplied by 

an analogue voltage of ±9V through ST21 which is 

sent to the printed circuit through ST 20. 

1 Polygon control 

dlabrc48 

dlabr097 

dlabr098 


Repair 

Printer 

Operating Voltage Supply 

The printed circuit E_GS01 gets its supply voltage 

through the SPI interface ST1 as source voltage of 

+6,5V. This voltage is stabilised to +5V by a linear 

regulator and supplies the Controller and the light 

sensors. 

The power voltages +24V and +36V are supplied 

through ST24. These voltages are led to circuit that 

serves as current limitation when the module is 

plugged under power. 

− The +24V are used to energise the feed and exit 

roller drive (DC motor) and the polygon drive. 

− The 36V supplies all stepper motor drives. This 

voltage is also used to derive via a switching 

regulator an additional +5V for the output stage 

supply, the supply of the sub- controller and the 

shift register. 

This way, the power unit is electrically separated by 

the logic part of the Controller and by this of the 

whore Printer. The signal transmission is ensured by 

corresponding optocouplers. 

A comparator circuit provides for a status signal of 

the three supply voltages. 

Controller Firmware Update 

In addition to the provided Update option via the SPI 

interface, the Controller can be programmed 

separately via ST2. The sub-controller can only be 

programmed on-board by means of a suitable PIN- 

Adapter. 

Debug Connection 

A non real time-capable RS232 monitor output is 

available on ST3 for Debut purposes. 


Printer 

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PE_GS01, Layout 

dlabr201 

Voltages 




– 9V Supply voltage 



Jumpers 

ST25 not plugged in 

Only for service: Activation of the display LEDs, operating conditions can be checked 

plugged in 

ST3 

RS232 monitor for Debug purposes (19200,N,1) 

ST29 

Pin connector as test pins for sensor signals 

11 +5V 

12 GND 

13 PE_LS2 

14 LASD_OK 

15 PE_LS4 

16 PE_LS3 

17 PE_LS1 

18 PE_LS8 

19 PE_LS7 

20 f_BOP Output frequency of the BOP sensor approx. 100 Hz without paper, 

1 KHz with paper; a significant difference is important because the 

thresholds change dynamically 


Repair 

Printer 

LED Display 

The contacts on ST25 must be plugged in 

(= LED enable) 

The status is displayed when the assembly group 

is initialised (from left to right). 

Power ok 

Reset 

BOP 

SV-SPI 

Lights when the supply voltages 24V, 36V and 5V on Power GND are ok 

Lights when the Reset line on the SPI Interface is active 

Lights when no paper is in front of the BOP sensor on the print roller (result of the 

assessment of the frequency f_BOP) 

Lights when the logic supply 5V of the logic source voltage 6,5V is ensured via the SPI 

interface 

Test Points 

MP1 +5V +5V logic supply of the 6,5V via the SPI Interface 


MP4 Steps Stepper motor clocks for the actuator of the flap control 

MP6 P5V Master frequency for the polygonal drive 1,399kHz 

MP7 P5V Logic supply 5V derived from 36V 

MP8 PGND GND against P5V 

MP9 — not used 

MP10 BOP BOP-Signal: low when no paper in front of the sensor 

MP11 BOL BOL-Signal: positive pulse of approx. 33µs always at the beginning of the line 

Connector Assignment 

see PE_GS01, connector assignment in 

register 6.2 


Printer 

Repair 

Circuit Diagram 

dlabe137 


Repair 

Printer 

PO_GS01 (L8.8060.2200.) - Power Monitor 


PO_GS01: L8.8060.2200. 

− Control and monitoring of the current supply of 

the Printer section 

− Control and monitoring of the Laser via the SPI 

command interface. 

All output voltages are A/D converted and can be 

checked. For this, the commands are checked at 

the SPI interface in the Microcontroller and the 

corresponding actions are initiated. 

The SPI interface implemented in the Controller is 

activated via differential drivers (RS422). 

dlabr034 

Remote Power Supply 

After the Reset of the Controller, the power 

voltages (24V, 36V, 22,5V) are switched off. They 

can be switched by the SPI command. 

All available output voltages of the power supply 

unit are checked at the Remote connection, are 

level-converted and are sent to the 11-input 10-Bit 

A/D converter. 

A simple instrumentation amplification circuit and 

their 2-pole measurement ensures that no 

inadmissible GND loops occur. 

The measuring values are constantly recorded in 

a program loop and compared to the reference 

values set by commands. The result of the 

monitoring is shown by the LEDs which light when 

the corresponding voltage is in the required range. 


Printer 

Repair 

Laser Remote 

After the Reset of the Controller, the Laser is 

switched off. It can be switched on, off and in 

Standby by the SPI command. 

The Laser current and the Laser power are 

constantly recorded by the A/D converter and the 

result is available in the Controller for the check 

by commands. 

The reference value of the Laser power can be 

set by the Controller by means of an electronic 

potentiometer. The last current value is stored in 

an EEPROM and is immediately available after 

switch-on. 

Debug Connection 

Debug connection: A non real-time capable 

RS232 monitor output is available on ST3 for 

Debug purposes. It also supplies the measuring 

values of all voltages following a special SPI 

command. 

Layout 

dlabr202 


Repair 

Printer 

Voltages 


+6,5V Logic source voltage 

+9V Supply voltage Printer 

- 9V Supply voltage Printer 

+ 15V Supply voltage Scanner 

- 15V Supply voltage Scanner 

+22,8V Lamp voltage Scanner 

+24V Supply voltage 


Jumpers 

Normal condition For the service: Jumper plugged in: 

J1 22,8V_ON Not plugged in 22,8V lamp voltage switched on when the LOCK switch is 

connected to the lamp (independent of the Software) 

J2 24V_ON Not plugged in 24V power voltage switched on (independent of the 

Software) 

J3 36V_ON Not plugged in 36V power voltage switched on (independent of the 

Software) 

J4 LAS_ON Not plugged in Laser switched on (independent of the Software) 

LED Display 

On PO_GS01 at the top, from left to right 

D23 +24V_AOM Lights when AOM amplifier_supply in tolerance 

D22 +22,8V Lights when voltage in tolerance 

D21 C_LAS_ON Lights when Laser current ≥ 3A 

D20 L2 No function 

D19 L1 No function 

D29 +6,5V Lights when source voltage for 5V logic supply of the Printer in tolerance 

D28 +36VP Lights when power supply of the Printer in tolerance 

D27 +24VP Lights when power supply of the Printer in tolerance 

D26 +5V Lights when logic voltage in tolerance 

D25 -15V Lights when analogue voltage of the Scanner in tolerance 

D24 +15V Lights when analogue voltage of the Scanner in tolerance 

D18 -9V Lights when analogue voltage of the Printer in tolerance 

D17 +9V Lights when analogue voltage of the Printer in tolerance 


Printer 

Repair 

Test Points 

MP1 +5 +5V logic supply derived from the +6,5V 


MP3 5VP +5V logic supply on potential of the laser power supply; tapped via the 

DC_DC converter from the above 5V 

MP4 PGND GND against +5VP 

MP5 PR Measuring value of the laser power to the A/D converter = 1/2 of the value 

of the laser power supply (measured against PGND) 

MP6 CR Measuring value of the laser current to the A/D converter = double value 

of the laser power supply (measured against PGND) 

Circuit Diagram 

dlabe138 


Repair 

Printer 

LA_GS01 – Distributor Board 


LA_GS01: L8.8060.2090. 

− Distributor board with voltage generation 

− Distributes the colour signals coming from the 

Printer control board PF_GS01. These signals 

are used to modulate the AOMs. 

dlabrf48 

Layout 

dlabr169 


Printer 

Repair 

LA_GS05 – Red Laser Diode 


− Generates the red laser beam 

− Ensures a constant temperature for the laser 

diode (temperature compensation generated on 

the board) 

dlabrg48 

LA_GS07 - Polygonal Drive 


LA_GS07 controls/monitors the polygonal rotation. 

The rotation speed must be constant so that the 

prints are exposed without distortion. 

dlabrc48 


Repair 

Printer 

LA_BE04 – AOM Amplifier, blue 

LA_BE04 – AOM Amplifier, green 

The intensity of the laser beam is influenced for 

each pixel in the acousto-optical modulators (AOM) 

as a function of the colour information: 

− AOM, blue (2) 

− AOM, green (1) 

dlabrd48 

1 AOM amplifier, green LA_BE04 

2 AOM amplifier, blue LA_BE04 

3 Red Laser diode LA_GS02 


Printer 

Repair 

Lane Distributor LD / Sheet Transfer ST 


LD = Lane Distributor 

ST = Sheet Transfer 

The lane distributor ensures the following 

functions: 

− Transport of the exposed prints from the 

transport unit to the Paper Processor (advance to 

the Sheet Transfer) 

− Back print 

− Support of the control strip box and transport of 

the control strip to the Paper Processor 

− Compensation of the mismatch between the 

Printer and the Paper Processor section 

dlabr079 

1 Sheet Transfer ST 

2 Lane Distribution 

3 Control strip box 

4 Back printer 

5 Transport Unit TU 

6 Sheet take-over from the TU 

7 Sheet transfer to ST 

dlabr176 


Repair 

Printer 

Sheet Transfer ST 

The sheet transfer ST takes the sheet from the lane 

distributor and transports it into the DEV tank of the 

Paper Processor. 

The transfer of the exposed prints from the lane 

distributor to the Paper Processor is performed as a 

function of the paper width and length: 

dlabr062 

2 lanes 1 lane 

Prints aligned on front Prints offset 

edge 

Paper width max. 102 mm max. 102 mm > 102 mm 

Paper length max. 178 mm > 178 mm max. 256 mm 

See also Flowcharts Lane distributor in this 

Register 

LD Parameters: Paper Widths / Distribution 

The middle of the lane distributor is 40 mm closer to 

the Printer front edge than the middle of the Paper 

Processor. 

Paper widths in Inch 2 lanes +Y (to the back) -Y (to the front) 

3,25 X 120 0 

3,5 X 120 0 

3,75 X 120 0 

4 X 120 0 

4,75 40 - 

5 40 - 

6 40 - 

6,5 40 - 

7 40 - 

8 40 - 

8,25 40 - 

3,5 control strip - 95 


Printer 

Repair 

LD_GS01 - Lane Distributor Control 


LD_GS01: 8.8060.2100. 

− Control of the lane distributor assembly groups 

(LD) 

− Control of the sheet transfer stepper motor (ST) / 


− Communication with the Printer Mainboard 

PF_GS01 

Position 

Lane Distributor, rear side 

dlabr118 


Repair 

Printer 

Layout 

dlabr203 

Voltages 



+ 24V Supply voltage (required for the output stage of the magnetic coupling) 


Jumpers 

J1 

Not plugged in 

Only for Service: Activation of the display LEDs, operating conditions can be checked 

plugged in 

J3 Not plugged in (no function) 

LED Display 

D2 LED red Lights when the SPI Controller is Reset 

D54 LED green Lights when +5V supply voltage is applied 

Test Points 

MP1 

GND 

MP2 PGND GND against 5V derived from the +36V supply voltage 


Printer 

Repair 

RD_GS01 - Back Printer Control 

Position 

Lane Distributor, bottom 

dlabr119 


Repair 

Printer 

Laser Fundamentals 

Colour Laser Scanner (Beam generation, Beam processing, Beam deflection) 

Beam 

Beam processing 

Beam deflection 

generation 

←--------------------------------Pre-Scan ---------------------------------------------------------→←-Post-Scan--→ 

1 Blue channel AOM.b AOM Blue 

2 Green channel AOM.g AOM Green 

3 Red channel AR.gb Ar-Ion laser, air-cooled, green+blue (514 mm + 458 nm) 

4 LED BK.gb Beam combination Blue R, Green T 

5 Polygon mirror BK.rgb Beam combination Red R, Green/ Blue T 

6 Postscan lens White channel BSP.b Beam splitter Blue 

7 Photopaper BSP.g Beam splitter Green 

8 Prescan lens green/blue channel BSP.r Beam splitter Red 

Int.b Polarisation filter 

LD.r Laser diode Red (685 nm) 

LK.gb Coupling fibre bundle 

PD.b Regulating photodiode Blue 

PD.g Regulating photodiode Green 

PD.r Regulating photodiode Red 

dlabr028 


Printer 

Repair 

Laser Module (LA) 

The colour laser scanner is used to expose in the 

Raster scan digital image data on special laser 

paper by means of 3 Laser beams (red, green, 

blue). 

Main components of the laser tube: 

− glass bulb filled with gas 

(on the d-lab.3 Argon) 

− 2 mirrors 

(the front one is partially transparent, the rear 

one is opaque) 

− H.V. electrodes to ignite (Ionisation) the gas 

1 Mirror (rear) 

2 High voltage generation + electrode 

3 Coupling + mirror (front) 

4 Laser beam 

5 Discharge 

dlabr147 

Beam Generation 

The electrons are excited by the applied high 

voltage to jump to a higher energy level. When 

the gas is discharged at the change to a lower 

energy level, light photons are generated which hit 

the mirrors, are reflected there and hit other 

charged atoms. The atoms that are hit release 

several light photons and this phenomenon 

continues (principle of a chain reaction). 

If the light amplifier in the active medium exceeds 

the losses of the waves reflected to and fro 

between the mirrors, the laser starts oscillating at 

a wave length which is characteristic for the laser 

material, producing a stationary wave field 

between the mirrors. One of the mirrors is faintly 

transparent to outcouple the laser beam from the 

resonator. 

Many laser materials, like Argon, can supply the 

amplification for a large number of different light 

frequencies. The Argon ion laser of the d-lab.3 

produces the blue (458 nm) and green (514 nm) 

beams which are available for the colour laser 

bundle at the coupling point. The fibre bundle 

guides the laser beams into the optical module 

where they are separated and focused in bundles 

by lens systems. 


Repair 

Printer 

Intensity of the Laser Beam / AOM 

The intensity of the beams is influenced by the 

acousto-optical modulators (AOM) for each pixel 

as a function of the colour information. 

In the AOM a crystal in the blue/green light path of 

the laser is oscillated by a frequency. Depending 

on the amplitude of the oscillation, the crystal 

becomes more or less translucent and by this 

changes the intensity of the laser beam. 

The intensity of the red laser diode is regulated 

directly by the preceding electronic. 

dlabrd48 

1 AOM LA_BE04 

2 AOM LA_BE04 

3 Red Laser diode LA_GS06 

Polarisation Filters 

The maximum density is set by means of the 

polarisation filters. 

The polarisation filters are controlled by stepper 

motors. 

Beam Focusing 

The beams are focused by partially transparent 

mirrors and are projected on the paper by the 

rotating polygonal mirror and a guide mirror. 

Start of Exposure 

The sheet front edge detection is defined by the 

sensor BOP (2), the exposure start, by the sensor 

BOL (1). 

dlabr097 


Printer 

Repair 

Laser Sources 

Laser sources Wave length Power in the image 

plane 

Power at the 

monitor diode 

Red channel (Laser diode) 680,0 nm 850 µW ± 5% 264 µW ± 5% 

Green channel (Argon laser) 514,5 nm 320 µW ± 5% 550 µW ± 5% 

Blue channel (Argon laser) 458,0 nm 125 µW ± 5% 900 µW ± 5% 

Modulation 

All channels can be regulated by polarisation filters (setting accuracy 

1,5% in the entire dynamic range. 

Red channel 

Direct current modulation of the Laser diode, definition of the time/time 

period (ref. BOL) for the suppression to calibrate the Feedback diode. 

Input signal 0-0,6 V on 50Ω 

Green and Blue channel 

Analogue AOM, input signal 0-0,6 V on 50Ω 

Laser Drift 

Gas lasers emit in general only a small 

percentage of their power as light, the major part 

is transformed to heat. 

Caution! 

The air exhaustion of the laser exhaust air at the 

back of the machine (5) must not be hindered 

because the service life of the laser tube drops if it 

gets too hot! 

6 

5 

4 

3 

1 

2 

dlabr154 


Repair 

Printer 

Setting the Pixel Coverage 

The three lasers Red, Green, Blue produce three 

pixels of the colours Cyan, Magenta, Yellow on 

the paper. 

Requirement: 

The three pixels are centred on top of each other: 

tolerance: 1 / 8 pixel width offset with respect to 

each other. 

Experience has shown that exceeded tolerances 

are judged very differently. In general, deviations 

of more than one pixel width are regarded as 

quality deterioration on prints from digital sources 

(graphics, letters, fine lines). On prints from films, 

deviations of about one pixel width are not visible 

so often. 

Adjustable: 

The service technician can adjust the pixel 

position in scanning direction, i.e. each colour can 

be shifted at a right angle to the paper transport 

direction. 

Not adjustable: 

The pixel position parallel to the paper transport 

direction cannot be adjusted in the field; this 

adjustment is only possible in the factory. 

If deviations occur in this direction, the colour 

laser scanner has to be replaced! 

Warning! 

Never open colour laser scanners! 

Risk of injuries caused by laser beams! 

Adjusting the Pixel Coverage 

Prerequisites: 

− Printer started 

− At least one paper magazine in the Printer 

− Paper data loaded for the inserted paper 

− PPL in tolerance 

Magnifying glass with a 10-fold magnification 

Keyboard 

Mouse 


Printer 

Repair 

There are 2 methods to set the pixel coverage of 

the 3 colours in Fast Scan direction: 

1. Approximate, pixelwise shift by means of the 

Pixel delay 

2. Fine shift of the colours with respect to each 

other with the Pixel shift in 1 / 8 pixel steps 

Pixels can only be shifted to the left. 

The pixel at the far left serves as reference for the 

adjustment and the other pixels are shifted to the 

left. 

− Print the test print TESTPRINT01.ARP 

− Assess the print, check pixel coverage faults 

− Set the pixel shift or delay 

− Repeat these adjustments until all 3 colours are 

centred on each other. 

Pixel Delay 

Increasing the value of one colour will shift the 

output of this colour to the left (holding up the 

beginning of the print). Values between 0 and 15 

are admissible. 

Pixel Shift 

The position of the colours Red, Green, Blue are 

described by a sequence of 4 cyclically connected 

ones and zeros. If one colour is to be shifted to the 

left by 1 / 8 pixel, the ones and the zeros must be 

moved to the right. 

The 8 values to be entered in the pixel shift are 

calculated by adding the 3-Bit combination of 

the three colours. 

The colours are shifted by shifting the ones to the 

right. The ones that are pushed out on the right side 

are added again on the left side (cyclical rotation). 

There are always 4 ones or 4 zeros together. 7 / 8 

pixels at max. can be shifted to the left. 

If 8 / 8 pixels are shifted, the initial status is obtained 

again. 

Starting position (presetting): 

R: 0 0 0 0 1 1 1 1 (2 0 ) 

G: 0 0 0 0 1 1 1 1 (2 1 ) 

B: 0 0 0 0 1 1 1 1 (2 2 ) 

Entry: 0 0 0 0 7 7 7 7 


Repair 

Printer 

Example: 

Red 

1 / 8 pixel to the left 

Green 

3 / 8 pixels to the left 

Blue remains unchanged 

Test of the correctness of this example: 

For Red 4 connected ones (and zeros), for Green 4 

connected zeros, for Blue 4 connected ones. All 

colours are described by 4 ones and 4 zeros. 

Incomplete quick test: 

The total of all digit numbers to be entered is 28. 

R: 1 0 0 0 0 1 1 1 (2 0 ) 

G: 1 1 1 0 0 0 0 1 (2 1 ) 

B: 0 0 0 0 1 1 1 1 (2 2 ) 

Entry: 3 2 2 0 4 5 5 7 

Saving the new Values 

The Setup values for the pixel shift and the pixel 

delay are saved on the Mainboard PR_GS01. 

Checking the current Setup values 

− Call up in the Service Script: 

Script Files\scripts_dlab\setup_dat\ 

pr_vers_setup.txt 

− Run the Script 

The Info window shows the current values (of the 

example) after Setup – values HAS (Byte): 

: 

PIXEL-Delay : 00 (RT), 00 (GN), 00(BL) 

PIXEL-Shift (hex) : 03, 02, 02, 00, 04, 05, 05, 07 

: 

: 

Editing the Setup values 

− Call up in the Service Script: 


setup_init_pr_00117.txt 

This Init file exists in 2 versions 

− Default 

setup_init_pr_00000.txt 

− Printer-specific with SN 

setup_init_pr_00XXX.txt 

This version must contain the same Setup 

values that were found with the sample script; 

if not, the sampled values must be entered 

here. 


Printer 

Repair 

− Enter new values directly into the Script at 

position X after .... 

Admissible setting range: 

Delay 0 ... 15 

Shift 0 ... 7 

########## Beginning of the Editing range ############# 

: 

: 

# Pixeldelay RT (0 ...15) 

calc $ has_b_02 = X 

# Pixeldelay GN (0 ...15) 


# Pixeldelay BL (0 ...15) 


# Pixelshift 1 (0...7) 




: 

: 



− Run the Script 

A confirmation is requested for every modified 

Setup value. 

Caution! 

Stop the procedure if modified values (old => new) 

are displayed that should not be modified. 

Check the output of the values of file 

pr_vers_setup.txt and enter them in 

setup_init_pr_00XXX.txt. 

− Close Service 

− Close the d-lab.3 program: 

Press the Windows key or + 

Double-click on Watchdog 

Close the Watchdog by clicking on X 

− Start the d-lab.3 program again: 

Click on the d-lab.3 icon on the Desktop. 

Only then will the modified Setup values become 

effective. 

− Check the modified values for pixel delay and 

pixel shift with TESTPRINT01.ARP 


Repair 

Printer 

Quick Version to define the Pixel Delay and the Pixel Shift 

No backup function 

The above setting is an iterative process. To prevent 

the repeated starting and closing of the d-lab.3 

program, a temporary Script can be used for the 

adjustment. Afterwards the new values have to be 

entered in the file setup_init_pr_00XXX.txt. 

− Set PBL in tolerance 

− Start Service 

− Check the current Setup values: 


pr_vers_setup.txt 

− Note down Delay and Shift 

The shift value that is output is the result of the 

added 3-Bit combination of Red, Green, Blue. 

This result must be calculated back to the 3 single 

colours by subtraction (see Pixel shift). 

Example: 

Shift 32204557 

− Script Files\scripts_dlab\ 

scripts_printer\data_la\ 

pixelshift_and_pixeldelay.txt 

Run the Script and enter Delay and Shift in the 

interrogation windows. 

Example: 

Delay Red 0, Green 2, Blue 0 

Shift Red 10000111 

Green 11100001 

Blue 00001111 

− Script Files\scripts_dlab\setup_dat\ 

testprint.txt 

Print the test print TESTPRINT01.ARP 

− Assess the print, check pixel coverage faults 


Printer 

Repair 

− Define the pixel shift or delay and enter the new 

values. 

Script Files\scripts_dlab\ 

scripts_printer\data_la\ 

pixelshift_and_pixeldelay.txt 

Example: Blue must move 3/8 pixels to the left 

Delay Red 0, Green 2, Blue 0 

Shift Red 10000111 

Green 11100001 

Blue 11100001 

− Print the test print TESTPRINT01.ARP Script 

Files\scipts_dlab\setup_dat\ 

testprint.txt 

For identification, the corresponding correction 

should be entered as back print. 

− The adjustment is repeated until all 3 colours are 

centred on each other: 

− Then enter the values found: 

Script Files\scipts_dlab\setup_dat\ 

setup_init_pr_00XXX.txt 

− Run the Script. 

A confirmation is requested for every modified 

Setup value. 

− Close Service 

− Close the d-lab.3 program: 

Press the Windows key or + 

Double-click on Watchdog 

Close the Watchdog by clicking on X 

− Start the d-lab.3 program again: 

Click on the d-lab.3 icon on the Desktop. 

Only then will the modified Setup values become 

effective. 

− Check the modified values for pixel delay and 

pixel shift with TESTPRINT01.ARP 

■ 


Repair 

Printer 

Removal, Installation, Adjustment 

The repair instructions describe the individual 

assembly groups in the order of the paper advance. 

The following data / worksteps are stated for each 

part to be replaced: 

Cause for the replacement 

Required tool 

Prerequisites (if necessary) 

These worksteps have to be carried out prior 

to the removal. 

Removal / Installation 

Install the assembly groups in reverse order. 

The installation is only described separately 

if the removal instructions are not detailed 

enough. 

Adjustment (if necessary) 


Printer 

Repair 

Mainboard Replacement (PF_GS01), Edition 3 

Allan key, size 3 

Open-end wrench, size 6 

The PCB PF_GS01 (1) is located behind the front 

panel 

− Switch off the Printer 

− To open the front door open first the upper door 

of the print engine 

− Press the button (see arrow), to open the front 

panel 

dlab2135 

Replacement is required in the following cases: 

− Communication problems with the Main 

Computer (read out of hardware and software 

versions is no longer possible). 

− Communication problems with the Printer 

assemblies (cables have been tested and were 

OK). 

The error symptoms could be similar to those 

generated by other units. 

A clear indication for problems on the Printer 

Mainboard is simultaneous lighting of all segments 

in the segment display (88). 

In order to check this jumper J5 must be plugged in. 

For the testing of the Mainboard there is a script 

available: 

scripts for service/initialisierung/ 

pr_board_selftest.txt 

dlab2101 


Repair 

Printer 

− There may be different versions of the Printer 

Mainboard (GS01) in the d-lab: 

L8.8060.2000.X only for d-lab.3 

(X stands for a letter, no LED display) 

- L8.8060.2000.0 only for d-lab.3 

- L8.8060.2340.0/1 only for d-lab.2 

- L8.8060.2340.2 for d-lab.2/3 and net-lab.12 

How this depends on the software is described in 

the section Software Transmission. 

Save setup values (if still possible) 

Usually it will not be possible any more to read out 

the setup values. 

Setup values are stored in the following locations: 

− In the folder C:\DLAB\D-lab Version\ Logfiles, 

File: printer_setup_protokoll.txt 

− Diskette enclosed with the shipment, 

File: printer_setup_write.txt 

Attention: 

The original setup values have probably been 

changed since production start at the customers’. 

This was necessary if assemblies were replaced or 

machine parameters were optimized. If the data, 

changed meanwhile, have not been saved the two 

files still contain the original data, i.e. as they were 

at the time of shipment. 

If saving is still possible then: 

− Change in the program to Service GUI 

− Execute the script scripts for 

service/setup/ 

printer_setup_backup.txt. The script 

printer_setup_write.txt 

is automatically created and saved in the same 

script folder. The file contains all setup values of 

the Printer and the AOM LUT. 

This script is used to restore the setup values 

after replacement of the GS01. 


Printer 

Repair 

− Determine the operation times of the gas laser: 

Execute the following script in the Service GUI : 

Scripts for service\printer\laser\ 

statistic_laser.txt 

Note values (number of ignition and 

burning time) 

− Document the reasons for the Printer Mainboard 

replacement by print examples if necessary. 

− Start the script Scripts for service/ 

initialisation/Shut_down_d-lab to 

switch off the power supply to the Mainboard. 

If the execution of scripts is no longer possible 

due to defects, switch off the machine. 

Replacing the Printer Mainboard 

− Wear the antistatic wrist strap and ground it to 

protect the components. 

− Push the Printer Mainboard with it holder to the 

left, to do so loosen the Allan screws (1). 

− Unplug the connections on the PCB: 

For plug 10 a size 6 open-end wrench must be 

used. 

− Disengage the 6 cams, replace the PF_GS01 

and engage the new PCB again in the 6 cams. 

− Plug the connections back in 

Attention: Do not turn plug 10 too far. 

− Fasten the holder of the Mainboard by means of 

four Allan screws. 

Check the jumper setting: 

J1 - not plugged in 

J2 - not plugged in 

J3 - plugged in (J1...J3 exists only on Mainboard 

8.8060.2000.X) 

J4 not plugged in (BOOT) 


(LED_ON, segment display on) 

J6 plugged in (R_CAN) 

dlab2102 


Repair 

Printer 

Transmit software and setup values to the 

Printer Mainboard (in this sequence) 

− Switch on voltages: 

Switch on d-lab, or execute the script Script 

for service/initialisation/ 

start_up_d-lab.txt 

Check the software on the Printer Mainboard 

The following software elements are stored on the 

Printer Mainboard, and in case of PCB replacement 

they must be updated: 

− Firmware Printer Mainboard (prhp.hex) 

− Firmware XILINXS (prxi.hex) 

− And further: 

Firmware Printer – Bootloader (bl.hex). 

This file is not replaced during the update. 

− SETUP parameters of the Printer assemblies 

On spare PCBs from stock there is usually an 

unknown firmware version (also see Important 

note, next page). 

The setup values do not correspond either to the 

repaired machine. (Usually default values) 

Therefore a software check for the new Printer 

Mainboard must be made: 

− Check via Service / Firmware Version. 

− Compare the displayed result with the required 

version of the software package present in the 

machine: 

The firmware belonging to a certain software 

package can be determined subsequently. 

− Activate the Windows Explorer (via Watchdog) 

− Open the file label.txt. Path: 

C:\SoftwareVersion/PR/Install/ 

PR_Vxxx-y/label.txt 

Information from Label.txt: 

Here HP stands for prhp.hex and XI for prxi.hex 


Printer 

Repair 

Download XILINKS (prxi) 

(by experience rarely necessary, takes about 5 min) 

− Service 


− LASER PRINTER*PR 

− xilinx pixel pipeline 

− Search file under 

− C:\Dlab\Dlabxxxx\Pr\Install\ 

Pr_Vxxx-y (see Note below) 

− prxi.hex 

− Path and file name are displayed in the upper 

window after clicking Open 

− Select download 

After a few seconds a window opens: 

Downloading Printer 

After the download an automatic reset is executed, 

the voltages remain on. 

Note: 

y stands for 6,7,Z. 

The main software packages also include the 

different software versions for the different types of 

the Printer Mainboard in the folder 

SystemversionXXXXX/pr/install. 

Always change to the respective path: 

− V xxxxxx-6 

for d-lab.3 with Mainboard 8.8060.2000.X 

(X = letter, PCB has no LED indication, only old 

machines) 

− V xxxxxx-7 

for all other d-lab.3, (PCB has an LED indication) 

− V xxxxxx-Z 

for all d-lab.2 and net-lab.12 


Repair 

Printer 

Download Firmware (prhp.hex) 

(if necessary, takes about 30 min) 

This applies to all downloads: 

By all means do not interrupt the download 

otherwise it cannot be repeated! 

Important note: 

With the introduction of the main software 7.50x the 

firmware structure of the Mainboard changed as 

well. 

A wrong download would make the board useless. 

And in another case if a further update is required a 

download of firmware would no longer be possible. 

Therefore consider the following information: 

− If with Service\ Firmware Version a firmware 

< 1.04.xx was determined on the replaced 

Mainboard, load prhp_kombi.hex. 

− If the determined firmware on the replaced 

Mainboard is 1.04 and higher load prhp.hex. 

− Enter the following path in the Service GUI: 


− LASER PRINTER*PR 

− HP printer main software+++ 

− Search file under 

− C:\Dlab\Dlabxxxx\Pr\Install\ 

Pr_Vxxx-y 

− prhp.hex (bzw.prhp_kombi.hex) 

− Path and file name are displayed in the upper 

window after clicking Open 

− Select download 

After a few seconds a window opens: 

Downloading Printer 

Once the window closes again the software 

download was successful. 


Printer 

Repair 

Loading setup values (with AOM LUT) 

− If the data of the diskette enclosed in the 

shipment are to be loaded, copy the file 

printer_setup_write.txt first with the 

Windows Explorer to the folder Scripts/Scripts for 

Service. 

− Change to Service-GUI/Scripts/ 

scripts for service/setup/ 

printer_setup_write.txt 

− Start the script with Execute 

− At the end of the script answer the prompt Save 

with YES 

Attention! 

This script loads the AOM LUT determined with the 

removed PCB. If the PCB replacement was 

somehow connected with a trigger problem of the 

red laser, and/or the AOM green and blue, the AOM 

characteristic curves must be determined again (see 

respective paragraph). 

If the setup values are no longer available they can 

be ordered again through the service from the 

manufacturer by specifying the machine number. 

(usually the following file has been saved there: 

printer_setup_write.txt) 


Repair 

Printer 

Adjustment of the video voltages: 

− Adjustment of the video voltages must be made 

prior to the determination of AOM characteristic 

curves. 

− Execute script Scripts/scripts for 

service/ 

printer/laser/register_mode_on.txt 

(Answer the prompt – Switch OFF dynamic noise 

reduction of laser? – with YES) 

− Accept the suggested values (0,0,0,0,100,5000) 

− Connect the Multimeter at the respective point 

and the plug housing (GND) (Illustration lower 

circles) 

− Adjust the video voltages with the respective 

controls (Illustration upper circles) 

− Adjust the following values: 

red 390mV +/- 30mV 

green, blue 365mV +/- 30mV 

− Execute the script Scripts/scripts for 

service/ 

printer/laser/register_mode_on.txt. 

(Answer the prompt – Switch OFF dynamic noise 

reduction of laser? – with YES) 

Final check and tests 

Checking the software versions: 

− Check the firmware version in the Service GUI, 

compare as explained in the procedure above. 

Check the setup values: 

− Start the script Scripts/scripts for 

service/setup/ 

printer_setup_backup.txt. 


Printer 

Repair 

− Print a test print. 

To do so execute Scripts/Scripts for 

service/ 

testprints/X-print.txt. 

Evaluate the parameter (BOL, pixel shift, center 

of laser line...) and correct if necessary. (In case 

of correction save the SETUP values again.) 

− Verify that jumper J5 of the Printer Mainboard is 

open (risk of light reflection). 

− For safety execute script scripts for 

service/initialisierung/ 

pr_board_selftest.txt again. 

− Run a communication test between the Printer 

Mainboard and the VIPS Board by executing the 

script: 

Script Files/scripts_Printer/ 

printer_general/test lvds short.txt 

Message at the end: 

Test ready /0 Error(s), LVDS-Interface o.K. 

− After end of this script the machine program must 

be started again with the ON button. 

− Statistics values laser: 

After replacement of the Printer Mainboard the 

runtime statistics of the laser must be started 

again. To do so execute the script: 

Scripts for service\printer\laser 

statistic_laser.txt 

Answer the questions with YES so the values for 

the gas laser are reset to zero. Counting of the 

number of ignitions and operating hours starts 

again. 


Repair 

Printer 

Replacing the Printer Power Supply Unit 

Replacement required: 

− Power supply unit defective 

− Fuse defective 

If the fuse is defective, replace the complete 

power supply unit. 

dlabr103 

The manufacturer warrants only full functionality on 

condition that the power supply unit has been 

revised in the manufacturer’s plant. 

1 Label (see Fig. below) 

2 PO_GS01 

Sticker 

dlabr104 


Printer 

Repair 

Hexagon socket screwdriver 4,0 

Open the bottom side cover: 

− Open the LH paper magazine door 

− Push the button (1) to open the side cover 

− Remove the power supply unit: 

4 screws (1) 

dlabr029 

dlabr215 


Repair 

Printer 

Replacing / adjusting the Guide Rails of the Paper Magazines, 

Replacing Light Sensor ML/MR_LS08 (locking detection) 


− Top / bottom guide rail damaged 

− Locking detection ML/MR_LS08 

defective 

Screwdriver 

− Remove the guide rail (4 screws) 

− Replace the light sensor: 

ML/MR_LS08 is accessible after the top guide rail 

has been removed. 

Readjust the guide rails: 

− Mount the right and left paper magazine fastening 

(Magazine Lock); do not tighten the screws 

− Mount the paper magazine 

− Adjust the guide rails in such a way that the 

magazine locks exactly into the drive 

− Tighten the screws, lacquer-seal them when 

necessary 


Printer 

Repair 

Replacing the Magazine Drive ML/MR 

The magazine drive ensures 2 functions: 

1. Driving the paper magazine 

2. Driving the cutter unit 


The paper magazine drive or the cutter drive do not 

function. 

Cross tip screwdriver 

Allan key 

− Remove the paper magazine 

− Unscrew the RH (1) or the LH cutter unit (2), 

2 screws 

− Remove the detection of the paper magazine 

coding (2) (2 screws; disconnect 2 cables) 

− Disconnect the connector (3) on the magazine 

drive 

− Disconnect the connection between the drive unit 

and the voltage connector 

− MR: pull the assembly group to the right 

− ML: pull the assembly group to the left 

− Take out the RH drive unit toward the front 

Caution! 

Do not pull the LH drive unit straight to the front! 

− Move the assembly group to the front first with 

the right side and then with the left side 

1 Cutter unit 

dlabr030 

dlabr100 


Repair 

Printer 

Replacing the Light Sensors of the Magazine Drive MD 

Light sensor defective: 

1. LH magazine drive 

− ML_LS01-06 Magazine coding 

− ML_LS07 Paper detection Shutter 

− ML_LS08 Locking detection 

2. RH magazine drive 

− MR_LS01-06 Magazine coding 

− MR_LS07 Paper detection Shutter 

− MR_LS08 Locking detection 

Hexagon socket screwdriver 


− If the light sensors are defective, replace GS 

(printed circuit): 

ML/MR_LS01-06 ML/MR_GS02 

ML/MR_LS07 ML/MR_GS03 

ML/MR_LS08 ML/MR_GS05 


Printer 

Repair 

Replacing the Cutter Unit CU 

Cutter unit defective 


Allan key 

Removal: 

− Remove the paper magazine 

− Dismount the cutter unit (1) 

(2 screws, see next fig.): 

− Remove the detection of the paper magazine 

coding (2 screws) 

− Disconnect the connector (3) 

− Pull the drive unit a little to the other side to 

interrupt the connection to the voltage 

connector, turn it and remove it to the front 

− Remove the cutter unit: Unscrew 2 screws 

− RHS (1) 

− LHS (2) 

1 LH paper magazine compartment 

dlabr100 

Installation: 

− Push in the cutter unit up to the holding point 

− Check that the connector has locked in 

− Give the handle of the cutter unit a vigorous push 

until the unit locks in at the end stop. 

− If this is not possible, check whether the guide lug 

finger is deformed. 

dlabr030 


Repair 

Printer 

Replacing the Light Sensors in the Cutter Unit CU 


1. LH cutter 

− SG_LS23 Detection home position cutter 

SG_LS24 Detection cutter cutting end 

− SG_LS21 Paper detection cutter 

SG_LS22 Splice detection 

2. RH cutter 

− SG_LS43 Detection home position cutter 

SG_LS44 Detection cutter cutting end 

− SG_LS41 Paper detection cutter 

SG_LS42 Splice detection 

Allan key 


− Remove the cutter unit 



Light sensors defective 

SG_LS21/22 

SG_LS23/24 

SG_LS41/42 

SG_LS43/44 

Replace GS 

SG_GS08 

SG_GS07 

SG_GS10 

SG_G09 


Printer 

Repair 

Replacing the Switching Gear SG 


The ML/MR → Sheet Bridge (SB) transfer does not 

work 

The assembly group has to be removed from the 

Printer for all jobs on the SG. 

Allan key 

Removal: 

− Remove Switching Gear (1): 

Pull the left bracket vigorously as the assembly 

group is very tight in the guide. 

Installation: 

− When mounting the assembly group, make sure 

that the guides lock under the pins with the 

springs. 

− The connector for the SG is located on the fan 

assembly group 

1 

d 

labr146 

Replacing the Printed Circuit SG_GS02 


If the SG_GS02 is defective, the paper cannot be 

turned round any more. 

Allan key 2,5 

Back of SG_GS02: 

Unscrew 3 Allan screws 2,5 

Caution! 

Mind the code disk .SGBE of the motor upon the 

removal / installation! 


Repair 

Printer 

Replacing the Motor SG_MO01 


If the motor is defective, the paper does not pass 

any more through the SG. 

The motor can only be replaced together with the 

sync disk. 

Allan key 2,0 

Allan key 3,0 angled 

Ball head screwdriver 3,0 

Dynamometer 

Removal: 

− Unscrew the .SGAJ cover: 

3 Allan screws 2,0 

− Cut the cable ties and unscrew the motor 

Installation: 

− Adjust the correct belt tension by shifting the 

motor 

− Screw on the motor very tight, using the angled 

screwdriver! 

Caution! 

When mounting the .SGAJ cover, make sure that a 

lock washer and a washer are used on each screw. 

If this is not done, the screw may damage the cable. 

Measure the belt tension with the dynamometer: 

1,0 N 


Printer 

Repair 

Replacing the Motor SG_MO02 


If the motor is defective, the rocker does not move 

any more. 

Allan key 2,5 

Removal: 

− Open the circlip (on coupling .SGAS) 

− Unscrew the motor through the holes in the 

holding plate 

− Remove the motor with the code disk and the 

crank 

− Dismount the motor, the code disk and the crank 

Installation: 

− Installation in reverse order 

− The parts cannot be mixed up when they are 

mounted. 

The slide bearings between the crank and the 

coupling must point to the inside to the motor! 

Replacing the toothed Belt 


Toothed belt torn or damaged 

Allan key 3,0 angled 

Ball head screwdriver 3,0 

Dynamometer 

− Unscrew the motor SG_MO01 so that the belt 

tension slackens 

− Change the belt and screw down the motor 


1,0 N 


Repair 

Printer 

Replacing the Transport Roller .SG11 


Transport roller damaged 

Allan keys 2,0 and 3,0 

Dynamometer 

Flat pliers 

− Remove the cover of the SG_GS04: 

Slacken 4 Allan screws 

− Remove the complete SG_GS04 with the GS 

support: 

− Remove one screw each on the left and on the 

right side of the GS 

− Disconnect the cable! 

− Unscrew the red handwheel 

− Unscrew the motor SG_MO01 so that the belt 

tension slackens; remove the belt 

− Unscrew the sync disk .SGKK and pull it off the 

shaft 

− Remove the pin from the shaft 

− Remove the circlip and the washer; pull out the 

ball bearing 

Other side: 

− Remove the circlip, pressure spring, washer 

− Pull out the ball bearing 

− Open the coupling (secured with a circlip) 

− Hang out the springs on the counter pressure 

roller .SGAQ 

− Use the pliers to detach the spring from the 

plate on the side of the motor SG_MO01 

− On the other side, the spring can be detached 

from the shaft 

− Remove the shaft with the transport roller 

Caution 

Make absolutely sure that the washer is between the 

ball bearing and the spring, otherwise the spring 

brushes directly on the bearing! 


1,0 N 


Printer 

Repair 

Replacing the Pressure Roller .SGAG / Torsion Spring .SGKC 


− Pressure roller damaged 

− If the cut is not accurate, the torsion springs must 

be replaced to ensure the prescribed pressure 

force. 

Flat pliers 

Screwdriver 

Dynamometer 100 N 

− Hang out the springs on the counter pressure 

roller .SGAQ 

− Use the pliers to detach the spring from the 

plate on the side of the motor SG_MO01 

− On the other side, the spring can be detached 

from the shaft 

− Open the circlips and take out the shaft with the 

pressure roller 

− Remove the circlip and the washer in front of the 

pressure roller 

− Pull the pressure roller with the bearings off the 

shaft 

Pressure force of the pressure roller: 74+/-4N 


Repair 

Printer 

Replacing the Light Sensors of the Switching Gear SG 


− SG_LS01 Paper detection, magazine RHS 

− SG_LS02 Paper detection, magazine LHS 

− SG_LS03 Remaining length detection, LHS 

− SG_LS04 Remaining length detection, RHS 

− SG_LS05 CU-SG-control 

− SG_LS06 CU-SG-control 

All other light sensors of the switching gear 

(SG_LS21-24 and SG_LS41-44) are located on the 

printed circuit in the Cutter Unit. 

To replace these light sensors, see 

Replace the light sensors in the cutter unit CU, 

earlier in register 6.4. 

Allen keys 2,5 angled and straight 

Watchmaker screwdriver 



SG_LS01 SG_GS03 (see below) 

SG_LS02 SG_GS04 



SG_LS05/06 SG_GS01 

Special case SG_LS01: 

Removal: 

The SG_GS03 can only be removed completed with 

the holding plate! 

− Turn up the guide plate .SGAF to get access to 

the screws. 

− Remove the cable FK 23 after the GS has been 

removed – use a screwdriver! 

Installation: 

When mounting the GS, make sure that all cables 

are flat inside the assembly group without loops. 

Extending cables may be torn off when the GS is 

installed in the Printer! 


Printer 

Repair 

Sheet Bridge SB, replacing Parts 

The following repairs may become necessary in 

the Sheet Bridge area: 

− Replacement of the sync disk and the outer 

toothed belt 

− Replacement of the sync disk and the inside 

toothed belt 

− Replacement of the transport rollers 

− Replacement of the pressure rollers 

− Replacement of the toothed belts 

− Replacement of the coupling wheel 

Allan key 3,0 

dlabr008 

− Open the locking (1) of the transport unit TU (red 

fastening screw) 

− Pull out the TU towards you 

− Remove the top part of the SB: 

Slacken 4 Allan screws 3,0 

− 2 screws are accessible through the hole in 

the top plate 

− All 4 screws are secured from below and 

therefore cannot get lost 

dlaba009 


Repair 

Printer 

Replacing the Sync Disks 7.8060.TUBH. / outer Toothed Belt 7.0389.6121. 

Dynamometer 

Seeger circlip ring pliers 3 – 10 mm ∅ 

− Remove the Seeger circlip ring 

− Replace the sync disks (1) and (3): 

The collar of the sync disks must be alternately 

on the belts. Risk of confusion! 

− Adjust the belt tension (2) by shifting the 

tensioning plate: 

The screw heads (4) to fasten the tensioning 

plate must not be on the belt side! 

dlabr207 

Measure the belt tension in position (2): 

1 Sync disk, flange out 

2 Test point of the belt tension 

3 Sync disk, flange in 

4 Screw head not on the belt side 

− Deflection of the toothed belt: 1,7 mm 

− Test load: 1,0 N 


Printer 

Repair 

Replacing the Sync Disks 7.8060.TUBH. / inside Toothed Belt 7.0389.6119. 

Allan key 3,0 

Dynamometer 

Seeger circlip ring pliers 3 – 10 mm ∅ 

− Remove the Seeger circlip ring 

− Replace the sync disks (1) and (2): 

The collar of the sync disks must be alternately 

on the belts. Risk of confusion! 

− Adjust the belt tension (3) by shifting the 

tensioning plate: 

The screw heads to fasten the tensioning plate 

must not be on the belt side! 

dlabr208 

Measure the belt tension in position (3): 

1 Sync disk, flange out 

2 Sync disk, flange in 

3 Test point of the belt tension 

4 Seeger circlip ring 



Replacing the Transport Rollers 

Allan key 3,0 

Seeger circlip ring pliers 

Dynamometer 

− Remove the sync disk 

− Remove the circlip from the ball bearing 

− Remove the transport shaft and pull out the 

transport roller 

If necessary, replace also the freewheel and the ball 

bearings when replacing the transport roller. 

Measure the belt tension in the indicated position 

(longest side): 




Repair 

Printer 

Replacing the Pressure Rollers 

Screwdriver 

Removal: 

− Open the circlips and remove the assembly group 

Installation: 

− Observe the exact position of the torsion spring 

when installing the assembly group! 

− If necessary, compare it with the mounting 

position in the transport unit (TU). 

1 Spring under the shaft 

2 Shaft plugged through the spring turns 

3 Spring rests on the shaft (behind circlip) 

dlabr209 

Replacing the Sheet Turnaround 

Removal: 

− Hold the sheet turnaround on both rods (1) and 

pull it out 

− Remove the printed circuit: 

It is attached to the pins in the sheet bridge. 

dlaba111 

Installation: 

− When mounting the sheet turnaround, push the 

belt back into the reference position 

dlaba112 


Printer 

Repair 

Transport Unit TU, replacing Parts 

− Open the locking (1) of the TU (red fastening 

screw) 

− Pull out the TU towards you 

− The transport unit has to be removed for some 

repair jobs: Remove 2 screws each (1) from the 

two telescopic rails 

dlaba009 

dlabr110 


Repair 

Printer 

Replacing / adjusting the toothed Belt (Switching Lug) 

− Replace the toothed belt 

Adjustment of the lateral guide elements (required 

when the toothed belt has to be replaced): 

− Slacken the screws 

− Fasten the lateral guide elements directly on the 

edge of the supporting plate 

− Tighten the screws 

− The adjustment is performed in the Service 

program. 

dlabr216 

Light Sensor TU_LS07 

Fork light sensor TU_LS07 defective (Home position 

sheet centring) 

Replace TU_LS07 (1): 

− Disconnect the connector 

Redefine the Setup value for the light sensor: 

− The adjustment is assisted by the Service 

program 

dlabr217 


Printer 

Repair 

Toothed Belt 

Adjust the belt tension in such a way that the belt 

can easily be pushed to and fro on the gear at the 

belt turning point. 

Caution! 

The motor shaft may be overstressed and may 

break if the belt is too tight. 

dlabr216 


Repair 

Printer 

Replacing the Centring Finger on the Sheet Centring Unit 


Removal: 

− Pull out the TU 

− Unlock the bottom unit and fold it down 

− Disconnect the connectors from TU_MO11 and 

TU_LS07 (directly on the component, not on the 

printed circuit) 

− Unscrew the sheet centring unit .TUA0 

− Unscrew the rails with the centring fingers 

(2 Allan screws 2,5): 

− LH side guide 8.8060.TU27. 

with spring-loaded centring fingers 

− RH side guide 8.8060.TU28. 

with fixed centring fingers 

The centring rail with the fixed centring fingers is 

always located on the side of motor TU_MO04. 

Installation: 

Be sure to keep the order! 

− Push in the guides (1) 

− Put the centring rail with the fixed centring fingers 

(2) on the guides, push it against the stop (4) and 

screw it on 

− Put the centring rail with the spring-loaded 

centring fingers (3) on the guides, push it against 

the stop (4) and screw it on 

− Open and close the sheet centring unit by hand 

to check the correct stop: 

The centring rail must always be on the stop, the 

guide must never be at the end of the chamfered 

slit. 

− When mounting the sheet centring unit .TUA0, 

make sure that the assembly group is accurately 

inserted in the centring bolts, otherwise no 

correct sheet centring is guaranteed. 

If additional toothed belts or the motor TU_MO04 

are replaced, the belt tension must be adjusted 

before the centring rails are mounted. 

1 Guides 

2 Centring rail with fixed centring fingers 

3 Centring rail with mobile centring fingers 

4 Stop 

dlabr212 


Printer 

Repair 

Replacing the Turntable 


In case of damage 

The turntable must be replaced together with the 

turntable shaft as the parts are lacquer-sealed! 

Allan key 3,0 

Seeger circlip ring pliers 

Removal: 

− Pull out the TU 

− Unlock the bottom unit and fold it down 

− Unscrew the cover of the printed circuit and 

disconnect all cables to drive unit 1: 

ST 6, 9, 10, 17, 21, 22, 23, 25 

− Tilt away the complete printed circuit with the 

carrier plate; unscrew 2 screws 

− Unscrew drive unit 1 and remove it towards 

the bottom: 5 screws (1) at the front, 3 screws 

at the back 

− Open the Seeger circlip ring and strip off the sync 

disk with the toothed belt 

Installation: 

Make sure that the assembly group is put exactly in 

the recesses when mounted, otherwise no correct 

paper transport can be guaranteed. 

1 Fastening screw (1st of 5 front) 

dlabr213 

Check the toothed belt tension 


Repair 

Printer 

Print Engine PE, replacing Parts 

Replacing the Motor PE_MO01 


Motor defective 

Allan keys 2,5 and 3 

Removal: 

− Pull out the PE 

− Remove the rear cover plate 

− Remove the sensor PE_LS05 (BOP), integrated 

on PE_GS03, 

− Disconnect the connector of the motor (in the top 

frame) 

− Open the fastening of the clutch for the motor 

shaft (on the side of the motor) 

− Dismount the motor: Unscrew 4 Allan screws 

Caution! 

The rear screw is difficult to access. Do not damage 

the belt underneath; cover it if necessary. 

Motor PE_MO01: Printing roller drive 

dlabr096 

Installation: 

− Insert the new motor: 

Do not damage the belt (cover it) 

− Screw on the motor 

− Fasten the clutch 

− Install the cable and connect it 

− Mount the sensor 

− Mount the plate 

Test the function in the Service program 


Printer 

Repair 





Screwdriver 

Removal: 


− Disconnect the cable of MO02 (at the bottom; 

brown) 

− Disconnect the sensor cable from PE_LS04 

− Unscrew the Allan screw 1,5 on the motor side of 

the clutch 

− Remove the motor plate with the motor and the 

sensor from the vibration absorbers: 

Unscrew 3 Allan screws 

− Detach the motor from the motor plate: 

4 slotted countersunk head screws 

Installation: 

1 Motor PE_MO02: Drive feed and exit roller PE 

2 Gearing 

dlabr099 

− Change the motor 

− Mount the motor plate: 

Mind the location of the vibration absorbers and 

the clutch; screw in the screws tight up to the 

stop (sleeve and rubber buffer) 

− Connect the motor and sensor cables 

Adjustment: 

Test the function in the Service program 


Repair 

Printer 

Replacing the Gearing 


Leaking oil, synchronisation problems caused by the 

gearing 

Allan keys 2,5 and 3 and 4 

if available, a second person to help 

Removal: 


− Unscrew the rear plate with the venting slits on 

the exposure slit 

− Open the bottom set of belts 

− Open the fastening of the gear coupling for the 

print roller: 2 Allan screws 

− Close the bottom set of belts again 

− Disconnect the motor cable (in the top frame) and 

remove the motor 

− Unscrew 3 fastening screws (vibration absorbing) 

outside the gearing 

− Remove the gearing with the motor plate and the 

motor PE_MO02 

Call a second person to help: If the gearing slips out 

of its bearing with the roller, the RH bearing of the 

roller may get damaged (loss of the accurate 

running properties). 

The closed belt bridge supports the print roller only 

to a limited extent. 

dlabr099 

1 Motor PE_MO02: Drive feed and exit roller PE 

2 Gearing 

− On the gearing side, open the fastening of the 

clutch for the motor MO02 (in dismounted 

condition) 

− Remove the motor plate with the motor from the 

gearing: 3 x vibration absorbers 

Installation: 

− Link the new gearing with the motor, fasten the 

clutch 

− Mount the complete unit, carefully insert the roller 

drive shaft and lock it with screws 

− Screw down 3 screws of the suspension points 

until the sleeves in the rubber buffers feel 

resistance 


Printer 

Repair 

− Fastening of the clutch for the shaft 

− Thread the motor cable and link it 

− Mount the rear plate 

Check the function in the Service program 




The flap control on the exposure slit does not move 

any more 

Allan key 4 

Service cables L9.8060.9001.1 and L9.8060.9002.1 

Removal: 


− Detach the spring (4) 

− Disconnect the connector (2) of MO03 (1) 

− Unscrew MO03 and remove it: 

2 fastening screws (5) 

Installation: 

− Screw on the new motor: 

Make sure that it does not rest on the holding 

plate cutout (distortion) 

The spring is attached again only after the check / 

adjustment. 

− Connect the service cable 

− Call up the service program and execute: 

Scripts/Scripts_printer/data_pe/klappe_ini.txt 

− Check the actuator function by means of Scripts: 

klappe_auf.txt and klappe_zu.txt 

In position "Flap open " (not init) push up the 

toggle without the spring. The actuator piston 

must not touch the toggle yet in this position 

(approx. 1/10 distance); if necessary, shift the 

holder of MO03 as appropriate by means of the 

screws (6). 

− Hang in the spring 

1 PE_MO03: Flap control 

2 Connector 

3 Toggle 

4 Spring 

5 Fastening screws 

6 Motor holder fastening screws 

dlabr197 


Repair 

Printer 

Replacing the Light Sensors PE_LS05 (BOP) 


Light sensor (integrated on PE_GS03; sensor sheet 

tip; transmitter/receiver LS) defective 

Allan key 3 



Removal: 



− Remove the holder with the sensor (2) 

− Disconnect the cable from PE_GS03 

− Unscrew PE_GS02 from the holder 

Installation: 

− Mount a new GS 

− Connect the cable 

− Mount the sensor with the holder 

− Mount the cover plate 

dlabr097 

1. Check the adjustment sensor 


− Call up the service program and execute: 

Scripts\printer\data_pe\ 

Lichtschranken\pe_ls05-begin of 

paper-sensor.txt 

− No. of cycles 0: The sensor is constantly 

checked 

− Enter the paper at PE at the bottom, mind the 

display in the field Information 

− The sensor function is OK when the message 

BOP see Paper is displayed 

2. Check BOP on the print 

(Script for this in preparation) 


Printer 

Repair 

Replacing the Light Sensors PE_LS06 (BOL) 


Light sensor (integrated on PE_GS02; sensor 

exposure start; Laser receiver part) defective 

Allan key 3 


Removal: 



− Disconnect the cable from PE_GS02 (1) 

− Remove 4 Allan screws on the outside of the GS 

support, see (1) in the fig. below 

− Remove the GS support with the PE_GS02 

through the opening in the cast part 

− Unscrew PE_GS02 from the GS support 

dlabr097 

Installation: 

− Mount a new GS on the GS support 

− Put back the complete unit (receiver opposite the 

mirror) and fasten it to the cast housing 

− Connect the cable 


1. Check the adjustment sensor 

Link the service cable, start the machine 

Observe the LED on the GS: When voltage is 

applied, this LED lights red; when the laser is 

switched on (part of the red laser is uncoupled via 

the mirror), the LED must turn off. It remains off 

during the whole operation. If the LED does not 

turn off (the latest when the print roller starts), the 

mirror position is not correct. 

Correction of the position by shifting the GS 

support in its screw-down holes. The machine 

can be started without the service cable, but this 

makes the shifting of the GS plate more difficult. 

2. Check the parameters of the laser array middle 

in the Service program (Script for this in 

preparation) 

dlabr098 


Repair 

Printer 

Replacing the Light Sensors PE_LS01/02/03/04/07/08 


Light sensor defective 

PE_LS01 LS before printing roller 

(on PE_GS04) 

PE_LS02 Flap control (fork light sensor) 

PE_LS03 LS behind printing roller 

(on PE_GS05) 

PE_LS04 Speed control for motor PE_MO02 

PE_LS07 Paper detection inlet PE 

(on PE_GS06) 

PE_LS08 Printing roller rotation control dlabr299 


Printer 

Repair 

Replacing the Set of Belts at the bottom 


Belts or rollers damaged by a paper jam 

Allan keys 3 and 4 

Screwdriver 

Spanners 13 and 9 

Removal: 


− Open the set of belts 

− Remove the locking lever on the left side: 

Remove the safety spring (1) 

− Remove the sensor holder (2) with sensor 

PE_LS02 

− Detach the spring (3) on the actuator 

− Open the circlip (4) on the toggle, push in 

actuator piston 

− Remove the toggle (5) 

− Dismount the sensor PE_GS03 (6) with the 

holder 

− Unscrew the Allan screws (7) (key size 13) on 

both sides of the cast frame: 

The set of belts only hangs on 1 supporting screw 

(8) on either side 

− Remove the supporting screw on the right side, 

only slacken it on the left side until the set of belts 

is free 

− Remove the set of belts 

dlabr289 

Installation: 

− Put the new set of belts in the supporting screws 

first, tighten the screws 

− Mount 2 Allan screws on either side 

− Check the belt mounting position 

− Mount sensor PE_GS03 

− Mount the toggle: 

Do not unscrew the eccentric screw (lacquersealed, 

specific gap dimension)! 

− Mount the sensor holder with sensor PE_LS02 

− Hang in the spring 

− Mount the locking lever 

− Close the set of belts 

dlabr290 


Repair 

Printer 

Adjust the belt tension 

− Turn the tensioning screws (1) at the ends of the 

belt bridge (accessible through the holes) ccw 

until it can be felt that the belt is not in mesh any 

more. From this point, turn cw until no spring 

force is felt any more. 

Do not check on the outer rollers as they have a 

larger diameter. 

− Count the turns between the two positions 

(approx. 6) and turn ccw half the number of turns 

dlabr298 


Printer 

Repair 

Replacing the Set of Belts at the top 

Set of belts at the top 9.8060.PEC0.0 


Belts and rollers damaged by a paper jam 

Removal/installation in case of scratches caused by 

the edge of the slit. 

Allan keys 3 and 4 

Screwdriver 

Do not slacken the eccentric of the toggle upon the 

removal, do not shift the actuators. In this case, 

reliable functioning would not be ensured any more! 

Removal 


− Remove the top guide plate 

− Push in the piston on the actuator PE_MO03 (1) 

(stiff!) 

− Remove the sensor holder (above 4) with sensor 

PE_LS02 

− Detach the tension spring (4) 

− Open the circlip (2) 

− Remove the toggle (3) 

− Detach the cable from the cable holder 

− Remove the sensor plate (6): 

Unscrew 2 screws at the front, remove the plate 

to the front 

− Unscrew 2 screws (below the cable collar) on the 

set of belts (5) and pull out the assembly group 

with the plate (cable holder) towards the front 

− Removal because of scratches: 

Check the front edge of the part, if necessary pull 

it off a little and clean it 

dlabr256 

Installation: 

Put a sheet of photographic paper 20x30 over the 

print roller, clamp the sheet on the left side under 

the set of belts: Absolutely necessary, otherwise the 

belts may slip off the belt rollers when the assembly 

group is mounted! 


Repair 

Printer 

− Move the set of belts to the back as far as 

possible (supporting it with your right hand, 

removed guide plate) and lower it: 

− The ball pins lock into the guide holes at the 

back 

− At the front, the pin must be in the plate (cable 

holder) 

− Fasten the plate and by this the whole assembly 

group 

− Check the correct belt position, if necessary, turn 

the belts to position them correctly 

− Mount the sensor plate and screw it on without 

shifting the belts off the rollers! 

− Mount the toggle: 

Push the bottom set of belts together a little to 

make the insertion easier and ensure that it locks 

correctly in the toggle. 

− Mount the sensor PE_LS02 

− Click in the cable 


− Mount the guide plate 

− Remove the photographic paper from the print 

roller, drive the print roller by turning the clutch. 

Never pull out the sheet because of the belt 

pressure! The belts may be relocated. 

The belt tension is set in the same way as on the 

bottom set of rollers. 

As the rear screw is not accessible, it should be 

checked before mounting a new assembly group 

that the two clamping screws lift the rail with the 

rollers off the side parts by approx. 2-3 turns. 


Printer 

Repair 

Replacing the complete Print Engine PE 


Printing roller damaged 

A second person is needed to replace the Print 

Engine as it weights approx. 50 kg. 

− Disconnect the Laser cable from the Laser: 


− Pull out the TU if necessary 

− Unscrew the cover from the Laser 

− Unscrew the locking screws on the cable 

− Strip off the Laser cable 

− Disconnect the power supply cable from the 

power supply unit 

− Disconnect the data cable from the SPI-GS 

− Remove the cable from the drag chain 

− Unscrew 4 fastening screws each on the 

telescopic rails: 

Push the PE in the machine, pushing the 

mounting hole of the telescopic rail over the 3 rd 

and then over the 4 th screw. 

− Hold the PE on the inner frame and lift it out, or 

push a mounting table under the PE so that the 

PE can sit on it 

− Push in the telescopic rails 

Height-adjust the TU, see Print Engine: Checking 

the Height Dimension in Register 10 

Make sure after the installation that the two cables 

on the laser diode lock correctly in the holder. 

dlabr145 


Repair 

Printer 

Replacing the Laser Module / Laser 

Warning! 

A laser beam of class 3B may be accessible after 

the removal of covers. 

Be sure to keep the mechanical laser shutter on 

the fibre coupling closed when working on the 

laser. 

Looking directly into lasers of class 3B is 

dangerous and can always hurt the eyes. 

Make sure during maintenance and repair work that 

the laser beam is not reflected into the eyes by parts 

or tools. 

Caution! 

The assembly group should never be opened. The 

Laser fibre cable is rigidly coupled with the Laser 

module. It must only be disconnected on the laser 

head itself. 

The following parts can be replaced: 

− Laser module 4.4150.1000 

− Laser 

7.8060.LUD0 

− Laser power supply unit 7.8060.LUC1 

− PE_GS01 (3) Distributor board 8.8060.2170 

− LA_GS07 Polygon drive (4) 7.4150.1558 

− LA_BE04 AOM green (5) 8.4150.1330 

− LA_BE04 AOM blue (6) 8.4150.1330 

Not replaceable: 

− LA_GS06 (1) 

− LA_GS05 (2) 

dlabrx48 


Printer 

Repair 

Replacing the Laser Module 



− Disconnect the Laser cable from the Laser: 


− Pull out the TU and remove it 

− Unscrew the Laser cover 

− Unscrew the locking screws on the cable 

− Strip off the cable 

− Remove the cable from the drag chain 

− Take off the mirror cover: 

4 Allan screws 

− Disconnect the connectors 

− Unscrew the fastening screws on the Laser 

module: 4 Allan screws 

− Disconnect the connectors 

− Lift the Laser module up and out, holding it by the 

handles 

1 Carrier frame 

2 Laser module 

dlabr076 


Repair 

Printer 

Replacing the Laser Head and adjusting the Fibre Coupling 

The Fibre can not be uncoupled from the module, 

but only from the Laser head. 

Purpose of the adjustment: 

Optimising the laser capacity by adjusting the fibre 

coupling on the laser head. 

Elements of the adjustment unit: 

− Fibre holder (1): Tube into which the fibre end is 

put 

− Adjustment screws (2): 

4 knurled screws, Allan screws (size 2) 

Always 2 screws are used for the horizontal and 

the vertical direction. The screws are locked with 

spring-loaded knurled nuts. The lock nuts should 

be tightened slightly for the adjustment so that 

the adjustment screws are pretensioned. 

Caution: Fine thread 

− Pressure screws (3): 

2 screws with a flat head and a spring-loaded 

Nylon tip are used for the fastening of the fibre in 

the adjustment unit. The screw on the laser side 

holds the fibre holder in the adjusted lateral 

position, the screw on the exit side fastens the 

lengthwise position of the fibre holder. 

− Fastening ring (4, no fig.) for the polarisation 

adjustment (must not be unscrewed!) 

− Allan screw (5), size 2 

dlabr107 

dlabr155 


Printer 

Repair 

Caution! 

Use only the rear black screw (3) on the fibre 

coupling to remove / insert the fibres upon the 

replacement of the laser or the laser module. 

If the 4 knurled screws (2) are slackened, the 

preadjustment (transmission of at least 40%) of the 

fibres is not given any more and the fibre 

transmission may be zero. 

Caution! 

The laser must be switched off when the fibre is 

replaced as otherwise laser radiation may occur. 

dlabx157 

Laser replacement: 

− Switch off the laser on the laser power supply unit 

dlabr105 


Repair 

Printer 

Fibre (1) 

General view 

Front view 

dlabr107 

Top plan view 

dlabr157 

dlabr155 

Power meter (e.g. Ophir Nova with filter or monitor 

diode in the laser scanning module) 

2 Allan keys, size 2 

− Completely unscrew the small Allan screw (5) 

− Slacken the pressure screw on the laser side until 

the fibre can be pulled out 

− Slacken the pressure screw on the exit side until 

the fibre holder can be pulled out 

− Put the fibre in the fibre holder in such a way that 

the pin on the fastening ring (4, no fig.) fits in the 

corresponding recess in the fibre holder 

− Mount the fibre holder with the fibre in the new 

laser 

− Tighten the pressure screws: 

1. Up to the stop position 

2. Slacken one turn 

dlabr156 


Printer 

Repair 

− The tip of the pressure screw on the exit side 

must engage in the nut of the fibre holder 

− Tighten the Allan screw (5) again 

− Switch on the laser 

Allan key size 2 

Adjustment of the vertical and horizontal position of 

the fibre: 

− Unscrew the lock nuts 

− Adjust the adjustment screws on the exit side in 

such a way that the maximum power of the laser 

light transmitted through the fibre is reached 

(check with the monitor diode) 

− Find the optimum fibre position by horizontal and 

vertical parallel shifting of the fibre: 

Optimise the adjustment of the two planes 

separately (check by means of the voltage on the 

monitor diode). For this, shift the fibres in one 

plane by means of the adjustment screws 

alternately on the laser side and on the exit side 

until the maximum transmission is reached. 

Caution! 

Make absolutely sure that the maximum possible 

transmission is reached as otherwise power 

fluctuations may occur due to temperature drifts. 

Tighten the lock nuts: 

The voltage value must not change. 


Repair 

Printer 

Replacing the Laser Power Supply Unit 

Allan key 3,0 

Dismount the laser power supply unit: 

− Disconnect the cables: 

1. Power cable for the laser 220 V on the right 

side of the Printer power supply unit 

(2 screws) 

2. Cable on the power supply unit 

3. Remote on PO_GS01 

− Unscrew the laser power supply unit (4 screws) 

and remove it 

dlabr170 

Replacing LA_GS01 LFB-Distributor 

LFB = Laser Feedback 

− Remove LA_GS01 (1): 

The GS is held at the back in 2 holders and is 

only locked in at the front. 

dlabrf48 

Replacing LA_GS07 Polygon Drive 

− Remove the GS: 4 screws 

Make sure that the screws do not fall into the 

printing roller! 

dlabrc48 


Printer 

Repair 

Replacing the AOM Amplifier 

AOM = acoustooptical Modulator 


AOM defective 

The d-lab.3 is equipped with an AOM amplifier each 

for the blue and the green laser beam: 

− LA_BE04 (1), blue 

− LA_BE04 (2), green 

Watchmaker screwdriver 

Allan key 

Replacement: 


− Draw the power plug 

− Unscrew the top screw (3), slacken the bottoms 

screw; do not disconnect the data cable (4) 

− Remove the AOM, disconnect the data cable (4) 

− LA_BE04 (1) 

− LA_BE04 (2) 

− Connect the new AOM to the data cable and the 

power supply: 

Adjust the AOM before screwing it down. 

− Find a new characteristic curve (adjustment by 

means of the Service program): 

For this, move an additional monitor diode into 

the light path 

− Screw down the AOM 

− Restart the d-lab.3 

dlabre48 

dlabr173 


Repair 

Printer 

Adjustment of the AOM Driver Electronic 

Adjust the potentiometers: 

− Bias Offset 

− Power 

− Move the 4 th monitor diode into the light path 

(green or blue) for the following adjustments and 

the recalibration 

− At 0 V input voltage, adjust the Bias such that the 

laser power is minimum 

− At 0,6 V input voltage, maximise the power with 

the potentiometer and turn it back approx. 5% 

− Recalibration in the Service program 


Printer 

Repair 

Lane Distributor LD, replacing Parts 

− Pull the lane distributor to the front on the 

telescopic rails 

− If required (for some components), dismount the 

lane distributor: 

− Screw 4 bolts into the lane distributor from 

below so that it can be deposited correctly 

− Lift the lane distributor off the telescopic rails 

dlabr039 

Replacing the Motors LD_MO01 to LD_MO05 



LD_MO01: Drive takeover section LD 

LD_MO02 Drive sheet distribution vertical 

LD_MO03 Drive sheet distribution horizontal 

LD_MO04 Drive exit station, 2 lanes 

LD_MO05 Drive back printer 

Position MO01 to MO04: See Fig. on the next page 

Allan key 3 

Dynamometer 


Removal: 

− Disconnect the motor connecting cables 

− Unscrew the motors 01, 02, 04; 

Slacken motor 03 first: Open the two belt 

tensioners on the opposite side 

− Remove the sync disk (circlip) 

Installation: 

− Mount the sync disk on the new motor 

− Mount the new motor 

− Connect the cables 


Repair 

Printer 

Adjust the belt tension: 

− Push the motor in tensioning direction (except 

MO03) and fasten it at the following tensioning 

torque (the weight of the motors has been 

considered): 

− Motor 01 

− Motor 02 

− Motor 03 

35 N 

6 N 

6 N 

− Motor MO04 is only mounted: 

The belt tension is set on the clamping pieces on 

the opposite side. Both belts (5) and (6) for MO03 

must be tensioned at 27 N. 

− Functional check of the motors with the Scripts: 

MO01.txt, MO02.txt, MO03test.txt, MO04.txt 

Connect the service cable and call up the above 

Script under: 

Scripts/scripts_printer/data_ld/motors 

− The cycle number to be entered in the Scripts 

defines the number of possible new starts at one 

call. The motor is running permanently until 

STOP is pressed. 

− In the Script MO03text.txt the sledge is held in 

the middle after an initialisation. After the value to 

be measured has been confirmed, the motor runs 

permanently with short halts until the operator 

presses the STOP key. 

dlabr291 

1 Belt tensioner 

R1 16 N 

R3 12 N 


Printer 

Repair 

Replacing the LD_GS01 (Lane Distributor Control) 


Faults due to a defective GS 

Allan key 2,5 

Removal: 

− Check the program version prior to the removal: 

Run Script and note down the version for 

prld.hex: 

Scripts/scripts_dlab/pr_vers_setup.txt 

− Remove the cover (3): 

− Slacken the screw (2) 

− Remove the screws (1) 

− Remove LD_GS01: 

Unscrew 4 screws (1) and remove the printed 

circuit towards the top (the printed circuit is only 

attached at the bottom) 

dlabr117 

Installation: 

− Mount the new GS: 

Installation in reverse order 

dlabr118 

Check: 

− Run the Script again, compare the version 

− If the version differs, load the appropriate file of 

the Software package with Service GUI / 

firmware_download 


Repair 

Printer 

Replacing Light Sensors 


LS defective 

LS 

LS01 

LS02 

LS04 

LS05 

LS06 

LS07 

LS08 

LS10 

on LD_GS: 

GS09 

GS07 

without GS 

GS05 

GS04 

GS03 

GS02 

GS08 



Removal: 

− Remove the GS with the defective LS: 

Disconnect the connector 

− For GS04, GS05, GS07, GS08, unlock the 

guide plate and the rear guide before. 

− For GS09 dismount the printer first. 

Installation: 

− Mount a new LS, connect the connector 

− For GS07 first unscrew the lateral screws used to 

fasten the guide plate so as not to damage the 

paper guide when moved in 

dlabr297 

Check: 

− Check the light sensors in the service program: 

Scripts/scriptes_printer/data_ld/ 

ld_lichtschranken/ld_lsxx.txt 

− Start the Script: Status off/on is displayed 

− When the LS is covered, O.K. must be pushed 

again and the new status is displayed 


Printer 

Repair 

Replacing toothed Belts 


Toothed belt damaged 

Allan keys 3 and 2,5 

Dynamometer 

Removal: 

− Unscrew the clamping piece or the motor for the 

respective belt, for the belts (5) and (6) open in 

addition the connection to the distributor slider 

− Remove the belts 

Installation: 

− Mount new belts 

− For the belts (5) and (6) make the connection to 

the slider again 

Adjust the belt tension: 

− The setting values described already under 

Changing the motor hold for the belts on the 

motors: 

− Motor 01 35 N 

− Motor 02 6 N 

− Motor 03 6 N 

− Motor 04 only mounted 

− Tension both belts (5 and 6) for MO03 at 27 N. 

− Setting values for the other belts: 

− R3 

12 N 

− R1 

16 N 

dlabr291 


Repair 

Printer 

Back Printer, replacing the Print Head 


Back Printer defective 

Allan keys 4; 2; 2,5 and 1,5 



Removal: 

− Replace the complete printer 

− Disconnect the cable to the GS 

FK29, KA107 

− Unscrew 2 Allan screws on either side 

− Remove the assembly group to the bottom 

− Replace the print head 

− Remove the ink ribbon cartridge (1) 

− Disconnect the flat cable 

− Unscrew 2 cross tip screws 

− Remove the print head (2) 

− Replace the printer belt drive motor (3) 

− Remove the ink ribbon cartridge 

− Disconnect the motor connections 

− Remove the driver on the belt drive (screwed 

on with an Allan screw) 

− Unscrew 4 Allan screws 

− Remove the motor 

dalbr134 

Installation: 

− Always in reverse direction 

1 Back printer ink ribbon magazine 

2 Print head paper feed 

3 Drive motor 

Check the print quality: 


− Call up the following Script under Service: 

Scripts/scripts_printer/data_ld/4x6fast.txt, 

D102x152.txt, D203x305.txt 


Printer 

Repair 

Readjust the print head counter plate: 

− Unscrew the stud bolts far enough so that the 

print head counter plate is fully on the top paper 

guide (up) when the two fastening screws are 

screwed on 

− Turn the stud bolts to the stop with respect to the 

top paper guide 

− Slacken the fastening screws 

Screw in the 4 stud bolts 0,5 turn 

The print head counter plate must have a distance 

of > 0,4 mm with respect to the bottom paper guide. 

Replacing RD_GS01 Back Printer Control 


Faults due to a defective GS 

Removal: 

− Check the program version prior to the removal: 

Run Script and note down the version for 

prrd.hex: 

Scripts/scripts_dlab/pr_vers_setup.txt 

− Disconnect all connectors from RD_GS01 

− Pull RD_GS01 off the 4 clamping pieces 

Installation: 

− Mount the new GS 

− Connect the connector 

dlabr119 

Check: 

− Run Script again, compare the version 

− If the version differs, load the appropriate file of 

the Software package with Service GUI / 

firmware_download 


Repair 

Printer 

Functional Check after the Replacement of Parts 

If parts are replaced on an assembly group which 

also influence the paper transport, a functional test 

with paper should be performed in the Service 

program. 

For this, the assembly group has to be pulled out 

and operated via the service cables. 

There are other Scripts available, besides the 

indicated ones: 

Scripts/scripts_printer/data_ld/allgemein/4x6slow.txt 

Scripts/scripts_printer/data_ld/allgemein/dplfast.txt 

Scripts/scripts_printer/data_ld/allgemein/ldls_prf.txt 

Scripts/scripts_printer/data_ld/allgemein/LD_vers.txt 

Scripts/scripts_printer/data_ld/allgemein/kontrollstreifen 

/cfast_go.txt 

Scripts/scripts_printer/data_ld/allgemein/kontrollstreifen 

/cslow_go.txt 

Scripts/scripts_printer/data_ld/motore/MO04kupl.txt 

Size 4x6 slow, without pressure, roller 

adjustment 

Size 4x6 with pressure by LD 

Light sensor test 

Version check LD and RSD 

Control strip test, quick 

Control strip test, slow 

Test magnetic clutch 


Printer 

Repair 

Sheet Transfer ST, replacing Parts 

− Slacken 1 screw (1) 

− Pull ST to the front 

dlabr062 

Replacing the Motor ST_MO01 



Allan key 1,5 

Removal: 

− Dismount the hand wheel (1): 

2 Allan screws on the shaft 

− Unscrew the metal bracket with handle (2) 

− Disconnect the connector (3) 

− Detach the motor from the clutch / the sync disk 

(4): 

2 Allan screws 

− Slacken the belt by unscrewing the motor plate: 

2 tensioning screw, 1 screw inside 

− Remove the motor plate 

− Unscrew the motor from the motor plate 

Installation: 

In reverse order 

− Tension the belt by shifting the motor plate 

− Install the assembly group and check the motor 

function in the Service program: 

Scripts/scripts_printer/data_ld/ST sheet 

Transfer 

dlabr293 


Repair 

Printer 

Replacing the toothed Belt 


Belt defective 

Allan key 1,5 


Removal: 

− Work steps as described under Replace motor 

ST_MO01 on the previous page 

− In addition: 

− Open the belt tensioner (1) 

− Remove the belt to be replaced 

Installation: 

− In reverse order 

Tension the belt: 

− Shift the motor plate and the belt tensioner 

dlabr294 

Replacing the flat Belts 


Belt defective 


Removal: 

− Unscrew the belt tensioner (1) of the larger 

toothed belt 

− Detach the spring (2) of the top guide shaft 

− Remove 3 circlips (3) from the guide roller and 

the large transport roller on the connector side (if 

necessary, unscrew the connector holder) 

− Remove the bearings of all 4 shafts and push the 

shafts towards the motor 

− Remove the flat belts (4) 

Installation: 

− Thread new toothed belts 

− Mount in reverse order 

− Tension the toothed belts, hang in the springs 

− Functional check: The belts run between the 

spacer rollers of the guide shafts 

dlabr295 


Printer 

Repair 

■ 


Repair 


Contents 

General Overview .................................................................................................................................... 7.1.1 

Sensors and Loads in the Paper Processor....................................................................................... 7.1.1 

Block Circuit Diagrams........................................................................................................................... 7.1.3 

General System.................................................................................................................................. 7.1.3 

PCBs .................................................................................................................................................. 7.1.4 

Signal Lists .............................................................................................................................................. 7.2.1 

Sensors / Loads ................................................................................................................................. 7.2.1 

Overview of the Connectors............................................................................................................... 7.2.4 

Functional Description ........................................................................................................................... 7.3.1 

Mechanical Structure.......................................................................................................................... 7.3.1 

Electrical Structure ............................................................................................................................. 7.3.3 

Paper Processor Control.................................................................................................................... 7.3.5 

AC/DC Power Supply ......................................................................................................................... 7.3.7 

Other PCBs ...................................................................................................................................... 7.3.10 

Repair ....................................................................................................................................................... 7.4.1 

Replacement of the Densitometer...................................................................................................... 7.4.1 

Replacing Printed Circuits .................................................................................................................. 7.4.3 

Replacing Relays ............................................................................................................................... 7.4.4 

Temperature Switch Dryer ................................................................................................................. 7.4.5 



Repair 

■ 


Repair 



Sensors and Loads in the Paper Processor 

Processor Block (PP) 

FA1PPP 

Cooling fan for DEV 

FA2PPP, FA3PPP Cooling fan for BF 

FA4PPP 

Cooling fan for STB 

FA5PPP 

Cooling fan for Processor block 

FA6PPP 

Cooling fan for transport motor 

FA7PPP 

Cooling fan for DEV circulation pump 

FS1PET - FS3PET Level switch effluent tanks 

FS1PRT - FS3PRT Level switch replenishment tanks 

FS1PRW 

Level switch water replenishment tanks 

FS2PRW 

Level switch evaporation measuring tanks 

FS1PTK - FS5PTK Level switch temperature control tanks 

HS1PCT - HS3PCT Temperature sensors control tanks 

HT1PCT 

Heater DEV 

HT2PCT 

Heater BF 

HT3PCT - HT5PCT Heater STB 

LS1PRD 

Mixer motor rotation control 

MO1PPD 

Main drive 

MO1PPP 

Circulation pump for DEV 

MO2PPP 

Circulation pump for BF 

MO3PPP - MO5PPP Circulation pump for STB1-3 

MO1PRD 

Replenisher Mixer 

MO1PRP 

Replenisher pump DEV 

MO2PRP 

Replenisher pump BF 

MO3PRP 

Replenisher pump STB 

MO1PRW 

Pump DEV water replenishment 

MO2PRW 

Pump BF water replenishment 

MO3PRW 

Pump STB 3 water replenishment 

MO4PRW 

Water pump evaporation compensation tank 

MO6PRW 


MO7PRW 


MS1PTK 

Switch of the Processor cover 

MS2PTK 

Switch of the BF replenisher tank cover 

MS3PTK 

Processor drive interrupt, when MS1PTK activated 

MS4PTK 

Switch of the DEV replenisher tank cover 

MS5PTK 

Switch of the STB replenisher tank cover 

Dryer (DH) 

LS1PDH Dryer fan control FA1PDH 

FA1PDH Dryer fan 

FA2PDH Dryer cooling fan 

FA3PDH Cooling fan for dryer block 

FA4PDH Cooling fan for FA1PIR 


FU1PDH Temp fuse 

HS1PDR Temp sensor dryer 

HT1PDH Dryer heater 1 


MS1PDH Dryer cover switch 

MS2PDH Dryer interrupt when MS1PDH is actuated 

TH1PDH Thermostat 

IR dryer (IR) 

HT1PIR IR dryer top 

HT2PIR IR dryer bottom 

FA1PIR Dryer fan top 

FA2PIR Dryer fan bottom 

LS1PIR Dryer fan control FA1PIR 

LS2PIR Paper detection 




LS6PIR IR dryer control 

LSAPIR Dryer fan control FA2PIR 

TH1PIR Thermostat 

Paper output (PO) 

FA1PPO Cooling fan of the densitometer 

LS1PPO Paper detection 1 




MG1PPO Pressure solenoid of the densitometer 

MO1PPO Drive paper exit 1 

MO2PPO Drive paper exit 2 

MG2PPO Transport direction switch-over 

Lane Shifter (LS) 

LS1PLS Detection Lane Shifter in reference position 

LS2PLS Detection flap in reference position 

MO1PLS Lane Shifter drive motor 

MO2PLS Flap movement 

Sorter (SO) 

LS1PSO Detection Sorter in reference position 

MO1PSO Sorter drive 

MS1PSO Sorter closed detection 

dlabr12 


Repair 


Block Circuit Diagrams 

General System 

dlabr030 



Repair 

PCBs 

55P-CPU 

dlabr170 

■ 


Repair 


Signal Lists 

Sensors / Loads 

Paper Processor Block (PP) 

Designation 

Function 

FA1PPP 

Cooling fan for DEV 

FA2PPP, FA3PPP Cooling fan for BF 

FA4PPP 

Cooling fan for STB 

FA5PPP 

Cooling fan for Processor block 

FA6PPP 

Cooling fan for transport motor 

FA7PPP 

Cooling fan for DEV circulation pump 

FS1PET - FS3PET Level switch of the effluent tanks 

FS1PRT - FS3PRT Level switch of the replenisher tanks 

FS1PRW 

Level switch of the water replenishing tanks 

FS2PRW 

Level switch of the evaporation measurement water tank 

FS1PTK - FS5PTK Level switch of the temperature control tanks 

HS1PCT - HS3PCT Temperature sensor of the control tanks 

HT1PCT 

Heater DEV 

HT2PCT 

Heater BF 

HT3PCT - HT5PCT Heaters STB 

LS1PRD 

Turning monitoring of the mixer motor 

MO1PPD 

Main drive 

MO1PPP 

Circulation pump for DEV 

MO2PPP 

Circulation pump for BF 

MO3PPP - MO5PPP Circulation pump for STB tanks 1-3 

MO1PRD 

Replenisher mixer 

MO1PRP 

Replenishing pump DEV 

MO2PRP 

Replenishing pump BF 

MO3PRP 

Replenishing pump STB 

MO1PRW 

Pump of the water replenishment DEV 

MO2PRW 

Pump of the water replenishment BF 

MO3PRW Pump of the water replenishment STB 3 

MO4PRW 

Water pump of the evaporation measuring tank 



MS1PTK 

Switch for the Processor cover 

MS2PTK 

Switch for the cover of the BF replenisher tank 

MS3PTK 

Interrupt of the Processor drive when MS1PTK is operated 

MS4PTK 

Switch for the cover of the DEV replenisher tank 

MS5PTK 

Switch for the cover of the STB replenisher tank 



Repair 

Dryer DH 

Designation 

Function 

LS1PDH Dryer fan monitoring FA1PDH 

FA1PDH Dryer fan 

FA2PDH Cooling fan for the dryer 

FA3PDH Cooling fan for the dryer block 



FU1PDH Temp fuse 

HS1PDR Temp sensor dryer 



MS1PDH Switch for the dryer cover 

MS2PDH Interrupt of the dryer drive when MS1PDH is operated 

TH1PDH Thermostat 

IR Dryer IR 

Designation 

HT1PIR 

HT2PIR 

FA1PIR 

FA2PIR 

LS1PIR 

LS2PIR 

LS3PIR 

LS4PIR 

LS5PIR 

LS6PIR 

LSAPIR 

TH1PIR 

Function 

IR dryer up 

IR dryer down 

Dryer fan up 

Dryer fan down 

Dryer fan monitoring FA1PIR 

Paper detection 




IR dryer monitoring 

Dryer fan monitoring FA2PIR 

Thermostat 


Repair 


Paper Exit PO 

Designation 

Function 

FA1PPO Cooling fan for densitometer 





MG1PPO Pressure magnet of the integrated densitometer 

MO1PPO Drive paper output 1 

MO2PPO Drive paper output 2 

MG2PPO Transport direction change-over 

Lane Shifter LS 

Designation 

LS1PLS 

LS2PLS 

MO1PLS 

MO2PLS 

Function 

Detection Lane Shifter in reference position 

Detection flap in reference position 

Lane Shifter drive motor 

Flap movement 

Sorter SO 

Designation 

LS1PSO 

MO1PSO 

MS1PSO 

Function 

Detection Sorter in reference position 

Sorter drive 

Detection Sorter closed 



Repair 

Overview of the Connectors 

Source 

0701.. 

Destination Connector Description 

CN 1 Fan FA1AMF 

55A-PWF CN 2 Pilot +8 V 

CN 2 55A-CPU CN 3 

55P-SSR 

CN 3 DC power supply Power supply units 

CN 4 Vacuum pump VP1AVC 100V 

Socket outlet 

200V 

CN 5 55P-CPU CN 7 

CN 6 SSR 2 Dryer fan 

Dryer heater 

SSR 3 

IRC CN 9 

CN 7 DC power supply SSRs, relay control 

CN 8 DC power supply 200 V 

CN 9 55A-MDV CN 1 +5 V, +8 V Pilot 

52A-MAD CN 1 

55A-CPU CN 1 

CN 10 AGFA CN 1, CN 3 +5 V, +/- 15 V, 

22,8 V Lamp voltage 

Sens line lamp 

Lamp thermostat 

CN 11 52A-MAD CN 1, 2 PA +24 V, PB +36 V 

55A-IFB CN 9 +24 V 

AGFA CN 2 FD +24 V 

CN 12 55P-MDV CN 2 

55P-IRC CN 14 

CN 14 Thermostat dryer 

55P-IRC CN 12 + 24 V 

55P-MDV CN 3 

CN 15 AGFA CN 7 200 V (switch-off of the print lamp when the cover is 

removed) 

CN 16 55A-IFB CN 18 


Repair 


Connections of GS 55A-CNR (Distributor Board) 

Connector Sensors Function 

CN1 FS1PTK Level switch of the DEV temperature control tank 

CN4 FS2PTK Level switch of the BF temperature control tank 

CN8 FS3PTK Level switch of the STB1 temperature control tank 



CN18 FS1PRW Level switch of the water replenishment tank 

CN20 FS2PRW Level switch of the water evaporation measurement tank 

CN2 FS1PRT Level switch of the DEV replenishment tank 

CN5 FS2PRT Level switch of the BF replenishment tank 

CN9 FS3PRT Level switch of the STB replenishment tank 

CN12 FS1PET Level switch of the DEV effluent tank 

CN15 FS2PET Level switch of the BF effluent tank 

CN17 FS3PET Level switch of the STB effluent tank 

CN19 MS4PTK Cover switch of the DEV replenishment tank 

CN21 MS2PTK Cover switch of the BF replenishment tank 

CN3 MS5PTK Cover switch of the STB replenishment tank 

CN6 MS1PTK Cover switch of the Processor 

CN10 MS1PDH Cover switch of the dryer 

CN16 FS1AST Level switch of the ASTOR system (not used) 

CN22 HS1PCT Temperature sensor of the DEV control tank 

CN24 HS2PCT Temperature sensor of the BF control tank 

CN25 HS3PCT Temperature sensor of the STB control tank 



Repair 

■ 


Repair 




The assembly groups of the Paper Processor are 

exchangeable thanks to clearly defined mechanical 

and electrical interfaces. 

dlabr041 

1 Processor tanks / racks: DEV, BF, STB1-3 13 Water replenishment tank 

2 Outlet Unit 14 Water replenishment: DEV, BF, STB3 

3 Shifter 15 Water replenishment measuring tank 

4 Preheating (IR heater) 16 Temperature control tanks (heater / temperature sensor) 

5 Dryer 17 Effluent tank: DEV, BF, STB 

6 Circulation pumps: DEV, BF, STB1-3 18 Fan 

7 Replenishing pumps: DEV, BF, STB 19 Mixer motor (replenisher tanks) 

8 Water replenishment: STB2, STB1 20 Dryer fan 

9 Main power supply unit 1) 21 Dryer rack 

10 Replenisher tanks: DEV, BF, STB 22 Dryer heater 

11 Effluent tank (valve): DEV, BF, STB 23 Main drive motor of the Paper Processor 

12 Processor tank (valve): DEV, BF, STB1-3 

1) 

AC supply transformer / 56A-FUR / 55A-PWF 

RY relay (1, 2, 3), SSR relay (2) 

DC supply PS1, 55A-PWD, RY relay (4) 



Repair 

Switches 

1 Main switch 

2 RCD device 

dlabr125 


Repair 



PCBs / Power Supply 

dlabr160 

1 ⎯ Densitometer board 2) 

2 55P-MDV Driver board for 

- Motors 

- Lane Shifter 

- Outlet Unit 

- Pressure solenoid of the densitometer measuring head 

- 24V DC fan 

3 SSR2 Activation of the dryer fan (connection on CL8) 1) 

4 SSR3 Activation of the IR dryer 1) 

5 56P-SDR Control of the water replenishment 

6 55P-CPU Main processor of the Paper Processor 

7 55P-IRC Control of the IR dryer (IR heater / IR dryer fan) 

8 55P-SSR Board with the Solid State Relays for the activation of the 

- Solution heaters 

- Pumps 

- Main drive motor 

- AC motor 3) 

9 55A-PWD Voltage control 

10 ⎯ Power supply 

11 56A-FUR Fuse board 

1) Both Solid State Relays are behind the 55P-CPU 

2) Replace the densitometer board only together with the measuring head 

3) The SSR for the dryer heater (SSR1) is located in the AC power supply 

A 

B 

Paper Processor electronic 

AC/DC power supply 



Repair 

Fuses 

dlabr164 

1 CP2, CP3, CP4 

CP1 

Safety cut-outs for the Printer 

Safety cut out main transformer 

2 F4-F6 Fine-wire fuse for the Paper Processor 


Repair 


Paper Processor Control 

1 55P-CPU 

2 56P-SDR 

3 55P-IRC 

4 55P-SSR 

dlabr016 

55P-CPU 

LEDs on 55P-CPU 

LED no.. 

D1 

D2 

55P-CPU 

Fast flashing (100 ms): download in process 

Slow flashing (1 s): normal operation 

Dryer ON/OFF 

DIP switches on 55P-CPU 

DIP switch 55P-CPU 

1 normal operation 



4 deleting the Flash-ROMs 



Repair 

55P-SSR 

Fuses and LEDs: 

Fuse SSR no. Load LED 

F1 (250 V/2,5 A) U1 DEV heater HT1PCT D1 

F2 (250 V/2,5 A) U2 BF heater HT2PCT D2 

F3 (250 V/2,5 A) U3 STB 1 heater HT3PCT 

F4 (250 V/2,5 A) U4 STB 2 heater HT4PCT D3 

F5 (250 V/2,5 A) U5 STB 3 heater HT5PCT 

F6 (250 V/5 A) U6 Main drive motor MO1PPD 

F7 (250 V/2,5 A) U7 Driver motor of the sorter MO1PSO 

F8 (250 V/2,5 A) U8 Circulation pumps DEV, BF and STB MO1PPP 

: 

: 

MO5PPP 

F9 (250 V/1 A) U9 DEV replenishing pump MO1PRP 

U10 BF replenishing pump MO2PRP 

U11 STB replenishing pump MO3PRP 

F10 (250 V/2 A) U16 Mixer of replenishment chemicals (CW) MO1PRD 

U17 Mixer of replenishment chemicals (ACW) MO1PRD 

F11 (250 V/5A) U 18 not used 

F12 (250 V/1 A) U12 DEV water replenishing pump MO1PRW 

U13 BF water replenishing pump MO2PRW 

U14 STB water replenishing pump MO3PRW 

U15 Water replenishing pump of the 

measuring tanks 

U19 ASTOR pump (not used) 


Repair 


AC/DC Power Supply 

1 Cover Paper Processor control 

2 Main switch 

3 RCD device 

4 AC power supply 

5 DC power supply 

6 Remove screws to open the cover 

dlabr165 

If necessary, the AC and DC power supply can be 

removed separately. 

DC Power Supply 

1 Power supply PS1 

- 24 V Power supply Scanner 

- 5 V Main power supply Printer 

- 5,2 V Densitometer power supply - 

24 V / 8 V Pilot power supply (Timer) 

2 55A-PWD 

dlabr166 

55A-PWD 

LEDs on 55A-PWD 

LED 

Function 

CD +5 V LED ON: faultless 

PA 24 V LED OFF: fault 

PB 36 V 

PB 36 V overvoltage LED ON: Supply voltage too high 

LED OFF: Supply voltage correct 



Repair 

55A-PWD 

DC/DC converter to generate the supply voltage 

(±12V) of the AD converter of the 55P-CPU (temperature 

measurement). The test pins +12 V and 

-12 V for the check of the AD converter supply 

voltage are located on the 55P-CPU. 

dlabr300 


Repair 


AC Power Supply 

AC power supply: 

1 55A-FUR Fuse board 

2 RY1 Relay AC 200 V / AC 100 V 



5 Main transformer 100 V power supply 

6 SSR1 Dryer heater 200 V On/Off 

7 SSR4 Main transformer On/Off 

8 CP 1 (10A) Fuse of the primary winding 

of the main transformer 

dlabr301 

55A-FUR 

Fuses on 55A-FUR 

Fuses max. current Use 

F1 T 2A Voltage control (mains) of GS 55A-PWF 

F2 T 2A Vacuum pump AC 100 V 

F3 T 5A Socket outlet AC 200 V 

F4 T 6,3A IR heater AC 200 V 

F5 T 6,3A IR heater AC 200 V 

F6 T 5A Fan-heater AC 200 V 

F7, F8, F9 T 6,3A not used 



Repair 

Other PCBs 

55P-MDV 

55P-MDV (1) 

dlabr168 

Densitometer Board 

Densitometer board (1) 

dlabr167 


Repair 


Densitometer, integrated 

The integrated densitometer should allow an 

automatic Setup routine for MBL, PBL and CBL. 

The routine is repeated upon the Auto-Setup until 

the test print values are in tolerance with the aim 

densities. 

The measuring values are compatible with those of 

the DENS1, provided the calibration has been 

performed with the same measuring plate. 

Procedure: 

A zeroing to D=0,10 in Y, M, C is performed 

immediately before each measurement. For this, the 

measuring head is pressed on the reference plate. 

The actual measuring procedure is triggered by the 

paper tip of the test print. The measuring head is 

pressed on the test print, the measuring lamp is 

switched on after 1 s and the preceding black/white 

pattern is expected (only for MBL, PBL, CBL) prior 

to the test print. If the pattern is not recognised after 

15 s the latest, an error message is displayed. 

After the correct detection of the preceding pattern, 

the measuring phase starts. One measurement 

each is performed in cycles every 20 ms for Y, M, C 

until the end of the measuring field is reached. The 

maximum value is calculated for each colour. 

Measuring values differing by more than 0,4 from 

the maximum value are eliminated; the remaining 

values are used to calculate the mean value. 

After the measurement, the measuring lamp is 

switched off and the measuring head is lifted. 

An error message appears if the measuring lamp 

fails. 

dlabr069 

Climatic Conditions Densitometer 

Temperature min. 20 ºC max. 20 ºC 

Relative humidity min. 15% 

Standby max. 85% at 35 ºC 90% at 30 ºC 

Operation max. 30% at 60 ºC 



Repair 

7-Segment Display 

Calibration: 

A Measuring phase calibration 

d Calculation phase calibration 

- Wait until the measuring head is lifted 

Test print MBL, PBL, CBL: 

- Standby mode 

- After receipt of the Paper Top signal 

(LS1PPO/LS2PPO have detected the test 

print) 

0 After a lead time of 1 s 

2 After detected black/white length 

3 After detected minimum white length (10 mm) 

F Measuring phase 

- End of measurement, check 

Test print: 

- After receipt of the Paper Top signal 

(LS1PPO/LS2PPO have detected the test 

print) 

1..C Detected field number in Hex code (see Table 

below) 

- Wait until LS1PPO/LS2PPO are free again 

Field 

number 

Hex 

code 

Code 

(test print) 

12 C M 

11 B L 

10 A K 

9 9 J 

8 8 I 

7 7 H 

6 6 G 

5 5 F 

4 4 E 

3 3 D 

2 2 C 

1 1 B 

0 0 A 

■ 


Repair 


Repair 

Replacement of the Densitometer 

Order no. 8506/600 

ABC-Code B9GPC 

Replacement of the densitometer: 

− Densitometer lamp defective 

− Electronic defective 

− Internal calculation error in the densitometer 

As the measuring head and the processor board 

are tuned, they must only be replaced together. 

See also Procedure between customers and the 

Agfa subsidiary in this register 

Uncovering the Densitometer board 

− Remove the covers from the dryer in the given 

order / direction 

dens17 

− Unscrew the cover of the densitometer board 

dens18 



Repair 

Procedure between Customers and the Agfa Subsidiary 

Return of the complete densitometer: 

− Control board (1) and 

− Measuring head (2) 

75% of the new price are credited for the returned 

densitometer. So, the customer has to pay 25% of 

the new price for the replacement densitometer. 

dlabr161 


Repair 


Replacing Printed Circuits 

1. 55P-MDV 

2. Densitometer board 

PP electronic 

1. 56P-SSR 

2. 55P-CPU 

3. 55P-IRC 

4. 55P-SSR 

In the DC power supply: 

1. 55A-FUR 

2. 55A-PWD 

In the AC power supply: 

1. Fuse board 



Repair 

Replacing Relays 

Dismount the AC power supply: 

− Remove 2 fastening screws (1) 

− Unscrew the cables: (2) turn cw 

− Pull the cables approx. 10 cm inside 

− Disconnect 4 connectors 

− Pull the unit approx. 10 cm to the front: 

Run the cables on the left side behind the unit 

Mind the cables on the left side when pushing in 

the unit: Run the cables again to the front and put 

them on the unit. 


Repair 


Temperature Switch Dryer 

Reset the temperature switch dryer: 

Press (1) 

dlabr124 



Repair 

■ 


Repair 

Software 

Contents 

Software Structure ..................................................................................................................................... 8.1 

Hardware Connection............................................................................................................................ 8.1 

Software Levels..................................................................................................................................... 8.2 

Software Structure of the Controller...................................................................................................... 8.3 

FL Controller ............................................................................................................................... 8.3 

Algorithms/Interface Controller ................................................................................................... 8.3 

CG Controller .............................................................................................................................. 8.3 

Image Management .............................................................................................................................. 8.4 


Software 

Repair 

■ 


Repair 

Software 

Software Structure 

The Main-PC controls all higher-ranking procedures. 

The Software responsible for the Hardware ensures 

the direct connection to the individual components 

of the Hardware, like loads and sensors. 

Hardware Connection 

rep140e 


Software 

Repair 

Software Levels 

The Software is split up into 4 levels in charge of 

special functions: 

1. Hardware functions: 

Hardware-related functions operating only 

one sensor or load. This also includes the 

initialisation of registers. 

2. Basic functions: 

Functions combining several Hardware 

functions. This includes initialisation functions 

and certain Hardware-related procedures, 

e.g. the execution of an exposure. 

3. Dispatcher or Main: 

Distributes the commands sent by the Main- 

PC to basic or Hardware functions. 

4. Interface: 

Software for the communication via a RS232 

interface or the CAN-Bus. This also includes the 

respect of certain error handling protocols. 


Repair 

Software 

Software Structure of the Controller 

The CG Controller and the FL Controller have to 

perform different functions. For this reason, the 

Software structure is different, above all as 

concerns the Interface and the Dispatcher. 

FL Controller 

Several functions have to be performed at the 

same time: 

− Interpreting arriving telegrams and responding to 

them 

− Sending CAN commands and assessing / 

transmitting the related acknowledgements 

− Performing basic functions simultaneously for 

several loads 

The Software on the FL Controller checks 

conditions in an endless cycle, responds to events 

and triggers the required action. This main loop 

(main function) runs through within 1-2 ms. 

Time-dependent actions are executed in 

Interrupts: 

− Response to telegrams from the RS232 interface 

− Response to telegrams from the CAN-Bus 

− Output of telegrams 

− Control of the motors via the PWM or CC mode 

Algorithms/Interface Controller 

Like the FL-Controller, commands are received 

and performed in a main loop. Besides this, 

Interrupt routines are running for time-dependent 

actions. 

CG Controller 

The CG Controller receives commands, confirms 

and executes them sequentially. 

After receipt of a telegram from the CAN-Bus, an 

appropriate function is called up by the Dispatcher. 

After it has been executed, a feedback message is 

sent via the CAN-Bus. 

Only the motors are controlled in Interrupts. 


Software 

Repair 

Image Management 

Order 501 Order 500 Order 499 

dlabr141 

8.4 2001-01-02 /PN 9009 AGFA d-lab.3 

■

Repair 

Maintenance 

Contents 

Maintenance Schedule and Maintenance Intervals ................................................................................ 9.1 

Maintenance Jobs performed by the Service Technician, yearly.......................................................... 9.3 

Whole Machine ..................................................................................................................................... 9.3 

Clean the inside Compartments..................................................................................................9.3 

Lubricate the plastic Gears ......................................................................................................... 9.3 

Scanner ................................................................................................................................................. 9.4 

Oil the Scanner Carriage ............................................................................................................ 9.4 

Negative Carrier: Lubricate the toothed Belts / Shafts (if required) ............................................ 9.4 

Negative Carrier: Clean the Roller Sets...................................................................................... 9.4 

Negative Mask: Lubricate the Pawl / the Holes (if required) ....................................................... 9.5 

Optical Area, clean...................................................................................................................... 9.5 

Transport Unit and Lane Distributor............................................................................................ 9.6 

Paper Processor ................................................................................................................................... 9.7 

Whole Machine ........................................................................................................................... 9.7 

Processing Racks ....................................................................................................................... 9.7 

Wet Section................................................................................................................................. 9.8 

Automatic Water Replenishment ................................................................................................ 9.8 

Cleaning the Evaporation Measuring Recipient.......................................................................... 9.9 

Dryer Rack .................................................................................................................................. 9.9 

Transport Belt ............................................................................................................................. 9.9 

Print Chute (if required)............................................................................................................... 9.9 

Inlet Rollers in front of the IR Dryer........................................................................................... 9.10 

IR Dryer (if required) ................................................................................................................. 9.10 

Outlet Unit ................................................................................................................................. 9.10 

Densitometer Area (Outlet Unit)................................................................................................9.10 

Paper Magazine Area left and right........................................................................................... 9.11 

Maintenance Jobs performed by the Service Technician, every 2 Years........................................... 9.12 

Replace the Laser ............................................................................................................................... 9.12 

End of the Maintenance Jobs.................................................................................................................. 9.12 

Check the Machine Functions............................................................................................................. 9.12 

Consumables / Cleaning Agents / Lubricants / Tools .......................................................................... 9.13 

Consumables ...................................................................................................................................... 9.13 

Cleaning Agents .................................................................................................................................. 9.13 

Lubricants............................................................................................................................................ 9.14 

Tools.................................................................................................................................................... 9.14 


Maintenance 

Repair 

■ 


Repair 

Maintenance 

Maintenance Schedule and Maintenance Intervals 

yearly 

x 

x 

x 

x 

x 

x 

x 

x 

x 

x 

x 

x 

x 

x 

x 

x 

x 

x 

x 

x 

x 

x 

x 

x 

x 

x 

x 

x 

x 

x 

x 

x 

x 

x 

x 

x 

x 

x 

every 

2 years 

Technician required 

Entire machine 

Clean the inner compartments 

Clean and grease all chains, gears and bearings 

Scanner 

Oil the scanner carriage 

Negative carrier: lubricate the toothed belt and the shafts 

Negative carrier: clean 2 roller sets 

Negative mask: lubricate the pawl / the holes in the bearing plate 

Optical area 

Clean the lamphouse area 

Clean the exposure filters 

Check / replace the mirror 

Check / replace the prism disk (mirror box) 

Clean the mirror box inside 

Clean the paper filter on the scanner carriage 

Clean the Zoom lens 

Printer: Transport Unit and Lane Distributor 

Check / replace the plastic bearings at the motor 

Check / replace the springs 

Toothed belt drive: Check / adjust the tension 

Clean the shifter shafts 

Clean the side plates 

Grease the bearing points 

Clean the rubber rollers 

Paper Processor, general 

Clean and grease all chains, gears, bearings 

Check circulation pumps, replenishing pumps, fans, hose fittings for tight 

seating/correct functioning 

Wet section, processing racks 

Clean the racks, check for smooth movement 

Check the slide bearings, roller shafts, springs, gears 

Check the backlash of the spring rollers; 

if necessary replace the bottom rollers and squeeze rollers 

Replace all sponge rubber rollers (squeeze area) 

Clean the bearing points and remove all crystals 

Lubricate the shaft bearing points 

Wet section, general 

Check the replenisher valves and replace them if necessary 

If required: Replace the circulation pumps 

Lubricate the mixer of chemistry 


Maintenance 

Repair 

yearly 

x 

x 

x 

x 

x 

x 

x 

x 

x 

x 

x 

x 

x 

x 

x 

x 

x 

x 

x 

x 

x 

x 

x 

x 

x 

x 

x 

x 

x 

x 

x 

x 

x 

every 

2 years 

Technician required 

Automatic water replenishment / Evaporation measuring recipient 

Clean the water tank and remove lime deposits, if necessary 

Clean evaporation measuring recipient 

Dryer rack 

Check the foam plastic rollers, replace if necessary 

Clean the removable rollers and the goffered plate 

Clean the large plastic roller 

Check the bearing blocks and replace them if necessary 

Check the chain tension, retention if necessary 

Lubricate the continuous drive chain 

Lubricate the (outer) gears 

Transport belt 

Check the transport belt, retention if necessary 

Print chute 

If required lubricate the gears and 

the bearing points of the rocker 

Inlet roller in front of the IR dryer 

Clean the inlet roller 

Lubricate the gears 

IR dryer 

Clean the rollers 

Clean and lubricate the continuous chain 

Clean and lubricate the plastic gears 

Outlet Unit 

Clean the Outlet Unit 

Check the rollers, if necessary, lubricate the plastic bearings and the bearing 

points of the mobile guide elements 

Replace the plastic gears if they are worn, otherwise lubricate them 

Densi area in the Outlet Unit 

Clean the densitometer area and the densitometer head 

Check the pressure mechanism 

Paper magazine area left and right 

Check the coupling, replace if necessary 

Check the closing lever 

Laser 

x x Replace the laser 

x 

End of the maintenance jobs 

x 

Check the machine functions 

x 

Check the perfect condition of the safety devices 


Repair 

Maintenance 

Maintenance Jobs performed by the Service Technician, yearly 

Maintenance by the service technician: 

once a year: 

− Replacement of expendable parts 

− Preventive replacement of parts 

− Greasing / lubrication of parts 

The Safety prescriptions on all machine stickers 

and in register 1 of this folder must be observed. 

Whole Machine 

Clean the inside Compartments 

− Remove the covers 

− Blow out the inside compartments including the 

air shafts 

− Clean the suction area of the cooling fans: 

− Grid 

− Fan blades 

− Cooling ribs of the heat exchanger 

Lubricate the plastic Gears 

Plastic gears: 

Lubricate the plastic gears with Klüberplex if they 

are noisy 


Maintenance 

Repair 

Scanner 

Oil the Scanner Carriage 

Oil the shaft on both sides of the 2 sinter bearings 

(1) with Constant OY 220, moving the 

scanner carriage to and fro 

dlabr161 

Negative Carrier: Lubricate the toothed Belts / Shafts (if required) 

Remove the negative carrier (4 screws) 

Unscrew the film supply 

Lubricate the toothed belt inside with Isoflex 

Topas NB 52 

Lubricate the shafts with Isoflex Topas NB 52 

Caution! 

Do not touch the red lacquered screw - bottom 

centre. Remove only the safety washers, push the 

little rollers to the front as shown in the magnified 

illustrations and grease the shafts. 

sp02 

Negative Carrier: Clean the Roller Sets 

Clean the 2 roller sets TR4 and TR5 and 

replace them if necessary 

− Replace the roller with ball bearings: 

CM+7.8506.5015.1 x 2 

CM+7.0371.0072.1 x 2 

dlabr066 


Repair 

Maintenance 

Negative Mask: Lubricate the Pawl / the Holes (if required) 

Lubricate the pawl and the holes in the bearing 

plate with Isoflex Topas NB 52 

sp04 

Optical Area, clean 

Caution! 

Be sure to switch off the lamp as otherwise the 

prism disk will burn. 

When cleaning the fragile glasses of the exposure 

filters with an optic cleaning cloth, slightly support 

the filter paddles from below as otherwise they 

might break. 

Carefully clean the lamphouse area (blow it 

out). 

Use optic pads for the following cleaning jobs. 

Clean the exposure filters 

Check the guide mirrors for damage and 

replace them if necessary 

Check the prism disk on the mirror box for dark 

spots (overheating) and replace it if 

necessary 

Open the frosted glass in the mirror box in the 

service mode (by means of the mirror box 

motor M01MB): Blow out the mirror box or 

clean it very carefully with optic pads 

Use optic pads for the following cleaning jobs. 

Open the shutter in the service mode 

(DS_MO01) 

Clean the paper filter on the scanner carriage 

Clean the viewing mirror 

Clean the top class of the Zoom lens 

Exit the service mode: 

This automatically resets the dust shutter (only 

in prototypes; will be omitted) 

dlabr060 


Maintenance 

Repair 

Transport Unit and Lane Distributor 

Check the plastic bearings of the motor and replace 

them if necessary 

Check the springs and replace them if 

necessary 

Check the tension of the toothed belt and adjust 

if necessary 

Clean the shafts and apply a very thin film of 

Constant OY 220 

Clean the slide plates with Agfa Cleaner 

Grease the bearing points with Constant OY 

220 

Clean the rubber roller with Lixtop plastic cleaner 

dlabr068 

dlabr079 


Repair 

Maintenance 


Whole Machine 

− Clean all chains, gears and bearings and grease 

them with Klübersynth 

Processing Racks 

Clean the racks and check them for smooth 

movement (25-60 Ncm) 

On all racks including the squeegee unit over 

the STB3 rack: 

Check the gears, roller shafts, slide bearings 

and springs for damage / wear and replace 


Check the position of the slide bearings: The 

nipple points to the inside (see figure) 

− Two squeeze rollers are the most critical points 

in all racks (see arrows in figure above). The 

stress is the strongest in the CD racks because 

they are very close to the liquid level: 

− Check the backlash of the squeeze rollers 

with AGFA Prestige paper or similar 

− If necessary, replace the bottom rollers 

(P3-E5146) and the squeeze rollers 

(P3-86682) 

− Replace all sponge rubber rollers for STB in the 

squeegee area 

− Clean the bearing points and remove the crystals 

in this area 

− To protect the dry running bearing points (above 

the liquid level) from the penetration of chemistry 

(crystals) and keep the rack torque small 

at the same time, the chemical-resistant 

Klüberplex (sealing grease) is recommended: 

Apply an evenly thin film on the shaft bearing 

points (take out the bearings and grease the inside). 

roll_02 


Maintenance 

Repair 

After mounting the unit, a small amount of the 

same grease can be applied to the rack inside 

while the rack is turned by hand in order to produce 

an even covering film (see arrow) 

sp14 

Wet Section 

If required replace the replenishment valves 

and the bellows of the pumps: 

CL+P4-3805(1/1) bellow 

CL+P4-1119(4/1) valve (PDM) 

CL+P4-6110(2/1) valve for STB (Teflon, lasts 

longer) 

If required (running noise) convert the pump: 

Pump type MD6 

Mixer of chemistry: Lubricate all belt 

turnaround pulleys and belt tensioners with 


sp17 

Automatic Water Replenishment 

Depending on the water hardness, lime may deposit 

in the tray and/or on the floater switches and 

impair the correct functioning of the water supply 

(evaporation compensation). 

Carefully remove lime residues from the water 

tanks, especially from the tank inside borders 

as the water creeps out there through the lime 

rests (capillary effect). As a result, 

the tank is emptied prematurely 

the water replenishment is increased 

the tank chemistry is diluted 

Clean the floater switches: They must move 

freely as otherwise the automatic water replenishment 

does not function correctly. 

sp31 


Repair 

Maintenance 

Cleaning the Evaporation Measuring Recipient 

Open the replenisher tank lid 

Check the black evaporation measuring recipient 

(see arrow) for lime deposits, remove 

the deposits, if any 

dlabr015 

Dryer Rack 

Remove the dryer rack 

Check the foam plastic rollers for wear and replace 


Thoroughly clean the large plastic roller underneath 

the removable rollers 

Check the bearing blocks and replace them if 

necessary 

Check the gears and replace them if necessary 

Check the chain tension and tension it if necessary 

Lubricate the continuous drive chain with 

Klübersynth 

Lubricate alle outer gears with Klüberplex 302B002 

Transport Belt 

Check the transport belt and retention it, if required 

Print Chute (if required) 

Lubricate the rocker gears with Klüberplex, the 

bearing points of the rocker with Constant OY 

220 

sp09 


Maintenance 

Repair 

Inlet Rollers in front of the IR Dryer 

Clean the inlet rollers 

Lubricate the gears with Klüberplex 

IR Dryer (if required) 

Move the sorter aside 

Remove the dryer cover: turn the screws 90º 

with a coin 

Disconnect the cable from the IR dryer (1) 

Loosen the knurled screw (2) of the IR dryer 

and remove the IR dryer 

Loosen 2 knurled screws (3) and take the 

insertion out of the IR dryer 

Clean the rollers: 

the inside light rubber rollers 

the black inlet and outlet rollers 

Clean the continuous chain and lubricate with 

Klübersynth 

Clean the plastic gears and lubricate with 

Klüberplex 

dlabr064 

Outlet Unit 

Remove the top cover of the Outlet Unit 

Clean the Outlet Unit 

Check the rollers for smooth movement and if 

necessary lubricate the plastic bearings and the 

bearing points of the mobile guide elements 

with Constant OY 220 

Replace the plastic gears if they are worn; 

otherwise lubricate with Klüberplex 

Densitometer Area (Outlet Unit) 

Clean the densitometer area of the Outlet Unit 

Carefully clean the densitometer head (Q-Tips) 

Check the pressure mechanism for smooth 

movement 


Repair 

Maintenance 

Paper Magazine Area left and right 

Coupling (1): visual check, replace if necessary 

Check the locking lever (2): The actuator roller 

should not slant 

dlabr159 


Maintenance 

Repair 

Maintenance Jobs performed by the Service Technician, every 2 Years 

Replace the Laser 

When the performance of the laser declines, a 

message on the screen informs the operator that 

the laser has to be replaced in a certain 

time. 

Caution! 

Replace the Laser by all means, otherwise the 

production quality will fall off. 

Replacement of the Laser: see Laser module / Laser, 

register 6.4 (Printer, Repair) 

End of the Maintenance Jobs 

Check the Machine Functions 

Check all functions of the machine as well as the 

perfect condition of the safety devices. 


Repair 

Maintenance 

Consumables / Cleaning Agents / Lubricants / Tools 

Consumables 

Chemistry 

CD 

BX 

SB 

Tank kit 

Order no. 

5FPKS 

5FPLU 

5FPMW 

5FFYK 

Paper 

Order no. 

10,2 5FM4L 

12,7 5FM5N 

15,2 5FM6P 

20,3 5FM8T 

Air filter 

Lamp house 

CCD 

Cutter area 

Paper Processor (1) 



Order no. 

CM+7.8061.LHL4.0 

CM+7.8061.FEL2.0 

CM+7.0431.7225.0 

CL+P3-E0898 

CL+P4-3812 

CL+P4-3812 

Chemical filters + Test strips 

Order no. 

Chemical filters CD, BX, SB1, SB2, SB3 92GP5 

Test strips — 

Other 

Order no. 

Farbband Rückseitendrucker 102-01-0003 

Kopierlampe 

YMHSY 

Cleaning Agents 

Part number Designation Use 

CM+9.9999.9231.0 Lixtop plastic cleaner Panel parts 

CM+9.9999.9274.0 Compressed air spray Dust removal 

CG+078047-0003 Optic Pads Optical parts 

CP+G-003T Agfa Cleaner Prevents static charges 

CM+8.8506.1330.0 Cleaning strips (3 pcs) Cleaning the APS negative mask 

CM+8.8506.1320.0 Cleaning strips (3 pcs) + 

Isopropanol bottle (empty) 

Cleaning the APS negative mask 


Maintenance 

Repair 

Lubricants 

Part number Designation Use 

CM+9.9999.9001.0 Never Seez Panelling parts: Ideal to loosen tight moving parts 

(alternative: graphitic agent) 

CM+9.9999.9247.0 Isoflex Topas NB 52 Dust removal: Heavy-duty lubricant, limited compatibility 

with plastic 

CM+9.9999.9271.0 Constant OY 220 Optical parts: Synthetic oil, universal applications, 

also for sinter and slide bearings 

CM+9.9999.9280.0 Klüberplex BE 31-503 Antistatic treatment: To oil heavy-duty friction 

points (chains) 

CM+9.9999.9281.0 Klübersynth GEM 4-460 Multifunctional oil: Special agent for heavily 

stressed slide surfaces (chains) 

Manufacturers 

Agfa offers these lubricants in Germany. If it is not 

possible to get them through Agfa in other countries, 

please contact directly the manufacturer's 

agency in your country. 

Product 

Never Seez 

Isoflex Topas NB 52 


Klüberplex BE 31-503 

Klübersynth GEM 4-460 

Agfa Cleaner 

Manufacturer 

Varybond Chemie AG 

Klüber Lubrication 




Agfa-Gevaert AG 

Tools 

Fork wrench 

Set of Allen keys with a ball head 2-8 mm 

Set of Allen keys 3 mm, 

250 mm long for the scanner adjustment 

Magnifying glass 

■ 


Repair 

General Data and Information 

Contents 

Technical Data .......................................................................................................................................... 10.1 

d-lab.3 General System....................................................................................................................... 10.1 

Main-PC .............................................................................................................................................. 10.3 

Prescanner / Scanner ......................................................................................................................... 10.3 

Printer.................................................................................................................................................. 10.4 

Paper Processor ................................................................................................................................. 10.5 

Densitometer............................................................................................................................. 10.6 

Standardisation / Screws..................................................................................................................... 10.7 

Optional Accessories .......................................................................................................................... 10.8 

Consumables ...................................................................................................................................... 10.9 

Glossary .................................................................................................................................................. 10.11 



Repair 

■ 


Repair 


Technical Data 

d-lab.3 General System 

Ambient conditions for test 

and operation 

− Ambient conditions for storage / transport: 

Temperature -50 °C to +60 °C 

Relative humidity 15% to 90% 

− Test conditions: 

Temperature +15 °C to +35 °C 


− Ambient conditions for operation: 

Room temperature +15 °C to +35 °C 


− Maximum ambient brightness: 

Printer / Paper Processor 10.000 Lux 

Paper magazines 

20.000 Lux 

Approval − Europe: EN 60950, EN 60204, EN 50082-1, EN 50081 

− USA / Canada: UL 122, C22.2 No. 950-M89(+D3), 

FCC 47 Part 15-A-C, 

FCC 47 Part 15-A-R 

Dimensions 

− Width PA + PP without 

Sorter extension: 2.260 mm 

− Depth: 770 mm 

− Height: 

1.730 mm 

− Weight: 

empty approx. 895 kg 

filled approx. 1.032 kg 

Electrical requirements − Installation 

V 200/210/230-240 1N~ V 400 3N~ 208 3~ 

A xxx/xxx/20 A 15 xxx 

50/60 Hz 

− Datasheet 

1N~ 200-240 V 

3N~ 400 V 

3~ 208 V 

Max. 4,4 KVA 

50 / 60 Hz 

− Input voltage range: ± 10% 

Film and negative sizes Film size Negative size 

110 negatives 

135 negatives Full frame, half frame, Panorama (colour and B/W) 

135 slides Colour 

IX240 negatives Classic, HighVision, Panorama (colour and B/W) 

120 negatives 6x4,5 cm to 6x9 cm 


General Data and Informations 

Repair 

Floor space for operation / 

service 

General 

− Right side 600 mm 

− Left side 1.100 mm 

− Front 

900 mm 

− Minimum distance to the wall: 

for operation 150 mm 

for service 600 mm 

Digital Minilab to print negative films, slides and images from digital 

sources and save digital data on digital storage media. 

− TFS Prescanner and high-power Main Scanner 

− Single sheet Printer with a digital exposure system (Laser) 

− Scanner and Printer integrated in one chassis 

− Paper Processor with Agfa-specific laser paper chemistry 

Interfaces 

− Ethernet for the data exchange and the connection of the external 

workstation or a lab network 

− External densitometer 

− Modem 

− Label printer for pricing 

Main control 

− Integrated Pentium-PC for the main control of the d-lab.3 

− NT operating system 

− Integrated disk drive, CD-ROM, Zip 

− Touch screen monitor as user interface 

Noise level 

58 dB(A) Standby 

65 dB(A) Print mode 

68 dB(A) Print mode with Sorter 

Optional accessories − Additional table for a larger working area 

− External label printer for pricing 

− Masks for the different negative sizes and slides 

− Options for other print processing functions 

Print sizes Minimum: 82 mm x 117 mm (3,25" x 4,75") 4,75" paper 

Maximum: 210 mm x 305 mm (8,25" x 12") 8,25" paper 

Production capacity 1.700 prints/hour (eff., including Indexprint) under the following 

conditions: 

− Film size 135-24, 24 normally exposed negatives 

− Print size 102x152 mm 

− 152 mm paper width 

Service cycle − Frequency: 6 months (probably) 

− Time input: 0,5 days (probably) 


Repair 


Main-PC 

Drives − Diskette 

− Zip 

− CD 

− PCM-CIA (rack for memory cards) 

Graphic card − Resolution: 1.024x768 pixels 

− Image recurrence frequency: >75Hz 

Hard disk capacity 

≥ 10 GByte 

Image processing card To generate the digital images 

Network card 1 

100 Mbit/sec for external network connection 

Network card 2 

10 Mbit/sec for internal communication 

Operating system Windows NT ≥ 4.0 

Timer board 

to control the switch-on and switch-off procedures 

Prescanner / Scanner 

Filter − Optimised filter set for negative films 

− Optimised filter set for slides (optional) 

Resolution for negative size − Prescanner: approx. 500 pixels per colour 

135 

− Main Scanner: approx. 6.000.000 pixels per colour 

Sensor type − Monochrome CCD sensor 2k x 3k pixels 



Repair 

Printer 

Laser recorder 

− Exposure by a Laser recorder 

− Paper transport speed 

− Laser wavelength: 

Blue 

Green 

Red 

100 mm/s 

458 nm 

514 nm 

680 nm 

− Scanning width 8,25" 

− Resolution 

400 dpi 

Paper magazines − Paper length 176 m 

Paper transport 

− Paper width 

3¼ - 8¼ Inch 

− Single-sheet transport on one lane, paper cut prior to the 

exposure, 

distance between 2 single sheets 25 mm 

− 2 paper magazines 

− Sheet rotation 

− Sheet centring 

− Lane distributor to supply 2 lanes in the Paper Processor 


Repair 



Floor space − Width: 770 mm (Processor) 

Floor space for operation / 

service 

Process capacity 

Processor type 

− Length: 

1.102 mm (without the Sorter extension) 

− Height: 

1.732 mm 

− Right side: 600 mm 

− Distance to the wall: 150 mm / 600 mm 

− 1.700 prints/hr 

− Two-lane stand-alone Paper Processor 

− Replenishing system 

− Rinse 

− 1 CD, 1 BX and 3 SB tanks 

− Integrated print sorter 

15 order buckets 

All print sizes can be sorted and deposited. 

− Integrated densitometer 

Process specifications 

Solution CD BX SB 

Process time (in sec.) 27 27 3 x 18 

Temperature (in ºC) 40 35 3 x 35 

Replenishment rate (ml/m²) 90 120 240 

Tank 

− Automatic mixing for the replenishment 

− Automatic water replenishment 

Tank capacity in litres CD BX SB 

Processing tank 18,4 18,4 3 x 13,2 

Replenisher tank 10 10 20 

Effluent tank 5 5 5 

Transport system 

− Two-lane transport by means of rollers 

− Single sheet: 

Minimum length 

117 mm 

Maximum width 

210 mm 

− Lane distributor: 

2 lanes up to 102 mm 

1 lane up to 210 mm 

− Transport speed: 2.969 mm/min (50/60 Hz) 

Dryer 

− Preheating by means of an IR dryer 

− Main heater with hot air 



Repair 

Densitometer 

Calibration Automatic prior to every measurement to D=0,10 (Y, M, C) 

Data rate 1.200 Baud: Print mode / factory-set 

(Jumper 1 and 2 not set) 

9.600 Baud: Test mode 

Interfaces 

Connector 3 (data interface acc. to RS232) 

Type: Sub-D 9 poles 

Jumper settings Jumper position Mode Baud rate 

Normal 1.200 

Machine selection 

Measuring characteristics 

Transport speed 

Normal: The Jumpers have no impact 

on the densitometer function in this 

position 

Do not set! Only for the assembly ! 

Densitometer may get damaged 

1.200 

Selection by means of soldering bridge Br1: 

Br1 open 

When Br1 is open, the transport speed can be selected with Br2 

Measuring range 

Reflection D=0,00 to 2,55 (minus the basic density) 

Measuring accuracy under the particular climatic conditions 

− Linearity, reproducibility: 

- to density 1,30 ± D=0,01 

- to density 2,00 ± D=0,02 

- to density 2,55 ± D=0,03 

Selection by means of soldering bridge Br2 (Br1 must be open): 

Br2 short-circuited V = 1.400 mm/min d-lab.3 Process 

— 


Repair 


Standardisation / Screws 

Flat head screws 

DIN 912 (inside the machine) 

− Thread: M3, M4, M6, M8 

− Length: 5, 8, 12, 16 mm 

− Surface: Zn 

Recessed countersunk head screws DIN 965 

− Thread: M3, M4 

− Length: 4, 6, 10 mm 


Cross recessed countersunk head 

screws 

DIN 7985 (fastenings visible on the outside of the machine) 

− Thread: M4 

− Length: 10 mm 




Repair 

Optional Accessories 

Type Order no. 

Additional paper magazines 8508/115 5BQVM 

Film mask 135H 8506/136 B72N5 

Film mask 135P 8506/137 B72O7 

Film mask 135HV 8506/138 B72PA 

Film mask 110 8506/139 B72QC 

Mirror box 120 8508/131 5AB7C 

Film mask 120 6x4,5 *** 8506/165 B72TJ 

Film mask 120 6x6 *** 8506/166 B72UL 

Film mask 120 6x7 *** 8506/167 B72VN 

Film mask 120 6x8 *** 8506/168 B72WP 

Film mask 120 6x9 *** 8506/169 B72XR 

Smart Media Card Adapter 9975/213 5DSFF 

Compact Flash Card Adapter 9975/214 5DSGH 

Air exhaustion adapter 125 mm 8060/350 5GVP2 

* Universal lens delivered instead of the standard lens (8060/305, 5FLMF) 

** LCD monitor delivered instead of the CRT monitor (8060/340, 5FLOK) 

*** Only in combination with the universal lens 


Repair 


Consumables 

Chemistry 

CD 

BX 

SB 

Tank kit 

Order no. 

5FPKS 

5FPLU 

5FPMW 

5FFYK 

Paper 

Order no. 

10,2 5FM4L 

12,7 5FM5N 

15,2 5FM6P 

20,3 5FM8T 

Air filter 

Lamp house 

CCD 

Cutter area 




Order no. 

CM+7.8061.LHL4.0 

CM+7.8061.FEL2.0 

CM+7.0431.7225.0 

CL+P3-E0898 

CL+P4-3812 

CL+P4-3812 

Chemical filters + Test strips 

Order no. 

Chemical filters CD, BX, SB1, SB2, SB3 92GP5 

Test strips — 

Other 

Order no. 

Farbband Rückseitendrucker 102-01-0003 

Kopierlampe 

YMHSY 



Repair 


Repair 


Glossary 

Acousto-optic 

AOM amplifier 

(acoustooptical 

Modulator) 

AVR Controller 

Banding 

Blemish 

BOL (begin of line) 

BOP (begin of paper) 

CC Mode 

(capture compare) 

CDS process 

(Correlated Double 

Sampling) 

Colour gradations 

Checks the interactions between high-frequency Ultrasonic and Hypersonic 

waves and electromagnetic waves. The occurring refractive and diffractive 

effects are used for the construction of light deflectors, light modulators, light 

switches and other acousto-optical components. 

The d-lab.3 features an AOM amplifier each for the blue and the green 

Laser beam. 

Upon a replacement, the characteristic curve has to be recreated 

(adjustment assisted by the service program). To create the characteristic 

curve, the service technician moves an additional monitor diode into the light 

path. 

Controller circuit (AVR = registered trademark) 

Caused by variations of the transport speed; cause: Irregular running of the 

motor, bumps against the exposure unit. 

Most clearly visible for the human eye at 0,7lp/mm 

Those pixels are considered as Blemish whose correction data exceeds the 

available storage range. 

Start of exposure 

Paper tip detection 

Interrupt routine (FL-Controller) for the motor control: 

A counter is active in the CC mode that triggers an Interrupt after a given 

time. The Port Pin must then be set explicitly in the Interrupt (see also PWM 

mode). 

Motors: Feeder motor (film width), film transport in the Feeder, Scanner 

sledge 

Improves the noise distance by means of the CDS method: Each pixel not 

only holds the actual pixel value, but also has a Dark Reference which 

accounts for local differences of the PRNU. The output signal is used to form 

the difference between these two signals. 

The two signals are found by a special CDS chip which exists separately for 

each quadrant. 

The CCD chip contains 6 additional arrays for each quadrant whose pixels 

are not active electrically. The average value of their content can be used as 

parameter to check the temperature and the dark current (Trigger to repeat 

the pixel correction in case the given tolerances are exceeded). 

1.024 gradations per colour 

Gradations per pixel = RxGxB = 1024x1024x1024 = 1.073.824 

DFÜ 

Remove data transmission for RDS (Remote Diagnose Service) 

Density gradations 1.024 

min. density 0,1 

max. density 2,1 

Differences are easier to discern for the human eye at low densities than at 

high densities. 

Laser power curve: Smallest gradations for lower densities. 

dpi (dots per inch) 

FAF (FIFO almost full) 

Resolution of digital images 

Buffer for the image data (FIFO) almost full 



Repair 

FIFO (first in, first out) 

FPGA (field 

programmable gate 

array) 

GUI (graphic user 

interface) 

Laser 

Laser diode 

Laser pixel size 

LFB 

LUT (look up table) 


Piko 

Polarisation filter 

Polygon 

PRNU 

PWM mode 

(pulse width 

modulation) 

RS232 

SPI Module 

UM 

Buffer for image data 

After the AD conversion, the image data is preprocessed in the FPGA, 

multiplexed (4:1) and sent to the image processing card in the Main-PC. 

Operator surface 

English shortcut for Light amplification by stimulated emission of radiation 

A semiconductor diode working in the near Infrared range in which the 

recombination of electrons and spaces at the p-n transition between a p and 

an n-conductive semiconductor material is used to generate and amplify light 

(see Semiconductor laser). 

0,06325 mm 

Laser Feedback 

The adjustment of the density-proportional image data to the paper to be 

exposed is performed in the LUTs, taking into account the laser properties and 

the transmission characteristic curves of the AOM amplifier. 

The memory of the Printer Mainboard can save LUTs for 2 paper types at the 

same time. 

Image data interface (differential pairs of lines) between the CG-Controller and 

the image processing board in the Main-PC. 

The pixel correction (Piko) is used to level the individual pixels of the CCD 

chip so that the black value (dark current) and the white value (sensitivity) 

are identical / reproducible for the subsequent signal processing. 

Light filter to alter the intensity of the spectral composition by using the 

polarisation condition of the light 

Rotating mirror to deflect the beam into the exposure unit PE 

CCD pixels: The dark current rises beyond a constant but pixel-dependent 

dark current rate linear with the scanning time. Owing to the sampling 

process, additional pixel-dependent voltage differences occur which are not 

time- and light-dependent (so-called PRNU). 

Interrupt routine (FL-Controller) for the motor control: 

The Controller can generate PWM by itself. In this case, the Controller gets an 

Interrupt whenever a new pulse is generated. However, not all IO-Pins of the 

Controller can be operated in this mode. The other Ports have to be controlled 

in the CC mode. 

Motors (FL-Controller): Filter wheel negative, KG filter paddles, wheel of the 

auxiliary shutter, film drive 

Motor (CG Controller): Shutter 

Serial interface between the Motherboard and the Main PC. 

The SPI module (Serial Peripheral Interface) controls the magazine drive. 

Digital Mask 

■ 


Repair 

Index 

Index 

A 

Additional Air / Exhaust Air .....................................2.4 

Algorithm/Interface Board..................................4.1.16 

Algorithm/Interface Controller............................4.3.28 

Ambient conditions for test and operation............10.1 

AOM...................................................................6.3.59 

AOM Amplifier....................................................6.3.51 

AOM Amplifier, replacing...................................6.4.52 

Approval................................................................10.1 

APS Magnetic Decoder .........................4.1.18, 4.3.30 

Assembly Groups ...................................................2.7 

Assembly Groups, allocation..................................2.5 

Assembly Groups, Scanner.................................4.2.1 

Auxiliary Shutter.................................................4.3.11 

B 

Back Printer, replacing the Print Head ..............6.4.59 

BIOS Settings .........................................................5.7 

Block Circuit Diagrams, Paper Processor ...........7.1.3 

Block Circuit Diagrams, Scanner.........................4.1.3 

Boards, replacing...............................................4.4.22 

C 

Calibration, Prescanner.....................................4.4.30 

Calibration, Scanner ..........................................4.4.27 

CAN Bus ............................................................4.3.34 

CCD ...................................................................4.3.18 

CCD Board ........................................................4.1.21 

CCD Group CG, signal list...................................4.2.4 

CCD Signal Processing.....................................4.3.22 

CG Controller.........................................4.1.19, 4.3.31 

Chemical containers ...............................................1.6 

Chemicals, storage.................................................1.9 

Circuit Diagrams ...................................................2.13 

Cleaning agents....................................................9.13 

Cleaning agents, tank cleaning ..............................1.6 

Commands .............................................................3.3 

Components, Scanner.........................................4.3.2 

Connectors, Paper Processor .............................7.2.4 

Consumables...............................................9.13, 10.9 

Copyright ................................................................1.3 

D 

Densitometer ........................................................10.6 

Densitometer, integrated ...................................7.3.11 

Densitometer, replacement .................................7.4.1 

Dimensions...........................................................10.1 

Disposal ..................................................................1.4 

Disposal, liquid residues.........................................1.6 

Disposal, spent processing solutions .....................1.5 

Driver Sensor Board ............................................4.1.9 

Drives.............................................................5.3, 10.3 

Drives, jumper settings ...........................................5.8 

Dryer .....................................................................10.5 

Dryer DH, signal list.............................................7.2.2 

Dust Shutter, repair .............................................4.4.6 

E 

Electrical requirements .........................................10.1 

Electrical Structure, basic machine ........................2.3 

Electrical Structure, Paper Processor .................7.3.3 

Electrical structure, Printer ..................................6.1.4 

Electrical Structure, Scanner...............................4.3.1 

End of the Maintenance Jobs...............................9.12 

Ethernet .............................................................4.3.34 

Ethernet Boards......................................................5.3 

Exposure Filters, replacing ..................................4.4.5 

Exposure Path ...........................................4.3.4, 4.3.6 

F 

FD/SD Output Stage..............................4.1.13, 4.3.25 

Film and negative sizes ........................................10.1 

Film Drive, components.....................................4.3.19 

Film Feeder FF, signal list ...................................4.2.3 

Film Guide, Adjustment .......................................4.4.9 

Film Guide, coarse Adjustment ...........................4.4.8 

Film stop key........................................................4.3.2 

Filter Wheel, replacing.........................................4.4.4 

FL Controller ..........................................4.1.14, 4.3.25 

Floor space ...........................................................10.5 

Floor space for operation / service .......................10.2 

Flow chart, main scan................................4.3.4, 4.3.5 

Flowcharts, Printer...............................................6.3.5 

G 

Glossary..............................................................10.11 

Graphic card .........................................................10.3 

Graphic Card ..........................................................5.3 

Guide Rails of the Paper Magazines, replacing 6.4.13 

H 

Hard disk.................................................................5.3 

I 

I 2 C Bus...............................................................4.3.35 

Image processing board .........................................5.6 

Image processing card .........................................10.3 

Interfaces ..............................................................10.2 

IR Dryer IR, signal list..........................................7.2.2 

K 

KG Filter Wheel ...................................................4.3.8 

KG Segment, repair.............................................4.4.1 

L 

Lamphouse LH, signal list ...................................4.2.2 

Lane Distributor Control.....................................6.3.54 

Lane Distributor LD............................................6.3.52 

Lane Distributor LD, List of Signals .....................6.2.9 

Lane Distributor LD, replacing Parts .................6.4.54 

Lane Shifter LS, signal list ...................................7.2.3 

Laser beam, safety precautions .............................1.8 

Laser Diode, red ................................................6.3.50 


Index 

Repair 

L (cont.) 

Laser Fundamentals ......................................... 6.3.57 

Laser Module .................................................... 6.3.38 

Laser Module / Laser, replacing ....................... 6.4.45 

Laser Module LA, List of Signals ........................ 6.2.8 

Laser Power Supply Unit, replacing.................. 6.4.51 

Laser recorder...................................................... 10.4 

Laser Unit LU, List of Signals ............................. 6.2.8 

Legal situation........................................................ 1.3 

Lens Group LG, signal list .................................. 4.2.3 

Lenses............................................................... 4.3.17 

LH Output Stage ................................... 4.1.12, 4.3.24 

Log files.................................................................. 3.3 

Log Files................................................................. 3.2 

Lubricants ............................................................ 9.14 

LVDS................................................................. 4.3.34 

M 

Magazine Drive MD .......................................... 6.3.26 

Magazine Drive ML/MR, replacing.................... 6.4.14 

Main control ......................................................... 10.2 

Main PC, Interfaces / Connections ........................ 5.1 

Main switch ......................................................... 7.3.2 

Main-PC ................................................................. 5.1 

Maintenance schedule........................................... 9.1 

Major assembly groups.......................................... 2.1 

Major assembly groups, Printer .......................... 6.3.1 

Mechanical structure, basic machine .................... 2.2 

Mechanical Structure, Paper Processor ............. 7.3.1 

Mechanical structure, Printer .............................. 6.1.3 

Mechanical Structure, Scanner........................... 4.3.1 

Mirror Box.......................................................... 4.3.10 

Mirror Box MB, signal list .................................... 4.2.3 

N 

Negative Carrier NC, signal list........................... 4.2.4 

Negative Carrier, Adjustments.......................... 4.4.20 

Negative Carrier, repair..................................... 4.4.14 

Negative Carrier: Lubricate the toothed 

Belts / Shafts...................................................... 9.4 

Negative Mask .................................................. 4.3.12 

Negative Masks Coding.................................... 4.3.12 

Network card........................................................ 10.3 

Noise level............................................................ 10.2 

O 

ON key ................................................................ 4.3.2 

Operating system................................................. 10.3 

Operating System .................................................. 5.9 

Optional Accessories ........................................... 10.8 

Options................................................................. 10.2 

P 

Paper Exit PO, signal list .................................... 7.2.3 

Paper Magazine Control ..................................... 6.1.7 

Paper Magazine, List of Signals ............... 6.2.3, 6.2.4 

Paper Processor Block, signal lists..................... 7.2.1 

Paper Processor Control .................................... 7.3.5 

Paper transport .................................................... 10.4 

P (cont.) 

Parts Functions .................................................... 2.11 

PC Mainboard Connections................................... 5.5 

PCBs, Paper Processor...................................... 7.3.3 

PC-Mainboard........................................................ 5.4 

PE_GS01, Connector Assignment ................... 6.2.22 

PF_GS01, replacing............................................ 6.4.2 

Photochemicals, Legal regulations .........................1.5 

Photographic paper, storage ................................. 1.9 

Pixel Correction................................................. 4.3.22 

Pixel Correction (Piko) ...................................... 4.4.28 

Pixel coverage, setting...................................... 6.3.61 

Pixel delay......................................................... 6.3.62 

Pixel delay / Pixel shift (quick version).............. 6.3.65 

Pixel shift........................................................... 6.3.62 

Polygonal Drive................................................. 6.3.50 

Power Monitor................................................... 6.3.45 

Precanner Adjustment ...................................... 4.4.23 

Prescanner............................................ 4.1.23, 4.3.14 

Prescanner SC, signal list................................... 4.2.4 

Print Engine PE................................................. 6.3.37 

Print Engine PE, List of Signals .......................... 6.2.7 

Print Engine PE, replacement........................... 6.4.44 

Print Engine PE, replacing Parts ...................... 6.4.33 

Print sizes............................................................. 10.2 

Printer Mainboard ................................. 6.2.11, 6.3.15 

Printer Mainboard PF, List of Signals ................. 6.2.2 

Printer Mainboard, Connector Allocation.......... 6.2.18 

Printer Mainboard, Technical Data ................... 6.3.24 

Process capacity.................................................. 10.5 

Process specifications ......................................... 10.5 

Processor type ..................................................... 10.5 

Production capacity.............................................. 10.2 

R 

Radio Shielding...................................................... 5.9 

RCD device......................................................... 7.3.2 

RDS functions ........................................................ 3.4 

Remote Diagnosis.................................................. 3.4 

Replacing the cutter Unit CU ............................ 6.4.16 

Replacing the Printer power supply unit ........... 6.4.11 

Resolution, main scan......................................... 4.3.4 

RS232 ............................................................... 4.3.34 

S 

Safety devices........................................................ 1.3 

Safety Instructions ................................................. 1.2 

Safety precautions for the handling of chemicals .. 1.6 

Safety Prescriptions ............................................... 1.3 

Scanner Carriage, oiling ........................................ 9.4 

Scanner Motherboard ............................. 4.1.6, 4.3.23 

Scanner SC, signal list........................................ 4.2.2 

Script Language daisy ........................................... 3.5 

Scripts .................................................................... 3.3 

Sensors / loads (list) scanner ............................. 4.2.1 

Sensors / Loads (lists), Paper Processor ........... 7.2.1 

Sensors / Loads in the Scanner.......................... 4.1.1 

Sensors and Loads, Paper Processor................ 7.1.1 

Sensors and Loads, Printer ................................ 6.2.1 


Repair 

Index 

S (cont.) 

Service Functions ...................................................3.1 

Service, every 2 Years .........................................9.12 

Service, yearly ........................................................9.3 

Sheet Bridge SB ................................................6.3.33 

Sheet Bridge SB, List of Signals..........................6.2.6 

Sheet Bridge SB, replacing Parts......................6.4.24 

Sheet Gear SG, List of Signals............................6.2.5 

Sheet Stocker SR ..............................................6.3.33 

Sheet Transfer ST .............................................6.3.52 

Sheet Transfer ST, List of Signals.....................6.2.10 

Sheet Transfer ST, replacing Parts ...................6.4.62 

Shutter, repair......................................................4.4.3 

Signals ..................................................................2.12 

Silver recovery........................................................1.6 

Software Structure..................................................8.1 

Sorter SO, signal list............................................7.2.3 

Standardisation / Screws......................................10.7 

Stepper Motor, Scanner ......................................4.2.5 

Switching Gear SG ............................................6.3.31 

Switching Gear SG, replacing ...........................6.4.18 

Symbols ..................................................................1.2 

T 

Tank capacity........................................................10.5 

Technical Data......................................................10.1 

Technical Documentation, structure.......................1.1 

Technical Documentation, use ...............................1.1 

Temperature Switch Dryer...................................7.4.5 

Text Styles ..............................................................1.2 

Timer board ...................................................5.6, 10.3 

Tools, Service Technician ....................................9.14 

Transport system..................................................10.5 

Transport Unit TU ..............................................6.3.34 

Transport Unit TU, List of Signals........................6.2.6 

Transport Unit TU, replacing Parts....................6.4.28 

W 

Water endangering class 1.....................................1.5 

Water Replenishment .............................................9.8 

Z 

Zoom / Fixed Focus Lens, replacing .................4.4.21 


Index 

Repair 

■

AGFA d-lab.3 Digital Compact Lab

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