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AGFA d-lab.3 Digital Compact Lab

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TECHNICAL DOCUMENTATION<br />

DD+18060022D0<br />

dlabr000<br />

<strong>AGFA</strong> d-<strong>lab.3</strong><br />

<strong>Digital</strong> <strong>Compact</strong> <strong>Lab</strong><br />

Printer<br />

Paper Processor<br />

Type 8060/100 (CE/UL)<br />

Type 8060/200 (CE/UL)<br />

Repair<br />

Edition 2001-01-02 /PN 9009_01


© 2001 Agfa-Gevaert AG. All rights reserved.<br />

No part of this documentation is allowed to be copied or transferred by any means or<br />

for any purpose without prior written autorisation by Agfa-Gevaert AG.<br />

All rights of design<br />

modifications and alterations of designations or<br />

indications of the scope of delivery reserved.<br />

Printed in Germany on<br />

paper made without chlorine.


List of Registers<br />

Edition<br />

Register<br />

Introduction...................................................................... 2001-01-02.................. 1<br />

Basic Machine ................................................................. 2001-01-02.................. 2<br />

Diagnosis / Troubleshooting ............................................ 2001-01-02.................. 3<br />

Scanner ........................................................................... 2001-01-02.................. 4<br />

Main-PC........................................................................... 2001-01-02.................. 5<br />

Printer .............................................................................. 2001-01-02.................. 6<br />

Paper Processor .............................................................. 2001-01-02.................. 7<br />

Software........................................................................... 2001-01-02.................. 8<br />

Maintenance .................................................................... 2001-01-02.................. 9<br />

General Data and Information.......................................... 2001-01-02................ 10<br />

Index................................................................................ 2001-01-02................ 11<br />

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


leere Seite<br />

leere Seite


Repair<br />

Introduction<br />

Contents<br />

Use of the Technical Documentation ....................................................................................................... 1.1<br />

Structure................................................................................................................................................ 1.1<br />

Symbols................................................................................................................................................. 1.2<br />

Text Styles............................................................................................................................................. 1.2<br />

Safety Instructions................................................................................................................................. 1.2<br />

Legal Situation............................................................................................................................................ 1.3<br />

Copyright ............................................................................................................................................... 1.3<br />

Safety Prescriptions .............................................................................................................................. 1.3<br />

General ....................................................................................................................................... 1.3<br />

For the Operation........................................................................................................................ 1.4<br />

For Service / Repair Work .......................................................................................................... 1.4<br />

For the Disposal of the machine .................................................................................................1.4<br />

Handling Photochemicals ......................................................................................................................... 1.5<br />

Legal Regulations.................................................................................................................................. 1.5<br />

Disposal................................................................................................................................................. 1.5<br />

Spent Processing Solutions ........................................................................................................ 1.5<br />

Liquid Residues........................................................................................................................... 1.6<br />

Chemical Containers................................................................................................................... 1.6<br />

Safety Precautions ................................................................................................................................ 1.6<br />

Use of the Laser Beam............................................................................................................................... 1.8<br />

Storage ........................................................................................................................................................ 1.9<br />

Chemicals ............................................................................................................................................. 1.9<br />

Photographic Paper............................................................................................................................... 1.9<br />

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


Introduction<br />

Repair<br />

■<br />

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


Repair<br />

Introduction<br />

Use of the Technical Documentation<br />

Structure<br />

The complete documentation is included in the<br />

scope of delivery of the machine<br />

Folder Customer Operator Technician Information<br />

Operation Use of the documentation<br />

✘<br />

Safety precautions<br />

Machine settings<br />

Production<br />

Maintenance (regular jobs to maintain the<br />

operation and keep the machine in good<br />

working order)<br />

Repair Diagnosis and repair of electronic /<br />

✘<br />

mechanical parts and complete<br />

assemblies<br />

Removal, installation, adjustment of<br />

single parts / complete assemblies<br />

Maintenance carried out by technicians<br />

(yearly, every two years)<br />

Circuit and reference diagrams: Signal<br />

tracing<br />

Spare parts list<br />

✘ ✘<br />

Finding a machine part and its part<br />

number<br />

Preinstallation<br />

(booklet)<br />

Installation<br />

(booklet)<br />

✘<br />

✘<br />

Preinstallation actions<br />

Installation performed by an Agfa<br />

technician<br />

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


Introduction<br />

Repair<br />

Symbols<br />

The symbols that are used have the following<br />

meaning:<br />

− General description<br />

− Operating steps<br />

− Prerequisite<br />

− Note<br />

− Safety instructions<br />

− Reference to another chapter<br />

− Tools and measuring means<br />

Text Styles<br />

The following text parts are highlighted in bold<br />

letters / italic letters in the technical<br />

documentation:<br />

1. Screen designations, e.g.:<br />

Example: Pressing OK will validate the<br />

displayed text and the Input screen is<br />

closed.<br />

2. Designations of buttons, e.g.:<br />

Strike Reorder to handle reorders<br />

3. Reference to other text parts in the technical<br />

documentation is indicated in italic letters,<br />

e.g.:<br />

See also the section Menu overview and<br />

Screen structure on the following pages.<br />

Safety Instructions<br />

The words Caution and Warning in the<br />

documentation and on the machine labels<br />

indicate the following risks:<br />

Caution!<br />

Low risk.<br />

Potentially dangerous situation. May cause<br />

minor injuries to persons or damage to property.<br />

Warning!<br />

Average risk.<br />

Possible danger. May cause severe injuries to<br />

persons and death.<br />

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


Repair<br />

Introduction<br />

Legal Situation<br />

The operation of the machines is ruled by the<br />

appropriate regulations for the place of installation<br />

in force in the country concerned.<br />

This technical documentation includes a EU<br />

conformity explanation (CE) about the<br />

harmonised standards that apply.<br />

Caution!<br />

The following safety regulations, warnings and<br />

instructions on machine labels must be<br />

observed by all means.<br />

The non-observance may be dangerous for<br />

persons, equipment and buildings: injuries,<br />

electric shocks, fire.<br />

The manufacturer and the service will not<br />

assume any responsibilities for accidents and<br />

damages resulting from incorrect operation.<br />

Copyright<br />

Copies of photographs, negatives and other<br />

pictures must not be made without the<br />

permission of the author. Under normal<br />

conditions, the Copyright is the property of the<br />

photographer. The one who orders the copy is<br />

not always the author of the material.<br />

Safety Prescriptions<br />

General<br />

Warning and instructions on machine stickers<br />

must be strictly observed.<br />

Safety devices:<br />

− Do not bypass or make inoperative built-in<br />

safety devices.<br />

− Do not modify presettings on safety<br />

components.<br />

− Replace fuses that have blown only by the<br />

same type of fuse: Value, switch-off<br />

characteristics.<br />

− Never modify the electrical switching circuit.<br />

<strong>AGFA</strong> d-<strong>lab.3</strong> 2001-01-02 /PN 9009 1.3


Introduction<br />

Repair<br />

For the Operation<br />

Do not operate the machine without the covers<br />

and panels. Persons who open or remove<br />

covers expose themselves to dangerous<br />

voltages or run other risks.<br />

Do not cover or block the venting openings in<br />

the housing: This may lead to overheating of<br />

single components.<br />

No objects or liquids should get into the<br />

machine through the venting openings: This<br />

may cause fire or electric shocks.<br />

Do not squeeze the power cable and install it in<br />

such a way that no one can step on the cable.<br />

Avoid excessive generation of dust as this may<br />

damage the components in the machine.<br />

For Service / Repair Work<br />

− Please respect the local safety precautions<br />

− Be sure to switch off the machine before<br />

service and repair jobs are performed<br />

− The machine is equipped with high-voltage<br />

carrying and fragile components. For this<br />

reason, the following jobs must only be<br />

performed by authorised service technicians:<br />

− Repairs on electrical components<br />

− Maintenance jobs / removal of parts and<br />

covers not described in this documentation<br />

− Use original Agfa spare parts: Only these parts<br />

have been tested for their safety and usability<br />

− When replacing electrical components:<br />

Observe the data given in the circuit and wiring<br />

diagrams.<br />

− At the end of all service / maintenance jobs:<br />

Check the general function of the machine as<br />

well as the correct condition of the safety<br />

devices.<br />

Disposal<br />

The machine must be disposed of as industrial<br />

waste.<br />

1.4 2001-01-02 /PN 9009 <strong>AGFA</strong> d-<strong>lab.3</strong>


Repair<br />

Introduction<br />

Handling Photochemicals<br />

Legal Regulations<br />

The machine is subject to the legal regulations<br />

about water:<br />

− Photochemicals are not allowed to be drained<br />

off into the public sewage system.<br />

− It must be checked whether residual<br />

substances can be avoided, reduced or<br />

recycled.<br />

− All photographic solutions as well as plastic<br />

containers holding harmful residues are<br />

considered to be special waste.<br />

− When storing spent processing solutions, it<br />

must be made sure that no waters are polluted,<br />

e.g. by unintentional leakage.<br />

The regulations about the handling and correct<br />

disposal of chemistry are different in each country.<br />

Information about the regulations in force can be<br />

obtained from:<br />

− The country’s authorities in charge<br />

− The nearest Agfa subsidiary<br />

Disposal<br />

Spent Processing Solutions<br />

The processing solutions used are usually only<br />

slightly water endangering (Water endangering<br />

class 1). For this reason, these solutions can be<br />

stored in commercial containers for<br />

photochemicals until their final disposal.<br />

For larger tanks, a conformity certificate is<br />

usually required.<br />

<strong>AGFA</strong> d-<strong>lab.3</strong> 2001-01-02 /PN 9009 1.5


Introduction<br />

Repair<br />

Liquid Residues<br />

All solutions that cannot be reused or that do not<br />

contain recyclable substances (film developer) are<br />

to be disposed of as special waste.<br />

Argentiferous solutions, in contrast, are liquid<br />

residual substances that can be used for silver<br />

recovery. For this reason, they should be<br />

collected separately from the other solutions.<br />

The disposal of argentiferous solutions should be<br />

ensured by fixing bath recycling firms that are<br />

normally also authorised to dispose of nonargentiferous<br />

solutions.<br />

For tank cleaning, cleaning agents based on<br />

peroxides are recommended. If these substances<br />

are used as prescribed, the local regulations<br />

about the draining of waste water are kept. This<br />

means that the cleaning and rinsing water of the<br />

tank cleaning can be drained into the public<br />

sewage system.<br />

Chemical Containers<br />

Rinse them with water used for the preparation<br />

of the solutions and provide for their recycling.<br />

Safety Precautions for the Handling of Chemicals<br />

Caution!<br />

The work with the machine involves the handling<br />

of slightly poisonous, irritating and etching<br />

substances. The user (employer)<br />

− has to elaborate operation instructions for the<br />

handling of dangerous substances and<br />

− provide for the instruction of his staff at least<br />

once a year.<br />

− Apart from this, the user must ensure sufficient<br />

aeration. The air in industrial workrooms should<br />

be exchanged at least eight to ten times per<br />

hour.<br />

1.6 2001-01-02 /PN 9009 <strong>AGFA</strong> d-<strong>lab.3</strong>


Repair<br />

Introduction<br />

All photographic developers contain substances<br />

which may irritate the skin, the mucous membrane<br />

and the eyes and which may cause allergic skin<br />

reactions affecting very sensitive persons. For this<br />

reason, avoid long or repeated skin contact,<br />

especially with developer solutions.<br />

For all jobs where photographic processing<br />

solutions may splash, e.g. preparing and filling in<br />

chemical solutions, cleaning processing racks<br />

etc.:<br />

− Wear protective gloves and change them every<br />

day, if possible; rinse all solutions that get on<br />

the skin with plenty of running water<br />

− Wear industrial glasses: If in spite of this,<br />

splashes do get into your eyes, wash them<br />

immediately with plenty of water, pulling apart<br />

the eyelids. Consult an oculist!<br />

Store chemicals and processing solutions in a<br />

safe place.<br />

<strong>AGFA</strong> d-<strong>lab.3</strong> 2001-01-02 /PN 9009 1.7


Introduction<br />

Repair<br />

Use of the Laser Beam<br />

The d-<strong>lab.3</strong> is equipped with an Argon ion laser of<br />

class 3B.<br />

In order to prevent damages caused by the laser<br />

beam, the latter is capsulated in the machine so<br />

that the whole machine can be classified Laser<br />

class 1.<br />

The laser beam cannot hit the operator when the<br />

d-<strong>lab.3</strong> is operated normally, even not when the<br />

machine doors are open.<br />

The laser and the laser module are identified by<br />

appropriate machine stickers.<br />

Warning!<br />

A laser beam of class 3B may be accessible after<br />

the removal of covers.<br />

Be sure to keep the mechanical laser shutter on<br />

the fibre coupling closed when working on the<br />

laser.<br />

Looking directly into lasers of class 3B is<br />

dangerous and can always hurt the eyes.<br />

Make sure during maintenance and repair work<br />

that the laser beam is not reflected by parts or<br />

tools and gets into the eyes.<br />

1.8 2001-01-02 /PN 9009 <strong>AGFA</strong> d-<strong>lab.3</strong>


Repair<br />

Introduction<br />

Storage<br />

Chemicals<br />

The chemicals should be stored and prepared<br />

according to the manufacturer’s information and<br />

advice.<br />

Photographic Paper<br />

All Color papers must always be stored in a cool<br />

and dry place.<br />

The best storage temperature is between +2 ºC<br />

and +10 ºC.<br />

Opened packages have to be stored at a<br />

relative humidity of 50-60%.<br />

Storage at 20 ºC over several days is possible<br />

without problems.<br />

Storage temperatures above 30 ºC should be<br />

avoided because they will cause visible<br />

alterations after only a few days.<br />

<strong>AGFA</strong> d-<strong>lab.3</strong> 2001-01-02 /PN 9009 1.9


Introduction<br />

Repair<br />

■<br />

1.10 2001-01-02 /PN 9009 <strong>AGFA</strong> d-<strong>lab.3</strong>


Repair<br />

Basic Machine<br />

Contents<br />

Major Assembly Groups ............................................................................................................................ 2.1<br />

Mechanical Structure............................................................................................................................. 2.2<br />

Electrical Structure ................................................................................................................................ 2.3<br />

Additional Air / Exhaust Air.................................................................................................................... 2.4<br />

Description.................................................................................................................................................. 2.5<br />

Allocation of Assembly Groups and Parts Functions ............................................................................ 2.5<br />

Scanner, PC, Printer ................................................................................................................... 2.5<br />

Paper Processor ......................................................................................................................... 2.6<br />

Names of Assembly Groups and Shortcuts ..........................................................................................2.7<br />

Parts Functions ................................................................................................................................... 2.11<br />

Signals....................................................................................................................................................... 2.12<br />

Circuit Diagrams - Scanner ..................................................................................................................... 2.13<br />

Connections Print Engine PE (1).... 2.1.8061.3003.0.......................................................................... 2.13<br />

Connection Print Engine PE (2) ..... 2.1.8061.3003.0.......................................................................... 2.14<br />

Connection Print Engine PE (3) ..... 2.1.8061.3003.0.......................................................................... 2.15<br />

Connections Film Feeder, Negative Carrier, Mirror Box FF-NC-MB.... 2.1.8061.3003.0.................... 2.16<br />

Circuit Diagrams - Printer........................................................................................................................ 2.17<br />

Printer Mainboard PF ..................... 2.1.8060.5003.0.......................................................................... 2.17<br />

RH Magazine Drive MR.................. 2.1.8060.5003.0..........................................................................2.18<br />

LH Magazine Drive ML................... 2.1.8060.5003.0..........................................................................2.19<br />

Sheet Gear SG............................... 2.1.8060.5003.0.......................................................................... 2.20<br />

Print Engine PE .............................. 2.1.8060.5003.0.......................................................................... 2.21<br />

Lane Distributor LD ........................ 2.1.8060.5003.0.......................................................................... 2.22<br />

Transport Unit TU........................... 2.1.8060.5003.0.......................................................................... 2.23<br />

Mains Connection and Power Supply.................................................................................................. 2.24<br />

<strong>AGFA</strong> d-<strong>lab.3</strong> 2001-01-02 /PN 9009 2.i


Basic Machine<br />

Repair<br />

Circuit Diagrams - Paper Processor .......................................................................................................2.25<br />

General Circuit Diagram ......................................................................................................................2.25<br />

Connections.........................................................................................................................................2.26<br />

Power Supply (AC) ..............................................................................................................................2.27<br />

Power Supply (DC) ..............................................................................................................................2.28<br />

55A-PWD (1/5) ....................................................................................................................................2.29<br />

55A-PWD (2/5) ....................................................................................................................................2.30<br />

55A-PWD (3/5) ....................................................................................................................................2.31<br />

55A-PWD (4/5) ....................................................................................................................................2.32<br />

55A-PWD (5/5) ....................................................................................................................................2.33<br />

55P-CNR .............................................................................................................................................2.34<br />

55P-CPU .............................................................................................................................................2.35<br />

55P-IRC (1/2) ......................................................................................................................................2.36<br />

55P-IRC (2/2) ......................................................................................................................................2.37<br />

55P-MDV (1/4).....................................................................................................................................2.38<br />

55P-MDV (2/4).....................................................................................................................................2.39<br />

55P-MDV (3/4).....................................................................................................................................2.40<br />

55P-MDV (4/4).....................................................................................................................................2.41<br />

55P-SSR..............................................................................................................................................2.42<br />

■<br />

2.ii 2001-01-02 /PN 9009 <strong>AGFA</strong> d-<strong>lab.3</strong>


Repair<br />

Basic Machine<br />

Major Assembly Groups<br />

dlabr003<br />

A<br />

Scanner<br />

B<br />

Main-PC<br />

C<br />

Printer<br />

D<br />

Paper Processor<br />

- Light<br />

- Image processing<br />

- Paper cutting<br />

- Paper development<br />

- Filtering<br />

- General control<br />

- Paper transport<br />

- Paper drying<br />

- Mirror Box<br />

- Timer function<br />

- Paper exposure<br />

- Order sorting<br />

- Film transport<br />

- Prescanner<br />

- Lens + CCD<br />

- Electronic<br />

<strong>AGFA</strong> d-<strong>lab.3</strong> 2001-01-02 /PN 9009 2.1


Basic Machine<br />

Repair<br />

Mechanical Structure<br />

dlabr218<br />

1 Print engine PE (exposure unit)<br />

2 Touch screen<br />

3 Processing racks<br />

4 Shifter (print chuter)<br />

5 Densitometer measuring head<br />

6 Sorter<br />

7 Infra-red predryer + dryer<br />

8 Replenisher tanks<br />

9 Drain cocks<br />

10 Lane distributor LD<br />

11 Cutter units CA + paper turnaround<br />

12 Paper transport TU<br />

13 Paper magazines<br />

2.2 2001-01-02 /PN 9009 <strong>AGFA</strong> d-<strong>lab.3</strong>


Repair<br />

Basic Machine<br />

Electrical Structure<br />

dlabr001<br />

1 Main-PC<br />

2 Driver sensor board<br />

3 Scanner motherboard with 6 plug-in boards<br />

4 Prescanner electronic<br />

5 Densitometer electronic<br />

6 Motor driver board<br />

7 Paper Processor control<br />

8 Paper Processor power supply unit<br />

9 Lane distributor control<br />

10 Back printer control<br />

11 CCD and Zoom electronic<br />

12 Paper magazine control<br />

13 Control Switching Gear + Paper Cutter Units CA<br />

14 Paper transport control<br />

15 Printer Mainboard<br />

16 Printer power supply unit + Power Monitor PCB<br />

17 Laser power supply unit<br />

18 Blue-Green Laser (beam generation)<br />

19 Control Print Engine PE<br />

20 Laser module (beam processing)<br />

21 Monitor (Touch Screen)<br />

22 Laser electronic<br />

23 Red Laser diode<br />

<strong>AGFA</strong> d-<strong>lab.3</strong> 2001-01-02 /PN 9009 2.3


Basic Machine<br />

Repair<br />

Additional Air / Exhaust Air<br />

The wet section of the Paper Processor is<br />

encapsulated; for this reason, warm air is only<br />

produced in the Printer part; see exhaust air of the<br />

laser (5).<br />

An adapter pipe end (hose dia. 125 mm) is available<br />

for the connection to an air exhaust system:<br />

Type 8060/370, ABC-Code 5GVP2<br />

dlabr154<br />

1 Additional air: Printer power supply unit<br />

2 Exhaust air: Laser and Printer power supply unit<br />

3 Additional air: Laser<br />

4 Additional air: Printer<br />

5 Exhaust Air: Laser<br />

6 Exhaust Air: Printer<br />

2.4 2001-01-02 /PN 9009 <strong>AGFA</strong> d-<strong>lab.3</strong>


Repair<br />

Basic Machine<br />

Description<br />

Allocation of Assembly Groups and Parts Functions<br />

Scanner, PC, Printer<br />

Sensors / loads; e.g.: TU_LS07<br />

− 1 st and 2 nd pos.: Assembly group<br />

− 3 rd pos.: Underline<br />

− 4 th and 5 th pos.: Function of the part<br />

− Current number in the assembly group<br />

Printed circuits; e.g.: MD_GS35<br />

− 1 st and 2 nd pos.: Assembly group<br />

− 3 rd pos.: Underline<br />

− 4 th and 5 th pos.: Function of the part<br />

− Current number in the assembly group<br />

See also the two following lists:<br />

1. Name of assembly groups and shortcuts<br />

2. Parts functions<br />

Cables, e.g.:<br />

KAXX<br />

8.8060.XXXX.X<br />

LD_GSXX:STXX<br />

Cable designation<br />

Cable reference number<br />

Address consisting of:<br />

- Functional assembly group<br />

- Function of the part<br />

- Connector designation<br />

The designations of the printed circuits on the<br />

board are not concerned by these agreements:<br />

8.8060.XXXX.X Part number of the board<br />

STXX<br />

Connector<br />

<strong>AGFA</strong> d-<strong>lab.3</strong> 2001-01-02 /PN 9009 2.5


Basic Machine<br />

Repair<br />

Paper Processor<br />

The usual designations are kept in the Paper<br />

Processor, e.g.:<br />

MO1PRP<br />

− 1st and 2 nd pos.: Function of the part<br />

− 3 rd pos.: Current number in the assembly group<br />

− 4 th position: Always P for Paper Processor<br />

− 5th and 6 th position: designation of the<br />

assembly group in which the part is located<br />

See the following lists:<br />

1. Names of assembly groups and shortcuts<br />

2. Parts functions<br />

2.6 2001-01-02 /PN 9009 <strong>AGFA</strong> d-<strong>lab.3</strong>


Repair<br />

Basic Machine<br />

Names of Assembly Groups and Shortcuts<br />

Shortcut<br />

BK<br />

CA<br />

CF<br />

CG<br />

CL<br />

CT<br />

CU<br />

DH<br />

DR<br />

DS<br />

EK<br />

ET<br />

FE<br />

FF<br />

FT<br />

FW<br />

IR<br />

LA<br />

LD<br />

LG<br />

LH<br />

LS<br />

LU<br />

MB<br />

MD<br />

MF<br />

MK<br />

ML<br />

MR<br />

NC<br />

NM<br />

PC<br />

PD<br />

PE<br />

PF<br />

Assembly group (English)<br />

Block assy<br />

Paper Cutter + Switching Gear<br />

Cartridge Feeder<br />

CCD-Group<br />

Cleaner<br />

Chemical Temperature<br />

Paper Cutter<br />

Dryer Heater<br />

Dryer<br />

Dust Shutter<br />

External Keyboard<br />

Effluent Tank<br />

Film Exit<br />

Film Feeder<br />

Film Take Up<br />

Filter Wheel<br />

Infra Red Heater<br />

Laser Module<br />

Lane Distributor<br />

Lens Group<br />

Lamp House<br />

Lane Shifter<br />

Laser Unit<br />

Mirror Box<br />

Magazine Drive<br />

Main Frame<br />

Magazine Lock<br />

Paper Magazine, left<br />

Paper Magazine, right<br />

Negative Carrier<br />

Negative Mask<br />

PC<br />

Processor Drive<br />

Print Engine<br />

Printer Frame<br />

<strong>AGFA</strong> d-<strong>lab.3</strong> 2001-01-02 /PN 9009 2.7


Basic Machine<br />

Repair<br />

Shortcut<br />

PO<br />

PO<br />

PP<br />

PP<br />

PR<br />

1)<br />

1)<br />

1)<br />

1)<br />

Assembly group (English)<br />

Power Module<br />

(Power Monitor + Printer Power Supply)<br />

Paper Outlet<br />

Printer Parts<br />

Paper Processor<br />

Printer<br />

PW<br />

RD<br />

RD<br />

RP<br />

RT<br />

RW<br />

SB<br />

SC<br />

SF<br />

SG<br />

SH<br />

SL<br />

SM<br />

SO<br />

SP<br />

SR<br />

ST<br />

SU<br />

SX<br />

TD<br />

TK<br />

TU<br />

ZH<br />

1)<br />

1)<br />

Power Supply Unit<br />

Back Printer<br />

Replenishment Mixer<br />

Replenishment Pump<br />

Replenisher Tank<br />

Replenishment Water<br />

Sheet Bridge<br />

Scanner<br />

Scanner Frame<br />

Switching Gear<br />

Shutter<br />

Single Lens<br />

Slide Mask<br />

Sorter<br />

Scanner Parts<br />

Sheet Stocker<br />

Sheet Transfer<br />

Shutter<br />

Strip Box<br />

Twin Drum Engine<br />

Tank<br />

Transport Unit<br />

Zoom Holder<br />

1)<br />

The shortcuts PO, PP and RD exist twice. But<br />

this should not cause confusion, owing to the<br />

different functions of these assembly groups.<br />

2.8 2001-01-02 /PN 9009 <strong>AGFA</strong> d-<strong>lab.3</strong>


Repair<br />

Basic Machine<br />

Assembly groups, position in d-<strong>lab.3</strong><br />

PO<br />

LS<br />

CG<br />

MD<br />

IC<br />

FL<br />

ET<br />

FD<br />

LD<br />

TK<br />

PD<br />

CT<br />

IR<br />

DH<br />

DR<br />

LH<br />

CT<br />

CT<br />

PP<br />

PP<br />

HP<br />

SO<br />

MB<br />

SL<br />

PP<br />

FF<br />

LG<br />

CC<br />

CF<br />

SC<br />

NM<br />

NC<br />

ST<br />

LD<br />

RP<br />

RD<br />

RD<br />

RW<br />

RD<br />

RT<br />

RT<br />

RT<br />

LA<br />

TU<br />

RD<br />

PE<br />

SB<br />

LU<br />

HP<br />

SR<br />

SG<br />

MR<br />

VO<br />

LU<br />

PO<br />

ML<br />

dlabr244.eps<br />

<strong>AGFA</strong> d-<strong>lab.3</strong> 2001-01-02 /PN 9009 2.9


Repair<br />

Basic Machine<br />

Parts<br />

Shortcut<br />

FA<br />

FS<br />

HT<br />

HS<br />

LS<br />

MS<br />

MO<br />

TH<br />

Assembly group (English)<br />

Fan<br />

Float Sensor<br />

Heater<br />

Heat Sensor<br />

Light Sensor<br />

MicroSwitch<br />

Motor<br />

Thermostat<br />

Certain positions in the descriptions of the sensors<br />

and loads indicate the function of a part:<br />

− 4 th and 5 th position for Scanner, PC, Printer<br />

− 1 st and 2 nd position for Paper Processor<br />

The lists of the loads and sensors are connected<br />

to the major assembly groups: See Signal lists in<br />

the sub-registers:<br />

− 4.2 Scanner<br />

− 6.2 Printer<br />

− 7.2 Paper Processor<br />

<strong>AGFA</strong> d-<strong>lab.3</strong> 2001-01-02 /PN 9009 2.11


Basic Machine<br />

Repair<br />

Signals<br />

dlab132e<br />

2.12 2001-01-02 /PN 9009 <strong>AGFA</strong> d-<strong>lab.3</strong>


Repair<br />

Basic Machine<br />

Circuit Diagrams - Scanner<br />

Connections Print Engine PE (1) 1.8061.3003.0<br />

<strong>AGFA</strong> d-<strong>lab.3</strong> 2001-01-02 /PN 9009 2.13


Repair<br />

Basic Machine<br />

Connection Print Engine PE (2) 1.8061.3003.0<br />

<strong>AGFA</strong> d-<strong>lab.3</strong> 2001-01-02 /PN 9009 2.14


Repair<br />

Basic Machine<br />

Connection Print Engine PE (3) 1.8061.3003.0<br />

<strong>AGFA</strong> d-<strong>lab.3</strong> 2001-01-02 /PN 9009 2.15


Repair<br />

Basic Machine<br />

Connections Film Feeder, Negative Carrier, Mirror Box FF-NC-MB 1.8061.3003.0<br />

<strong>AGFA</strong> d-<strong>lab.3</strong> 2001-01-02 /PN 9009 2.16


Repair<br />

Basic Machine<br />

Circuit Diagrams - Printer<br />

Printer Mainboard PF 1.8060.5003.0<br />

<strong>AGFA</strong> d-<strong>lab.3</strong> 2001-01-02 /PN 9009 2.17


Repair<br />

Basic Machine<br />

RH Magazine Drive MR 1.8060.5003.0<br />

<strong>AGFA</strong> d-<strong>lab.3</strong> 2001-01-02 /PN 9009 2.18


Repair<br />

Basic Machine<br />

LH Magazine Drive ML 1.8060.5003.0<br />

<strong>AGFA</strong> d-<strong>lab.3</strong> 2001-01-02 /PN 9009 2.19


Repair<br />

Basic Machine<br />

Sheet Gear SG 1.8060.5003.0<br />

<strong>AGFA</strong> d-<strong>lab.3</strong> 2001-01-02 /PN 9009 2.20


Repair<br />

Basic Machine<br />

Print Engine PE 1.8060.5003.0<br />

<strong>AGFA</strong> d-<strong>lab.3</strong> 2001-01-02 /PN 9009 2.21


Repair<br />

Basic Machine<br />

Lane Distributor LD 1.8060.5003.0<br />

<strong>AGFA</strong> d-<strong>lab.3</strong> 2001-01-02 /PN 9009 2.22


Repair<br />

Basic Machine<br />

Transport Unit TU 1.8060.5003.0<br />

<strong>AGFA</strong> d-<strong>lab.3</strong> 2001-01-02 /PN 9009 2.23


Repair<br />

Basic Machine<br />

Mains Connection and Power Supply<br />

dlabr136d<br />

<strong>AGFA</strong> d-<strong>lab.3</strong> 2001-01-02 /PN 9009 2.24


Repair<br />

Basic Machine<br />

Circuit Diagrams - Paper Processor<br />

General Circuit Diagram<br />

<strong>AGFA</strong> d-<strong>lab.3</strong> 2001-01-02 /PN 9009 2.25


Repair<br />

Basic Machine<br />

Connections<br />

<strong>AGFA</strong> d-<strong>lab.3</strong> 2001-01-02 /PN 9009 2.26


Repair<br />

Basic Machine<br />

Power Supply (AC)<br />

<strong>AGFA</strong> d-<strong>lab.3</strong> 2001-01-02 /PN 9009 2.27


Repair<br />

Basic Machine<br />

Power Supply (DC)<br />

<strong>AGFA</strong> d-<strong>lab.3</strong> 2001-01-02 /PN 9009 2.28


Repair<br />

Basic Machine<br />

55A-PWD (1/5)<br />

<strong>AGFA</strong> d-<strong>lab.3</strong> 2001-01-02 /PN 9009 2.29


Basic Machine<br />

Repair<br />

55A-PWD (2/5)<br />

2.30 2001-01-02 /PN 9009 <strong>AGFA</strong> d-<strong>lab.3</strong>


Repair<br />

Basic Machine<br />

55A-PWD (3/5)<br />

<strong>AGFA</strong> d-<strong>lab.3</strong> 2001-01-02 /PN 9009 2.31


Basic Machine<br />

Repair<br />

55A-PWD (4/5)<br />

2.32 2001-01-02 /PN 9009 <strong>AGFA</strong> d-<strong>lab.3</strong>


Repair<br />

Basic Machine<br />

55A-PWD (5/5)<br />

<strong>AGFA</strong> d-<strong>lab.3</strong> 2001-01-02 /PN 9009 2.33


Basic Machine<br />

Repair<br />

55P-CNR<br />

2.34 2001-01-02 /PN 9009 <strong>AGFA</strong> d-<strong>lab.3</strong>


Repair<br />

Basic Machine<br />

55P-CPU<br />

<strong>AGFA</strong> d-<strong>lab.3</strong> 2001-01-02 /PN 9009 2.35


Basic Machine<br />

Repair<br />

55P-IRC (1/2)<br />

2.36 2001-01-02 /PN 9009 <strong>AGFA</strong> d-<strong>lab.3</strong>


Repair<br />

Basic Machine<br />

55P-IRC (2/2)<br />

<strong>AGFA</strong> d-<strong>lab.3</strong> 2001-01-02 /PN 9009 2.37


Basic Machine<br />

Repair<br />

55P-MDV (1/4)<br />

2.38 2001-01-02 /PN 9009 <strong>AGFA</strong> d-<strong>lab.3</strong>


Repair<br />

Basic Machine<br />

55P-MDV (2/4)<br />

<strong>AGFA</strong> d-<strong>lab.3</strong> 2001-01-02 /PN 9009 2.39


Basic Machine<br />

Repair<br />

55P-MDV (3/4)<br />

2.40 2001-01-02 /PN 9009 <strong>AGFA</strong> d-<strong>lab.3</strong>


Repair<br />

Basic Machine<br />

55P-MDV (4/4)<br />

<strong>AGFA</strong> d-<strong>lab.3</strong> 2001-01-02 /PN 9009 2.41


Basic Machine<br />

Repair<br />

55P-SSR<br />

•<br />

2.42 2001-01-02 /PN 9009 <strong>AGFA</strong> d-<strong>lab.3</strong>


Repair<br />

Diagnosis / Troubleshooting<br />

Contents<br />

Service Functions ...................................................................................................................................... 3.1<br />

Access................................................................................................................................................... 3.1<br />

Log Files................................................................................................................................................ 3.2<br />

Scripts ................................................................................................................................................... 3.3<br />

Commands............................................................................................................................................ 3.3<br />

Remote Diagnosis with the RDS System................................................................................................. 3.4<br />

Script Language Daisy............................................................................................................................... 3.5<br />

Conversions .......................................................................................................................................... 3.6<br />

Key Words............................................................................................................................................. 3.6<br />

Grammar............................................................................................................................................... 3.6<br />

Commands.......................................................................................................................................... 3.10<br />

msgbox ..................................................................................................................................... 3.10<br />

wait............................................................................................................................................ 3.10<br />

include....................................................................................................................................... 3.10<br />

trace .......................................................................................................................................... 3.10<br />

cmd, answer, comment, var_read, var_ask_int........................................................................ 3.11<br />

var_ask_string........................................................................................................................... 3.11<br />

MiniCalc - calc........................................................................................................................... 3.12<br />

String Allocation – var_set ........................................................................................................ 3.12<br />

Example of a Script................................................................................................................... 3.13<br />

Exiting the Service Mode......................................................................................................................... 3.15<br />

<strong>AGFA</strong> d-<strong>lab.3</strong> 2001-01-02 /PN 9009 3.i


Diagnosis / Troubleshooting<br />

Repair<br />

■<br />

3.ii 2001-01-02 /PN 9009 <strong>AGFA</strong> d-<strong>lab.3</strong>


Repair<br />

Diagnosis / Troubleshooting<br />

Service Functions<br />

Access<br />

The Service Functions are only accessible when the<br />

user logging in has the right of access.<br />

All menus and functions are accessible in the<br />

service mode (unlimited right of access).<br />

− Call-up of the main menu line:<br />

Test<br />

Service<br />

The service operator interface is displayed<br />

(language: English).<br />

Service functions:<br />

− Configuration<br />

− Software Information<br />

− Firmware Download<br />

− Firmware Version<br />

− Logfiles<br />

− Scripts<br />

− Commands<br />

− Film Drive<br />

− Paper Processor<br />

− Printer<br />

− Image Processor<br />

− Timer board<br />

− Software<br />

A touch screen, a mouse and a keyboard are<br />

used for the input and output of all servicerelevant<br />

data.<br />

<strong>AGFA</strong> d-<strong>lab.3</strong> 2001-01-02 /PN 9009 3.1


Diagnosis / Troubleshooting<br />

Repair<br />

Log Files<br />

Command and data strings can be recorded during<br />

the operation and saved in Log files for the analysis<br />

of malfunctions. They are saved on the hard disk or<br />

on external storage media and can be called up on<br />

the machine or transmitted via remote data<br />

transmission.<br />

Logbooks:<br />

− Communication:<br />

Communication between Main and Subs<br />

− Error:<br />

Error and time span between errors<br />

− Service call:<br />

The technician has to confirm his service call<br />

(repair and preventive maintenance) in this<br />

Logbook. The time elapsed since the last service<br />

call is calculated automatically.<br />

− Modifications:<br />

− Repairs are entered in this Logbook by the<br />

technician.<br />

− PCBs with version number coding and new<br />

Software versions are entered automatically.<br />

− Extensive conversion kits are entered<br />

automatically from a diskette.<br />

− Single exchange parts and small conversion<br />

kits are entered by the technician.<br />

− Versions:<br />

New Software and version numbers of boards<br />

are entered in addition in this Logbook.<br />

− Laser:<br />

Check of the beam capacity and entry in this<br />

Logbook. If the limit value is reached, an<br />

message to replace will appear.<br />

3.2 2001-01-02 /PN 9009 <strong>AGFA</strong> d-<strong>lab.3</strong>


Repair<br />

Diagnosis / Troubleshooting<br />

Scripts<br />

The Script language daisy developed for the d-<strong>lab.3</strong><br />

will be used to create test routines. The directory<br />

Scripts contains ready test routines to activate and<br />

check sensors and loads. For this reason, the<br />

modification / recreation of scripts should only be<br />

necessary in exceptional cases.<br />

See Script language daisy in this register.<br />

Commands<br />

For the analysis of the Log files, i.e. the command<br />

execution recorded there, an overall knowledge of<br />

the commands is required.<br />

The transmission of commands and replies<br />

requires a special protocol based on telegrams.<br />

<strong>AGFA</strong> d-<strong>lab.3</strong> 2001-01-02 /PN 9009 3.3


Diagnosis / Troubleshooting<br />

Repair<br />

Remote Diagnosis with the RDS System<br />

The RDS functions (Remote Diagnose Service)<br />

integrated in the machine shortens service calls or<br />

eliminates them altogether:<br />

Defective Hardware and operating errors can be<br />

recognised by means of the RDS.<br />

For this reason, the d-<strong>lab.3</strong> can be linked with the<br />

PC of a service organisation via a network, remote<br />

data transmission or the Internet. This PC can be<br />

used to monitor, analyse, call up and edit data:<br />

Data can be checked in remote Offline mode:<br />

− Production statistics<br />

− Customer and machine data<br />

− MBL and PBL values<br />

− Measuring values of the chemical test strips<br />

− Configuration files<br />

− Software versions<br />

− Indices of the installed Hardware<br />

− Log files<br />

− Monitoring of the machine functions<br />

The remote control of the machine is possible in<br />

remote Online mode (activation of production<br />

procedures).<br />

Defective Hardware and operating errors can be<br />

recognised by means of the RDS.<br />

3.4 2001-01-02 /PN 9009 <strong>AGFA</strong> d-<strong>lab.3</strong>


Repair<br />

Diagnosis / Troubleshooting<br />

Script Language Daisy<br />

The script language daisy can be used to program<br />

own test routines (scripts) in addition to the existing<br />

scripts.<br />

service_gui1<br />

service_gui2<br />

<strong>AGFA</strong> d-<strong>lab.3</strong> 2001-01-02 /PN 9009 3.5


Diagnosis / Troubleshooting<br />

Repair<br />

Conversions<br />

− italics<br />

for non-terminal symbols<br />

− Non-proportional fond bold<br />

for key words and characters<br />

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

end of the line<br />

Key Words<br />

Letter fonts:<br />

Capital and small letters are not checked (case<br />

insensitive).<br />

answer ask_int ask_string calc<br />

dump end_loop include loop msgbox<br />

parameter_file set timeout trace<br />

trace_file trace_var<br />

Grammar<br />

daisy<br />

: EOF<br />

| expr_list EOF<br />

expr_list<br />

: expression NL<br />

| expression NL expr_list<br />

expression<br />

: answer<br />

| cmd<br />

| comment<br />

| dump<br />

| include<br />

| loop_head expr_list loop_tail<br />

| msgbox var<br />

| parameter_file file<br />

| timeout int<br />

| trace<br />

| trace_file file<br />

| wait<br />

| var_ask<br />

| var_calc<br />

| var_read<br />

| var_set<br />

3.6 2001-01-02 /PN 9009 <strong>AGFA</strong> d-<strong>lab.3</strong>


Repair<br />

Diagnosis / Troubleshooting<br />

loop_head : loop int NL<br />

| 4 int NL<br />

loop_tail<br />

: end_loop<br />

| 5<br />

wait<br />

: wait int<br />

| 6 int<br />

include<br />

: include file<br />

| 9 file<br />

trace<br />

: trace rest_of_line<br />

| trace_var var<br />

| 8 rest_of_line<br />

cmd<br />

: cmd string reg_string<br />

| 1 string reg_string<br />

answer<br />

: answer reg_string<br />

| answer reg_string int<br />

comment<br />

: # rest_of_line<br />

| 0 rest_of_line<br />

var_read<br />

: read_int var<br />

| read_string var<br />

var_set<br />

: set var assignop<br />

var_set_expr<br />

var_set_expr<br />

: var_set_expr addop var_st<br />

| var_st<br />

var_st<br />

: q_string<br />

| string<br />

| var<br />

| var vs int<br />

<strong>AGFA</strong> d-<strong>lab.3</strong> 2001-01-02 /PN 9009 3.7


Diagnosis / Troubleshooting<br />

Repair<br />

var_ask<br />

: ask_string var var<br />

| ask_string var var int<br />

| ask_int var var<br />

| ask_int var var int<br />

| ask_int var var int int int<br />

var_calc<br />

: calc var assignop expr<br />

expr<br />

: expr addsubop term<br />

| term<br />

term<br />

: term mulop factor<br />

| factor<br />

factor<br />

: po expr pc<br />

| int<br />

| var<br />

int<br />

: digit<br />

| digit int<br />

reg_string<br />

: string<br />

| reg_expr<br />

| reg_expr reg_string<br />

| string reg_string<br />

reg_expr<br />

: var vs int vs<br />

| wildcard<br />

q_string<br />

: q char_seq q<br />

| string<br />

string<br />

: daisy_char<br />

| daisy_char string<br />

char_seq<br />

: char<br />

| char char_seq<br />

var<br />

: vid int<br />

3.8 2001-01-02 /PN 9009 <strong>AGFA</strong> d-<strong>lab.3</strong>


Repair<br />

Diagnosis / Troubleshooting<br />

//<br />

// terminal symbols<br />

//<br />

addop : +<br />

addsubop : addop<br />

| subop<br />

assignop : =<br />

char<br />

: each element of the character<br />

string except NL and "<br />

daisy_char<br />

digit<br />

EOF<br />

file<br />

mulop<br />

: ASCII characters ranging<br />

0x2b (+) – 0x5f(_)<br />

: one of<br />

0 1 2 3 4 5 6 7 8 9<br />

: End of file<br />

: A valid file name<br />

: one of<br />

* /<br />

NL<br />

: Line separator,<br />

\n and \r\n are accepted<br />

pc : )<br />

po : (<br />

q : "<br />

subop : -<br />

vid : $<br />

vs : !<br />

wildcard : %<br />

<strong>AGFA</strong> d-<strong>lab.3</strong> 2001-01-02 /PN 9009 3.9


Diagnosis / Troubleshooting<br />

Repair<br />

Commands<br />

msgbox<br />

Msgbox var<br />

Creation of a message box with the text of variables.<br />

The message box comprises two push buttons: Ok and Cancel.<br />

After pressing Cancel, the Script is terminated, otherwise it is continued.<br />

Example:<br />

calc $1 = 4 * 5<br />

set $2 = "PP Result: " + OK + " " + $1<br />

msgbox $2<br />

wait<br />

wait int<br />

The program run is stopped for ms.<br />

Example:<br />

Wait 1000<br />

include<br />

Include file<br />

The indicated file is included in the Script, recursive including being trapped.<br />

Example:<br />

include q:\dlabscripts\a.txt<br />

trace<br />

trace rest_of_line<br />

trace var<br />

8 rest_of_line<br />

The variable or the String are output in the Trace window and the Tracefile is<br />

output<br />

Example:<br />

trace_var $1<br />

trace hello world, it is 11:20 now<br />

3.10 2001-01-02 /PN 9009 <strong>AGFA</strong> d-<strong>lab.3</strong>


Repair<br />

Diagnosis / Troubleshooting<br />

cmd, answer, comment, var_read, var_ask_int<br />

ask_int var text len min max<br />

User input, a dialogue appears for the entry of numeric values.<br />

var and text are variables, len, min and max are optional<br />

Integers.<br />

Example:<br />

set $1 = "Please enter a digit number:"<br />

ask_int $3 $1 2 10 80<br />

set $1 = "The variable $3 has the value: " + $3<br />

msgbox $1<br />

var_ask_string<br />

ask_string var text len<br />

User input, a dialogue appears for the entry of the character string<br />

value.<br />

var and text are variables, len, min and max are optional<br />

Integers.<br />

Example:<br />

set $1 = "Please enter a character string:"<br />

ask_string $3 $1 6<br />

set $1 = "The variable $3 has the value: " + $3<br />

msgbox $1<br />

<strong>AGFA</strong> d-<strong>lab.3</strong> 2001-01-02 /PN 9009 3.11


Diagnosis / Troubleshooting<br />

Repair<br />

MiniCalc - calc<br />

MiniCalc is an Interpreter to calculate numeric<br />

expressions. The basic calculation operations (+ -<br />

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

((4+7)*8) of expressions are supported. The result<br />

must be allocated to a variable, variables and<br />

Integers are admissible as operands.<br />

Syntax:<br />

calc var = expr<br />

Example:<br />

calc $1 = 10<br />

calc $2 = 90<br />

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

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

msgbox $4<br />

String Allocation – var_set<br />

Example:<br />

calc $1 = 4 * 10<br />

set $2 = "ipv" + $1<br />

msgbox $2<br />

# variable are indicated with leading zeros<br />

set $2 = "ipv" + $1!6<br />

msgbox $2<br />

3.12 2001-01-02 /PN 9009 <strong>AGFA</strong> d-<strong>lab.3</strong>


Repair<br />

Diagnosis / Troubleshooting<br />

Example of a Script<br />

#<br />

# timeout for scriptfile<br />

#<br />

#timeout 50000<br />

# send command to IP<br />

#<br />

cmd IP IASCAN3072204801<br />

#<br />

# wait max. 1 second for the answer and extract the last 8<br />

# characters in the variable $3<br />

#<br />

answer IASCAN$3!8! 1000<br />

#<br />

# shows the last 8 characters<br />

#<br />

set $2 = "the last 8 characters of the answer: " + $3<br />

set $2 = $2 + ". Is this answer ok ?"<br />

#msgbox $2<br />

set $2 = "Please enter a two-digit number:"<br />

ask_int $2 $2 1 1 4<br />

msgbox $2<br />

cmd IP IASCAN30722048$2!2!<br />

calc $1 = 0<br />

loop 10<br />

# loopcounter<br />

calc $1 = $1 + 1<br />

# send command to IP<br />

#<br />

cmd IP IASCAN3072204801<br />

#<br />

# wait max. 1 second for the answer and extract the last 8<br />

# characters in the variable $3 3000<br />

#<br />

answer IASCAN$3!8!<br />

<strong>AGFA</strong> d-<strong>lab.3</strong> 2001-01-02 /PN 9009 3.13


Diagnosis / Troubleshooting<br />

Repair<br />

# build trace string<br />

set $2 = "loop " + $1 + "answer: " + $3<br />

# write trace message<br />

trace_var $2<br />

# wait 3 seconds<br />

wait 3000<br />

end_loop<br />

set $4 = "release frame, command: IFSCAN " + $3!8<br />

trace_var $4<br />

cmd IP IFSCAN$3!8!<br />

wait 3000<br />

3.14 2001-01-02 /PN 9009 <strong>AGFA</strong> d-<strong>lab.3</strong>


Repair<br />

Diagnosis / Troubleshooting<br />

Exiting the Service Mode<br />

After the service mode has been exited, a Reset is<br />

performed for all assembly groups.<br />

The start screen of the d-<strong>lab.3</strong> user interface is<br />

displayed.<br />

Caution!<br />

The service technician has to make sure that the<br />

assembly groups are not in error conditions which<br />

cannot be recognised by the Software during the<br />

Reset.<br />

002<br />

<strong>AGFA</strong> d-<strong>lab.3</strong> 2001-01-02 /PN 9009 3.15


Diagnosis / Troubleshooting<br />

Repair<br />

■<br />

3.16 2001-01-02 /PN 9009 <strong>AGFA</strong> d-<strong>lab.3</strong>


Repair<br />

Scanner<br />

Contents<br />

General Overview .................................................................................................................................... 4.1.1<br />

Sensors / Loads in the Scanner ......................................................................................................... 4.1.1<br />

Block Circuit Diagrams........................................................................................................................... 4.1.3<br />

Scanner, Data / Signals...................................................................................................................... 4.1.3<br />

General Scanner Control.................................................................................................................... 4.1.4<br />

Image Recording................................................................................................................................ 4.1.5<br />

Scanner Motherboard......................................................................................................................... 4.1.6<br />

Driver Sensor Board........................................................................................................................... 4.1.9<br />

LH Output Stage............................................................................................................................... 4.1.12<br />

FD/SD Output Stage ........................................................................................................................ 4.1.13<br />

FL Controller..................................................................................................................................... 4.1.14<br />

Algorithm/Interface Board ................................................................................................................ 4.1.16<br />

APS Magnetic Decoder .................................................................................................................... 4.1.18<br />

CG Controller ................................................................................................................................... 4.1.19<br />

CCD Board....................................................................................................................................... 4.1.21<br />

Image Data....................................................................................................................................... 4.1.22<br />

Prescanner....................................................................................................................................... 4.1.23<br />

Signal Lists .............................................................................................................................................. 4.2.1<br />

Description / Abbreviations of Assembly Groups ............................................................................... 4.2.1<br />

Scanner SC / Scanner Parts SP ........................................................................................................ 4.2.2<br />

Lamphouse LH................................................................................................................................... 4.2.2<br />

Mirror Box MB .................................................................................................................................... 4.2.3<br />

Lens Group LG................................................................................................................................... 4.2.3<br />

Film Feeder FF................................................................................................................................... 4.2.3<br />

Negative Carrier NC........................................................................................................................... 4.2.4<br />

Prescanner SC................................................................................................................................... 4.2.4<br />

CCD Group CG .................................................................................................................................. 4.2.4<br />

Other Sensors .................................................................................................................................... 4.2.4<br />

Activation of Motors and Loads............................................................................................................. 4.2.5<br />

Stepper Motor Data............................................................................................................................ 4.2.5<br />

<strong>AGFA</strong> d-<strong>lab.3</strong> 2001-01-02 /PN 9009 4.i


Scanner<br />

Repair<br />

Functional Description............................................................................................................................4.3.1<br />

Mechanical Structure / Electrical Structure.........................................................................................4.3.1<br />

Components .......................................................................................................................................4.3.2<br />

ON and Film Stop Key........................................................................................................................4.3.2<br />

Scanner Optic.....................................................................................................................................4.3.3<br />

Functional Description............................................................................................................................4.3.4<br />

After the Insertion of a Film ................................................................................................................4.3.4<br />

Exposure Path ....................................................................................................................................4.3.4<br />

Main Scan Cycle.................................................................................................................................4.3.5<br />

Functions and Properties of the Components in the Exposure Path ................................................4.3.6<br />

Lamphouse.........................................................................................................................................4.3.6<br />

Halogen Lamp ....................................................................................................................................4.3.6<br />

Filters..................................................................................................................................................4.3.6<br />

Light Shutter LH_MO03 / CG_MO03..................................................................................................4.3.9<br />

Mirror Box .........................................................................................................................................4.3.10<br />

Auxiliary Shutter (Dust shutter / frosted glass) .................................................................................4.3.11<br />

Negative Mask..................................................................................................................................4.3.12<br />

Prescanner / Scanner.......................................................................................................................4.3.14<br />

Lenses ..............................................................................................................................................4.3.17<br />

CCD (Main Scan) .............................................................................................................................4.3.18<br />

Functions and Properties of the Components of the Film Drive ......................................................4.3.19<br />

Position of the Feeders FF_MO01 ...................................................................................................4.3.19<br />

Film Transport in the Feeder FF_MO02...........................................................................................4.3.20<br />

Position of the Film Drive Roller FF_MO04......................................................................................4.3.20<br />

Position of the Gear FF_MO03.........................................................................................................4.3.20<br />

Film Drive NC_MO01 .......................................................................................................................4.3.21<br />

Magnet Negative Pressure NC_MG01 .............................................................................................4.3.21<br />

Scanner Carriage SC_MO01............................................................................................................4.3.21<br />

4.ii 2001-01-02 /PN 9009 <strong>AGFA</strong> d-<strong>lab.3</strong>


Repair<br />

Scanner<br />

Control.................................................................................................................................................... 4.3.23<br />

Scanner Motherboard....................................................................................................................... 4.3.23<br />

LH Output Stage............................................................................................................................... 4.3.24<br />

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

FL Controller..................................................................................................................................... 4.3.25<br />

Algorithm/Interface Controller .......................................................................................................... 4.3.28<br />

APS Magnetic Decoder .................................................................................................................... 4.3.30<br />

CG Controller (CCD Group Controller) ............................................................................................ 4.3.31<br />

CG_GS01 - CCD Board ................................................................................................................... 4.3.32<br />

Driver Sensor Board......................................................................................................................... 4.3.33<br />

Bus Systems and Interfaces................................................................................................................. 4.3.34<br />

CAN Bus........................................................................................................................................... 4.3.34<br />

LVDS ................................................................................................................................................ 4.3.34<br />

RS232 .............................................................................................................................................. 4.3.34<br />

Ethernet............................................................................................................................................ 4.3.34<br />

I 2 C Bus ............................................................................................................................................. 4.3.35<br />

Repair / Adjustments............................................................................................................................... 4.4.1<br />

KG Segment....................................................................................................................................... 4.4.1<br />

Shutter................................................................................................................................................ 4.4.3<br />

Filter Wheel ........................................................................................................................................ 4.4.4<br />

Dust Shutter ....................................................................................................................................... 4.4.6<br />

2-Film Feeder..................................................................................................................................... 4.4.7<br />

Negative Carrier ............................................................................................................................... 4.4.14<br />

Replacing the Zoom / Fixed Focus Lens..........................................................................................4.4.21<br />

Replacing the Boards ....................................................................................................................... 4.4.22<br />

Precanner Adjustment...................................................................................................................... 4.4.23<br />

Prescanner Adjustment with Film..................................................................................................... 4.4.24<br />

Scanner Calibration.......................................................................................................................... 4.4.27<br />

Prescanner Calibration..................................................................................................................... 4.4.30<br />

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


Scanner<br />

Repair<br />

■<br />

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


Repair<br />

Scanner<br />

General Overview<br />

Sensors / Loads in the Scanner<br />

Lamphouse (LH)<br />

LH_LS01 Initialisation filter wheel<br />

LH_LS02 Initialisation KG filter paddles<br />

LH_LS03 Initialisation light shutter CLOSED<br />

LH_MO01 Filter wheel drive<br />

LH_MO02 KG filter paddles<br />

LH_MO03 Wheel light shutter drive<br />

LH_MS01 Monitoring lamphouse opening<br />

LH_FA01 Cooling of the filter group<br />

LH_FA02 Cooling of the el. rack<br />

LH_LA01 Scanner light 250W / 24V<br />

LH_GS01 Flow sensor<br />

Mirror Box (MB)<br />

MB_MO01 Mirror box motor (frosted glass flap)<br />

MB_LS01 Position monitoring of the mirror box motor<br />

Film Feeder (FF)<br />

FF_LS01 Feeder zero position monitoring<br />

FF_LS02 Detection: Film in Feeder<br />

FF_LS04 Detection: Film in front of rocker<br />

FF_LS05 Detection: Rocker up<br />

FF_LS06 Detection: Rocker down<br />

FF_LS07 Detection: Film driver roller up<br />

FF_LS08 Detection: Film driver roller down<br />

FF_MO01 Feeder motor (film width adjustment)<br />

FF_MO02 Film transport in Feeder<br />

FF_MO03 Rocker movement<br />

FF_MO04 Film driver roller position<br />

Film Feeder (FF)<br />

NC_LS01 -<br />

NC_LS06 Film mask coding<br />

NC_LS07 Position monitoring auxiliary drive LHS<br />

NC_LS08 Position monitoring auxiliary drive RHS<br />

NC_MO01 Film drive<br />

NC_MO02 Position motor auxiliary drive LHS<br />

NC_MO03 Position motor auxiliary drive RHS<br />

NC_MG01 Negative pressure solenoid<br />

Prescanner (SC)<br />

SC_LS01 Scanner sledge zero position monitoring<br />

SC_MO01 Scanner sledge motor<br />

Dust Shutter (DS) (prototypes)<br />

DS_LS01 Initialisation auxiliary shutter<br />

DS_MO01 Auxiliary shutter motor<br />

CCD Group (CG)<br />

CG_MO01 Zoom: Rotation of the chip through 90°<br />

CG_FA01 Cooling CCD<br />

dlabr188<br />

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


Repair<br />

Scanner<br />

Block Circuit Diagrams<br />

Scanner, Data / Signals<br />

dlabr090<br />

<strong>AGFA</strong>d-<strong>lab.3</strong> 2001-01-02 /PN 9009 4.1.3


Scanner<br />

Repair<br />

General Scanner Control<br />

dlabr044<br />

1 Scanner lamp 9 Film pressure<br />

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

3 Filter wheel colour 11 Dust shutter<br />

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

5 Frosted glass of mirror box 13 CCD fan<br />

6 Film Feeder 14 Prescanner, SC-Controller<br />

7 Negative carrier 15 Lamphouse fan<br />

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

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


Repair<br />

Scanner<br />

Image Recording<br />

dlabr042<br />

<strong>AGFA</strong>d-<strong>lab.3</strong> 2001-01-02 /PN 9009 4.1.5


Scanner<br />

Repair<br />

Scanner Motherboard<br />

LH<br />

FD/SD<br />

FL<br />

A/I<br />

APS<br />

CG<br />

LH Output stage<br />

FD/SD Output stage<br />

FL Controller<br />

Algorithm/Interface Board<br />

APS Magnetic decoder<br />

CG Controller<br />

dlab045e<br />

4.1.6 2001-01-02 /PN 9009 <strong>AGFA</strong> d-<strong>lab.3</strong>


Repair<br />

Scanner<br />

Scanner Motherboard: LEDs<br />

LED Sensor Function ON when<br />

D1 LH_LS01 Light sensor for Zero Positioning Filter wheel Light sensor open<br />

D2 LH_LS02 Light sensor for Zero Positioning KG-Filter Light sensor open<br />

D3 LH_LS03 Light sensor for Zero Positioning Shutter Light sensor open<br />

D4 LH_LS04 (not used) —<br />

D7 DS_LS01 Light sensor for Zero Positioning Dust Shutter Light sensor open<br />

LH_LS05<br />

D8 — Service PC Timer (not used) —<br />

D9 — Sensor Service switch on (S3)<br />

<strong>AGFA</strong>d-<strong>lab.3</strong> 2001-01-02 /PN 9009 4.1.7


Scanner<br />

Repair<br />

Scanner Motherboard: Connection of the Loads, Sensors, Boards<br />

dlab080e<br />

4.1.8 2001-01-02 /PN 9009 <strong>AGFA</strong> d-<strong>lab.3</strong>


Repair<br />

Scanner<br />

Driver Sensor Board<br />

dlabr047<br />

<strong>AGFA</strong>d-<strong>lab.3</strong> 2001-01-02 /PN 9009 4.1.9


Scanner<br />

Repair<br />

Driver Sensor Board: LEDs<br />

LED Sensor Function ON when<br />

D4 MB_LS01 Light sensor for mirror box Mirror box pushed in<br />

D8 FF_LS05 Light sensor for gear position Gear up<br />

D9 FF_LS06 Light sensor for gear position Gear down<br />

D11 FF-LS01 Zero position feeder width Light sensor open<br />

D12 FF_LS07 Position Feeder auxiliary drive Feeder auxiliary drive up<br />

D13 FF_LS08 Position Feeder auxiliary drive Feeder auxiliary drive down<br />

D14 NC_LS07 Left auxiliary drive Light sensor open<br />

D15 NC_LS08 Right auxiliary drive Light sensor open<br />

D16 NC_LS01<br />

D17 NC_LS02<br />

D18 NC_LS03 Negative carrier Light sensor open<br />

D19 NC_LS04<br />

D20 NC_LS05<br />

D21 NC_LS06<br />

D25 FF_LS04 Film detection Film in front of gear<br />

D26 FF_LS02 Film detection Film in Feeder<br />

D27 SC_LS01 Zero position prescanner carriage Light sensor open<br />

D30 MB_MO01 Frosted glass Frosted glass up<br />

D31 FF_MO04<br />

D32 FF_MO03<br />

D33 NC_MO03<br />

D34 NC_MO02<br />

D35 NC_MG01<br />

D37 FF_MO01_DIR<br />

D38 FF_MO01_CLK<br />

D39 FF_MO02_DIR<br />

D40 FF_MO02_CLK<br />

D41 FF_MO01_ENA<br />

D42 FF_MO02_ENA<br />

4.1.10 2001-01-02 /PN 9009 <strong>AGFA</strong> d-<strong>lab.3</strong>


Repair<br />

Scanner<br />

Driver Sensor Board: Connection of the Loads, Sensors<br />

dlabr043<br />

<strong>AGFA</strong>d-<strong>lab.3</strong> 2001-01-02 /PN 9009 4.1.11


Scanner<br />

Repair<br />

LH Output Stage<br />

dlabr067<br />

LH Output Stage: LEDs<br />

LED Sensor LED Sensor LED Sensor<br />

D10 LH_MO01_IO D17 LH_MO03_I1 D24 LH_MO04_IO<br />

D11 LH_MO01_I1 D18 LH_MO02_IO D25 MS2_OUT<br />

D12 LH_MO01_DIR D19 LH_MO02_I1 D26 MS2_IN<br />

D13 LH_MO01_CLK D20 LH_MO02_DIR D27 CG_MO01_DIR<br />

D14 LH_MO03_CLK D21 LH_MO02_CLK D28 LH_MO04_I1<br />

D15 LH_MO03_DIR D22 LH_MO04_CLK D29 CG_MO01_BUSY<br />

D16 LH_MO03_IO D23 LH_MO04_DIR<br />

4.1.12 2001-01-02 /PN 9009 <strong>AGFA</strong> d-<strong>lab.3</strong>


Repair<br />

Scanner<br />

FD/SD Output Stage<br />

dlabr085<br />

LED FD/SD Output Stage<br />

D1<br />

TEMP_ERR<br />

LED Film Advance Master<br />

D9<br />

Reset<br />

<strong>AGFA</strong>d-<strong>lab.3</strong> 2001-01-02 /PN 9009 4.1.13


Scanner<br />

Repair<br />

FL Controller<br />

dlab081e<br />

4.1.14 2001-01-02 /PN 9009 <strong>AGFA</strong> d-<strong>lab.3</strong>


Repair<br />

Scanner<br />

FL Controller: LEDs<br />

LED<br />

D1<br />

D2<br />

D3<br />

D4<br />

D5<br />

D6<br />

D7<br />

D8<br />

D9/STATUS<br />

D38/TX<br />

D39/TX<br />

D40/RX<br />

D40/RX<br />

Function<br />

Software internal<br />

Software internal<br />

without function<br />

without function<br />

without function<br />

flashes, when a stepper motor runs in PWM mode<br />

flashes, when a stepper motor runs in CC mode<br />

flashes, when film advance is active;<br />

if LED does not flash, the software has crashed<br />

on, when film advance not in Reset<br />

CAN<br />

RS232<br />

CAN<br />

RS232<br />

<strong>AGFA</strong>d-<strong>lab.3</strong> 2001-01-02 /PN 9009 4.1.15


Scanner<br />

Repair<br />

Algorithm/Interface Board<br />

dlab082e<br />

4.1.16 2001-01-02 /PN 9009 <strong>AGFA</strong> d-<strong>lab.3</strong>


Repair<br />

Scanner<br />

Algorithm/Interface Board: LEDs<br />

LED<br />

D1<br />

D2<br />

D3<br />

D4<br />

D5<br />

D6<br />

D7<br />

D8<br />

D9/STATUS<br />

D10/TX<br />

D11/RX<br />

D12/LNK<br />

D13/SEL<br />

D14/RX<br />

D15/TX<br />

Function<br />

Software internal (Watchdog)<br />

Software internal<br />

flashes while motor moves during film positioning<br />

flashes during interrupt, when prescanner can receive data<br />

flashes when controller active;<br />

if LED does not flash, the software has crashed<br />

ON when controller not in Reset<br />

Ethernet<br />

Ethernet<br />

Ethernet Link = cable connected<br />

Ethernet<br />

CAN<br />

CAN<br />

<strong>AGFA</strong>d-<strong>lab.3</strong> 2001-01-02 /PN 9009 4.1.17


Scanner<br />

Repair<br />

APS Magnetic Decoder<br />

ST1<br />

I²C<br />

EEPROM<br />

I²C Bus<br />

CAN<br />

PCA82C250<br />

CAN Bus<br />

A<br />

D<br />

8<br />

Microcontroller<br />

SAB 163CS<br />

FIFO<br />

SM_CLK<br />

Microcontroller<br />

SAB 167CS<br />

FILM_IN<br />

PERFO<br />

A<br />

D<br />

8<br />

Microcontroller<br />

SAB 163CS<br />

FIFO<br />

ST6<br />

Bootstrap<br />

Logic<br />

Reset<br />

Logic<br />

APS-Magnetic decoder: LEDs<br />

LED Function<br />

D11 Fast flashing: Slow running light:<br />

D12 Magnetic data being processed Waiting for data<br />

D13<br />

D14 Flashes for successful evaluation of the<br />

magnetic data (per frame)<br />

D7 Fast flashing: Slow running light:<br />

D8 Magnetic data being processed verarbeitet Waiting for data<br />

D9<br />

D10<br />

D31<br />

D32<br />

D33<br />

D34<br />

D40<br />

D29<br />

D27<br />

D35<br />

D36<br />

D37<br />

Flashes for successful evaluation of the<br />

magnetic data (per frame)<br />

Heartbeat<br />

Fifo<br />

CAN<br />

CAN<br />

CAN<br />

hw_spec_007<br />

4.1.18 2001-01-02 /PN 9009 <strong>AGFA</strong> d-<strong>lab.3</strong>


Repair<br />

Scanner<br />

CG Controller<br />

dlab083e<br />

<strong>AGFA</strong>d-<strong>lab.3</strong> 2001-01-02 /PN 9009 4.1.19


Scanner<br />

Repair<br />

CG-Controller: LEDs<br />

LED<br />

D1<br />

D2<br />

D3<br />

D4<br />

D5<br />

D6<br />

D7<br />

D8<br />

D9<br />

D10<br />

D11<br />

D12<br />

D13<br />

D14<br />

D15<br />

D16<br />

D17<br />

D18<br />

D19/RxD<br />

D20/TxD<br />

D21<br />

D22/+3.3<br />

D23/+5A<br />

Function<br />

Heartbeat: flashes (approx. every second), when film advance is active.<br />

If LED does not flash, the software has crashed<br />

Software internal<br />

on when FPGA not in Reset<br />

on when Controller not in Reset<br />

CAN<br />

CAN<br />

3.3 V<br />

5 V<br />

4.1.20 2001-01-02 /PN 9009 <strong>AGFA</strong> d-<strong>lab.3</strong>


Repair<br />

Scanner<br />

CCD Board<br />

dlabr084e<br />

<strong>AGFA</strong>d-<strong>lab.3</strong> 2001-01-02 /PN 9009 4.1.21


Scanner<br />

Repair<br />

Image Data<br />

CCD resolution:<br />

2 K x 3 K = 6.000.000 pixel<br />

The image data is transmitted analogue to the CG<br />

board and are digitised there by means of<br />

Correlated Double Sampling:<br />

Each pixel is digitised twice (dark and bright value).<br />

The dark value is subtracted from the bright value.<br />

The CCD is output from 4 quadrants, allowing a<br />

higher speed.<br />

Resolution of the AD converter:<br />

12 Bit = 4.096 steps<br />

Speed of the AD converter:<br />

The output of a complete image takes about<br />

180 ms.<br />

dlab121e<br />

The lens and the CCD are adjusted fixedly with<br />

respect to each other:<br />

Always replace the two units together in the field!<br />

4.1.22 2001-01-02 /PN 9009 <strong>AGFA</strong> d-<strong>lab.3</strong>


Repair<br />

Scanner<br />

Prescanner<br />

dlab091e<br />

<strong>AGFA</strong>d-<strong>lab.3</strong> 2001-01-02 /PN 9009 4.1.23


Scanner<br />

Repair<br />

■<br />

4.1.24 2001-01-02 /PN 9009 <strong>AGFA</strong> d-<strong>lab.3</strong>


Repair<br />

Scanner<br />

Signal Lists<br />

Description / Abbreviations of Assembly Groups<br />

Abbreviation<br />

BK<br />

CF<br />

CG<br />

CL<br />

CU<br />

DS<br />

EK<br />

FE<br />

FF<br />

FT<br />

FW<br />

LG<br />

LH<br />

MB<br />

NC<br />

NM<br />

SC<br />

SF<br />

SH<br />

SL<br />

SM<br />

SP<br />

ZH<br />

Assembly Groups<br />

Block assy<br />

Cartridge Feeder<br />

CCD-Group<br />

Cleaner<br />

Paper Cutter<br />

Dust Shutter<br />

External Keyboard<br />

Film Exit<br />

Film Feeder<br />

Film Take Up<br />

Filter Wheel<br />

Lens Group<br />

Lamp House<br />

Mirror Box<br />

Negative Carrier<br />

Negative Mask<br />

Scanner<br />

Scanner Frame<br />

Shutter<br />

Single Lens<br />

Slide Mask<br />

Scanner Parts<br />

Zoom Holder<br />

The abbreviations of sensors and loads indicate<br />

their assembly group, e.g.:<br />

MB_MO01 = Mirror box motor<br />

See Allocation of Assembly Groups and Parts<br />

Functions, register 2<br />

<strong>AGFA</strong> d-<strong>lab.3</strong> 2001-01-02 /PN 9009 4.2.1


Scanner<br />

Repair<br />

Scanner SC / Scanner Parts SP<br />

No. Designation Task Control<br />

SC_LS01 Light sensor Zero position Scanner carriage FL-Controller<br />

SC_MO01 Stepper motor 5 Ph. Motor scanner carriage,<br />

FL-Controller<br />

U = 24V, Iph = 0,75A<br />

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

Lamphouse LH<br />

Mechanically split up into the modules LA (Lamphouse) and FG (Filter group)<br />

No. Designation Task Control<br />

LH_LS01 Fork light sensor Filter wheel initialisation FL-Controller<br />

LH_LS02 Fork light sensor Initialisation KG filter paddle FL-Controller<br />

LH_LS03 Fork light sensor Light shutter initialisation – CLOSED CG- Controller<br />

LH_LS05 Fork light sensor Initialisation wheel auxiliary shutter FL- Controller<br />

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

FL-Controller<br />

fmax = 3,5 kHz, Iph = 3,4 A, U = 36V<br />

Half step<br />

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

FL-Controller<br />

fmax = 3,5 kHz, Iph = ?, U = 36V<br />

Half step values<br />

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

FL-Controller<br />

fmax = 4,0 kHz, Iph = 3,5A,<br />

Half step<br />

U = 36V<br />

LH_MS01 Interlock switch Lamphouse opening control for lamp change —<br />

(risk of glare)<br />

LH_MS02 Interlock switch Filter wheel motor, switch off the segment motor —<br />

to clean the filter !<br />

LH_FA01 Fan Filter group cooling<br />

—<br />

U = 24V (not switched)<br />

LH_LA01 Halogen lamp Scanner light 250W / 24V —<br />

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

functionally belonging here) corresponds to PIKO<br />

frosted glass!<br />

U = 36V , Iph = 1,7 Amax.<br />

DS_LS01 Fork light sensor Initialisation wheel auxiliary shutter (functionally<br />

belonging here)<br />

—<br />

4.2.2 2001-01-02 /PN 9009 <strong>AGFA</strong> d-<strong>lab.3</strong>


Repair<br />

Scanner<br />

Mirror Box MB<br />

No. Designation Task Control<br />

MB_MO01 DC motor Mirror box motor (frosted glass flap),<br />

FL-Controller<br />

U = 12V<br />

MB_LS01 Fork light sensor Position monitoring of mirror box motor (frosted FL-Controller<br />

glass flap)<br />

MB_COD — Mirror box coding Driver Sensor<br />

MB_DONE — Signal from Hardware that the motor was stopped Driver Sensor<br />

MB_OK — Signal that the mirror box has been pushed in Driver Sensor<br />

Lens Group LG<br />

No. Designation Task Control<br />

LG_HS01 Temperature Temp. compensation for fixed focus lens sensor CG-Controller<br />

sensor<br />

on CCD Controller<br />

Film Feeder FF<br />

No. Designation Task Control<br />

FF_LS01 Fork light sensor Feeder zero position monitoring (Init. Feeder FL-Controller<br />

motor)<br />

FF_LS02 Reflex-LS3 Detection whether film in Feeder FL-Controller<br />

FF_LS04 Reflex-LS3 Detection whether film in front of gear FL-Controller<br />

FF_LS05 Fork light sensor Detection gear up FL-Controller<br />

FF_LS06 Fork light sensor Detection gear down FL-Controller<br />

FF_LS07 Fork light sensor Detection film drive roller up FL-Controller<br />

FF_LS08 Fork light sensor Detection film drive roller down FL-Controller<br />

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

FL-Controller<br />

U = 24V, Iph= 0,9A<br />

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

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

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

<strong>AGFA</strong> d-<strong>lab.3</strong> 2001-01-02 /PN 9009 4.2.3


Scanner<br />

Repair<br />

Negative Carrier NC<br />

No. Designation Task Control<br />

NC_LS01- Fork light sensor Negative carrier coding FL-Controller<br />

NC_LS06<br />

NC_LS07 Fork light sensor Position monitoring auxiliary drive LHS FL-Controller<br />

NC_LS08 Fork light sensor Position monitoring auxiliary drive RHS FL-Controller<br />

NC_MG01 Lifting magnet Magnet negative pressure FL-Contr, U = 24V FL-Controller<br />

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

NC_MO02 DC motor Position motor auxiliary drive LHS, U = 12V FL-Controller<br />

NC_MO02_<br />

DONE<br />

— Signal from hardware that motor has been<br />

stopped<br />

NC_MO03 DC motor Position motor auxiliary drive RHS, U = 12V FL-Controller<br />

NC_MO03_<br />

DONE<br />

— Signal from hardware that motor has been<br />

stopped<br />

Prescanner SC<br />

No. Designation Task Control<br />

SC_LS01 Fork light sensor Zero position monitoring Scanner carriage FL-Controller<br />

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

CCD Group CG<br />

No. Designation Task Control<br />

CG_MO01 Motor Zoom: Chip rotation 90° CG-Controller<br />

CG_FA01 Fan Cooling CCD (not switched) CG-Controller<br />

Other Sensors<br />

No. Designation Task<br />

FILM_NOTAUS<br />

FILM_FWD<br />

FILM_REW<br />

general keys Emergecy OFF switch<br />

Film transport (advance)<br />

Film transport (backward)<br />

TEMP_ERR — Temperature control of the drivers for the stepper motors for film<br />

advance and scanner on FD/SD output stage<br />

4.2.4 2001-01-02 /PN 9009 <strong>AGFA</strong> d-<strong>lab.3</strong>


Repair<br />

Scanner<br />

Activation of Motors and Loads<br />

Stepper Motor Data<br />

Name Designation Motor type,<br />

angle<br />

Operating<br />

mode<br />

Rated<br />

voltage<br />

[V]<br />

Starting/<br />

breaking<br />

current<br />

[A]<br />

Running<br />

current<br />

[A]<br />

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

0,9°<br />

FF_MO01 Feeder motor 2PH, 1.8° Full step 24 0,9<br />

FF_MO02 Film transport in 2PH, 1.8° Full step 24 0,9<br />

Feeder<br />

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

0,9° (24)<br />

LH_MO02 KG filter 2PH, 1.8° Half step 32 – 40 2,0 2,0 1,0<br />

0,9° (24)<br />

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

0,9° (24)<br />

NC_MO01 Film drive 5PH, 0.72° Full step 0,95<br />

SC_MO01 Scanner carriage 5PH, 0.72° Full step 0,75<br />

Stop<br />

current<br />

[A]<br />

Direction of rotation / transport (cw turning) (3)<br />

Name Control, output Direction of rotation<br />

stage (1)<br />

with DIR=High (2)<br />

DS_MO01 FL, LH LHS OPEN-CLOSED frosted glass<br />

FF_MO01 FL, DS — Feeder closes<br />

FF_MO02 FL, DS — Film moving out of the Feeder<br />

LH_MO01 FL, LH LHS R-Neg, R-Dia, G-Neg, G-Dia, ....<br />

LH_MO02 FL, LH LHS Filter is turned out<br />

LH_MO03 CG, LH LHS See separate description<br />

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

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

(1) FL FL Controller<br />

GG GC Controller<br />

LH LH Output Stage<br />

DS Driver/Sensor-Board<br />

FD/SD FD/SD Output Stage<br />

(2) The direction for DIR=High is defined when looking<br />

on the turning motor shaft.<br />

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

turning motor.<br />

<strong>AGFA</strong> d-<strong>lab.3</strong> 2001-01-02 /PN 9009 4.2.5


Scanner<br />

Repair<br />

■<br />

4.2.6 2001-01-02 /PN 9009 <strong>AGFA</strong> d-<strong>lab.3</strong>


Repair<br />

Scanner<br />

Functional Description<br />

Mechanical Structure / Electrical Structure<br />

The Scanner assembly groups are exchangeable<br />

thanks to clearly defined mechanical and electrical<br />

interfaces.<br />

1<br />

SK01 LH<br />

SK02 FD/SD<br />

SK03 FL<br />

SK04 A/I<br />

SK05 APS<br />

SK06 CG<br />

Mechanical structure:<br />

1 Film Feeder<br />

2 Lamphouse<br />

3 Filter<br />

4 Mirror box<br />

5 Film Take Up<br />

6 Negative carrier<br />

7 Prescanner<br />

8 Fan for film advance electronic<br />

9 CCD fan<br />

10 CCD<br />

11 Print chuter<br />

12 Zoom / fixed focus lens<br />

dlab143<br />

Electrical structure:<br />

1 Motherboard with<br />

LH Output Stage<br />

FD/SD Output Stage<br />

FL Controller<br />

A/I Board<br />

APS Magnetic Decoder<br />

CG Controller<br />

2 Driver Sensor Board<br />

3 SC_GS01 Prescanner Board<br />

4 ZO_GS01 Zoom Board<br />

5 CG_GS01 CCD Board<br />

4<br />

5<br />

2<br />

3<br />

dlabr144<br />

<strong>AGFA</strong> d-<strong>lab.3</strong> 2001-01-02 /PN 9009 4.3.1


Scanner<br />

Repair<br />

Components<br />

− Control (motherboard with PCBs) and<br />

light source / lamphouse (1)<br />

− Exposure filter (2)<br />

− Mirror box (3)<br />

− Film advance<br />

− Film Feeder (4)<br />

− Negative carrier (5)<br />

− Prescanner (6)<br />

− Film advance electronic<br />

− CCD fan (7) and CCD (8):<br />

The air is sucked in through the film chuter (9)<br />

and guided to the electronic through the fan.<br />

− Zoom (10)<br />

− Fan (11) for film advance electronic<br />

Film advance: see also Functions and Properties of<br />

the Components of the Film Drive in this register<br />

dlabr018<br />

ON and Film Stop Key<br />

− ON key (1)<br />

− TIMER lamp (2)<br />

− Film stop key (3)<br />

dlabr1778<br />

4.3.2 2001-01-02 /PN 9009 <strong>AGFA</strong> d-<strong>lab.3</strong>


Repair<br />

Scanner<br />

Scanner Optic<br />

dlab149e<br />

<strong>AGFA</strong> d-<strong>lab.3</strong> 2001-01-02 /PN 9009 4.3.3


Scanner<br />

Repair<br />

Functional Description<br />

After the Insertion of a Film<br />

− The film is caught by the transport roller TR3 in<br />

the Film Feeder.<br />

− The Prescanner moves into the negative mask<br />

and performs the calibration:<br />

Brightness and colour measurement of the<br />

printing lamp light<br />

− The Prescanner scans the film; the TFS and the<br />

exposure parameters are defined.<br />

− The film is scanned after the CCD calibration:<br />

The exposure data is calculated and exposed by<br />

the exposure unit.<br />

Exposure Path<br />

− Prescan to define the APL (automatic<br />

positioning logic) and TFS values<br />

− Infrared scan to define the film grain,<br />

scratches and fluffs (on CCD area)<br />

− The adjustment of the negative size to the<br />

CCD chip size is done by the Zoom or fixed<br />

focus lens.<br />

− Main scan by means of CDD with a resolution<br />

of 2.048x3.064 pixels<br />

dalbr133<br />

1 Lamp<br />

2 Exposure filters<br />

3 Mirror box<br />

4 Film advance<br />

5 Lens<br />

6 CCD area<br />

4.3.4 2001-01-02 /PN 9009 <strong>AGFA</strong> d-<strong>lab.3</strong>


Repair<br />

Scanner<br />

Main Scan Cycle<br />

Filter<br />

wheel in R<br />

Scan pos.<br />

Fully close light shutter<br />

Slip<br />

correction<br />

Close negative<br />

pressure<br />

Open<br />

dust<br />

shutter<br />

Red scan<br />

Exposure<br />

red at 70 ms<br />

pixel exposure<br />

time<br />

Filter wheel in<br />

G Scan position<br />

Output<br />

red image<br />

Green scan<br />

Exposure<br />

green at 100 ms<br />

pixel exposure<br />

time<br />

Filter wheel in<br />

B Scan pos.<br />

Output<br />

green<br />

image<br />

Blue scan<br />

Exposure<br />

blue at 220 ms<br />

pixel exposure<br />

time<br />

Filter wheel in<br />

IR Scan pos.<br />

Move out<br />

KG filter<br />

Output<br />

blue<br />

image<br />

Filter wheel in<br />

Prescan pos.<br />

Move in<br />

KG filter<br />

Output<br />

IR image<br />

IR Scan<br />

Exposure<br />

IR at 60 ms<br />

pixel exposure<br />

time<br />

Close<br />

dust<br />

shutter<br />

Terminate Scan<br />

Open negative<br />

pressure<br />

Fully open<br />

light shutter<br />

Film transport<br />

next frame<br />

dlabfe11<br />

<strong>AGFA</strong> d-<strong>lab.3</strong> 2001-01-02 /PN 9009 4.3.5


Scanner<br />

Repair<br />

Functions and Properties of the Components in the Exposure Path<br />

Lamphouse<br />

− KG5+IR-UV: Cold glass and IR absorption for<br />

heat filtering<br />

− RG850 for Infrared Scan<br />

− Light dimmer (Mask filter)<br />

− Light shutter<br />

− Exposure filter wheel with 8 positions:<br />

red, green, blue always for frame and slide, light<br />

dimmer, free<br />

Halogen Lamp<br />

The lamp is subject to warming up and ageing<br />

effects. The Prescanner is used instead of a<br />

sensor to measure the lamp brightness<br />

(calibration measurement of each film).<br />

Filters<br />

The lamp drift is compensated by the white<br />

balance in comparison with the RGB colour filters<br />

and the calibration of the Prescanner (only<br />

negative, no slide).<br />

The RG850 filter for the IR-Scan has also to be<br />

calibrated. As the KG5 filter is always in the light<br />

path upon the RGB Scan, it is always calibrated<br />

automatically as well.<br />

Colour Filter Wheel: 50% Filter<br />

For the fast mirror box 135, the 50% filter in the<br />

colour filter wheel has to be moved in for the<br />

Prescan; also for the calibration of the Prescanner<br />

in order to prevent thermal overload of the film<br />

(Fading).<br />

The 50% filter itself need not be calibrated.<br />

4.3.6 2001-01-02 /PN 9009 <strong>AGFA</strong> d-<strong>lab.3</strong>


Repair<br />

Scanner<br />

Filter Wheel LH_MO01<br />

The filter wheel stepper motor is connected to the<br />

filter wheel by a toothed belt. The filter wheel can<br />

hold eight filters (in cw order):<br />

1. free<br />

2. RED-Negative<br />

3. RED-Slide<br />

4. GREEN-Negative<br />

5. GREEN-Slide<br />

6. BLUE-Negative<br />

7. BLUE-Slide<br />

8. Light dimmer<br />

The zero position is reached with light sensor<br />

LH_LS01.<br />

The motor is energised by different currents via<br />

LH_MO01_I0 and LH_MO01_I1:<br />

A<br />

B<br />

Arrow<br />

dlabr153<br />

Zero position (position for the 1 st exposure)<br />

Initialisation position (Position LH_LS01)<br />

Direction of rotation<br />

I0 0 1 0 1<br />

I1 0 0 1 1<br />

Current 100% 72% 38% 0%<br />

The motor runs in half step mode:<br />

− Step angle 1,8°<br />

− Transmission of 3:1.<br />

The filter wheel is turned through 0.3° per step.<br />

150 steps must be performed between the filters.<br />

− Direction of rotation of the filter with a cw turning<br />

motor: RED-Negative, RED-Slide, GREEN-<br />

Negative, etc.<br />

− Zero position of the light sensor with a cw turning<br />

motor: 6° before the RED-Negative filter<br />

− Clock: Indicated by LH_MO01_CLK<br />

− Direction: Can be selected by LH_MO01_DIR<br />

− When the lamphouse opens, the stepper motor is<br />

switched off.<br />

<strong>AGFA</strong> d-<strong>lab.3</strong> 2001-01-02 /PN 9009 4.3.7


Scanner<br />

Repair<br />

KG Filter Wheel LH_MO02<br />

The KG filter wheel consists of two paddles:<br />

− The 1 st paddle (A) is linked rigidly with the motor<br />

shaft by a toothed belt.<br />

− The 2 nd paddle (B) is fastened on the motor shaft<br />

and can be turned.<br />

Both arms are linked by a spring which presses the<br />

KG5+IR-IV filter against the stop.<br />

The paddles can be pushed into the light path up to<br />

a stop, the light sensor LH_LS02 being covered.<br />

This is the starting position (KG+IR-UV filter in the<br />

light path).<br />

When the paddles are moved out of the light path<br />

by one filter position, the RG850 filter is in the light<br />

path. This filter is used for the Infrared Scan.<br />

When the filter is moved into the light path from the<br />

initial position, the first paddle moves (with the light<br />

dimmer) into the light path against the spring<br />

mechanism. In this position, two filters are in the<br />

light path: The KG+IR-UV filter and the light dimmer.<br />

Filter Positions<br />

When the filter is out of the light path, the light<br />

sensor is uncovered. When the KG+IR-UV filters is<br />

moved in, the light sensor (2) is covered. If the<br />

motor continues to turn, the KG5-IR+UV filter is<br />

pressed against the stop (1) by a spring, the light<br />

dimmer is moved in.<br />

A 1st paddle<br />

B 2nd paddle<br />

1 RG850-filter (IR-Scan)<br />

2 Stop<br />

3 Motor shaft<br />

4 Mask filter<br />

5 KG5+IR-UV filter<br />

dlabr021<br />

Filter<br />

moved out<br />

RG850 filter<br />

moved in<br />

KG5+IR-UV filter<br />

moved in<br />

(initial position)<br />

KG5+IR-UV and light<br />

dimmer moved in<br />

dlabr022/dlabr023<br />

4.3.8 2001-01-02 /PN 9009 <strong>AGFA</strong> d-<strong>lab.3</strong>


Repair<br />

Scanner<br />

The motor is energised by different currents via<br />

LH_MO02_I0 and LH_MO02_I1:<br />

I0 0 1 0 1<br />

I1 0 0 1 1<br />

Current 100% 72% 38% 0%<br />

The clock for the motor is defined by<br />

LH_MO02_CLK, the direction is selected via<br />

LH_MO02_DIR.<br />

When the lamphouse is opened, the stepper motor<br />

is switched off.<br />

Settings<br />

− KG: KG5 and UV-IR blocking for colour scans<br />

− RG: RG850 + IR band for IR Scans<br />

− KG + 20%: Calibration for shutter damping<br />

Light Shutter LH_MO03 / CG_MO03<br />

The exposure is executed by a rotating disk (light<br />

shutter / Shutter). The two wings cover the light<br />

path. The cutout (72°) releases the light path (2)<br />

during an exposure.<br />

The light shutter is driven by stepper motor<br />

LH_MO03.<br />

The light sensor LH_LS03 (1) opens just before the<br />

shutter completely opens the light path from the<br />

CLOSED position.<br />

The motor is energised by different currents via<br />

LH_MO03_I0 and LH_MO03_I1. The clock for the<br />

motor is defined by LH_MO03_CLK and the<br />

direction is selected by LH_MO03_DIR.<br />

The motor has a step angle of 1,8°. As the motor is<br />

operated in half steps, the actual step angle is 0,9°.<br />

dlabr024<br />

1 Light sensor LH_LS03<br />

2 Light path<br />

Arrow Direction of rotation of a cw turning motor<br />

(looking on the shaft)<br />

<strong>AGFA</strong> d-<strong>lab.3</strong> 2001-01-02 /PN 9009 4.3.9


Scanner<br />

Repair<br />

Mirror Box<br />

The mirror box influences the overall brightness<br />

and the illumination.<br />

The two mirror boxes can be changed any<br />

number of times. When a mirror box is changed, a<br />

complete initialisation including a calibration is<br />

performed.<br />

Mirror Box Versions<br />

− Fast for size 135 and smaller<br />

(small light transmission, hence faster)<br />

− Slow for sizes as of 4.5x6<br />

(large light transmission, hence slower)<br />

Mirror Box Motor MB_MO01<br />

Motor MB_MO01 can be used to fold an additional<br />

frosted glass in the light path. A control disk is<br />

fastened to the motor that covers the light sensor<br />

with varying segments.<br />

The motor position is defined by the light sensor<br />

MB_LS01. On the basis of the run times, the<br />

Software determines in which position the motor<br />

is.<br />

The motor stops automatically at a dark-light<br />

transition of the light sensor (signal MB_DONE).<br />

When the motor is switched back on, it moves<br />

automatically to the next position. The position<br />

can be defined by the varying length of the<br />

segments.<br />

It must be observed that the motor continues<br />

turning up to 30°.<br />

dlabr020<br />

4.3.10 2001-01-02 /PN 9009 <strong>AGFA</strong> d-<strong>lab.3</strong>


Repair<br />

Scanner<br />

Auxiliary Shutter (Dust shutter / frosted glass)<br />

Only in prototype, omitted in mass production<br />

The shutter consists of a sector disk with 2 sectors.<br />

One sector is open, the other one comprises a<br />

pinhole plate with a defined transmission.<br />

Auxiliary Shutter Motor DS_MO01<br />

The auxiliary shutter covers the lens and serves as<br />

additional frosted glass for the pixel correction of the<br />

CCD.<br />

The auxiliary shutter consists of a paddle (directly<br />

linked with the stepper motor) with 2 filter sets. The<br />

frosted glass is mounted in one of them, the other<br />

one is fitted with a dark glass.<br />

The auxiliary shutter is driven by the stepper motor<br />

DS_MO01. It can take three positions:<br />

− Open (A)<br />

− Dark (B), initial position<br />

(closed, dust protection)<br />

− Frosted glass (C)<br />

Light sensor DS_LS01 is used for the zero<br />

positioning of the shutter in home position (B). This<br />

means that is opens when the dark field covers the<br />

light path.<br />

Stops prevent the auxiliary shutter from moving<br />

beyond the indicated positions.<br />

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

(half step) this corresponds to 32 steps of the<br />

stepper motor DS_MO01.<br />

The motor is operated by different currents via<br />

DS_MO01_I0 and DS_MO01_I1:<br />

dlabr026<br />

1 Light sensor DS_LS01<br />

2 Frosted glass PIKO<br />

3 Dark field<br />

4 Light path<br />

Arrow Direction of rotation of the cw turning motor<br />

(looking on the shaft)<br />

I0 0 1 0 1<br />

I1 0 0 1 1<br />

Current 100% 72% 38% 0%<br />

The motor clock is given via DS_MO01_CLK, the<br />

direction, via DS_MO01_DIR.<br />

<strong>AGFA</strong> d-<strong>lab.3</strong> 2001-01-02 /PN 9009 4.3.11


Scanner<br />

Repair<br />

Negative Mask<br />

Negative Mask Versions<br />

− 135 frame<br />

− APS<br />

− Rollfilm 120 (4,5x6, 6x6, 6x7, 6x9)<br />

− Slide 135 (small APS slide, no large sizes)<br />

Negative Masks Coding<br />

Position of the light sensors when the negative<br />

carrier is removed and turned:<br />

NC_LS01 NC_LS02 NC_LS03 NC_LS04 NC_LS05 NC_LS06<br />

dlabr120<br />

Negative mask NC_LS01 NC_LS02 NC_LS03 NC_LS04 NC_LS05 NC_LS06<br />

None 0 0 0 0 0 0<br />

135 FF (full frame) 1 1 1 1 1 1<br />

135 P (Panorama) 1 1 1 0 0 1<br />

135 HF (half frame) 1 1 1 0 0 0<br />

135 Hi Vision 1 1 1 1 0 1<br />

135 Fileprint 1 1 1 1 1 0<br />

135 with glass 1 1 1 0 1 0<br />

APS without magnetic reader 1 1 0 1 1 0<br />

APS with magnetic reader 0 1 0 1 1 0<br />

APS PIE mask 0 1 0 0 1 1<br />

110 (Pocket) 1 1 1 0 1 1<br />

120 6*4,5 1 1 0 1 1 1<br />

120 6*6 1 0 1 1 1 1<br />

120 6*7 1 0 0 1 1 1<br />

120 6*8 0 1 1 1 1 1<br />

120 6*9 0 1 0 1 1 1<br />

Slide not inserted => slide mask 0 0 0 1 0 1<br />

Slide inserted => slide mask 0 0 0 1 1 1<br />

4.3.12 2001-01-02 /PN 9009 <strong>AGFA</strong> d-<strong>lab.3</strong>


Repair<br />

Scanner<br />

Position Auxiliary Drive LHS NC_MO02 / Position Auxiliary Drive RHS NC_MO03<br />

The auxiliary drives are positioned by DC motors:<br />

− NC_MO02 Auxiliary drive LHS<br />

− NC_MO03 Auxiliary drive RHS<br />

A control disk is used for the positioning of the<br />

auxiliary drives which activates and deactivates a<br />

light sensor (1) as a function of the angle:<br />

− NC_LS07 Auxiliary drive LHS<br />

− NC_LS08 Auxiliary drive RHS<br />

Upon the initialisation, the initial position must be<br />

found by means of the following signals:<br />

− NC_LS07 / NC_MO02_DONE LHS<br />

− NC_LS08 / NC_MO03_DONE RHS dlabr027<br />

The frosted glass turns in the indicated direction. In<br />

the figure, the auxiliary drive is in the bottom<br />

position.<br />

It must be observed that the motor continues turning<br />

approx. 30° when lowered. When lifted, the motor<br />

must press against a spring and therefore does not<br />

afterrun so much.<br />

The DC motor is switched off automatically by the<br />

Hardware at the dark/bright transition (DONE signal<br />

going to High).<br />

Upon the initialisation, the current position can be<br />

defined by time measurements on the light<br />

sensor (1).<br />

<strong>AGFA</strong> d-<strong>lab.3</strong> 2001-01-02 /PN 9009 4.3.13


Scanner<br />

Repair<br />

Prescanner / Scanner<br />

− Transport, positioning (APL = automatic<br />

positioning logic, slip correction) and exposure of<br />

the inserted film for the Prescan and the main<br />

scan<br />

− Definition of the film and negative-specific<br />

exposure data (TFS) as well as of the exposure<br />

time for the main scan by the Prescanner<br />

− Digitising of the frames for the main scan by the<br />

CCD (exposure of the frame on the CCD)<br />

− The Prescanner is used to define the specific<br />

properties of the film prior to the main scan, like<br />

position and colour / density values of each<br />

individual frame / slide.<br />

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

is created by the CCD unit (Main-Scan) and sent<br />

to the Main PC for image processing (image<br />

processing board).<br />

Prescanner<br />

Structure:<br />

The Prescanner has a density line and three colour<br />

lines fitted with photodiodes. Each colour line is<br />

1 mm wide and is 8 mm away from the other colour<br />

lines. The width of the density line is reduced by a<br />

shutter in the paper filter (ensures higher optical<br />

resolution).<br />

The structure of the lines for RGB is identical:<br />

They consist of 32 photodiodes, the first four and<br />

the last four being switched in pairs. This way, there<br />

are 24 individually addressable photodiodes that can<br />

be used as a function of the film size.<br />

The line for the density consists of 32 photodiodes<br />

switched in groups (as a function of the film size).<br />

The photodiodes are connected to amplifiers after<br />

they have been switched together which have the<br />

following functions:<br />

4.3.14 2001-01-02 /PN 9009 <strong>AGFA</strong> d-<strong>lab.3</strong>


Repair<br />

Scanner<br />

Amplifiers, functions:<br />

− Setting the optimum amplification for the check of<br />

the photodiodes. For optimum utilisation of the<br />

modulation of the AD converter, the amplification<br />

factor for the current / voltage conversion can be<br />

modified.<br />

− Converting the current of the photodiodes into a<br />

voltage.<br />

Only the current of a photodiode is proportional<br />

to the infalling light. For this reason, the light<br />

must be measured here. The AD converter<br />

switched behind can only measure voltages.<br />

The amplification of the current/voltage converter is<br />

adjustable by the film drive processor.<br />

Functions:<br />

− The Prescanner is used to analyse the frames<br />

prior to the actual exposure and main scan<br />

procedure in the d-<strong>lab.3</strong>:<br />

For the Prescan, the Prescanner is moved into<br />

the light path and the film is passed over the<br />

Prescanner. For single frames, the Prescanner is<br />

put under the stationary frame. The film is<br />

digitised at low resolution while the colour and<br />

density values of the entire film including the<br />

border are collected.<br />

− The digitised data is transmitted to the FL<br />

Controller where the required integration times<br />

are found for each colour depending on:<br />

− the density of the individual frame<br />

− the colour corrections as a function of the film<br />

mask<br />

− the colour corrections as a function of a<br />

general colour cast on the film, e.g. on<br />

artificial light shots<br />

− Reading the DX code<br />

− Detecting the image boundaries for the<br />

subsequent image positioning<br />

− Exact image positioning during the film transport<br />

<strong>AGFA</strong> d-<strong>lab.3</strong> 2001-01-02 /PN 9009 4.3.15


Scanner<br />

Repair<br />

The Prescanner collects the following data:<br />

− Brightness of the colours RGB<br />

− Density of the frame<br />

− Perforation<br />

− DX coding<br />

This data is edited and made available for the<br />

following actions and algorithms:<br />

− APL (Automatic Position Logic)<br />

− Slip correction<br />

− TFS (Total Film Scanning)<br />

− DX coding<br />

− Lamp brightness monitoring<br />

4.3.16 2001-01-02 /PN 9009 <strong>AGFA</strong> d-<strong>lab.3</strong>


Repair<br />

Scanner<br />

Lenses<br />

− Fixed focal length for film sizes 135 and smaller<br />

− Zoom for all sizes<br />

The Zoom lens has a rotating chip structure<br />

because of the 120 size (4,5x6). The CCD is<br />

turned when the negative carrier is changed.<br />

The lens is only changed by the service.<br />

A lens change implies a complete initialisation as<br />

is the case upon switch-on.<br />

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

The lens is used to show the negative image in such<br />

a way that it can be reproduced on the CCD with a<br />

slight lack of coverage of the size.<br />

To reproduce a 120 frame 4,5 x 6, the CCD is<br />

turned through 90° by a motor.<br />

The sharp reproduction of the frame on the CCD is<br />

ensured by the Autofocus function of the Zoom.<br />

Three colour extracts of the frame are projected on<br />

the monochrome CCD by means of the exposure<br />

filters.<br />

The board on which the CCD is mounted prepares<br />

the analogue signals for the AD converter of the CG<br />

Controller (CCD group) on the Motherboard.<br />

For quicker availability of the image data, the CCD<br />

is divided into 4 quadrants which are read out<br />

concurrently.<br />

The Zoom electronic mounted on the side of the<br />

Zoom has been matched to the corresponding<br />

Zoom and cannot be replaced separately.<br />

The CCD with 2048x3072 pixels (on the CD board)<br />

used to capture the images is directly connected to<br />

the Zoom. The Zoom and the CCD form a unit and<br />

must be replaced together.<br />

<strong>AGFA</strong> d-<strong>lab.3</strong> 2001-01-02 /PN 9009 4.3.17


Scanner<br />

Repair<br />

CCD (Main Scan)<br />

CCD Rotation with 4,5x6 Negatives CG_MO01<br />

This DC motor turns the CCD through 90°.<br />

The feedback signal CG_MO01_BUSY remains<br />

active until the motor is switched off.<br />

If the level is changed by CG_MO01, the motor<br />

turns in the other direction.<br />

The motor is automatically switched off when it<br />

hits a stop and the current rises. A special<br />

mechanism makes sure that the motor is not<br />

switched off by the higher starting current when<br />

it starts running.<br />

4.3.18 2001-01-02 /PN 9009 <strong>AGFA</strong> d-<strong>lab.3</strong>


Repair<br />

Scanner<br />

Functions and Properties of the Components of the Film Drive<br />

dlabr142<br />

1 Film advance incl. Film Feeder + Film mask 8 Fan for film advance electronic<br />

2 Film Feeder 9 Dust/auxiliary shutter<br />

3 Lamphouse 10 Zoom / fixed focus lens<br />

4 Exposure filters 11 CCD fan<br />

5 Mirror box 12 CCD (Main Scan)<br />

6 Film mask 13 Film chute<br />

7 Prescanner<br />

Position of the Feeders FF_MO01<br />

The Feeder motor opens the jaws in the Film<br />

Feeder. The motor has a step angle of 1,8°.<br />

− The zero position can be defined by the light<br />

sensor FF_LS01. It turns on when the Feeder is<br />

closed. The light sensor lights up when the<br />

Feeder is closed.<br />

The Feeder closes when the motor is turning cw.<br />

− The motor is energised by FF_MO01_ENA<br />

− FF_MO01_DIR indicates the direction<br />

− FF_MO01_CLK clocks the motor<br />

<strong>AGFA</strong> d-<strong>lab.3</strong> 2001-01-02 /PN 9009 4.3.19


Scanner<br />

Repair<br />

Film Transport in the Feeder FF_MO02<br />

The motor FF_MO02 draws the film into the Feeder<br />

and transports it to the gear.<br />

The motor has a step angle of 1,8°. The<br />

transmission to the drive is 1:1.<br />

When the motor is turning cw, the film is exited from<br />

the Feeder.<br />

− Light sensor FF_LS02 recognises whether a film<br />

has been inserted in the Feeder<br />

− Light sensor FF_LS04 recognises whether the<br />

film is in front of the gear<br />

− FF_MO02_ENA energises the motor<br />

− FF_MO02_DIR indicates the direction<br />

− FF_MO02_CLK clocks the motor<br />

Position of the Film Drive Roller FF_MO04<br />

This DC motor positions the film drive roller in the<br />

Feeder.<br />

The light sensors FF_LS07 and FF_LS08 indicate<br />

the top and bottom position of the gear.<br />

The motor remains switched on until the film drive<br />

roller has reached its end position.<br />

Position of the Gear FF_MO03<br />

This DC motor positions the gear.<br />

The light sensors FF_LS05 and FF_LS06 indicate<br />

the top and bottom position of the gear.<br />

The motor remains switched on until the gear has<br />

reached its end position.<br />

4.3.20 2001-01-02 /PN 9009 <strong>AGFA</strong> d-<strong>lab.3</strong>


Repair<br />

Scanner<br />

Film Drive NC_MO01<br />

The stepper motor NC_MO01 transports the film<br />

from the gear to the negative mask and further on.<br />

The motor has a step angle of 0,72°. The film is<br />

advanced 125µm per step.<br />

The film position is monitored by the Scanner.<br />

The motor is operated with different currents via<br />

NC_MO01_I0 and NC_MO01_I1.<br />

The clock for the motor is defined by<br />

NC_MO01_CLK; the direction is selected by<br />

NC_MO01_DIR.<br />

A High level on DIR makes the motor turn cw,<br />

looking on the shaft.<br />

Magnet Negative Pressure NC_MG01<br />

The magnet NC_MG01 holds the frame in the<br />

negative mask.<br />

Scanner Carriage SC_MO01<br />

The stepper motor SC_MO01 moves the<br />

Prescanner. The motor has a step angle of 0,72°.<br />

The zero position can be reached by means of<br />

light sensor SC_LS01.<br />

The Scanner is in home position when it is not in<br />

the light path. In this position, the light sensor is<br />

closed.<br />

When the motor is turning cw (when looking on<br />

the motor shaft), the Scanner is moved into the<br />

light path.<br />

The motor is energised by different currents via<br />

SC_MO01_I0 and SC_MO01_I1.<br />

The clock for the motor is defined by<br />

SC_MO01_CLK; the direction is selected by<br />

SC_MO01_DIR.<br />

A High level on DIR makes the motor turn cw,<br />

looking on the shaft.<br />

<strong>AGFA</strong> d-<strong>lab.3</strong> 2001-01-02 /PN 9009 4.3.21


Scanner<br />

Repair<br />

Concept of the CCD Signal Processing<br />

In order to improve the noise distance, the so-called<br />

CDS method (Correlated Double Sampling) is used:<br />

There is not only the actual pixel value for each<br />

pixel, but also a dark reference which takes into<br />

account local differences of the PRNU. PRNU are<br />

pixel-dependent voltage differences which do not<br />

depend on the time and the light.<br />

The two signals are found by a special CDS chip<br />

which exists separately for each quadrant of the<br />

CCD chip. The difference between these two signals<br />

is the output signal.<br />

The CCD chip comprises 6 additional lines per<br />

quadrant whose pixels are not active electrically.<br />

The average value of their contents serves as<br />

parameter to check the temperature or the dark<br />

current.<br />

Frosted Glass for Pixel Correction (Piko)<br />

A frosted glass is mounted in addition in the mobile<br />

pallet of the auxiliary shutter (dust shutter for the<br />

lens).<br />

− It is used for the calculation of the parameters<br />

needed for the multiplicative pixel correction.<br />

− It should ensure an optimum homogeneous and<br />

dustfree illumination.<br />

4.3.22 2001-01-02 /PN 9009 <strong>AGFA</strong> d-<strong>lab.3</strong>


Repair<br />

Scanner<br />

Control<br />

The Motherboard links the various Scanner<br />

components: It holds a number of single boards<br />

which are connected to external components.<br />

Apart from this, the Motherboard provides the<br />

interfaces for a number of external components.<br />

The Main-PC controls the Scanner Hardware. The<br />

commands are sent to an FL Controller via an<br />

RS232 interface which transmits them via a CAN-<br />

Bus, or processes them itself, as required.<br />

Most of the components can output board-specific<br />

data via an I 2 C-Bus, e.g. version numbers.<br />

See Block circuit diagram Scanner Hardware in<br />

Register 4.1.<br />

Scanner Motherboard<br />

− The Motherboard can receive other boards.<br />

− The Motherboard distributes the load and sensor<br />

signals to the plug-in boards.<br />

− The power supply for the entire Hardware is<br />

connected to the Motherboard and filtered before<br />

it is made available to the boards, sensors and<br />

loads.<br />

− The Motherboard ensures the filtering of the<br />

signals and, if required, also the power supply for<br />

sensors that are directly connected to the<br />

Motherboard.<br />

− The Motherboard has an interface to the Main-<br />

PC (RS232) and a connection for the CAN-Bus.<br />

See Motherboard and LEDs in Register 4.1.<br />

<strong>AGFA</strong> d-<strong>lab.3</strong> 2001-01-02 /PN 9009 4.3.23


Scanner<br />

Repair<br />

Power Supply<br />

The various components are energised via the<br />

Motherboard. The current comes from the power<br />

supply unit of the Printer energies by the power<br />

connection of the Paper Processor.<br />

Connecting voltages<br />

Voltage max. current Remark<br />

+5V 10A Switching power supply unit<br />

+15V 3A Linear regulation<br />

-15V 3A Linear regulation<br />

+24V 6A, temporarily 10A Switching power supply unit<br />

+36V 6A, 8A for 200 ms Switching power supply unit<br />

LH Output Stage<br />

The LH output stage is located in the lamphouse.<br />

The motors are driven by the<br />

LH output stage:<br />

− LH_MO1<br />

− LH_MO2<br />

− LH_MO3<br />

− LH_MO4<br />

− CG_MO01<br />

Stepper motor filter wheel<br />

Stepper motor filter wheel paddle<br />

Stepper motor shutter<br />

Stepper motor auxiliary shutter<br />

DC motor to turn the CCD<br />

The signals for the stepper motors LH_MO01 and<br />

LH_MO02 are switched off in addition via<br />

LH_MS2_IN. This signal generates the lamphouse<br />

opening for cleaning / changing a lamp.<br />

See Driver Sensor Board and LEDs in Register<br />

4.1.<br />

4.3.24 2001-01-02 /PN 9009 <strong>AGFA</strong> d-<strong>lab.3</strong>


Repair<br />

Scanner<br />

FD/SD Output Stage (Film drive / Scanner drive)<br />

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

the stepper motors for the film advance and the<br />

Scanner carriage. The motors are 5-phase<br />

motors. PLDs are used for the activation that have<br />

to be programmed. The two connectors ST2 and<br />

ST3 are provided for the programming.<br />

The driver board gets the control signals via the<br />

Motherboard. The motor signals are also<br />

transmitted via the Motherboard.<br />

If the output stages get too hot, the driver board<br />

sends an error signal through the line TEMP_ERR<br />

that can be processed by the FL Controller.<br />

See FD/SD Output Stage and LEDs in<br />

Register 4.1<br />

FL Controller<br />

− This is the central control processor for the<br />

Scanner Hardware with an interface to the Main-<br />

PC (connection via RS232).<br />

− The commands received by the Main-PC are<br />

either transmitted to other components via the<br />

CAN-Bus, or they are processed by the FL<br />

Controller itself.<br />

− Control of motors, loads and sensors of the film<br />

advance. The status of the motors and the film<br />

can be checked by means of various sensors,<br />

mainly light sensors.<br />

− Control of the Prescanner. The TFS data is<br />

transmitted to the Main-PC (Ethernet). To ensure<br />

a clock-synchronous operation of the Prescanner<br />

and the film advance or Scanner motor, these<br />

clocks are divided and alternately sent to the<br />

Prescanner.<br />

− Monitoring of the voltages (by means of the AD<br />

converter of C167) and the temperature of the<br />

Scanner Hardware<br />

− Master for CAN-Bus and I 2 C-Bus<br />

See FL Controller and LEDs in Register 4.1.<br />

<strong>AGFA</strong> d-<strong>lab.3</strong> 2001-01-02 /PN 9009 4.3.25


Scanner<br />

Repair<br />

Properties:<br />

− SAB 167CR as Microcontroller<br />

− 1Mbyte Flash to store codes and data (externally<br />

programmable by means of a Bootstrap logic)<br />

− 1Mbyte SRAM for data<br />

− 1Mbyte additional Flash (only equipped as an<br />

option) for special data<br />

− Bootstrap logic to program the Microcontroller<br />

from a PC (via RS232)<br />

− 1 SIO establishing the connection to the Main-PC<br />

(2 nd SIO is an option)<br />

− CAN-interface for the communication with other<br />

components of the SC Hardware<br />

− Temperature sensor (approximate measurement)<br />

− <strong>Digital</strong> inputs/outputs to control the loads and<br />

check the sensors<br />

− Analogue inputs to measure / control external<br />

voltages / temperature<br />

− I²C-EEPROM to store board-specific data, e.g.<br />

board numbers<br />

MAIN function:<br />

In the MAIN function, the following actions are<br />

performed:<br />

− Updating the status registers for the sensors<br />

− Execution of State machines for certain<br />

procedures (initialisation, exposure, etc.)<br />

− Interpretation of telegrams from the Main-PC<br />

− Editing telegrams<br />

− to the Main-PC<br />

− for the CAN-Bus<br />

− Transformation of messages from CAN-Bus to<br />

telegrams on the Main-PC<br />

− Performance of commands of the Main-PC<br />

− Check of certain statuses (doors, temperatures)<br />

4.3.26 2001-01-02 /PN 9009 <strong>AGFA</strong> d-<strong>lab.3</strong>


Repair<br />

Scanner<br />

Functions:<br />

− Control of stepper motors (film drive, Scanner<br />

carriage, filter wheel, KG filter, auxiliary shutter,<br />

Feeder motor, film transport in the Feeder)<br />

− Control of the DC motors (gear, position of film<br />

drive roller, mirror box motor, position of the<br />

auxiliary drive left/right)<br />

− Control of fans (negative cooling)<br />

− Control of the magnet for the negative pressure<br />

− Control of the Feeder<br />

− Control of the film drive (film pulled in, film<br />

positioned, APL)<br />

− Voltage monitoring<br />

− Temperature monitoring (on the FL Controller<br />

and the output stages for the stepper motors)<br />

− Monitoring of the temperature switch<br />

− Monitoring of the sensors<br />

− Check of the Film mask coding<br />

− Control and monitoring of the mirror box (type of<br />

mirror box, move in frosted glass)<br />

− Assessment of keys<br />

<strong>AGFA</strong> d-<strong>lab.3</strong> 2001-01-02 /PN 9009 4.3.27


Scanner<br />

Repair<br />

Algorithm/Interface Controller<br />

Functions:<br />

− Activation of the Prescanner and adjustment of<br />

the stepper motor clocks for the Prescanner<br />

− Assessment of the data for the APL (Automatic<br />

positioning logic) and slip correction<br />

− Calculation / performance of the slip correction<br />

− Entry of the TFS data from the Prescanner<br />

− Scanner configuration<br />

− Interface to the APS magnetic decoder<br />

(Assessment of the DX coding)<br />

− Transfer of the TFS data to the Main-PC<br />

(Ethernet)<br />

The A/I Controller processes the following data<br />

flows:<br />

− Data from the Prescanner via special interface<br />

and FIFO<br />

− Data from the APS magnetic decoder via the<br />

CAN-Bus<br />

− Data to the Main PC via the Ethernet<br />

This data is needed for the following functions :<br />

− Calibration of the Prescanner<br />

− Entry of the reference data for single frames and<br />

for a film (brightness adjustment)<br />

− Monitoring of the lamp light<br />

− Entry of the Prescan data<br />

− Normalisation of the Prescan data with the<br />

reference data (brightness adjustment)<br />

− Resorting of the Prescan data for the transfer to<br />

the Main PC<br />

− Calculation of the APL<br />

− Slip monitoring<br />

− Transfer of the APS magnetic data to the Main<br />

PC via the Ethernet<br />

− Positioning of the Prescanner<br />

4.3.28 2001-01-02 /PN 9009 <strong>AGFA</strong> d-<strong>lab.3</strong>


Repair<br />

Scanner<br />

The TFS is not performed on the algorithm board,<br />

but on the PC (see previous section FL Controller)<br />

See Algorithm/interface board and LEDs in<br />

Register 4.1.<br />

Properties:<br />

− SAB 167CR as Microcontroller<br />

− 1Mbyte Flash to store codes and data (externally<br />

programmable by means of a Bootstrap logic)<br />

− 1Mbyte SRAM for data<br />

− Bootstrap logic to program the Microcontroller<br />

from a PC (RS232)<br />

− CAN-interface for the communication with other<br />

components of the SC Hardware<br />

− I²C-EEPROM to store board-specific data, e.g.<br />

board numbers.<br />

− LEDs to show the internal statuses<br />

− Selection of the clocks for the Prescanner.<br />

By means of a selector logic, the clocks of the<br />

film advance or Scanner motor can be sent to the<br />

Prescanner undivided or divided in two. This<br />

allows the Prescanner to synchronise with the<br />

film or carriage movement.<br />

− Ethernet Controller (10 MBit) for fast data<br />

transfer to the Main-PC<br />

<strong>AGFA</strong> d-<strong>lab.3</strong> 2001-01-02 /PN 9009 4.3.29


Scanner<br />

Repair<br />

APS Magnetic Decoder<br />

The APS magnetic decoder uses the data of the<br />

magnetic track of an APS film and processes<br />

them. The data is transmitted to the<br />

algorithm/interface board for further assessment.<br />

Coding on APS films:<br />

− 2 magnetic tracks on which the operator can<br />

save data by means of the APS camera<br />

− 2 magnetic tracks on which the photofinisher can<br />

alter or add product-specific data<br />

− Film-specific information can be saved in the film<br />

tip area<br />

− Data that only holds for one frame (picture title,<br />

aspect ratio, exposure data) is recorded in the<br />

so-called negative data area<br />

See APS Magnetic Decoder and LEDs in<br />

Register 4.1.<br />

Superior data for Photofinishing<br />

Magnetic image data for Photofinishing<br />

Optical image data of the manufacturer<br />

Magnetic camera image data (customer entries,<br />

e.g. size)<br />

Optical camera image data (customer entries, e.g.<br />

size)<br />

• Panorama<br />

•• Classic<br />

__ High Vision<br />

Superior optical data of the camera (exposure<br />

conditions, e.g. flash)<br />

Superior magnetic data of the camera (exposure<br />

conditions, e.g. flash)<br />

Superior optical data of the manufacturer<br />

4.3.30 2001-01-02 /PN 9009 <strong>AGFA</strong> d-<strong>lab.3</strong>


Repair<br />

Scanner<br />

CG Controller (CCD Group Controller)<br />

− Control of the exposure by way of loads / sensors<br />

(e.g. turning CCD, shutter motor)<br />

− Black value corrections (control of the voltage for<br />

the SW balance for CCD)<br />

− Dark and light current measurements<br />

− Preprocessing of the image data of the CCD<br />

(Digitising of the image data)<br />

− Transfer of the image data: After the AD<br />

conversion, the image data is preprocessed in<br />

the FPGA (Field Programmable Gate Array),<br />

multiplexed 4:1 and transmitted to the image<br />

processing card (VIPS) in the Main-PC in the via<br />

an LVDS interface.<br />

− Setting the clock phase for the AD conversion<br />

See CG Controller and LEDs in Register 4.2.<br />

Properties:<br />

− SAB 167CR as Microcontroller<br />

− 1Mbyte Flash to store codes and data (externally<br />

programmable by means of a Bootstrap logic).<br />

The Flash also holds the programming of the<br />

FPGA.<br />

− 1Mbyte SRAM for data<br />

− CAN-Bus for the communication with other<br />

components of the SC-Hardware<br />

− <strong>Digital</strong> inputs/outputs to control the loads and<br />

check the sensors<br />

− FPGA (freely programmable logic): Control of the<br />

CCD and preprocessing of the image by the CCD<br />

− Four fast AD converters with a 12 Bit resolution<br />

for the image signals from the four quadrants of<br />

the CCD<br />

− Transmission of the image data to the Main-PC<br />

via multiplexed LVDS lines<br />

− Transmission of the control signals to the CCD<br />

board via differential lines<br />

− D/A converter for the adjustment of the black<br />

value on the CCD<br />

− I²C-EEPROM to store board-specific data, e.g.<br />

board numbers<br />

<strong>AGFA</strong> d-<strong>lab.3</strong> 2001-01-02 /PN 9009 4.3.31


Scanner<br />

Repair<br />

CG_GS01 - CCD Board<br />

− CG_GS01 is linked rigidly with the lens<br />

− Monochrome CCD chip<br />

− Processing of the control signals (level<br />

conversion) for the CCD<br />

− Adjustment of the image signals<br />

(preamplification) of the CCD for the AD<br />

converter on the CG Controller<br />

− Setting of the voltages for the black value<br />

balance<br />

The level of the current supply of the CCD with<br />

respect to GND is shifted by means of the SW<br />

balance so that an easy activation of the video<br />

preamplifiers is possible. The analogue data is<br />

transmitted to the CG Controller.<br />

The CCD board gets the following control signals<br />

from the CG Controller:<br />

− Clock (10MHz)<br />

− vertical and horizontal synch signals<br />

− special signals for the output of the CCD lines<br />

Differential line pairs ensure an almost troublefree<br />

transmission.<br />

The dark current of the CCD can be balanced by<br />

means of a black value balance of the CG<br />

Controller.<br />

To get optimum conditions for the preamplification<br />

of the image signals, the whole power supply of the<br />

CCD can be shifted. This is achieved via the input of<br />

the black value balance.<br />

See CCD board and LEDs in Register 4.1.<br />

4.3.32 2001-01-02 /PN 9009 <strong>AGFA</strong> d-<strong>lab.3</strong>


Repair<br />

Scanner<br />

Driver Sensor Board<br />

The driver sensor board is located above the film<br />

advance, behind the mirror box.<br />

All loads and sensors of the film drive are<br />

connected here (except the Prescanner).<br />

See Driver Sensor Board and LEDs in Register<br />

4.1.<br />

<strong>AGFA</strong> d-<strong>lab.3</strong> 2001-01-02 /PN 9009 4.3.33


Scanner<br />

Repair<br />

Bus Systems and Interfaces<br />

CAN Bus<br />

The CAN Bus is used for the internal<br />

communication of the Scanner Hardware.<br />

The following units are connected to the CAN Bus:<br />

− FL Controller as Master<br />

− Algorithm/interface board<br />

− CG Controller<br />

− APS Cartridge Feeder<br />

− Zoom (Lens Group)<br />

The ID of the CAN nodes is set in the Software and<br />

not by way of DIP switches.<br />

The Software protocol is specified in Register 8<br />

Software.<br />

LVDS<br />

Interface (differential line pairs) between the CG<br />

Controller and the image processing board in the<br />

Main PC.<br />

RS232<br />

Serial interface between the Motherboard and the<br />

Main PC.<br />

Ethernet<br />

There are 2 network boards with a transmission<br />

speed of 10 MBit/sec and 100 MBit/sec in the<br />

Main PC.<br />

The 10 MBit board is used for the data transfer<br />

between the algorithm/interface board and the<br />

image processing board (VIPS) in the Main PC.<br />

The 100 MBit board connects the d-<strong>lab.3</strong> to an<br />

external network.<br />

4.3.34 2001-01-02 /PN 9009 <strong>AGFA</strong> d-<strong>lab.3</strong>


Repair<br />

Scanner<br />

I 2 C Bus<br />

The 2-Bit bus on the Motherboard links all boards<br />

of the Scanner on which Hardware and Software<br />

conditions are checked. There is an EEPROM on<br />

each one of these boards.<br />

The version number coding of the board is<br />

checked on the I 2 C-Bus.<br />

Version Number Coding of the Boards in the Film Advance<br />

To facilitate the maintenance and troubleshooting,<br />

the development status of the larger boards is<br />

recognised while the d-<strong>lab.3</strong> is running and is<br />

reported to the Main-PC.<br />

− When the Layout / the component equipment is<br />

changed, an Index is counted up on the board<br />

concerned so that the current machine<br />

configuration can be recognised in case of<br />

problems.<br />

− The version number is saved in the serial<br />

EEPROM X24C02.<br />

− The EPROM’s of all new boards are linked by a<br />

2-Bit-Bus (I 2 C-Bus) on the Motherboard.<br />

− The FL Controller can address each EEPROM<br />

individually and check the version number via this<br />

Bus during operation.<br />

<strong>AGFA</strong> d-<strong>lab.3</strong> 2001-01-02 /PN 9009 4.3.35


Scanner<br />

Repair<br />

■<br />

4.3.36 2001-01-02 /PN 9009 <strong>AGFA</strong> d-<strong>lab.3</strong>


Repair<br />

Scanner<br />

Repair / Adjustments<br />

KG Segment<br />

1 IR filter (golden shining side up)<br />

2 Belt<br />

3 Light dimmer<br />

4 KG5 glass<br />

5 UV/IR filter, swivelling<br />

Toothed belt adjustment:<br />

Belt tension 110 Hz ± 10%<br />

Meter<br />

F = 1,2 ± 0,1 N<br />

with 2 mm deflection<br />

(see Fig. on the next page)<br />

The steel core ends of the belt are opposite the<br />

test point<br />

Belt tension meter or meter<br />

Calliper gauge<br />

− Check the belt tension with a belt tension meter<br />

dlabr219<br />

dlabr220<br />

1 Toothed belt<br />

2 Steel core cut<br />

3 Measuring head (frequency measurement on the<br />

other side of the steel core ends)<br />

<strong>AGFA</strong> d-<strong>lab.3</strong> 2001-01-02 /PN 9009 4.4.1


Scanner<br />

Repair<br />

− Check the belt deflection<br />

dlabr221<br />

1 Toothed belt<br />

2 Steel core cut<br />

4.4.2 2001-01-02 /PN 9009 <strong>AGFA</strong> d-<strong>lab.3</strong>


Repair<br />

Scanner<br />

Shutter<br />

Toothed belt:<br />

Visual check: Must not brush<br />

Toothed belt pulley on the motor:<br />

Starting torque of the clamp<br />

1,8 Nm ± 0,1 Nm<br />

Toothed belt pulleys (visual check)<br />

In alignment<br />

Height mismatch ≤ 1 mm<br />

Toothed belt:<br />

Belt tension 191 Hz ± 10%<br />

Alternative F = 1,1 ± 0,1 N<br />

with 2 mm deflection<br />

Belt tension meter or meter<br />

Calliper gauge<br />

− Check the belt tension with a belt tension meter<br />

− Check the belt deflection<br />

dlabr222<br />

1 Toothed belt<br />

2 Steel core cut<br />

3 Markings (must point towards each other)<br />

4 Measuring head<br />

dlabr223<br />

1 Toothed belt<br />

2 Steel core cut<br />

3 Markings (must point towards each other)<br />

<strong>AGFA</strong> d-<strong>lab.3</strong> 2001-01-02 /PN 9009 4.4.3


Scanner<br />

Repair<br />

Filter Wheel<br />

Replacing the Filter Wheel<br />

Screwdriver<br />

− Unscrew 4 screws (see arrow)<br />

− Disconnect the cable<br />

− Remove the filter wheel and mount it again<br />

Toothed belt:<br />

Belt tension<br />

Alternative<br />

150 - 190 Hz<br />

F = 3,2 ± 0,3 N<br />

with 2 mm deflection<br />

(= belt thickness)<br />

dlabr059<br />

Belt tension meter or meter<br />

Calliper gauge<br />

− Check the belt tension with a belt tension meter<br />

1 Toothed belt<br />

2 Steel core cut<br />

3 Markings (must point towards each other)<br />

4 Measuring head<br />

5 Cast cutout<br />

6 Filter wheel<br />

dlabr224<br />

4.4.4 2001-01-02 /PN 9009 <strong>AGFA</strong> d-<strong>lab.3</strong>


Repair<br />

Scanner<br />

− Check the belt deflection<br />

1 Toothed belt<br />

2 Steel core cut<br />

3 Markings (must point towards each other)<br />

4 Cast cutout<br />

5 Filter wheel<br />

dlabr225<br />

Replacing single Exposure Filters<br />

Caution!<br />

Be sure to switch off the lamp, otherwise the prism<br />

glass will burn.<br />

− Lock the lamp opening mechanism with the<br />

black lever.<br />

− Slightly lift the filter cover (1) and pull it off to<br />

the front (2): The exposure filter wheel is accessible<br />

− Turn the filter wheel until the desired filter is accessible.<br />

Confusion is not possible, thanks to<br />

the fool-proof shape of each individual filter and<br />

the filter holder.<br />

− Visual check<br />

− The spring must jam the filter safely (no gap<br />

between the spring and the glass filter)<br />

− The spring ends must rest safely against the<br />

inner stop (spring locking; the spring is<br />

slightly pretensioned towards the inside)<br />

dlabr058<br />

dlabr060<br />

<strong>AGFA</strong> d-<strong>lab.3</strong> 2001-01-02 /PN 9009 4.4.5


Scanner<br />

Repair<br />

Replacing the Filter Motor / the Light Sensor<br />

Toothed belt pulley motor:<br />

Clamping tool<br />

Starting torque 1,8 Nm ± 0,1 Nm<br />

Light sensor:<br />

Axial distance to filter wheel (visual check)<br />

> 0,5 mm<br />

Toothed Belt Pulleys, Adjustment<br />

Toothed belt pulleys:<br />

Aligned<br />

Height mismatch ≤ 1 mm<br />

The belt must not brush<br />

Dust Shutter<br />

Omitted in mass production<br />

Light sensor:<br />

− The paddle must not brush:<br />

A Paddle centred between the base and cover<br />

plate and parallel<br />

B Paddle brushes on the sliding foil; parallel<br />

alignment with the base plate<br />

C Paddle not at an angle on the motor shaft or<br />

sagging; unparalleled alignment with respect<br />

to the base plate; the paddle only brushes<br />

on the sliding foil at the end of the swivel<br />

area<br />

− Light sensor position<br />

Move the paddle in home position (initialisation)<br />

Offset adjustment by the Software; no light sensor<br />

adjustment required.<br />

1 Paddle<br />

2 Sliding foil<br />

3 Cover plate<br />

4 Base plate<br />

dlabr226<br />

4.4.6 2001-01-02 /PN 9009 <strong>AGFA</strong> d-<strong>lab.3</strong>


Repair<br />

Scanner<br />

2-Film Feeder<br />

Dismounting the 2-Film Feeder<br />

Short screwdriver<br />

− Unscrew the screw and<br />

− Pull out the cover to the front<br />

− Dismount the 2-Film Feeder:<br />

It is fastened on the negative carrier with 3<br />

screws.<br />

− Remove the screws (1)<br />

− Lift the Feeder up and off<br />

1<br />

dlabr190<br />

1<br />

dlabr191<br />

All units are easily accessible after the Feeder has<br />

been removed. For this reason, the removal and<br />

installation are not described in detail here.<br />

<strong>AGFA</strong> d-<strong>lab.3</strong> 2001-01-02 /PN 9009 4.4.7


Scanner<br />

Repair<br />

Film Guide, coarse Adjustment<br />

An adjustment becomes necessary when the gear<br />

position on the shafts changes, e.g. after the replacement<br />

of the toothed belt.<br />

− Unscrew the cover plate<br />

− Remove gear B and turn the stop ring to the<br />

RH end of shaft B<br />

− Detach skid A from shaft A (grub screws)<br />

− Hold shaft A tight and turn gear A until the<br />

threadless end of the shaft is just reaching<br />

2 mm out of the associated bush. The shoulder<br />

of gear A must not slip out of its hole!<br />

− Push skid A to the middle up to the stop and<br />

fasten it on shaft A<br />

− Turn gear A approx. half a ccw turn<br />

− Detach skid B from shaft B (grub screws)<br />

− Push skid B out up to the stop<br />

− Relocate shaft B until the threadless end of the<br />

shaft is just reaching 2 mm out of the associated<br />

bush<br />

1A Skid A 1B Skid B<br />

2A Shaft A 2B Shaft B<br />

3A Gear A 3B Gear B<br />

4 Stop ring<br />

5 Cover plate<br />

6 Lug<br />

dlabr245<br />

− Fasten skid B again on shaft B so that the shaft<br />

extends 2 mm and the skid is completely at the<br />

outer edge<br />

− Push skid B to skid A, hold them tight<br />

− Turn the stop ring until skid B starts moving to<br />

the right<br />

− Put on gear B<br />

− Screw on the cover plate<br />

− Move the Feeder in position 120 and in zero<br />

position:<br />

In none of the two positions should the threadless<br />

end of a shaft reach into the associated<br />

bush (overtravel 0,5 - 1,8 mm).<br />

− If necessary, repeat the coarse adjustment<br />

4.4.8 2001-01-02 /PN 9009 <strong>AGFA</strong> d-<strong>lab.3</strong>


Repair<br />

Scanner<br />

Installing the Feeder<br />

− Lift the top film transport roller<br />

− Put the Feeder on the negative carrier on a<br />

slant from above, inserting the film exit flap<br />

between the top and bottom film transport<br />

roller.<br />

− Screw on the Feeder<br />

Film Guide, Adjustment<br />

− Position (alignment) of the Feeder skids with<br />

respect to the negative mask 135FF:<br />

Feeder skids adjusted to the film transport<br />

width in the negative mask; adjustment including<br />

the slant of the skids<br />

∆x = 0 ± 0,3 mm (metal gauge 35)<br />

− Close the driver to the gauge width<br />

− Detach the Feeder skids from the shaft<br />

− Push them manually towards the inserted<br />

metal gauge 135 and jam them<br />

− Fasten the skids<br />

∆x is the widest distance between the metal<br />

gauge and the left or right Feeder skid<br />

− Open and close the skids several times<br />

electrically and check the dimension<br />

1 Negative mask 135F<br />

2 Feeder<br />

3 Gauge<br />

dlabr233<br />

Film guide widths of the Feeder:<br />

135 35,15 - 35,65 mm<br />

110 16,00 - 16,50 mm<br />

120 62,20 - 62,70 mm<br />

IX240 24,05 - 24,55 mm<br />

<strong>AGFA</strong> d-<strong>lab.3</strong> 2001-01-02 /PN 9009 4.4.9


Scanner<br />

Repair<br />

Detection of the Film Transport Width<br />

Zero position gauge<br />

− Insert the zero position gauge<br />

− Turn the toothed belt wheel to close the Feeder<br />

skids until the gauge 135 is jammed (zero position)<br />

− Slacken the light sensor actuator and pull it out<br />

of the light sensor<br />

− Push the actuator back into the light sensor until<br />

the latter lights<br />

− Fasten the actuator again<br />

− Open the skids to size 120 (Service)<br />

− Move the skids back into home position<br />

− The gauge must fit again with a play of<br />

±0,1 mm, correct if necessary, or repeat the<br />

adjustment<br />

In home position, the skids are asymmetric with<br />

respect to the optical axis.<br />

1 Light sensor actuator<br />

dlabr246<br />

2-Film Feeder, Adjustments<br />

Meter<br />

Toothed belt tension, width adjustment:<br />

Force F = 1,5 - 2,5 N with a<br />

Path ∆x = 2 mm<br />

Toothed belt tension, additional drive:<br />

Force F = 2-3 N with a<br />

Path ∆x = 2 mm<br />

dlabr227<br />

4.4.10 2001-01-02 /PN 9009 <strong>AGFA</strong> d-<strong>lab.3</strong>


Repair<br />

Scanner<br />

Feeder rocker<br />

Feeler gauge<br />

− Feeder rocker (visual check)<br />

Swivel area smooth moving<br />

Move the rocker up and down in the service<br />

mode.<br />

− Position rocker up<br />

Height between film skid in negative carrier 135<br />

and bottom rocker edge<br />

x =≥ 1,5 mm<br />

− Position rocker down<br />

Height between film skid in negative carrier 135<br />

and top rocker edge<br />

min.<br />

max.<br />

x =≥ 1,0 mm<br />

The bottom rocker edge must not<br />

be under the stopping slant<br />

1 Negative mask<br />

2 Feeder rocker<br />

dlabr228<br />

− Rollers in the rocker (visual check):<br />

− Free moving (not brushing anywhere)<br />

− Rubber rings not damaged<br />

1 Negative mask<br />

2 Negative mask, stopping slant<br />

dlabr229<br />

<strong>AGFA</strong> d-<strong>lab.3</strong> 2001-01-02 /PN 9009 4.4.11


Scanner<br />

Repair<br />

Additional drive:<br />

− Pressure force of the counter roller in closed<br />

condition, measured under spring load when<br />

the air gap between the rollers disappears<br />

(before the rollers are lifted)<br />

7 - 9 N (meter)<br />

− Film tractive force; drive active, force to stop<br />

the film while the drive is running<br />

F ≥ 2,0 N (test leader, spring balance)<br />

Light sensors FF_LS02 and FF_ LS04:<br />

− Height of the light sensors<br />

Distance between varnished surface on<br />

Feeder cast part and front surface of reflected<br />

light sensor<br />

FF_LS02 and FF_LS04<br />

x = 8,5 ± 0,5 mm (calliper gauge)<br />

dlabr231<br />

Adjustment of the Feeder:<br />

− x direction:<br />

Distance between the upper FF rocker and the<br />

negative carrier 135FF<br />

∆x = 0,5 ± 0,1 mm (feeler gauge)<br />

− Operate the rocker manually:<br />

Dimension at the narrowest point ∆x<br />

dlabr232<br />

1 Negative mask<br />

2 Feeder rocker<br />

4.4.12 2001-01-02 /PN 9009 <strong>AGFA</strong> d-<strong>lab.3</strong>


Repair<br />

Scanner<br />

− Light sensor actuator:<br />

15 ± 0,1 mm after the adjustment with the<br />

metal gauge (15 mm wide)<br />

Adjust the Feeder and move it into zero position<br />

(distance 15 mm, move the driver in closed direction<br />

of the skids)<br />

− Detach the light sensor actuator and move it<br />

into the light sensor from the outside until<br />

the latter responds<br />

− Fasten the light sensor actuator<br />

− After opening the skids to size 120 and<br />

closing them again to zero position, the dimension<br />

between the skids must be again<br />

15 ± 0,1 mm.<br />

− If necessary, correct the light sensor actuator<br />

1 Light sensor actuator<br />

2 Gauge<br />

dlabr234<br />

<strong>AGFA</strong> d-<strong>lab.3</strong> 2001-01-02 /PN 9009 4.4.13


Scanner<br />

Repair<br />

Negative Carrier<br />

Removing the Negative Carrier<br />

Some parts, e.g. the film drive and rocker motors,<br />

are only accessible after removal of the negative<br />

carrier.<br />

Screwdriver<br />

Caution!<br />

Do not unscrew the red lacquer-sealed banjo<br />

bolts.<br />

− Unscrew the marked screws (arrows)<br />

− Lift off the negative carrier<br />

#negcar01<br />

1 Banjo bolt: Do not touch!<br />

2 Active film exit<br />

4.4.14 2001-01-02 /PN 9009 <strong>AGFA</strong> d-<strong>lab.3</strong>


Repair<br />

Scanner<br />

Changing the Lifting Magnet, toothed Belt and auxiliary Drive Shaft<br />

Allen key<br />

Screwdriver<br />

Lifting magnet:<br />

− Unscrew the marked screws (grub screws)<br />

− Pull off the magnet<br />

Belt:<br />

− Pull off the additional gear incl. the armature<br />

plate<br />

− Change the belt<br />

Auxiliary drive shaft:<br />

− Unscrew the holder (3 screws)<br />

− Pull out the shaft; the bearings can be removed<br />

after the lock washer has been removed<br />

− Mind the correct position of the holder when<br />

mounting it again (see Figure)<br />

dlabr247<br />

1 Magnet<br />

2 Armature plate<br />

3 Gear<br />

4 Holder<br />

5 Auxiliary drive shaft<br />

6 Lock washer<br />

<strong>AGFA</strong> d-<strong>lab.3</strong> 2001-01-02 /PN 9009 4.4.15


Scanner<br />

Repair<br />

Working on the Rockers<br />

The removal and installation of the two rocker<br />

motors and eccentric blocks are identical<br />

− Unscrew the cover plate incl. the light sensor<br />

− Pull out the motor<br />

− Remove the lock washer on the eccentric block<br />

Caution!<br />

Do not dismantle the eccentric block, only replace<br />

it as a complete unit.<br />

− Pull out the eccentric block:<br />

The preceding gear need not be removed; only<br />

rocker shaft A has to be pulled out a little.<br />

− Dismounting the rocker:<br />

− Remove the lock washer from the rocker eccentric<br />

− Pull out rocker shaft B:<br />

Mind the washers; note down the position<br />

− Remove the lock washer in the rocker<br />

Caution!<br />

Do not try to detach the rocker eccentric from the<br />

rocker.<br />

− Pull off the rocker with the eccentric<br />

See Figure on the next page<br />

4.4.16 2001-01-02 /PN 9009 <strong>AGFA</strong> d-<strong>lab.3</strong>


Repair<br />

Scanner<br />

1a Cover plate A 1b Cover plate B<br />

2a Motor A 2b Motor B<br />

3a Eccentric block A 3b Eccentric block B<br />

4a Rocker shaft A 4b Rocker shaft B<br />

5a Rocker 5b Rocker eccentric<br />

dlabr251<br />

<strong>AGFA</strong> d-<strong>lab.3</strong> 2001-01-02 /PN 9009 4.4.17


Scanner<br />

Repair<br />

Mounting the rocker:<br />

− Remove the guide plates<br />

− Remove the bottom rubber roller:<br />

− Jam the shaft: Push a pin or a hexagon key<br />

through the hole in the motor shaft<br />

− Unscrew the marked screw<br />

− Pull off the roller<br />

− Push the rocker with the inserted spring a few<br />

mm on the shaft; for the spring position see<br />

Figure below<br />

− Turn the rocker until it sits on the motor shaft<br />

(eccentric hangs down)<br />

− Turn the spring until the long leg is on the<br />

rocker: The leg moves away from the rubber<br />

roller towards the motor shaft.<br />

− Push the rocker incl. spring completely on the<br />

shaft: The short leg of the spring slides into the<br />

recess on the shaft.<br />

− Turn the rocker against the spring tension until<br />

it rests on the negative carrier (eccentric is also<br />

in contact)<br />

− Fasten the bottom rubber roller again on the<br />

motor shaft<br />

− Put the lock washer in the rocker<br />

− Screw the blades on the negative carrier<br />

1 Blades<br />

2 Motor shaft<br />

3 Bottom rubber roller<br />

4 Rocker<br />

dlabr252<br />

4.4.18 2001-01-02 /PN 9009 <strong>AGFA</strong> d-<strong>lab.3</strong>


Repair<br />

Scanner<br />

Changing the Light Sensors for the Negative Carrier Coding<br />

− Press down the snap locks of the light sensor<br />

holder a little and push the unit to the back<br />

− Lift off the light sensor<br />

dlabr249<br />

1 Light sensor holder with light sensor<br />

2 Cover plate<br />

3 Locking knob<br />

Changing the Negative Carrier Lock<br />

Caution!<br />

Change only the complete lock.<br />

− Change:<br />

− Unscrew the cover plate (2 screws)<br />

− Remove the lock<br />

− Installation:<br />

Mind the correct position of the locking knob<br />

(see Figure above)<br />

<strong>AGFA</strong> d-<strong>lab.3</strong> 2001-01-02 /PN 9009 4.4.19


Scanner<br />

Repair<br />

Negative Carrier, Adjustments<br />

Belt tension:<br />

F = 1 N results in a<br />

2 - 3 mm deflection or<br />

160 ± 20 Hz<br />

1 Tensioning roller<br />

dlabr235<br />

Meter or belt tension meter<br />

Pressure force of the counter rollers in closed<br />

condition, measured under spring load when the<br />

air gap between the rollers disappears (before the<br />

rollers are lifted):<br />

left (TR4) 7 - 9 N<br />

right (TR5) 7 -10 N<br />

Meter<br />

Film tractive force per drive, always one drive active,<br />

force to stop the film while the drive is running:<br />

F ≥ 5,0 N always for TR4 / TR5<br />

Test leader, spring balance<br />

4.4.20 2001-01-02 /PN 9009 <strong>AGFA</strong> d-<strong>lab.3</strong>


Repair<br />

Scanner<br />

Replacing the Zoom / Fixed Focus Lens<br />

Screwdriver<br />

− Dismount the fan (2 screws)<br />

− Remove the film chuter (4 screws)<br />

dlabr113<br />

− Carefully turn the CCD cw through 90º by hand:<br />

The connectors are then accessible<br />

− Remove 2 connectors<br />

− Remove the Zoom / the fixed focus lens<br />

(4 screws, see arrows)<br />

dlabr114<br />

dlabr189<br />

<strong>AGFA</strong> d-<strong>lab.3</strong> 2001-01-02 /PN 9009 4.4.21


Scanner<br />

Repair<br />

Replacing the Boards<br />

− Remove the cover (1)<br />

For better access, the complete Motherboard<br />

with the boards can be lifted approx. 10 cm and<br />

locked:<br />

− Push in the locking tongue<br />

− Pull the locking lever in the lamphouse to the<br />

front<br />

− Remove the board:<br />

Hold the board only by the handles provided for<br />

this.<br />

dlabr002<br />

038a<br />

4.4.22 2001-01-02 /PN 9009 <strong>AGFA</strong> d-<strong>lab.3</strong>


Repair<br />

Scanner<br />

Precanner Adjustment<br />

The sledge motor is directly accessible, the<br />

toothed belt and the scanner sledge, after the<br />

negative carrier has been removed.<br />

Reference value for the toothed belt tension:<br />

with approx. 2,5N the deflection is 3 mm<br />

All measuring cells are located directly on the<br />

scanner board. The board can be removed without<br />

problems from the scanner sledge and put back.<br />

dlabr250<br />

1 Scanner tray<br />

2 Sledge motor<br />

3 Toothed belt<br />

4 Scanner sledge<br />

5 Scanner board<br />

<strong>AGFA</strong> d-<strong>lab.3</strong> 2001-01-02 /PN 9009 4.4.23


Scanner<br />

Repair<br />

Prescanner Adjustment with Film<br />

− Mirror box pushed in<br />

− Lamp switched on<br />

− Prescanner adjustment film available<br />

When the lamp switch is operated and the machine<br />

is switched on, the lamp holder must not be<br />

moved out as otherwise the exposure filters will<br />

burn.<br />

The adjustment film ETN is used to measure the<br />

two tracks of the DX code simultaneously.<br />

Definitions:<br />

V front near the operator<br />

H back away from the operator<br />

XX No. of DX codes read at the front<br />

YY No. of DX codes read at the back<br />

Do not cut the adjustment film into pieces as otherwise<br />

no exact measurement is possible!<br />

The display does no longer show the measured<br />

average signal amplitude, but the absolute number<br />

of DX codes read.<br />

DX Reading<br />

Open the LOG file and check the DX values<br />

4.4.24 2001-01-02 /PN 9009 <strong>AGFA</strong> d-<strong>lab.3</strong>


Repair<br />

Scanner<br />

Remove the following parts / covers:<br />

1. Negative carrier<br />

2. Mirror box<br />

3. Film supply + Film Feeder<br />

4. Lamphouse lid<br />

5. Air filter cover<br />

6. Front cover (grey):<br />

lift a little at the back (arrow 1) and then pull it<br />

off to the front (arrow 2), see Figure below<br />

7. PC cover<br />

8. Film Take Up<br />

dlabr174<br />

Allen key, short<br />

− Push the scanner sledge to the left:<br />

Take the paper filter (1) and push it to the left<br />

up to the stop<br />

− Slacken 3 scanner tray fastening screws (2)<br />

with the Allen key<br />

dlabr058<br />

dlabr172<br />

<strong>AGFA</strong> d-<strong>lab.3</strong> 2001-01-02 /PN 9009 4.4.25


Scanner<br />

Repair<br />

− 2 mm Allen key long (approx. 23 cm)<br />

− Open the front door<br />

− Adjust the scanner:<br />

The screw can be reached through the hole (1)<br />

with the long Allen key<br />

If the Prescanner can only be set in tolerance<br />

when the scanner tray is at the back stop, the<br />

cone shaft unit (single frame positioning) must be<br />

replaced.<br />

As this unit is adjusted as a complete unit, it can<br />

only be replaced completely (part no. on demand).<br />

dlabr171<br />

dlabr248<br />

Adjustment Film, Scope of Delivery<br />

Pcs. Designation Part no.<br />

1 Test film with 2 DX tracks CM+9.8506.9931.1<br />

1 Allen key CM+9.9999.1036.0<br />

1 Instruction<br />

The attached Allen key cannot be used for the<br />

adjustment of the d-<strong>lab.3</strong>.<br />

4.4.26 2001-01-02 /PN 9009 <strong>AGFA</strong> d-<strong>lab.3</strong>


Repair<br />

Scanner<br />

Scanner Calibration<br />

The following calibration procedures are performed<br />

automatically when required. It is not necessary<br />

that a technician or the operator intervenes.<br />

The Scanner contains several optical elements<br />

which are calibrated automatically.<br />

− Replacement of the light sensors in the lamphouse:<br />

The film drive software automatically finds the<br />

exact positions of the 3 light sensors in the<br />

lamphouse and the light sensor of the KG segments<br />

when the corresponding routines are<br />

called up. The positions are stored internally in<br />

an EEPROM.<br />

− White balance:<br />

Red, green, blue scan without a film to check<br />

the balance.<br />

Brightness changes, above all of the lamp<br />

brightness, are compensated.<br />

− CCD pixel correction<br />

Calibration Procedures, Correlations<br />

Performed upon:<br />

Calibration<br />

Pixel<br />

correction<br />

White<br />

balance<br />

IR adjustment<br />

Shutter<br />

damping<br />

Prescan<br />

Switch-on X X X X X<br />

Lamp change X X X X<br />

Mirror box inserted X X X X<br />

Negative carrier inserted (X) X X X<br />

Prescanner calibrated X X<br />

CCD dark reference defined X X X<br />

− X:<br />

The calibrations marked by an X must be performed<br />

when the corresponding component is<br />

modified.<br />

− (X):<br />

Required when a negative carrier is inserted for<br />

a different frame size.<br />

<strong>AGFA</strong> d-<strong>lab.3</strong> 2001-01-02 /PN 9009 4.4.27


Scanner<br />

Repair<br />

Order of Calibration Procedures<br />

− Pixel correction<br />

− Dark<br />

− Bright<br />

− White balance (filter / lamp calibration)<br />

− Prescanner<br />

− RGB<br />

− IR<br />

− Shutter damping<br />

− Zoom lens<br />

Pixel Correction (Piko)<br />

This calibration ensures that the CCD chip is<br />

standardised and supplies the same signals for all<br />

pixels. Only then can the CCD be used as tool for<br />

other calibrations, e.g. for the white balance.<br />

The pixel correction is always performed when<br />

modifications are carried out on the light path<br />

which have an impact on the spacial light distribution<br />

on the CCD (e.g. lamp change, cleaning of<br />

filters and other optical components) or when the<br />

electrical properties of the chip themselves change<br />

(e.g. due to temperature).<br />

Compulsory pixel correction:<br />

− At the first switch-over to a larger size<br />

− After the installation of the mirror box<br />

− After the lamp has been moved in, even if it<br />

was not changed.<br />

− After the change of the negative mask<br />

Blemish correction:<br />

Here, defective CCD pixels are found.<br />

4.4.28 2001-01-02 /PN 9009 <strong>AGFA</strong> d-<strong>lab.3</strong>


Repair<br />

Scanner<br />

White Balance<br />

A white balance is performed when<br />

− the light quantity on the CCD absolute and in its<br />

spectral composition has changed<br />

− a pixel correction has been performed since the<br />

last white balance<br />

The white balance ensures that an image signal of<br />

4.095 means "white without a film". On this basis,<br />

an appropriate exposure time can be controlled as<br />

a function of the film mask and the film density.<br />

The lamp brightness is monitored for each film by<br />

the Prescanner.<br />

The overall calibration of the Prescanner is performed<br />

by force when the mirror box or the lamp is<br />

changed. Otherwise for each film when an overdrive<br />

of a photocell is recognised.<br />

<strong>AGFA</strong> d-<strong>lab.3</strong> 2001-01-02 /PN 9009 4.4.29


Scanner<br />

Repair<br />

Prescanner Calibration<br />

Calibration Methods<br />

No. Calibration Remark<br />

1 Finding the zero position Position in which the light sensor responds (Prescanner<br />

moves to the left)<br />

2 Finding the print position Scanner keeps on moving until the density array is<br />

exactly under the right perforation (maximum light)<br />

3 Finding the Scan position Scanner keeps on moving until the density array is<br />

exactly under the left perforation<br />

4 Setting the amplification factors for<br />

the colour arrays for the negative<br />

scan<br />

5 Finding the amplification factors for<br />

the colour arrays to define the lamp<br />

brightness<br />

6 Setting the amplification factors for<br />

density, DX, Perfo<br />

7 Measuring the light without a film<br />

(bright alignment)<br />

The amplification factors are adjusted until no photodiode<br />

is overdriving. The mask factor is switched off<br />

(on 1). Illumination with white light (no IR).<br />

The amplification setting is calculated on the basis of<br />

the setting of the amplification factors for the colour<br />

arrays for the negative scan in such a way that the<br />

photodiodes are driven to half output. This amplification<br />

setting is kept up to the next white balance of the<br />

Main Scanner. The measurement of the lamp brightness<br />

serves to trigger a white balance of the Main<br />

Scanner.<br />

The amplification factors are adjusted until no photodiode<br />

is overdriving. In contrast to the colour arrays,<br />

the mask factor is adjusted as well. Light adjustment<br />

as above.<br />

The resulting values for all photodiodes are used as<br />

reference for the Scan.<br />

8 Measuring the lamp brightness No actual calibration of the Prescanner, but described<br />

here as it is necessary as Trigger for the white balance<br />

of the Main Scanner.<br />

Along with the amplification factors defined before<br />

(half full-scale deflection) the Prescanner moves in<br />

scanning position without a film with white light (no<br />

IR). While it is moving, the measuring values are integrated<br />

for each colour over a fixed path.<br />

If the deviation from the last measuring value is too<br />

important (spectral or in terms of brightness), a new<br />

white balance of the Main Scanner is performed.<br />

If the deviation is small, the measuring values are<br />

used for the correction of the integration times.<br />

Not calibrated<br />

Mask factor (component tolerance, depending on the<br />

selected amplification) and dark Offset<br />

4.4.30 2001-01-02 /PN 9009 <strong>AGFA</strong> d-<strong>lab.3</strong>


Repair<br />

Scanner<br />

Moment of Execution of the Calibration Methods<br />

Moment<br />

New start<br />

Mirror box change<br />

Negative carrier change<br />

Insertion of a film strip<br />

(prior to the Prescan)<br />

Start of the exposure of<br />

single frames<br />

Calibration method<br />

Finding the zero position<br />

Finding the print position<br />

Finding the Scan position<br />

Setting the amplification factors for the colour arrays:<br />

Negative scan and determination of the lamp brightness<br />

Setting the amplification factors for density, DX, Perfo;<br />

Measurement of the light quantity as reference<br />

Finding the zero position<br />

Finding the print position<br />

Finding the Scan position<br />

Setting the amplification factors for the colour arrays:<br />

Negative scan and determination of the lamp brightness<br />

Setting the amplification factors for density, DX, Perfo;<br />

Measurement of the light quantity as reference<br />

Finding the zero position<br />

Finding the print position<br />

Finding the Scan position<br />

Setting the amplification factors for the colour arrays:<br />

Negative scan and determination of the lamp brightness<br />

Setting the amplification factors for density, DX, Perfo;<br />

Measurement of the light quantity as reference<br />

Measuring the lamp brightness<br />

Setting the amplification factors for the colour arrays for the negative<br />

scan<br />

Measuring the light without a film (bright adjustment)<br />

Measuring the lamp brightness<br />

Setting the amplification factors for the colour arrays for the negative<br />

scan<br />

Measuring the light without a film (bright adjustment)<br />

<strong>AGFA</strong> d-<strong>lab.3</strong> 2001-01-02 /PN 9009 4.4.31


Scanner<br />

Repair<br />

■<br />

4.4.32 2001-01-02 /PN 9009 <strong>AGFA</strong> d-<strong>lab.3</strong>


Repair<br />

Main-PC<br />

Contents<br />

Overview ..................................................................................................................................................... 5.1<br />

Main-PC ................................................................................................................................................ 5.1<br />

Interfaces / Connections ....................................................................................................................... 5.1<br />

Drives .................................................................................................................................................... 5.3<br />

Hard Disk .............................................................................................................................................. 5.3<br />

Graphic Card......................................................................................................................................... 5.3<br />

Ethernet Boards .................................................................................................................................... 5.3<br />

PC-Mainboard ....................................................................................................................................... 5.4<br />

Timer Board .......................................................................................................................................... 5.6<br />

Image Processing Board (VIPS) ........................................................................................................... 5.6<br />

BIOS Settings........................................................................................................................................ 5.7<br />

Jumper Settings of the Drives ............................................................................................................... 5.8<br />

Operating System.................................................................................................................................. 5.9<br />

Radio Shielding ..................................................................................................................................... 5.9<br />

Functional Description ............................................................................................................................ 5.10<br />

Repair ........................................................................................................................................................ 5.11<br />

Removal of the PC .............................................................................................................................. 5.11<br />

<strong>AGFA</strong> d-<strong>lab.3</strong> 2001-01-02 /PN 9009 5.i


Main-PC<br />

Repair<br />

■<br />

5.ii 2001-01-02 /PN 9009 <strong>AGFA</strong> d-<strong>lab.3</strong>


Repair<br />

Main-PC<br />

Overview<br />

Main-PC<br />

dlabr014<br />

Interfaces / Connections<br />

dlabr287<br />

1 Machine sticker 1 Power supply 8 Network 2<br />

2 AC Input 9 Network 1<br />

3 Printer 10 Graphic card<br />

4 Scanner 11 Parallel Port<br />

5 PCMCIA Controller 12 Keyboard<br />

6 Timer board 13 Mouse<br />

7 Image processing<br />

<strong>AGFA</strong> d-<strong>lab.3</strong> 2001-01-02 /PN 9009 5.1


Main-PC<br />

Repair<br />

Serial Interfaces / 8-port SIO (RS232)<br />

ST01<br />

ST02<br />

ST03<br />

ST04<br />

ST05<br />

ST06<br />

ST07<br />

ST08<br />

ST09<br />

3 wires<br />

7 wires<br />

7 wires<br />

3 wires<br />

3 wires<br />

7 wires<br />

3 wires<br />

3 wires<br />

8-port SIO<br />

dlabr046<br />

label_2<br />

Plug / Cable Port#-COM Port# -board Registry Module<br />

ST01 / KA204 — — — goes to Scanner Motherboard Bu09<br />

ST02 COM4 Extern7 MO Modem<br />

ST03 COM5 Extern6 BC Bar code reader<br />

ST04 COM6 Extern5 PC Pricing unit (PRU)<br />

ST05 / KA05 COM7 Extern1 PP Paper Processor<br />

ST06 COM8 Extern8 Touch Screen<br />

ST07 / KA41 COM9 Extern2 PR Printer<br />

ST08 COM10 Extern4 DM External Densitometer<br />

ST09 — — — goes to PC (8-port SIO, RS232)<br />

— COM1 PC internal TI Timer board<br />

— COM3 PC internal FL Film advance<br />

5.2 2001-01-02 /PN 9009 <strong>AGFA</strong> d-<strong>lab.3</strong>


Repair<br />

Main-PC<br />

Drives<br />

Drives (drive letter):<br />

1. Hard disk<br />

− 1. Partition (C)<br />

− 2. Partition (D)<br />

2. CD-ROM (E)<br />

3. ZIP Drive (F)<br />

4. PCM-CIA rack for memory cards<br />

− Rack 1 (G *)<br />

− Rack 2 (H *)<br />

5. 3,5“ Disk drive (A)<br />

* Drive letters cannot be allocated permanently.<br />

The first Slot occupied gets the letter.<br />

dlabr108<br />

Hard Disk<br />

Harddisk with 2 partitions:<br />

C:\ 2 GB NTFS NT 4.0 / SP6<br />

D:\ max. GB NTFS<br />

Graphic Card<br />

Resolution: 1.024x768 Pixel<br />

Image recurrence frequency: >75Hz<br />

Ethernet Boards<br />

− 10 Mbit/s Internal use<br />

− 100 Mbit/s Connection for external network<br />

<strong>AGFA</strong> d-<strong>lab.3</strong> 2001-01-02 /PN 9009 5.3


Main-PC<br />

Repair<br />

PC-Mainboard<br />

Set the Jumpers in accordance with the internal<br />

speed of the processor (preset for Pentium II,<br />

450 MHz):<br />

CPU BUS Frequency Multiple Frequency CPU:PCI<br />

Intel<br />

Freq. Mult. BUS F FS0 FS1 FS2 FS3 BF0 BF1 BF2 BF3 MS0 MS1<br />

CPU Model MHz<br />

MHz<br />

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]<br />

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]<br />

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]<br />

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]<br />

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]<br />

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]<br />

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]<br />

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]<br />

dlab192e<br />

5.4 2001-01-02 /PN 9009 <strong>AGFA</strong> d-<strong>lab.3</strong>


Repair<br />

Main-PC<br />

PC Mainboard Connections<br />

CPU_FAN<br />

CHA_FAN<br />

JTCPU<br />

Wake on LAN<br />

Panel Connector<br />

to CPU – cooling fan<br />

to front fan<br />

temperature sensor for the<br />

sensor for the CPU,<br />

measuring point (see fig.<br />

below)<br />

to Timer board<br />

ATX Power Switch to<br />

Timerboard (see fig. right)<br />

dlabr253<br />

Temperature sensor on heat sink: Test point (1)<br />

dlabr281<br />

<strong>AGFA</strong> d-<strong>lab.3</strong> 2001-01-02 /PN 9009 5.5


Main-PC<br />

Repair<br />

Timer Board<br />

PCI-Slot #3<br />

The Timer board is connected to the Mainboard by<br />

2 cables:<br />

− Cable 1 (A) supplies the Timer board with the<br />

Standby voltage of +5 V<br />

− Cable 2 (B) switches on the PC<br />

The operating voltage of +5 V is sent to the Timer<br />

board via the ISA or PCI rack, or else via ST08<br />

(Pin 3 +5 Volt, Pin 4 GND).<br />

The d-<strong>lab.3</strong> is switched on step by step via<br />

ST01 - ST06.<br />

dlab285<br />

Image Processing Board (VIPS)<br />

− 200 MHz<br />

− 2 Texas Instruments DSP Processors<br />

− 512 MByte<br />

The image processing board is supplied by +5 V via<br />

a Y cable.<br />

dlabr286<br />

1 Printer<br />

2 Scanner<br />

5.6 2001-01-02 /PN 9009 <strong>AGFA</strong> d-<strong>lab.3</strong>


Repair<br />

Main-PC<br />

BIOS Settings<br />

AWARD Bios Version<br />

− ASUS P3V133 BIOS Revision 1002<br />

Main<br />

− Supervisor Password<br />

− Halt on<br />

on request<br />

all, but keyboard<br />

Advanced - Chip Configuration<br />

Advanced - I/O Device Configuration<br />

− Serial Port 2<br />

Disabled<br />

Advanced - PCI Configuration<br />

− Slot 1 IRQ 11<br />

− Slot 2 IRQ 10<br />

− Slot 3 IRQ 9<br />

− Slot 4 IRQ<br />

NA<br />

Advanced - PCI Configuration - PCI / PNP ISA IRQ Resource Exclusion<br />

− IRQ 3 Used By ISA No/ICU COM 2<br />

− IRQ 4 Used By ISA No/ICU COM 1<br />

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

− IRQ 7 Used By ISA No/ICU Parallel Port<br />

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

− IRQ 10 Used By ISA Yes VIPS board<br />

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

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

− IRQ 14 Used By ISA No/ICU IDE 1<br />

− IRQ 15 Used By ISA No/ICU IDE 2<br />

Advanced - Shadow Configuration<br />

Power<br />

− Power Savings<br />

Power - Up Control<br />

Power - Hardware Monitor<br />

Boot<br />

− 1 DIE Hard Drive<br />

− 2 ATAPI CD-ROM<br />

− 3 Removable Device<br />

− 4 Other Boot Device<br />

Type of hard disc<br />

CD-ROM drive<br />

Legacy Floppy<br />

None<br />

<strong>AGFA</strong> d-<strong>lab.3</strong> 2001-01-02 /PN 9009 5.7


Main-PC<br />

Repair<br />

Jumper Settings of the Drives<br />

Hard disk:<br />

Master active, 10 GB<br />

Jumper settings<br />

The Jumpers allow the selection of the following<br />

options (architecture with 16 logic heads):<br />

MASTER active<br />

SLAVE active<br />

Cable select<br />

SLAVE Present<br />

Reserved<br />

Pin designation<br />

A-B and G-H<br />

A-B and C-D<br />

A-B and E-F<br />

E-F and G-H<br />

I<br />

1 Jumper block<br />

2 AT I/F Connector<br />

3 Pin 1 (on Power Connector)<br />

4 Pin A<br />

dlabr282<br />

CD-ROM (Master)<br />

dlabr283<br />

ZIP Drive (Slave)<br />

1 Jumper block<br />

2 Slave (Drive 1, factory setting)<br />

3 Cable Select<br />

4 Master (Drive D)<br />

5 reserved (do not use!)<br />

dlabr284<br />

5.8 2001-01-02 /PN 9009 <strong>AGFA</strong> d-<strong>lab.3</strong>


Repair<br />

Main-PC<br />

Operating System<br />

Windows NT 4.0 / SP6<br />

Radio Shielding<br />

EN 55022 Class B<br />

<strong>AGFA</strong> d-<strong>lab.3</strong> 2001-01-02 /PN 9009 5.9


Main-PC<br />

Repair<br />

Functional Description<br />

The d-<strong>lab.3</strong> is supplied with a quasi industrial PC. It<br />

is located at the back of the Scanner area.<br />

The Main-PC<br />

− functions together with the d-<strong>lab.3</strong> Main Software<br />

as central control unit for the operation and the<br />

service.<br />

− controls via the Main Software the interaction of<br />

the major assembly groups: Scanner, Printer and<br />

Paper Processor.<br />

− calculates the images to be exposed by the Laser<br />

(the image processing card is located in the<br />

Main-PC).<br />

− serves as input device for digital files (format:<br />

jpg) to be printed, from CD, Zip, disk or PCM-CIA<br />

− controls the monitor (graphic card)<br />

− has an integrated Timer for the control of the<br />

machine (Timer card)<br />

dlabr014<br />

5.10 2001-01-02 /PN 9009 <strong>AGFA</strong> d-<strong>lab.3</strong>


Repair<br />

Main-PC<br />

Repair<br />

Removal of the PC<br />

− Remove the cover (1)<br />

− Upon the first removal:<br />

Loosen the PC fastening screws (2) and (3)<br />

− Pull out the PC, disconnect it and take it out<br />

− Installation in reverse order<br />

dlabr254<br />

<strong>AGFA</strong> d-<strong>lab.3</strong> 2001-01-02 /PN 9009 5.11


Main-PC<br />

Repair<br />

■<br />

5.12 2001-01-02 /PN 9009 <strong>AGFA</strong> d-<strong>lab.3</strong>


Repair<br />

Printer<br />

Contents<br />

General Overview ....................................................................................................................................6.1.1<br />

Sensors and Loads in the Printer.......................................................................................................6.1.1<br />

Mechanical Structure .........................................................................................................................6.1.3<br />

Electrical Structure.............................................................................................................................6.1.4<br />

Paper Magazine Control ....................................................................................................................6.1.7<br />

Designations / List of Signals ................................................................................................................6.2.1<br />

Main Assembly Groups......................................................................................................................6.2.1<br />

Printer Mainboard PF.........................................................................................................................6.2.2<br />

Paper Magazine LH ML .....................................................................................................................6.2.3<br />

Paper Magazine RH MR ....................................................................................................................6.2.4<br />

Sheet Gear SG...................................................................................................................................6.2.5<br />

Transport Unit TU / Sheet Bridge SB.................................................................................................6.2.6<br />

Print Engine PE..................................................................................................................................6.2.7<br />

Laser Module LA................................................................................................................................6.2.8<br />

Laser Unit LU .....................................................................................................................................6.2.8<br />

Lane Distributor LD ............................................................................................................................6.2.9<br />

Sheet Transfer ST............................................................................................................................6.2.10<br />

Printer Mainboard (Printer Mainboard L8.8060.2000.B)..................................................................6.2.11<br />

Printer Mainboard, Connector Allocation .........................................................................................6.2.18<br />

PE_GS01, Connector Assignment...................................................................................................6.2.22<br />

Functional Description ...........................................................................................................................6.3.1<br />

Major Assembly Groups.....................................................................................................................6.3.1<br />

Paper Transport and Exposure..........................................................................................................6.3.2<br />

Switch-on and Reset Behaviour of the Printer...................................................................................6.3.3<br />

Flowcharts, Transport Unit.................................................................................................................6.3.5<br />

Flowcharts, Lane Distributor / Sheet Transfer .................................................................................6.3.10<br />

PF_GS01 – Printer Mainboard..............................................................................................................6.3.15<br />

Functional Description, general .......................................................................................................6.3.15<br />

Functional Description, Image Processing ......................................................................................6.3.16<br />

PF_GS01 - Technical Data ..............................................................................................................6.3.24<br />

Magazine Drive MD................................................................................................................................6.3.26<br />

ML_GS01_GS – LH Magazine Drive MR_GS01_GS - RH Magazine Drive ..................................6.3.26<br />

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

left / right) .........................................................................................................................................6.3.30<br />

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


Printer<br />

Repair<br />

Switching Gear SG ................................................................................................................................6.3.31<br />

SG_GS01 – Switching Gear Control................................................................................................6.3.31<br />

Sheet Stocker SR...................................................................................................................................6.3.33<br />

Sheet Bridge SB.....................................................................................................................................6.3.33<br />

Transport Unit TU ..................................................................................................................................6.3.34<br />

Functional Description......................................................................................................................6.3.34<br />

TU_GS01 (Transport Unit Control)...................................................................................................6.3.35<br />

Print Engine PE......................................................................................................................................6.3.37<br />

Functional Description......................................................................................................................6.3.37<br />

Laser Module....................................................................................................................................6.3.38<br />

PE_GS01..........................................................................................................................................6.3.39<br />

PO_GS01 (L8.8060.2200.) - Power Monitor ....................................................................................6.3.45<br />

LA_GS01 – Distributor Board...........................................................................................................6.3.49<br />

LA_GS05 – Red Laser Diode...........................................................................................................6.3.50<br />

LA_GS07 - Polygonal Drive .............................................................................................................6.3.50<br />

LA_BE04 – AOM Amplifier, blue LA_BE04 – AOM Amplifier, green ...............................................6.3.51<br />

Lane Distributor LD / Sheet Transfer ST .............................................................................................6.3.52<br />

Functional Description......................................................................................................................6.3.52<br />

LD Parameters: Paper Widths / Distribution ....................................................................................6.3.53<br />

LD_GS01 - Lane Distributor Control ................................................................................................6.3.54<br />

RD_GS01 - Back Printer Control......................................................................................................6.3.56<br />

Laser Fundamentals..............................................................................................................................6.3.57<br />

Colour Laser Scanner (Beam generation, Beam processing, Beam deflection) .............................6.3.57<br />

Laser Module (LA)............................................................................................................................6.3.58<br />

Setting the Pixel Coverage ...................................................................................................................6.3.61<br />

6.ii 2001-01-02 /PN 9009 <strong>AGFA</strong> d-<strong>lab.3</strong>


Repair<br />

Printer<br />

Removal, Installation, Adjustment ........................................................................................................6.4.1<br />

Mainboard Replacement (PF_GS01), Edition 3 ................................................................................6.4.2<br />

Replacing the Printer Power Supply Unit.........................................................................................6.4.11<br />

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

ML/MR_LS08 (locking detection).....................................................................................................6.4.13<br />

Replacing the Magazine Drive ML/MR ............................................................................................6.4.14<br />

Replacing the Cutter Unit CU...........................................................................................................6.4.16<br />

Replacing the Switching Gear SG ...................................................................................................6.4.18<br />

Sheet Bridge SB, replacing Parts ....................................................................................................6.4.24<br />

Transport Unit TU, replacing Parts ..................................................................................................6.4.28<br />

Print Engine PE, replacing Parts......................................................................................................6.4.33<br />

Replacing the Laser Module / Laser ................................................................................................6.4.45<br />

Lane Distributor LD, replacing Parts ................................................................................................6.4.54<br />

Sheet Transfer ST, replacing Parts..................................................................................................6.4.62<br />

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


Printer<br />

Repair<br />

■<br />

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


Repair<br />

General Overview<br />

Sensors and Loads in the Printer<br />

Transport unit<br />

Loads:<br />

TU_MO01 Drive takeover section (stepper motor) TU1<br />

TU_MO02 Drive transfer section (stepper motor) TU1<br />

TU_MO03 Drive sheet rotation (stepper motor)<br />

TU_MO04 Drive sheet centring (stepper motor)<br />

TU_MO05 Drive takeover section (stepper motor) TU2<br />

TU_MO06 Drive transfer section (stepper motor) TU2<br />

TU_MO07 Roller lift-off takeover section (linear actuator) TU1<br />

TU_MO08 Roller lift-off transfer section (linear actuator) TU1<br />

TU_MO09 Pressure plate lift-off (linear actuator)<br />

TU_MO10 Roller lift-off takeover section (linear actuator) TU2<br />

TU_MO11 Roller lift-off transfer section (linear actuator) TU2<br />

TU_MO12 Roller lift-off transfer section TU2<br />

TU_MO13 Roller lift-off takeover section TU2<br />

TU_MO21 Sheet flap drive<br />

SB_MO01 Stepper motor sheet flap (on steering roller)<br />

Sensors:<br />

TU_LS01 to TU_LS06 Transport unit light sensors<br />

TU_LS07 Fork light sensor for Home position sheet centring<br />

Sheet transfer ST<br />

Loads / Sensors:<br />

ST_MO01 Drive for sheet transfer, two lanes<br />

ST_LS01/02 free + time constant = ST free<br />

Printer<br />

Exposure unit<br />

Loads:<br />

PE_MO01 Print roller drive (stepper motor)<br />

PE_MO02 Inlet and outlet roller drive (geared DC motor)<br />

PE_MO03 Flap drive (linear drive)<br />

Sensors:<br />

PE_LS01 Light sensor in front of print roller<br />

PE_LS02 Flap control (fork light sensor)<br />

PE_LS03 Light sensor behind print roller<br />

PE_LS04 Speed control of PE_MO02<br />

PE_LS05 Sensor sheet pick-up, BOP sensor<br />

(transmitter/receiver LS)<br />

PE_LS06 Sensor exposure start BOL sensor<br />

(Laser receiver part)<br />

PE_LS07 Paper detection inlet PE (reflected light sensor)<br />

PE_LS08 Print roller rotation control (reflected light sensor)<br />

Paper supply<br />

Paper detection:<br />

ML_LS07 / MR_LS07 / SG_LS21 / SG_LS41 /<br />

SG_LS01 / SG_LS02 /SG_LS03 / SG_LS04<br />

Splice detection :<br />

SG_LS22 / SG_LS42<br />

Lane distributor LD<br />

Loads:<br />

LD_MO01 Drive for LD takeover<br />

LD_MO02 Drive for upright distribution<br />

LD_MO03 Drive for horizontal distribution<br />

LD_MO04 Drive for LD exit<br />

LD_MO05 Drive for back printer<br />

Sensors:<br />

LD_LS01 Signal for back printer<br />

LD_LS02 STOP LD_MO01, parking before distribution<br />

LD_LS03 Paper width 102 (shift yes/no)<br />

LD_LS04 Reference distribution<br />

LD_LS05 STOP LD_MO02, sheet in position<br />

LD_LS06 Check distribution free yes/no<br />

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

LD_LS10 STOP control strip threading<br />

LD_LS11 Control strip yes/no<br />

dlabr122<br />

<strong>AGFA</strong> d-<strong>lab.3</strong> 2001-01-02 /PN 9009 6.1.1


Repair<br />

Printer<br />

Mechanical Structure<br />

dlabr061<br />

1 Lamphouse LH 11 Magazine drive MD (ML)<br />

2 Sheet transfer ST 12 Laser power supply unit<br />

3 Zoom / CCD 13 Power supply PW<br />

4 Lane distributor LD 14 Laser (Fibre)<br />

5 Back printer RD 15 Print engine PE<br />

6 Control strip box SX 16 Laser module<br />

7 Sheet bridge SB 17 Paper transport and exposure<br />

8 Magazine drive MD (MR) 18 Transport unit TU<br />

9 Cutter unit CU 19 Film chuter<br />

10 Sheet gear SG 20 Sheet stocker SR<br />

<strong>AGFA</strong> d-<strong>lab.3</strong> 2001-01-02 /PN 9009 6.1.3


Printer<br />

Repair<br />

Electrical Structure<br />

dlabr051<br />

1 Lane distributor control 10 Laser power supply<br />

2 Back printer control 11 Blue-Green Laser (beam generation)<br />

3 CCD and Zoom electronic 12 Laser module (beam processing)<br />

4 Paper magazine drive RHS 13 Laser electronic<br />

5 Paper transport control 14 Red Laser diode<br />

6 Printer Mainboard PF_GS01 (complete Printer control)<br />

7 Paper magazine drive LHS<br />

8 Printer power supply<br />

9 Power monitor PO_GS01<br />

6.1.4 2001-01-02 /PN 9009 <strong>AGFA</strong> d-<strong>lab.3</strong>


Repair<br />

Printer<br />

Voltage Distribution in the Printer<br />

dlabe148<br />

<strong>AGFA</strong> d-<strong>lab.3</strong> 2001-01-02 /PN 9009 6.1.5


Printer<br />

Repair<br />

Voltages on the d-<strong>lab.3</strong><br />

24 V switchable measurable Voltage for Printer and Scanner<br />

(switched together !)<br />

36 V switchable measurable Voltage for Printer and Scanner<br />

(switched together!)<br />

28 V not switchable measurable AOM – voltage<br />

22,8<br />

V<br />

switchable and<br />

interruptible on<br />

primary side by<br />

Interlock switch<br />

measurable<br />

Scanner lamp voltage<br />

5 V not switchable measurable Scanner – Microcontroller voltage<br />

± 15<br />

V<br />

not switchable measurable Scanner and red Laser diode<br />

(switched together!)<br />

6,5 V not switchable measurable 5 V Printer – Microcontroller voltage<br />

± 9 V not switchable measurable Analogue voltage<br />

Laser Remote<br />

input<br />

(switchable)<br />

Laser Remote<br />

input<br />

(switchable)<br />

can be<br />

checked via<br />

SPI Power<br />

module<br />

can be<br />

checked via<br />

SPI Power<br />

module<br />

Unloading circuit on the Laser:<br />

− after switch-on approx. 20 min until a stable status is<br />

reached<br />

− after switch-off approx. 5 min for the fan afterrun<br />

Circuit of the Standby mode:<br />

− after activation and switch-back approx. 3 min until a<br />

stable status is reached<br />

Available test points result from the descriptions<br />

of the individual printed circuits.<br />

see Register 6.3<br />

6.1.6 2001-01-02 /PN 9009 <strong>AGFA</strong> d-<strong>lab.3</strong>


Repair<br />

Printer<br />

Paper Magazine Control<br />

dlabe139<br />

SG<br />

MK<br />

SU<br />

ML<br />

MR<br />

Sheet gear SG<br />

Paper magazine lock MK<br />

Shutter SU<br />

Paper magazine drive left ML<br />

Paper magazine drive right MR<br />

<strong>AGFA</strong> d-<strong>lab.3</strong> 2001-01-02 /PN 9009 6.1.7


Printer<br />

Repair<br />

■<br />

6.1.8 2001-01-02 /PN 9009 <strong>AGFA</strong> d-<strong>lab.3</strong>


Repair<br />

Printer<br />

Designations / List of Signals<br />

Main Assembly Groups<br />

BK<br />

CU<br />

LD<br />

LA<br />

LU<br />

MD<br />

MK<br />

ML<br />

MR<br />

PE<br />

PF<br />

PO<br />

PP<br />

PR<br />

RD<br />

SB<br />

SG<br />

SR<br />

ST<br />

SU<br />

SX<br />

TU<br />

Block assy<br />

Paper Cutter<br />

Lane Distributor<br />

Laser Module<br />

Laser Unit<br />

Magazine Drive<br />

Magazine Lock<br />

Paper Magazine Left<br />

Paper Magazine Right<br />

Print Engine<br />

Printer Frame<br />

Power Module<br />

(Power Monitor + Printer Power Supply)<br />

Printer Parts<br />

Printer<br />

Back Printer<br />

Sheet Bridge (transfer SG → TU)<br />

Sheet Gear (transfer ML/MR → SB)<br />

Sheet Stocker<br />

Sheet Transfer (transfer ST → Paper Processor)<br />

Shutter<br />

Strip box<br />

Transport unit<br />

The loads and sensors are allocated to the<br />

assembly groups by means of shortcuts, e.g.:<br />

PE_GS01 = printed circuit in the print engine<br />

For more detailed explanations see Names of<br />

components / Allocation of assembly groups and<br />

parts functions in Register 2.<br />

<strong>AGFA</strong> d-<strong>lab.3</strong> 2001-01-02 /PN 9009 6.2.1


Printer<br />

Repair<br />

Printer Mainboard PF<br />

Printed circuit Part number Function<br />

PF_GS01 8.8060.2000. Printer Mainboard; SPI Mainboard for Printer section<br />

PO_GS01 8.8060.2200. Power Monitor; monitoring and control of the voltage supply (incl.<br />

laser)<br />

Motor Part number Function<br />

PF_MO01 — Fan, printer frame<br />

Power supply Part number Function<br />

PF_BE01 7.8060.PWA1. Printer power supply unit<br />

Microswitch Part number Function<br />

PF_MS01 — Switch for front door<br />

PF_MS02 — Switch for Print Engine<br />

6.2.2 2001-01-02 /PN 9009 <strong>AGFA</strong> d-<strong>lab.3</strong>


Repair<br />

Printer<br />

Paper Magazine LH ML<br />

Printed circuit Part number Function assigned to<br />

ML_GS01 8.8060.2150. Magazine control RH / LH Distributor board<br />

ML_GS02 — Magazine coding ML_LS01 to ML_LS06<br />

ML_GS03 50A-SN4 Paper detection SU ML_LS07<br />

ML_GS04 50A-LED Magazine change ML_LA01, ML_LA02<br />

ML_GS05 — Magazine lock detection ML_LS08<br />

Light sensor Type Function on Printed Circuit<br />

ML_LS01 Reflex-LS Sensor 1 magazine coding LH ML_GS02<br />

ML_LS02 Reflex-LS Sensor 2 magazine coding LH ML_GS02<br />

ML_LS03 Reflex-LS Sensor 3 magazine coding LH ML_GS02<br />

ML_LS04 Reflex-LS Sensor 4 magazine coding LH ML_GS02<br />

ML_LS05 Reflex-LS Sensor 5 magazine coding LH ML_GS02<br />

ML_LS06 Reflex-LS Sensor 6 magazine coding LH ML_GS02<br />

ML_LS07 Reflex-LS Sensor paper detection shutter LH ML_GS03<br />

ML_LS08 Fork light sensor Sensor magazine lock detection LH ML_GS05<br />

LED Type Function on Printed Circuit<br />

ML_LA01 LED indication LED magazine control LH ML_GS04<br />

Motor Type Function<br />

ML_MO01 Stepper motor Drive paper transport magazine LH<br />

ML_MO02 Stepper motor Drive magazine core LH<br />

Magnet Type Function<br />

ML_MG01 Magnetic coupling Coupling roller set of magazine LH<br />

ML_MG02 Magnetic coupling Coupling roller set of cutter LH<br />

<strong>AGFA</strong> d-<strong>lab.3</strong> 2001-01-02 /PN 9009 6.2.3


Printer<br />

Repair<br />

Paper Magazine RH MR<br />

Printed circuit Part number Function assigned to<br />

MR_GS01 8.8060.2150. Magazine control RH / LH Distributor board<br />

MR_GS02 — Magazine coding MR_LS01 to MR_LS06<br />

MR_GS03 50A-SN4 Paper detection-SU MR_LS07<br />

MR_GS04 50A-LED Magazine change MR_LA01, MR_LA02<br />

MR_GS05 — Magazine lock detection MR_LS08<br />

Light sensor Type Function on Printed Circuit<br />

MR_LS01 Reflex-LS Sensor 1 magazine coding RH MR_GS02<br />

MR_LS02 Reflex-LS Sensor 2 magazine coding RH MR_GS02<br />

MR_LS03 Reflex-LS Sensor 3 magazine coding RH MR_GS02<br />

MR_LS04 Reflex-LS Sensor 4 magazine coding RH MR_GS02<br />

MR_LS05 Reflex-LS Sensor 5 magazine coding RH MR_GS02<br />

MR_LS06 Reflex-LS Sensor 6 magazine coding RH MR_GS02<br />

MR_LS07 Reflex-LS Sensor paper detection shutter RH MR_GS03<br />

MR_LS08 Fork light sensor Sensor magazine lock detection RH MR_GS05<br />

LED Type Function on Printed Circuit<br />

MR_LA01 LED indication LED magazine control RH MR_GS04<br />

Motor Type Function<br />

MR_MO01 Stepper motor Drive paper transport magazine RH<br />

MR_MO02 Stepper motor Drive magazine core RH<br />

Magnet Type Function<br />

MR_MG01 Magnetic coupling Coupling roller set of magazine LH<br />

MR_MG02 Magnetic coupling Coupling roller set of cutter LH<br />

6.2.4 2001-01-02 /PN 9009 <strong>AGFA</strong> d-<strong>lab.3</strong>


Repair<br />

Printer<br />

Sheet Gear SG<br />

Printed circuit Part number Function assigned to<br />

SG_GS01 8.8060.2070. CU-SG-control SG_LS05, SG_LS06<br />

SG_GS02 8.8060.2180. SG-distributor Distributor board<br />

SG_GS03 8.8060.2130. Reflex sensor_3 SG_LS01<br />

SG_GS04 8.8060.2120. Reflex sensor_2 SG_LS02<br />

SG_GS05 8.8060.2120. Reflex sensor_2 SG_LS03<br />

SG_GS06 8.8060.2130. Reflex sensor_3 SG_LS04<br />

SG_GS07 52A-SN1-B Cutter position LH SG_LS23, SG_LS24<br />

SG_GS08 50A-SN3 Paper detection cutter LH SG_LS21, SG_LS22<br />

SG_GS09 52A-SN1-A Cutter position RH SG_LS43, SG_LS44<br />

SG_GS10 50A-SN3 Paper detection cutter RH SG_LS41, SG_LS42<br />

Light sensor Type Function on Printed Circuit<br />

SG_LS01 Reflex LS Paper detection magazine RH SG_GS03<br />

SG_LS02 Reflex LS Paper detection magazine LH SG_GS04<br />

SG_LS03 Reflex LS Remaining length detection for SG_GS05<br />

magazine LH<br />

SG_LS04 Reflex LS Remaining length detection for SG_GS06<br />

magazine RH<br />

SG_LS05 — CU-SG-control SG_GS01<br />

SG_LS06 — CU-SG-control SG_GS01<br />

SG_LS21 Reflex LS Paper detection cutter LH SG_GS08<br />

SG_LS22 Reflex LS Splice detection LH SG_GS08<br />

SG_LS23 Fork light sensor Home position cutter LH SG_GS07<br />

SG_LS24 Fork light sensor End of cut, cutter LH SG_GS07<br />

SG_LS41 Reflex LS Paper detection cutter RH SG_GS10<br />

SG_LS42 Reflex LS Splice detection RH SG_GS10<br />

SG_LS43 Fork light sensor Home position cutter RH SG_GS09<br />

SG_LS44 Fork light sensor End of cut, cutter RH SG_GS09<br />

Motor Type Function<br />

SG_MO01 Stepper motor Drive paper transport gear<br />

SG_MO02 Stepper motor Drive gear position<br />

SG_MO05 Fan Fan paper supply<br />

SG_MO21 DC motor Drive cutter LH<br />

SG_MO41 DC motor Drive cutter RH<br />

<strong>AGFA</strong> d-<strong>lab.3</strong> 2001-01-02 /PN 9009 6.2.5


Printer<br />

Repair<br />

Transport Unit TU / Sheet Bridge SB<br />

The Sheet Bridge (SB) is a part of the Transport<br />

Unit (TU), and therefore assigned to it.<br />

Printed circuit Part number Function assigned to<br />

TU_GS01 8.8060.2030. TU-Distributor Distributor board<br />

TU_GS02 8.8060.2110. Reflex sensor_1 TU_LS01<br />

TU_GS03 8.8060.2110. Reflex sensor_1 TU_LS02<br />

TU_GS04 8.8060.2110. Reflex sensor_1 TU_LS03<br />

TU_GS05 8.8060.2110. Reflex sensor_1 TU_LS05<br />

TU_GS06 8.8060.2110. Reflex sensor_1 TU_LS06<br />

Light sensor Type Function on Printed Circuit<br />

TU_LS01 Reflex LS Inlet takeover section TU1:<br />

TU_GS02<br />

Paper detection before 1st roller set<br />

TU_LS02 Reflex LS Exit takeover section TU1:<br />

TU_GS03<br />

Paper detection after turntable, before last<br />

roller set<br />

TU_LS03 Reflex LS Inlet takeover section TU1:<br />

TU_GS04<br />

Paper detection after sheet centring<br />

TU_LS05 Reflex LS Inlet takeover section TU2:<br />

TU_GS05<br />

Paper detection after Print Engine<br />

TU_LS06 Reflex LS Exit takeover section TU2:<br />

TU_GS06<br />

Paper detection at transfer TU to LD after last<br />

roller set<br />

TU_LS07 Fork light sensor Home position sheet centring —<br />

Motor Type Function<br />

TU_MO01 Stepper motor Drive takeover section TU1 – from SG to TU<br />

8.8888.8888.<br />

TU_MO02 Stepper motor Drive transfer section TU1 – from TU to PE<br />

TU_MO03 Stepper motor Drive sheet rotation<br />

TU_MO04 Stepper motor Drive sheet centring<br />

TU_MO05 Stepper motor Drive takeover section TU2 – from PE to TU<br />

TU_MO06 Stepper motor Drive transfer section TU2 – from TU to LD<br />

TU_MO07 Linear actuator Roller lift-off takeover section TU1<br />

TU_MO08 Linear actuator Roller lift-off transfer section TU1<br />

TU_MO09 Linear actuator Turntable lift-off<br />

TU_MO10 Linear actuator Roller lift-off takeover section TU2<br />

TU_MO11 Linear actuator Roller lift-off transfer section TU2<br />

TU_MO12 Linear actuator Roller lift-off transfer section TU2<br />

TU_MO13 Linear actuator Roller lift-off takeover section TU1<br />

TU_MO21 Stepper motor Drive sheet bridge<br />

SB_MO01 Stepper motor Drive sheet bridge guide roller (in TU)<br />

6.2.6 2001-01-02 /PN 9009 <strong>AGFA</strong> d-<strong>lab.3</strong>


Repair<br />

Printer<br />

Print Engine PE<br />

Printed circuit Part number Function assigned to<br />

PE_GS01 8.8060.2170. PE distributor Distributor board<br />

PE_GS02 8.8060.2050. BOL: Laser detection PE_LS06<br />

PE_GS03 8.8060.2060. BOP: Sheet detection PE_LS05<br />

PE_GS04 8.8060.2110. Reflex sensor_1 PE_LS01<br />

PE_GS05 8.8060.2110. Reflex sensor_1 PE_LS03<br />

PE_GS06 8.8060.2110. Reflex sensor_1 PE_LS07<br />

Light sensor Type Function on Printed Circuit<br />

PE_LS01 Reflex LS LS before printing roller PE_GS04<br />

PE_LS02 Fork light sensor LS for flap control actuator —<br />

PE_LS03 Reflex LS LS after printing roller PE_GS05<br />

PE_LS04 Fork light sensor Speed control for PE_MO02 —<br />

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

PE_LS06 Laser receiver part Sensor exposure start (BOL) PE_GS02<br />

PE_LS07 Reflected light LS Paper detection inlet PE PE_GS06<br />

Motor Type Function<br />

PE_MO01 Stepper motor<br />

Drive printing roller<br />

8.8060.4800.<br />

PE_MO02 DC motor Drive feed and exit roller PE<br />

PE_MO03 Linear actuator Flap control on PE<br />

<strong>AGFA</strong> d-<strong>lab.3</strong> 2001-01-02 /PN 9009 6.2.7


Printer<br />

Repair<br />

Laser Module LA<br />

Some sensors and loads (see *) cannot be replaced<br />

individually. In case of a defect, replace Laser<br />

module (colour laser recorder 4.4150.1000.)<br />

Printed circuit Part number Function<br />

LA_GS01 * 8.8060.2090. LFB-distributor (LFB = Laser-Feedback)<br />

LA_GS02 * 8.8060.2080. LFB, monitor diode red<br />

LA_GS03 * 8.8060.2080. LFB, monitor diode green<br />

LA_GS04 * 8.8060.2080. LFB, monitor diode blue<br />

LA_GS05 * 8.8394.5880. Voltage regulator LD/MOD;<br />

Voltage regulation laser module<br />

LA_GS06 * 8.8394.5800. L/D-modulator analogue<br />

LA_GS07 * — Polygon drive<br />

LA_GS08 * 8.8060.2080 LFB, monitor diode total<br />

Motor Type Function<br />

LA_MO01 * Stepper motor Drive polarisation filter red<br />

LA_MO02 * Stepper motor Drive polarisation filter green<br />

LA_MO03 * Stepper motor Drive polarisation filter blue<br />

LA_MO04 * Stepper motor Polygon drive<br />

Magnet Type Function<br />

LA_MG01 — Shutter<br />

AOM Type Function<br />

LA_BE04 — AOM amplifier, blue<br />

LA_BE04 — AOM amplifier, green<br />

Laser Unit LU<br />

Diverse Part number Function<br />

LU_BE01 7.8060.LUC1. Laser power supply<br />

LU_BE02 7.8060.LUD0. Laser<br />

6.2.8 2001-01-02 /PN 9009 <strong>AGFA</strong> d-<strong>lab.3</strong>


Repair<br />

Printer<br />

Lane Distributor LD<br />

Printed circuit Part number Function assigned to<br />

LD_GS01 8.8060.2100. LD-distributor Distributor board<br />

LD_GS02 8.8060.2110. Reflex sensor_1 LD_LS08<br />

LD_GS03 8.8060.2110. Reflex sensor_1 LD_LS07<br />

LD_GS04 8.8060.2110. Reflex sensor_1 LD_LS06<br />

LD_GS05 8.8060.2110. Reflex sensor_1 LD_LS05<br />

LD_GS06 8.8060.2110. Reflex sensor_1 LD_LS03<br />

LD_GS07 8.8060.2110. Reflex sensor_1 LD_LS02<br />

LD_GS08 8.8060.2110. Reflex sensor_1 LD_LS10<br />

LD_GS09 8.8060.2110. Reflex sensor_1 LD_LS01<br />

Light sensor Type Function on Printed Circuit<br />

LD_LS01 Reflex LS Paper detection back printer LD_GS09<br />

LD_LS02 Reflex LS Parking position before distribution LD_GS07<br />

LD_LS03 Reflex LS Check of paper width before distribution LD_GS06<br />

LD_LS04 Fork light sensor Reference position horizontal distribution —<br />

LD_LS05 Reflex LS Paper detection after distribution - back LD_GS05<br />

LD_LS06 Reflex LS Paper detection after distribution - front LD_GS04<br />

LD_LS07 Reflex LS Paper detection exit LD back LD_GS03<br />

LD_LS08 Reflex LS Paper detection exit LD front LD_GS02<br />

LD_LS10 Reflex LS Threading stop control strip LD_GS08<br />

Motor Type Function<br />

LD_MO01 Stepper motor Drive takeover section LD<br />

LD_MO02 Stepper motor Drive distribution vertical<br />

LD_MO03 Stepper motor Drive distribution horizontal<br />

LD_MO04 Stepper motor Drive exit station, 2 lanes, separately controllable by magnetic<br />

coupling<br />

LD_MO05 Stepper motor Drive back printer<br />

Magnet Type Function<br />

LD_MG01 Magnetic coupling Magnetic coupling in exit station LD<br />

<strong>AGFA</strong> d-<strong>lab.3</strong> 2001-01-02 /PN 9009 6.2.9


Printer<br />

Repair<br />

Sheet Transfer ST<br />

Printed circuit Part number Function assigned to<br />

ST_GS01 50A-SN2A Paper detection LD_LS11, LD_LS12<br />

ST_GS02 — — —<br />

Light sensor Type Function on Printed Circuit<br />

LD_LS11 Reflex LS Paper detection<br />

LS before sheet transfer (back)<br />

LD_LS12 Reflex LS Paper detection > 152 mm;<br />

LS before sheet transfer (front)<br />

ST_GS01<br />

ST_GS01<br />

6.2.10 2001-01-02 /PN 9009 <strong>AGFA</strong> d-<strong>lab.3</strong>


Repair<br />

Printer<br />

Printer Mainboard (Printer Mainboard L8.8060.2000.B)<br />

Connector Assignment<br />

ST 1: SPI – Interface reserve<br />

PIN Signal name Comment I/O<br />

1 GND GNB reference potential O<br />

2 /RESET_SPI Interface RESET O<br />

3 + 6,5 V Source voltage O<br />

4 + 6,5 V Source voltage O<br />

5 + SDO Data output + O<br />

6 - SDO Data output - O<br />

7 + SDI Data input + I<br />

8 - SDI Data input - I<br />

9 + CLK Clock signal + O<br />

10 - CLK Clock signal - O<br />

11 + SS Chip select + O<br />

12 - SS Chip select - O<br />

13 + INT Operator prompting + I<br />

14 - INT Operator prompting - I<br />

15 GND Reference potential GND O<br />

16 GND Reference potential GND O<br />

ST 2: SPI – Interface reserve<br />

PIN Signal name Comment I/O<br />

1 GND Reference potential GND O<br />

2 /RESET_SPI Interface RESET O<br />

3 + 6,5 V Source voltage O<br />

4 + 6,5 V Source voltage O<br />

5 + SDO Data output + O<br />

6 - SDO Data output - O<br />

7 + SDI Data input + I<br />

8 - SDI Data input - I<br />

9 + CLK Clock signal + O<br />

10 - CLK Clock signal - O<br />

11 + SS Chip select + O<br />

12 - SS Chip select - O<br />

13 + INT Operator prompting + I<br />

14 - INT Operator prompting - I<br />

15 GND Reference potential GND O<br />

16 GND Reference potential GND O<br />

<strong>AGFA</strong> d-<strong>lab.3</strong> 2001-01-02 /PN 9009 6.2.11


Printer<br />

Repair<br />

ST 3: SPI – Interface MR<br />

PIN Signal name Comment I/O<br />

1 GND Reference potential GND O<br />

2 /RESET_SPI Interface RESET O<br />

3 + 6,5 V Source voltage O<br />

4 + 6,5 V Source voltage O<br />

5 + SDO Data output + O<br />

6 - SDO Data output - O<br />

7 + SDI Data input + I<br />

8 - SDI Data input - I<br />

9 + CLK Clock signal + O<br />

10 - CLK Clock signal - O<br />

11 + SS Chip select + O<br />

12 - SS Chip select - O<br />

13 + INT Operator prompting + I<br />

14 - INT Operator prompting - I<br />

15 GND Reference potential GND O<br />

16 GND Reference potential GND O<br />

ST 4: SPI – Interface ML<br />

PIN Signal name Comment I/O<br />

1 GND Reference potential GND O<br />

2 /RESET_SPI Interface RESET O<br />

3 + 6,5 V Source voltage O<br />

4 + 6,5 V Source voltage O<br />

5 + SDO Data output + O<br />

6 - SDO Data output - O<br />

7 + SDI Data input + I<br />

8 - SDI Data input - I<br />

9 + CLK Clock signal + O<br />

10 - CLK Clock signal - O<br />

11 + SS Chip select + O<br />

12 - SS Chip select - O<br />

13 + INT Operator prompting + I<br />

14 - INT Operator prompting - I<br />

15 GND Reference potential GND O<br />

16 GND Reference potential GND O<br />

6.2.12 2001-01-02 /PN 9009 <strong>AGFA</strong> d-<strong>lab.3</strong>


Repair<br />

Printer<br />

ST 5: SPI – Interface TU<br />

PIN Signal name Comment I/O<br />

1 GND Reference potential GND O<br />

2 /RESET_SPI Interface RESET O<br />

3 + 6,5 V Source voltage O<br />

4 + 6,5 V Source voltage O<br />

5 + SDO Data output + O<br />

6 - SDO Data output - O<br />

7 + SDI Data input + I<br />

8 - SDI Data input - I<br />

9 + CLK Clock signal + O<br />

10 - CLK Clock signal - O<br />

11 + SS Chip select + O<br />

12 - SS Chip select - O<br />

13 + INT Operator prompting + I<br />

14 - INT Operator prompting - I<br />

15 GND Reference potential GND O<br />

16 GND Reference potential GND O<br />

ST 6: SPI – Interface PO<br />

PIN Signal name Comment I/O<br />

1 GND Reference potential GND O<br />

2 /RESET_SPI Interface RESET O<br />

3 + 6,5 V Source voltage O<br />

4 + 6,5 V Source voltage O<br />

5 + SDO Data output + O<br />

6 - SDO Data output - O<br />

7 + SDI Data input + I<br />

8 - SDI Data input - I<br />

9 + CLK Clock signal + O<br />

10 - CLK Clock signal - O<br />

11 + SS Chip select + O<br />

12 - SS Chip select - O<br />

13 + INT Operator prompting + I<br />

14 - INT Operator prompting - I<br />

15 GND Reference potential GND O<br />

16 GND Reference potential GND O<br />

<strong>AGFA</strong> d-<strong>lab.3</strong> 2001-01-02 /PN 9009 6.2.13


Printer<br />

Repair<br />

ST 7: SPI – Interface SG<br />

PIN Signal name Comment I/O<br />

1 GND Reference potential GND O<br />

2 /RESET_SPI Interface RESET O<br />

3 + 6,5 V Source voltage O<br />

4 + 6,5 V Source voltage O<br />

5 + SDO Data output + O<br />

6 - SDO Data output - O<br />

7 + SDI Data input + I<br />

8 - SDI Data input - I<br />

9 + CLK Clock signal + O<br />

10 - CLK Clock signal - O<br />

11 + SS Chip select + O<br />

12 - SS Chip select - O<br />

13 + INT Operator prompting + I<br />

14 - INT Operator prompting - I<br />

15 GND Reference potential GND O<br />

16 GND Reference potential GND O<br />

ST 8: SPI – Interface LD<br />

PIN Signal name Comment I/O<br />

1 GND Reference potential GND O<br />

2 /RESET_SPI Interface RESET O<br />

3 + 6,5 V Source voltage O<br />

4 + 6,5 V Source voltage O<br />

5 + SDO Data output + O<br />

6 - SDO Data output - O<br />

7 + SDI Data input + I<br />

8 - SDI Data input - I<br />

9 + CLK Clock signal + O<br />

10 - CLK Clock signal - O<br />

11 + SS Chip select + O<br />

12 - SS Chip select - O<br />

13 + INT Operator prompting + I<br />

14 - INT Operator prompting - I<br />

15 GND Reference potential GND O<br />

16 GND Reference potential GND O<br />

17 CANH CAN – HIGH O<br />

18 CANL CAN - LOW O<br />

19 GND Reference potential GND O<br />

20 GND Reference potential GND O<br />

6.2.14 2001-01-02 /PN 9009 <strong>AGFA</strong> d-<strong>lab.3</strong>


Repair<br />

Printer<br />

ST 9: SPI – Interface PE<br />

PIN Signal name Comment I/O<br />

1 GND Reference potential GND O<br />

2 /RESET_SPI Interface RESET O<br />

3 + 6,5 V Source voltage O<br />

4 + 6,5 V Source voltage O<br />

5 + SDO Data output + O<br />

6 - SDO Data output - O<br />

7 + SDI Data input + I<br />

8 - SDI Data input - I<br />

9 + CLK Clock signal + O<br />

10 - CLK Clock signal - O<br />

11 + SS Chip select + O<br />

12 - SS Chip select - O<br />

13 + INT Operator prompting + I<br />

14 - INT Operator prompting - I<br />

15 GND Reference potential GND O<br />

16 GND Reference potential GND O<br />

ST 19: External programming voltage<br />

PIN Signal name Comment I/O<br />

1 VPP External programming voltage I<br />

2 GND Reference potential GND O<br />

ST 20: External RESET<br />

PIN Signal name Comment I/O<br />

1 /EXT_RESET External RESET I<br />

2 GND Reference potential GND O<br />

ST 23: Control Interface<br />

PIN Signal name Comment I/O<br />

1 GND Reference potential GND O<br />

2 RXD RS 232 Data input I<br />

3 TXD RS 232 Data output O<br />

<strong>AGFA</strong> d-<strong>lab.3</strong> 2001-01-02 /PN 9009 6.2.15


Printer<br />

Repair<br />

ST 26: CAN – Interface<br />

PIN Signal name Comment I/O<br />

1 GND Reference potential GND O<br />

2 CANH CAN – HIGH I/O<br />

3 CANL CAN – LOW I/O<br />

4 GND Reference potential GND O<br />

The connectors ST 21, ST 22,ST 24 and ST 28<br />

have no significance.<br />

Their use does not make sense at present.<br />

ST 31: ISP– Programming connector<br />

PIN Signal name Comment I/O<br />

1 ISPCLK Programming clock O<br />

2 MODE Mode line O<br />

3 ISPDI Prog. data O<br />

4 ISPSDO Read data O<br />

5 ISPEN Enable O<br />

6 ISPRES Reset O<br />

7 + 5 Operating voltage +5 V I<br />

8 GND Reference potential GND I<br />

Jumper Assignment and LED<br />

D 1 = LED_ROT ><br />

Lights when an SPI module has logged in an<br />

Interrupt<br />

J 1 = nc<br />

J 2 = nc<br />

J 4 = nc<br />

J 5 = nc<br />

J 6 = plugged in<br />

ISPEN is passive<br />

Vacant<br />

Not plugged in, CPU works in<br />

normal mode<br />

All displays are passive<br />

CAN termination resistance<br />

active<br />

Test Points<br />

MP 3<br />

MP 4<br />

MP 23<br />

= +5 V<br />

= GND<br />

= Not used (no significance)<br />

6.2.16 2001-01-02 /PN 9009 <strong>AGFA</strong> d-<strong>lab.3</strong>


Repair<br />

Printer<br />

Printer Controller, Structure<br />

XILINX<br />

progr.<br />

Decoder<br />

isp LSI<br />

1032E-70LT<br />

LED - Monitor<br />

D0 - D15<br />

CS<br />

D 0 - D15<br />

P 3.0 - P 3.7<br />

A 0 - A 11<br />

SPI 1<br />

SPI -<br />

Interface<br />

SSC<br />

High - Speed Synchronous Serial Interface<br />

/RD ; /WR<br />

/RESET<br />

SPI 12<br />

CLK<br />

CLK1<br />

CLK2<br />

CLK3<br />

/RESET<br />

/RES<br />

Taktgenerator<br />

CLK 39,32 MHz<br />

CLK 1 19,66 MHz<br />

CLK 2 9,83 MHz<br />

CLK 3 4,91 MHz<br />

RESET<br />

WDT<br />

UB-NMI<br />

CLK 1<br />

/RESET<br />

/NMI<br />

P 3<br />

P 3<br />

µC<br />

C 167 CR<br />

P 1; P 4<br />

P 0<br />

Steuerl.<br />

Adr.<br />

Daten<br />

Adr.<br />

Daten<br />

Decoder<br />

A12 - A19<br />

CS4<br />

isp LSI<br />

1032E-70LT<br />

A12 - A19<br />

CS0 - CS3<br />

CS<br />

HW_ADR 1<br />

bis<br />

HW_ ADR 15<br />

Steuerl.<br />

CAN<br />

CAN-Interface<br />

P 4.5 - P 4.6<br />

RS 232/1<br />

RS 232/2<br />

RS 232/3<br />

RS 232 Interface<br />

P 3.10 - P 3.11<br />

Steuerl.<br />

Adr.<br />

Daten<br />

CS<br />

Flash - Memory<br />

AM 29 F 040<br />

512 k x 8<br />

Flash - Memory<br />

AM 29 F 040<br />

512 k x 8<br />

Flash - Memory<br />

AM 29 F 040<br />

512 k x 8<br />

Flash - Memory<br />

AM 29 F 040<br />

512 k x 8<br />

Bank 1<br />

CS 0<br />

Bank 3<br />

CS 2<br />

INT 0 - 4<br />

P 2.0 - P 2.7<br />

PORT 2<br />

INT 5,6 - SPI<br />

INT 7 - RS 232<br />

16<br />

SRAM<br />

HM 628512<br />

128 k x 8<br />

SRAM<br />

HM 628512<br />

128 k x 8<br />

Bank 2<br />

CS 1<br />

P 7.0 - P 7.7<br />

PORT 7<br />

8<br />

SRAM<br />

HM 628512<br />

128 k x 8<br />

SRAM<br />

HM 628512<br />

128 k x 8<br />

Bank 4<br />

CS 3<br />

P 5.0 - P 5.15<br />

INT 1 ( Timer )<br />

PORT 5<br />

nur Input<br />

P 5.13<br />

16<br />

P 6.5 - P 6.7<br />

PORT 6<br />

reserviert<br />

3<br />

P 8.0 - P 8.7<br />

PORT 8<br />

8<br />

main_con.skd<br />

<strong>AGFA</strong> d-<strong>lab.3</strong> 2001-01-02 /PN 9009 6.2.17


Printer<br />

Repair<br />

Printer Mainboard, Connector Allocation<br />

Bu 1<br />

Middle contact<br />

Housing<br />

Bu 2<br />

Middle contact<br />

Housing<br />

Bu 3<br />

Middle contact<br />

Housing<br />

Video output voltage red channel<br />

0... 600 mV<br />

analogue GND<br />

Video output voltage blue channel<br />

0... 600 mV<br />

analogue GND<br />

Video output voltage green channel<br />

0... 600 mV<br />

analogue GND<br />

Bu 4<br />

LVDS Interface<br />

1 GND<br />

2 GND<br />

3 n.c.<br />

4 AFULL+ + differential Output FIFO-Flag almost full<br />

5 AFULL- – differential Output FIFO-Flag almost full<br />

6 RXCLKIN+ + differential Input Channel Link Receiver Clock<br />

7 RXCLKIN- – differential Input Channel Link Receiver Clock<br />

8 GND<br />

9 Reserve Output (CM2)<br />

10 GND<br />

11 Reserve Input (CM1)<br />

12 RXIN0+ + differential Input Channel Link Receiver data channel 0<br />

13 RXIN0- – differential Input Channel Link Receiver data channel 0<br />

14 B_START+ + differential Output image start (not used)<br />

15 B_START- – differential Output image start (not used)<br />

16 n.c.<br />

17 GND<br />

18 Reserve Output (CM3)<br />

19 GND<br />

20 RXIN2+ + differential Input Channel Link Receiver data channel 2<br />

21 RXIN2- – differential Input Channel Link Receiver data channel 2<br />

22 RXIN1+ + differential Input Channel Link Receiver data channel 1<br />

22 RXIN1- – differential Input Channel Link Receiver data channel 1<br />

24 Reserve Input (CM0)<br />

25 GND<br />

26 GND<br />

ST10<br />

Middle contact<br />

Housing<br />

ST11<br />

Middle contact<br />

Housing<br />

Input measuring voltage laser energy green channel<br />

(0...) 1,87... 2,07V<br />

analogue GND<br />

Input measuring voltage laser energy blue channel<br />

(0...) 1,87... 2,07V<br />

analogue GND<br />

6.2.18 2001-01-02 /PN 9009 <strong>AGFA</strong> d-<strong>lab.3</strong>


Repair<br />

Printer<br />

ST13 Test plug FIFO Operation: n.c<br />

1 PIXB0 Pixel data blue data bit 0<br />

2 PIXB1 Pixel data blue data bit 1<br />

3 PIXB2 Pixel data blue data bit 2<br />

4 PIXB3 Pixel data blue data bit 3<br />

5 PIXB4 Pixel data blue data bit 4<br />

6 PIXB5 Pixel data blue data bit 5<br />

7 PIXB6 Pixel data blue data bit 6<br />

8 PIXB7 Pixel data blue data bit 7<br />

9 PIXB8 Pixel data blue data bit 8<br />

10 PIXB9 Pixel data blue data bit 9<br />

ST14 Test plug FIFO Operation: n.c<br />

1 PIXG0 Pixel data green data bit 0<br />

2 PIXG1 Pixel data green data bit 1<br />

3 PIXG2 Pixel data green data bit 2<br />

4 PIXG3 Pixel data green data bit 3<br />

5 PIXG4 Pixel data green data bit 4<br />

6 PIXG5 Pixel data green data bit 5<br />

7 FIFOCLR FIFO clear<br />

8 FIFOCLK FIFO read clock<br />

9 FIFORD FIFO read enable<br />

10 DARK Dark signal for the red laser diode control<br />

ST15 Test plug FIFO Operation: n.c<br />

1 PIXG6 Pixel data green data bit 6<br />

2 PIXG7 Pixel data green data bit 7<br />

3 PIXG8 Pixel data green data bit 8<br />

4 PIXG9 Pixel data green data bit 9<br />

5 PIXR0 Pixel data red data bit 0<br />

6 PIXR1 Pixel data red data bit 1<br />

7 PIXR2 Pixel data red data bit 2<br />

8 PIXR3 Pixel data red data bit 3<br />

9 PIXR4 Pixel data red data bit 4<br />

10 PIXR5 Pixel data red data bit 5<br />

ST16 Test plug FIFO Operation: n.c<br />

1 PIXR6 Pixel data red data bit 6<br />

2 PIXR7 Pixel data red data bit 7<br />

3 PIXR8 Pixel data red data bit 8<br />

4 PIXR9 Pixel data red data bit 9<br />

5 ZEILENSYNCHRON Line end detection<br />

6 BILDSYNCHRON Image end detection<br />

7 FE FIFO empty<br />

8 FAF FIFO almost full<br />

9 FF FIFO full<br />

10 BILDSTART<br />

<strong>AGFA</strong> d-<strong>lab.3</strong> 2001-01-02 /PN 9009 6.2.19


Printer<br />

Repair<br />

ST17 Trailing cable to the print engine<br />

1 GND<br />

2 GND<br />

3 +BOL + differential Input BOL<br />

4 -BOL – differential Input BOL<br />

5 GND<br />

6 GND<br />

7 +BOP + differential Input BOP<br />

8 -BOP – differential Input BOP<br />

9 +FSS + differential Input Facet sync signal<br />

10 -FSS + differential Input Facetted sync signal<br />

11 +DARK + differential Output Dark signal<br />

12 -DARK – differential Output Dark signal<br />

13 GND<br />

14 GND<br />

ST18 Trailing cable to the LFB distributor<br />

1 +9PM analogue Source voltage +9V<br />

2 AGND_PM AGND_K<br />

3 +DOUTM + differential, serial data output<br />

4 -DOUTM – differential, serial data output<br />

5 +9PM analogue Source voltage +9V<br />

6 AGND_PM AGND_K<br />

7 +DINM + differential, serial data input ADC<br />

8 -DINM – differential, serial data input ADC<br />

9 RGND_PM GND<br />

10 RGND_PM GND<br />

11 -/CS-DAC – differential Output Chip select DAC<br />

12 +/CS-DAC + differential Output Chip select DAC<br />

13 -/CS-ADC – differential Output Chip select ADC<br />

14 +/CS-ADC + differential Output Chip select ADC<br />

15 AGND_PM AGND_K<br />

16 -9PM analogue Source voltage -9V<br />

17 +SCLK + differential Output Serial clock<br />

18 -SCLK – differential Output Serial clock<br />

19 AGND_PM AGND_K<br />

20 -9PM analogue Source voltage -9V<br />

ST25 Analogue Source voltage<br />

1 +9V<br />

2 0V_A (analogue GND)<br />

3 0V_A (analogue GND)<br />

4 -9V<br />

6.2.20 2001-01-02 /PN 9009 <strong>AGFA</strong> d-<strong>lab.3</strong>


Repair<br />

Printer<br />

ST29 Logic Source voltage<br />

1 +6,5V<br />

2 +6,5V<br />

3 +6,5V<br />

4 GND (digital GND)<br />

5 GND (digital GND)<br />

6 GND (digital GND)<br />

ST30 FPGA Boundary Scan Operation: n.c<br />

1 BSCAN-TDI Test Data Input<br />

2 BSCAN-TCK Test Clock<br />

3 BSCAN-TMS Test Mode Select<br />

4 BSCAN-TDO Test Data Output<br />

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

operating voltage and clearing of the configuration<br />

memory as Input held low FPGA in wait state prior to<br />

the configuration start<br />

6 n.c.<br />

ST32 FPGA Down Load Operation: n.c<br />

1 +5V<br />

2 GND<br />

3 CCLK Clock input<br />

4 DONE bi-directional signal, as Output shows the status of the<br />

initialisation, as Input delays the global Logic reset and<br />

the Output enable<br />

5 DIN Data input<br />

6 /PROG initialises the configuration process<br />

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

operating voltage and clearing of the configuration<br />

memory as Input held low FPGA in wait state prior to<br />

the configuration start<br />

8 RSTX Reset FPGA logic<br />

ST 33<br />

ST 34<br />

Test point for EOL signal<br />

Test point for Picture work<br />

ST 35 Read back FPGA Operation: n.c.<br />

1 GND<br />

2 TRIG Trigger<br />

3 RBT Read back trigger<br />

4 RBD Read back date<br />

XS 1 Screen LVDS cable Operation: n.c<br />

XS 2<br />

Screen cable LFB distributor<br />

<strong>AGFA</strong> d-<strong>lab.3</strong> 2001-01-02 /PN 9009 6.2.21


Printer<br />

Repair<br />

PE_GS01, Connector Assignment<br />

ST1 SPI-Interface<br />

1 GND Logic GND of the Printer<br />

2 /RESET Reset input for the Controller<br />

3 +6,5V Logic - Source voltage<br />

4 +6,5V<br />

5 +IN SPI-Input<br />

6 –IN<br />

7 +OUT SPI-Output<br />

8 –OUT<br />

9 +CLK SPI-CLK-Input<br />

10 –CLK<br />

11 +SS Slave-Select- Input<br />

12 –SS<br />

13 +INT Interrupt request Output<br />

14 –INT<br />

15 GND Logic GND of the Printer<br />

16 GND<br />

ST2 Programming connector<br />

1 +5V Programmer power supply<br />

2 /SS Slave-Select<br />

3 nc<br />

4 MOSI SPI-Input<br />

5 PROG Programming signal<br />

6 MISO SPI-Output<br />

7 GND<br />

8 SCK SPI-PROG clock<br />

9 GND<br />

10 RESET<br />

ST3 RS232- Monitor (test plug)<br />

1 GND<br />

2 TXD Output<br />

3 RXD Input<br />

6.2.22 2001-01-02 /PN 9009 <strong>AGFA</strong> d-<strong>lab.3</strong>


Repair<br />

Printer<br />

ST5 RS422 – Connection to the Printer Mainboard<br />

1 GND<br />

2 GND<br />

3 +BOL Begin of Line – Signal Output<br />

4 –BOL<br />

5 GND<br />

6 GND<br />

7 +BOP Begin of Paper – Signal Output<br />

8 –BOP<br />

9 +FSS Facet sync – Signal Output<br />

10 ..<br />

11 +DARK<br />

12 –DARK<br />

13 GND<br />

14 GND<br />

ST6 PE_LS6 (Begin of Line-Sensor)<br />

1 +6,5V Source voltage<br />

2 +BOL Signal<br />

3 GND<br />

4 –BOL Signal<br />

ST7 2-Ph-Stepper motor polarisation filter red<br />

1 W1A<br />

2 W1E<br />

3 W2A<br />

4 W2E<br />

ST8 2-Ph-Stepper motor polarisation filter green<br />

1 W1A<br />

2 W1E<br />

3 W2A<br />

4 W2E<br />

ST9 2-Ph-Stepper motor polarisation filter blue<br />

1 W1A<br />

2 W1E<br />

3 W2A<br />

4 W2E<br />

ST10 2-Ph-Actuator flap drive<br />

1 W1A<br />

2 W1E<br />

3 W2A<br />

4 W2E<br />

<strong>AGFA</strong> d-<strong>lab.3</strong> 2001-01-02 /PN 9009 6.2.23


Printer<br />

Repair<br />

ST11 DC motor supply and exit roller drive<br />

1 V+<br />

2 V-<br />

ST12 PE-LS7 Reflected light sensor print roller rotation control<br />

1 +5V<br />

2 Signal input<br />

3 GND<br />

4 GND<br />

ST13 PE-LS4 Fork light sensor Speed – Sensor supply and exit roller<br />

1 +5V<br />

2 GND<br />

3 Signal input<br />

ST14 PE_LS2 Fork light sensor flap (not used)<br />

1 +5V<br />

2 GND<br />

3 Signal input<br />

ST15 PE_LS5 BOP sensor<br />

1 +5V<br />

2 Signal input (Frequency)<br />

3 GND<br />

4 nc<br />

ST17 PE_LS1 LS in front of print roller<br />

1 +5V<br />

2 Signal input<br />

3 GND<br />

4 GND switched to LED switch-off<br />

ST18 PE_LS3 LS behind print roller<br />

1 +5V<br />

2 Signal input<br />

3 GND<br />

4 GND<br />

ST19 Connection for polygonal drive<br />

1 +24V supply voltage<br />

2 PGND<br />

3 LOCKED Feedback „f_END reached“<br />

4 START/STOP ON/OFF of the polygonal drive<br />

5 PGND<br />

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

7 nc<br />

8 F_POLY Generator frequency for polygonal drive<br />

6.2.24 2001-01-02 /PN 9009 <strong>AGFA</strong> d-<strong>lab.3</strong>


Repair<br />

Printer<br />

ST20 Operating voltage supply for analogue voltage<br />

1 +9V<br />

2 AGND<br />

3 –9V<br />

4 AGND<br />

ST21 Connection to the red laser diode triggering (will be modified)<br />

1 +9V Supply voltage<br />

2 AGND<br />

3 -9V Supply voltage<br />

4 AGND<br />

5 nc<br />

6 LAS_OK Feedback<br />

ST22 PE_LS7 LS at input PE<br />

1 +5V<br />

2 Signal input<br />

3 GND<br />

4 GND switched to LED switch-off<br />

ST23 2-Ph stepper motor print roller<br />

1 W1A Winding switched parallel<br />

2 W2A<br />

3 W1E<br />

4 W2E<br />

5 W3A<br />

6 W4A<br />

7 W3E<br />

8 W4E<br />

ST24 Power voltage supply<br />

1 +36V, max. 2A<br />

2 GND f. 36V<br />

3 +24V, max. 3A<br />

4 GND f. 24V<br />

ST27 Shutter connection (always linked with 24V)<br />

1 +24V<br />

2 PGND<br />

ST28 Spare sensor not mounted<br />

1 +5V<br />

2 Signal input<br />

3 GND<br />

4 Nc<br />

<strong>AGFA</strong> d-<strong>lab.3</strong> 2001-01-02 /PN 9009 6.2.25


Printer<br />

Repair<br />

ST29 Pin connector strip as test pins<br />

1 +5V<br />

2 GND<br />

3 PE_LS2<br />

4 LASD_OK<br />

5 PE_LS4<br />

6 PE_LS3<br />

7 PE_LS1<br />

8 PE_LS8<br />

9 PE_LS7<br />

10 f_BOP<br />

ST30 LED heater<br />

1 +24V, max. 2A<br />

2 PGND<br />

■<br />

6.2.26 2001-01-02 /PN 9009 <strong>AGFA</strong> d-<strong>lab.3</strong>


Repair<br />

Printer<br />

Functional Description<br />

Major Assembly Groups<br />

dlabr061<br />

1 Lamphouse LH 11 Magazine drive MD (ML)<br />

2 Sheet transfer ST 12 Laser power supply unit<br />

3 Zoom / CCD 13 Power supply PW<br />

4 Lane distributor LD 14 Laser (Fibre)<br />

5 Back printer RD 15 Print engine PE<br />

6 Control strip box SX 16 Laser module<br />

7 Sheet bridge SB 17 Paper transport and exposure<br />

8 Magazine drive MD (MR) 18 Transport unit TU<br />

9 Cutter unit CU 19 Film chuter<br />

10 Sheet gear SG 20 Sheet stocker SR<br />

<strong>AGFA</strong> d-<strong>lab.3</strong> 2001-01-02 /PN 9009 6.3.1


Printer<br />

Repair<br />

Paper Transport and Exposure<br />

− The print size is cut immediately after the paper<br />

has been extracted from the magazine (CU).<br />

− The single prints are advanced by means of a<br />

sheet gear (SG) which allows free selection of<br />

access to the magazines.<br />

− The sheet bridge (SB) feeds the single sheet into<br />

the transport unit (TU).<br />

− When the paper is drawn out of the RH<br />

magazine, the sheet is transported into the sheet<br />

stocker (SR) by the sheet rocker (SR) after the<br />

stop.<br />

When the rocker has changed position, the sheet<br />

is fed into the TU via the sheet bridge.<br />

− In the transport unit (TU) the sheet is turned (if<br />

required), centred and advanced to the print<br />

roller in the print engine (PE).<br />

− The paper is exposed in the print engine. The<br />

complete Laser module (LM) with the guide<br />

mirror sits on the print engine.<br />

− The exposed sheets are transmitted to the lane<br />

distributor (LD) in the exit area of the transport<br />

unit (TU). In the lane distributor, the following<br />

operations are performed:<br />

− Back print (2 lines)<br />

− Distribution of the exposed single sheets on<br />

2 lanes or<br />

− Mismatch compensation for larger sizes<br />

(required because of the difference between<br />

the centred advance in the Printer and in the<br />

Paper Processor)<br />

− The sheet transfer (ST) advances the sheets in<br />

pairs or offset to the Paper Processor.<br />

The Printer frame carrying the above assembly<br />

groups comprises in addition the Scanner, the<br />

power supply with all associated printed circuits<br />

(GS) and the wiring. The frame ensures the<br />

required light-tightness.<br />

All assembly groups are accessible from the front<br />

or from the left side through the doors.<br />

6.3.2 2001-01-02 /PN 9009 <strong>AGFA</strong> d-<strong>lab.3</strong>


Repair<br />

Printer<br />

Switch-on and Reset Behaviour of the Printer<br />

Switch-on Behaviour of the Machine<br />

− Main switch (1) on the Paper Processor ON<br />

− Mains voltage present on the Main-PC<br />

− Main-PC in Sleep mode (Timer plug-in unit in<br />

operation)<br />

− Printer and Scanner unit dead<br />

dlabr125<br />

The Timer switches on the Main-PC in<br />

accordance with the preset switch-on time<br />

1 Main switch<br />

2 RCD device<br />

The operating and user systems are booted<br />

The mains voltage for the Paper Processor and<br />

the power supply unit of the Printer / Scanner (via<br />

interface RS232) is switched on<br />

All secondary voltages (except the 24V/36V<br />

motor, laser, lamp voltage) are switched on<br />

The booting on the Printer Mainboard is started;<br />

all registers are initialised<br />

The FPGA is loaded (freely programmable logic<br />

circuit)<br />

Command interface to the Main-PC available<br />

Initialisation of the SPI interface (prerequisite:<br />

Reset by the Printer-µC on P4.4 inactive)<br />

The power voltages are switched on by a<br />

command of the Main-PC via the Printer<br />

Mainboard<br />

Check of the status of the motor voltages by the<br />

AVR Controller on the SPI interfaces<br />

<strong>AGFA</strong> d-<strong>lab.3</strong> 2001-01-02 /PN 9009 6.3.3


Printer<br />

Repair<br />

Behaviour upon Printer Shut-down<br />

− The Main-PC triggers a command to switch off<br />

the power voltages<br />

− The AVR Controllers supply a voltage failure<br />

message<br />

− The Main-PC switches off the supply voltage of<br />

the power supply unit<br />

Reset of the Main PC<br />

A Reset sent by the Main PC to the Printer µC can<br />

be generated via a separate line. This Reset also<br />

resets the AVR Controllers, i.e. all motors are<br />

stopped.<br />

The AVR Controller in the power monitor is not<br />

reset automatically and can thus remain in the old<br />

switching status.<br />

6.3.4 2001-01-02 /PN 9009 <strong>AGFA</strong> d-<strong>lab.3</strong>


Repair<br />

Printer<br />

Flowcharts, Transport Unit<br />

Paper Feed (Magazines, Rocker, Bridge)<br />

SG_LS02<br />

free<br />

yes<br />

LH magazine<br />

Which<br />

magazine?<br />

RH magazine<br />

Switch rocker<br />

Switch rocker<br />

TU_LS01<br />

free<br />

TU_LS01<br />

free<br />

Remove paper from magazine<br />

Cut paper<br />

Rewind paper<br />

Remove paper from magazine<br />

Cut paper<br />

Rewind paper<br />

Switch rocker<br />

Transport up to TU_LS01<br />

dlabrfe01<br />

<strong>AGFA</strong> d-<strong>lab.3</strong> 2001-01-02 /PN 9009 6.3.5


Printer<br />

Repair<br />

Sheet Rotation / Sheet Centring<br />

no<br />

Sheet


Repair<br />

Printer<br />

Roller Feed<br />

Paper in<br />

TU_LS04 and<br />

sheet centring<br />

ready<br />

yes<br />

PE_LS01<br />

free<br />

yes<br />

Transport up to PE_LS01<br />

Timer<br />

run down and<br />

image data<br />

confirmed<br />

yes<br />

Put on sheet<br />

Open TU_TR02<br />

Start Timer<br />

dlabfe03<br />

<strong>AGFA</strong> d-<strong>lab.3</strong> 2001-01-02 /PN 9009 6.3.7


Printer<br />

Repair<br />

Roller Exit, Part 1<br />

Paper<br />

in PE_LS03<br />

and roller exit<br />

Part 1<br />

ready<br />

yes<br />

Open TU_TR04<br />

no<br />

Sheet


Repair<br />

Printer<br />

Roller Exit, Part 2<br />

TU_LS06<br />

free and<br />

roller exit Part 1<br />

ready<br />

yes<br />

Close TU_TR05<br />

Transport up to TU_LS06<br />

dlabfe05<br />

<strong>AGFA</strong> d-<strong>lab.3</strong> 2001-01-02 /PN 9009 6.3.9


Printer<br />

Repair<br />

Flowcharts, Lane Distributor / Sheet Transfer<br />

Distributor Feed<br />

LD_LS02<br />

free<br />

yes<br />

Transport up to LD_LS02<br />

Control of paper width with<br />

LD_LS03<br />

dlabfe06<br />

6.3.10 2001-01-02 /PN 9009 <strong>AGFA</strong> d-<strong>lab.3</strong>


Repair<br />

Printer<br />

Back Print<br />

Paper in<br />

LD_LS01<br />

yes<br />

Load lead<br />

Enable step pulses<br />

Print<br />

position<br />

reached<br />

yes<br />

Print test<br />

Disable step pulses<br />

dlabfe07<br />

<strong>AGFA</strong> d-<strong>lab.3</strong> 2001-01-02 /PN 9009 6.3.11


Printer<br />

Repair<br />

Sheet Distribution – Two Sheets Side by Side, one Lane<br />

LD_LS05<br />

and LD_LS06<br />

free<br />

yes<br />

Move distributor to the right<br />

Transport up to LD_LS06<br />

left/one lane<br />

Distributor<br />

right<br />

no<br />

LD_LS07<br />

and LD_LS08<br />

free<br />

yes<br />

Centre sheet<br />

Distribute sheet<br />

Transport up to<br />

LD_LS07<br />

LD_LS02<br />

free<br />

yes<br />

Distribute sheet<br />

LD_LS07<br />

and LD_LS08<br />

free<br />

Transport up to LD_LS07<br />

LD_LS08<br />

free<br />

yes<br />

Transport up to LD_LS08<br />

no<br />

Sheet


Repair<br />

Printer<br />

Sheet Transfer to Paper Processor – Two Sheets Side by Side, one Lane<br />

Distributor<br />

ready<br />

yes<br />

no<br />

Transport up to ST_LS01/02<br />

Paper in<br />

ST_LS01 or<br />

ST_LS02<br />

yes<br />

Transfer<br />

ready<br />

Transport up to Paper Processor<br />

Transfer to Paper Processor with Vpp<br />

Vpp = Highest speed<br />

dlabfe09<br />

<strong>AGFA</strong> d-<strong>lab.3</strong> 2001-01-02 /PN 9009 6.3.13


Printer<br />

Repair<br />

Sheet Transfer to Paper Processor – Two Sheets offset<br />

Paper in<br />

ST_LS01 or<br />

ST_LS02<br />

yes<br />

Transport up to Paper Processor<br />

Transfer to Paper Processor with Vpp<br />

Vpp = Highest speed<br />

dlabfe10<br />

6.3.14 2001-01-02 /PN 9009 <strong>AGFA</strong> d-<strong>lab.3</strong>


Repair<br />

Printer<br />

PF_GS01 – Printer Mainboard<br />

Functional Description, general<br />

PF_GS01 (8.8060.2000)<br />

Functions:<br />

1. Image data processing<br />

2. Printer control<br />

In detail:<br />

− Transformation of the serial image data stream<br />

(input) to the 3 parallel currents RGB: serial clock<br />

40 MHz<br />

− Data buffering in the FIFO:<br />

1,2 pixel lines for an image width of 8,5 Inch<br />

− Facet correction for each one of the 18 facets for<br />

RGB: < 1%<br />

− Correction Laser noise: ± 4%<br />

− Correction Laser drift<br />

− LUT calculation<br />

− Pixel delay: up to 16 pixels<br />

− Pixel shift in 1/8 pixel steps<br />

− Definition of the line beginning by means of the<br />

register value<br />

− Pixel register for text exposures<br />

− LUT calculation: Adjustment of the densityproportional<br />

image data to the sensitivity of the<br />

paper, taking into account the transfer<br />

characteristics of AOM, Polygon, corrections<br />

dlabr135<br />

<strong>AGFA</strong> d-<strong>lab.3</strong> 2001-01-02 /PN 9009 6.3.15


Printer<br />

Repair<br />

Functional Description, Image Processing<br />

General Task<br />

This part of the printed circuit has the task to<br />

transfer the serial image data stream coming from<br />

the image processing to three parallel data pipelines<br />

(RGB), include various correction mechanisms in<br />

the calculation and make available three analogue<br />

signals whose amplitude and timing are adjusted to<br />

the output medium of the print engine. The<br />

description below follows the signal stream.<br />

LVDS Interface<br />

The image data coming from the image processing<br />

unit is transmitted to the Printer Mainboard via the<br />

LVDS interface by serial transmission.<br />

1. The LVDS Channel Link Receiver DS 90CR284<br />

can receive serial data on 5 line pairs (4 data +<br />

1 clock pair) and convert it to a 28-bit parallel<br />

data word. Four line pairs on the Printer<br />

Mainboard (3 data + 1 clock pair) are used for<br />

the serial transmission and converted to an<br />

18-bit data word (16 Bit pixel data + 2 Bit control<br />

data for the Low and High part). A pixel date<br />

(32 Bit) is composed of two time-multiplex<br />

transmitted 16-bit data words (Low + High part).<br />

The serial clock frequency is 40 Mhz.<br />

2. The differential driver sends the FIFO status<br />

(FAF) via the LVDS interface.<br />

Sync FIFO<br />

The data paralleled by the Channel Link Receiver is<br />

entered in a FIFO. The FIFO is used to buffer and<br />

synchronise the image data for the subsequent<br />

image processing units. It is read with the pixel<br />

clock under Pipeline control. The FIFO consists of<br />

four circuits (each one organised 4096 x 9 Bit) which<br />

are circuited to 4096 x 32 Bit.<br />

For an image width of 8,5 inch, 1,2 pixel lines can<br />

be buffered so that the Retrace time can be used for<br />

the data transfer – reduction of the data rate.<br />

6.3.16 2001-01-02 /PN 9009 <strong>AGFA</strong> d-<strong>lab.3</strong>


Repair<br />

Printer<br />

FPGA<br />

FPGA (Field Programmable Gate Array ): After the<br />

supply voltage has been applied, its function must<br />

be loaded which is done by the Microcontroller (µC),<br />

allowing Updates in the field.<br />

The FPGA represents the central processing unit for<br />

the data pipeline in which the process control, the<br />

pixel processing, error corrections, service modes,<br />

the communication with the µC are implemented.<br />

Communication of the Microcontroller with the<br />

modules is via a<br />

13-bit wide internal data bus. Address, data and<br />

control signals from the µC are latched with the<br />

master clock (60,9 MHz).<br />

FPGA Module:<br />

1. Address decoder<br />

It decodes the synchronised controller addresses<br />

and generates select signals for the individual<br />

modules.<br />

2. Address generator<br />

It minimises the signal lines to the µC (7 instead<br />

of 18 address lines). When a certain field is<br />

addressed, the generator is active. The<br />

addresses for the external LUT red, green, blue<br />

and the internal RAM and ROM are formed. The<br />

µC has only one address for each memory bank.<br />

To address the memory cells of a number n of a<br />

bank, the µC must call the bank address n times,<br />

e.g. 2 18 times when reading or writing an LUT<br />

page of a colour. The address is incremented by<br />

1 at every computer access. The internal address<br />

counter must be cleared by a command prior to<br />

every new memory bank access.<br />

3. Image detector<br />

It stores the 8 low order Bits of the first pixel of<br />

each image in an internal register which can be<br />

read by the µC during the time until the next<br />

image is output and which holds an image<br />

number between 1 and 99.<br />

<strong>AGFA</strong> d-<strong>lab.3</strong> 2001-01-02 /PN 9009 6.3.17


Printer<br />

Repair<br />

4. Begin Off Line (BOL-Module)<br />

It is controlled by the Pipeline control. At the end<br />

of an exposure line, the 4 highest order Bits of<br />

the red pixel bus are separated from the DAC by<br />

the module-internal logic and replaced by the<br />

4 Bit register data and a clock is generated for<br />

the red DAC. This results in an analogue voltage<br />

selectable in 16 steps by the Software and used<br />

to trigger the red laser so that a BOL pulse can<br />

be generated. Apart from this, the initialisation<br />

prerequisites for the triggering of the red laser<br />

diode (Laser off BOL register = 0h, Dark<br />

active) as well as the laser enable/disable control<br />

are materialised in this module after the supply<br />

voltage has been applied.<br />

5. Facet correction<br />

The facet correction is used to compensate minor<br />

colour-dependent differences (


Repair<br />

Printer<br />

Owing to the freely programmable limits, there<br />

is a window comparator for each colour whose<br />

window can be shifted within a certain range<br />

and whose window width is variable. From the<br />

counted errors conclusions can be drawn about<br />

the drift direction which can be compensated by<br />

readjusting the laser energy between the<br />

images as well as about the noise amplitude.<br />

7. LUT address multiplexers<br />

The LUT address multiplexers (RGB) send the<br />

pixel data resulting from the calculation (Laser<br />

enable) or the address generator (Laser disable<br />

and µC access) to the LUT addresses in<br />

accordance with the operating mode. For this,<br />

appropriate control signals are generated for<br />

the LUTs (Chipselect, Output enable, Write<br />

enable) and the LUT data multiplexers (Read<br />

enable, Write enable).<br />

8. LUT data multiplexers<br />

The LUT data multiplexers (RGB) control the bidirectional<br />

Input/Output of the FPGA on the<br />

LUT data lines for the reading or writing. When<br />

the µC is writing, the data is sent from the<br />

internal data bus to the LUT data lines of the<br />

corresponding colour. When the µC reads a<br />

LUT, the data of this LUT is switched to the<br />

internal data bus.<br />

9. LUT Switch<br />

The Printer Mainboard holds memories for two<br />

LUT´s for each colour. The Software switchover<br />

between the two LUT´s happens in this<br />

module. Apart from this, the border exposure is<br />

set until the end of an image.<br />

10. Mode<br />

In this module, the various operating modes of<br />

the data pipeline are set. The Software writes a<br />

7-bit date into the mode register. A mode is set<br />

as a function of the Pipeline control and the<br />

date in the mode register.<br />

<strong>AGFA</strong> d-<strong>lab.3</strong> 2001-01-02 /PN 9009 6.3.19


Printer<br />

Repair<br />

The following modes are available:<br />

Printer mode dyn. Laser noise correction on<br />

Printer mode dyn. Laser noise correction off<br />

Register mode 1<br />

Data is taken from the three colour registers and output after the signal<br />

BOL with the loaded line length until mode 0000 is set.<br />

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

with the loaded line length until mode 0000 is set, every second pixel<br />

being blanked.<br />

Register mode 3 Data is taken from the three colour registers and output at the next BOL<br />

with the loaded line length until mode 0000 is set, always two pixels are<br />

unblanked and two pixels are blanked.<br />

Register mode 4 Data is taken from the three colour registers and output at the next BOL<br />

with the loaded line length until mode 0000 is set, always 256 pixels are<br />

unblanked and 256 pixels are blanked.<br />

Register mode 5 Data is taken from the three colour registers and output quasi statically<br />

without a signal BOL.<br />

FIFO data read by µC<br />

Red channel on max. intensity<br />

Switching of the red laser triggering in the static or dynamic mode<br />

11. Pipeline control<br />

Central control for the data pipeline.<br />

It generates clocks and control signals for the<br />

internal modules and external units (FIFO, LUT,<br />

Latch, DAC, ADC).<br />

It controls the process of a pixel line:<br />

BOL detection = line start start line exposure<br />

end line exposure Retrace (EOL, Dark) <br />

line end, red laser set to BOL value.<br />

A 16-bit counter linked with comparators<br />

generates the control signals for the<br />

corresponding phase. Fixedly programmed<br />

comparators exist for the Retrace and the line<br />

end. The comparators for the start and end of<br />

the line exposure are programmable. They are<br />

used to define the image width and image<br />

position. Other modules for the image start and<br />

end detection, the dark signal generation and a<br />

logic for the facet address generation and<br />

synchronisation have been integrated.<br />

12. Pixel delay<br />

A pixel delay module has been implemented for<br />

each of the three colours (RGB). These<br />

modules are in the data pipeline and allow the<br />

delay of the pixel data of each colour by entire<br />

pixel clocks independent of each other. The<br />

delay can be programmed between 1 and<br />

16 pixels.<br />

6.3.20 2001-01-02 /PN 9009 <strong>AGFA</strong> d-<strong>lab.3</strong>


Repair<br />

Printer<br />

13. Pixel shift<br />

In the Pixel shift module, three independent<br />

clocks are generated for the red, green and<br />

blue DAC. A Software-programmable shift<br />

register exists for each colour. The shift<br />

registers allow the shift of the DAC-Clocks at a<br />

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

of the pixel coverage of the three colours is<br />

possible in steps of 1/8 pixels.<br />

14. Red correction<br />

The red correction comprises an 8-bit wide<br />

register that can be loaded by the Software.<br />

The content of the register is calculated in the<br />

calculation module in the same way as the<br />

noise correction of grn/blu. Hence, a fine<br />

adjustment of the red channel by ± 4% is<br />

possible.<br />

15. Service<br />

In the service module, the 32-bit wide pixel data<br />

is divided to the three channels (RGB).<br />

Depending on the selected operation mode and<br />

the status of the Pipeline control, the pixel data<br />

is put on the data pipeline or sent to the µC<br />

data bus by the FIFO or the registers. Three<br />

implemented 10-bit registers, one for each<br />

colour, enable the Software to save any pixel<br />

value for each colour which can be used for the<br />

internal test image generation or the horizontal<br />

image border exposure (see 10. Mode).<br />

16. Status<br />

In the status module, the different Pipeline<br />

conditions are assessed and error messages<br />

are generated. The µC can check the status.<br />

Some of the signals are indicated in addition by<br />

LEDs on the Mainboard.<br />

The following conditions can be checked and<br />

are indicated:<br />

Status Display Data bit LED<br />

FIFO empty FIFO Flag direct D0 none<br />

FIFO almost full FIFO Flag direct D1 D37 yellow<br />

FIFO full FIFO Flag direct D2 none<br />

End Of Line (EOL) Line retrace D3 D33 yellow<br />

Work Image output D4 D34 yellow<br />

Image Error Image data line unequal exposure line D5 D4 red<br />

Facet synch. Facet counter asynchronous D6 D3 red<br />

Laser status Laser enable/disable D7 none<br />

FIFO-Empty-Latch Saved FIFO empty during exposure (Error) D8 D36 yellow<br />

FIFO-Full-Latch Saved FIFO full during exposure (Error) D9 D38 yellow<br />

<strong>AGFA</strong> d-<strong>lab.3</strong> 2001-01-02 /PN 9009 6.3.21


Printer<br />

Repair<br />

17. Calculation<br />

The noise correction values for green and blue<br />

and the value of the red correction are<br />

calculated with the facet correction values<br />

separately for each colour. As these are small<br />

percentage values, the errors are simply added.<br />

The result is one Byte for each colour that is<br />

limited to FFh in the addition with carryover. In<br />

the mode „Noise correction off“ a fixed value<br />

corresponding to an error of 0 % is added with<br />

the facet correction values instead of the noise<br />

data and red correction. The 8-bit correction<br />

values are used along with the 10-bit pixel data<br />

to form an 18-bit address for each colour for the<br />

following LUTs.<br />

18. Version<br />

Here, a rereadable version number of the FPGA<br />

program is stored.<br />

19. Red laser<br />

There are two different trigger circuits for the<br />

red laser diode at present:<br />

- Only dynamic triggering<br />

- Dynamic and static triggering (Default)<br />

The appropriate triggering can be selected by<br />

the Software. The required control signals for<br />

the red laser are generated.<br />

Look Up Table (LUT)<br />

In the LUTs the density-proportional image data is<br />

adjusted to the output medium while the<br />

characteristics of the lasers and the transfer<br />

characteristics of the actuators are taken into<br />

account. The Printer Mainboard holds two SRAM<br />

banks 256k x 16 for each colour.<br />

It is possible to save LUT data for two paper types<br />

at the same time. The density-proportional pixel<br />

data coming from the FPGA and carrying a<br />

correction value form an 18-bit LUT-address for<br />

each colour. The addressed memory cell holds the<br />

12-bit wide result from the transformation of the<br />

density-proportional pixel data with the paper<br />

characteristic (conversion into performanceproportional<br />

data), the following multiplication with<br />

the reciprocal correction data and subsequent<br />

transformation of the AOM characteristic.<br />

6.3.22 2001-01-02 /PN 9009 <strong>AGFA</strong> d-<strong>lab.3</strong>


Repair<br />

Printer<br />

Latch<br />

The LUTs are topped by a 16-bit Latch for each<br />

colour. The Latches are used to synchronise and<br />

buffer the asynchronous LUT data with the pixel<br />

clock.<br />

<strong>Digital</strong> Analogue Converter (DAC)<br />

The DAC converts the 12-bit wide image date into<br />

an analogue current between 0 and 20 mA as a<br />

function of its clock. The Printer Mainboard holds a<br />

DAC for each colour whose clock can be controlled<br />

independent of the others (see 4.13. Pixel shift).<br />

Current/Voltage Conversion & 50 Ohm Line Adjustment<br />

The output currents are transformed to analogue<br />

voltages which are amplified by operational<br />

amplifiers and ride on the cables with 50 ohms<br />

(RGB). The voltage amplitude is 0... 600mV.<br />

Level Adjustment & Amplification<br />

The circuit filters out the noise part of the energy of<br />

the green and blue laser channels measured by the<br />

monitor diode and amplifies the total noise<br />

amplitude by a factor 10.<br />

High Speed Analogue-<strong>Digital</strong> Converter (ADC)<br />

The 2-channel ADC converts the amplified noise<br />

signals of the green and blue laser channel to one<br />

Byte each. Digitising is in real time for each colour,<br />

i.e. at every pixel clock. The digital values are<br />

validated in the FPGA for the calculation.<br />

<strong>AGFA</strong> d-<strong>lab.3</strong> 2001-01-02 /PN 9009 6.3.23


Printer<br />

Repair<br />

PF_GS01 - Technical Data<br />

Layout<br />

dlabr179<br />

Voltages PF_GS01<br />

+ 5V Logic supply<br />

+ 6,5 V Logic source voltage<br />

+ 9V Supply voltage<br />

– 9V Supply voltage<br />

6.3.24 2001-01-02 /PN 9009 <strong>AGFA</strong> d-<strong>lab.3</strong>


Repair<br />

Printer<br />

Jumpers<br />

J1 not plugged in<br />

J2 not plugged in<br />

J3 plugged in Main clock for data pipeline (60,929170 MHz)<br />

J4 not plugged in<br />

J5 not plugged in The Jumper must not remain plugged in during normal operation!<br />

Only for the LEDs active, the operating conditions can be checked<br />

service: plugged in<br />

J6 plugged in CAN-termination resistor active<br />

LED Display<br />

D1 LED red Lights when the Reset line on the SPI Interface is active<br />

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

D3 LED red Polygon facet not synchronous<br />

D4 LED red Picture error<br />

D33 LED yellow End of line (EOL), during Lineretrace<br />

D34 LED yellow Picture work, lights during the image output<br />

D35 LED yellow no significance<br />

D36 LED yellow FIFO empty latch<br />

lights when a communication error occurs with the LVDS interface<br />

D37 LED yellow FIFO almost full<br />

D38 LED yellow FIFO full latch, communication error with the LVDS interface<br />

Test Points<br />

MP3 +5V<br />

MP4 GND GND against +5V<br />

MP7 +5V (digital)<br />

MP8 +3,3V(digital)<br />

MP9<br />

Video output voltage Red channel<br />

MP10<br />

Video analogue GND<br />

MP11<br />

Video output voltage Blue channel<br />

MP12<br />

Video output voltage Green channel<br />

MP13<br />

Measuring voltage laser energy Green channel<br />

MP14<br />

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

MP15<br />

Measuring voltage laser voltage Blue channel<br />

MP16<br />

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

MP23<br />

Not used<br />

ST33<br />

Test point for EOL signal<br />

ST34<br />

Test point for Picture Work<br />

Connector Allocation<br />

see Printer Mainboard in register 6.2<br />

<strong>AGFA</strong> d-<strong>lab.3</strong> 2001-01-02 /PN 9009 6.3.25


Printer<br />

Repair<br />

Magazine Drive MD<br />

ML_GS01_GS – LH Magazine Drive<br />

MR_GS01_GS - RH Magazine Drive<br />

Functional Description<br />

MD = Magazine Drive<br />

ML_GS01_GS – Magazine Drive 8.8060.2150.<br />

MR_GS01_GS - Magazine Drive 8.8060.2150.<br />

Drive of the Paper magazines:<br />

− Paper Magazine (ML)<br />

− Paper Magazine (MR)<br />

The central control unit SPI (Serial Peripheral<br />

Interface) comprises the following functional<br />

assembly groups:<br />

− DC/DC converter to supply the +5 V operating<br />

voltage<br />

− Voltage monitoring of the +36 V and +24 V power<br />

voltages<br />

− RS232 interface to output the test displays of the<br />

AVR module with the following settings:<br />

− Transfer rate = 19,2 kBaud<br />

− Data bits = 8<br />

− Stop bits = 1<br />

− Parity = None<br />

− Protocol = Xon / Xoff<br />

− RESET generator to link the various RESET<br />

sources.<br />

− Clock generator 8 MHz<br />

− The SPI interface drivers with a transfer rate of<br />

1Mbit/s.<br />

6.3.26 2001-01-02 /PN 9009 <strong>AGFA</strong> d-<strong>lab.3</strong>


Repair<br />

Printer<br />

Paper Magazine Coding<br />

Slide closed<br />

■ Slide open<br />

PATTERN<br />

PAPER SIZE<br />

1 2 3 4 5 6<br />

3.25 inch (82 mm) • • <br />

3.50 inch (89 mm) • • •<br />

3.75 inch (95 mm) • • •<br />

4.00 inch (102 mm) • • • <br />

4.75 inch (120 mm) • • • GLOSSY •<br />

5.00 inch (127 mm) • • MATTE ••<br />

6.00 inch (152 mm) • CUSTOM1 •<br />

6.50 inch (165 mm) • • CUSTOM2 <br />

7.00 inch (178 mm) • •<br />

8.00 inch (203 mm) • •<br />

8.25 inch (210 mm) • <br />

Magazine Drive, Functional Assembly Groups<br />

− Sensor signal for the measuring length (PSG,<br />

NSG): It is sent directly by the SPI module sheet<br />

gear SG_GS01 and defines the<br />

distances between two sensors for which a step<br />

number is defined. This step number is made<br />

available for the calculation of the winding core.<br />

− Magazine Lock that holds the magazine and<br />

sends a signal via LS08 when a magazine has<br />

been put in.<br />

− The magazine change indication informs the<br />

operator when to change a magazine. LED_RT<br />

active = magazine change not allowed!<br />

− The Shutter assembly group is mechanically<br />

coupled to the magazine and sends a signal via<br />

LS07 when paper has been transported out of<br />

the magazine.<br />

− The magazine coding encompasses the<br />

reflected light sensors LS01 to LS06. These<br />

sensors are used to detect the paper type and<br />

the format after the magazine has been put in.<br />

The format is set by the mechanical slides on the<br />

magazine.<br />

− Drive of the magazine core: The motor MO02 is<br />

driven directly by the AVR Controller. It is<br />

responsible for the formation of a paper loop in<br />

the magazine. The loop must be large enough so<br />

that a maximum paper size can be supplied<br />

quickly and at any time by motor1.<br />

<strong>AGFA</strong> d-<strong>lab.3</strong> 2001-01-02 /PN 9009 6.3.27


Printer<br />

Repair<br />

− The paper transport drive MO01 and the<br />

magnetic couplings MG01 and MG02 together<br />

form a functional assembly group. They advance<br />

the photographic paper from the paper loop in<br />

the magazine to the sheet gear assembly group<br />

for further handling.<br />

− The assembly groups of the RH paper magazine<br />

(MR) and the LH paper magazine (ML) only differ<br />

by their mechanical structure.<br />

See also PORT allocation in Register 6.2<br />

Position<br />

ML_GS01 / MR_GS01 are screwed directly to the<br />

magazine drive assy left / right (8.8060.MD01. /<br />

MD02.).<br />

The assembly group must be dismounted to change<br />

the GS.<br />

Layout<br />

dlabr204<br />

6.3.28 2001-01-02 /PN 9009 <strong>AGFA</strong> d-<strong>lab.3</strong>


Repair<br />

Printer<br />

Voltages<br />

+ 5V Logic supply<br />

+ 6,5V Logic source voltage<br />

+ 24V Supply voltage<br />

+ 36V Power voltage supply<br />

Jumper<br />

J1<br />

not plugged in<br />

Only for the service:<br />

plugged in<br />

Activation of the display LEDs, operating conditions can be checked<br />

LED Display<br />

D12 LED green Lights when logic voltage +5V is present<br />

D22 LED red Lights when Reset of the GS is active;<br />

Reset can be triggered manually with S2<br />

D13 LED yellow Only for development work; is active when the AVR Controller is<br />

triggered via an external programming unit<br />

Test Points<br />

MP1 + 5V<br />

MP2 GND GND against +5V<br />

MP3 not used<br />

MP4 not used<br />

MP5 not used<br />

<strong>AGFA</strong> d-<strong>lab.3</strong> 2001-01-02 /PN 9009 6.3.29


Printer<br />

Repair<br />

ML_GS02 / MR_GS02 and ML_GS05 /MR_GS05<br />

(Magazine Coding, Locking Detection; left / right)<br />

Positions<br />

Two printed circuits per magazine compartment:<br />

− Mx_GS02 in the support (magazine coding<br />

detection)<br />

− Mx_GS05 lateral, turned to the Shutter<br />

(locking detection)<br />

6.3.30 2001-01-02 /PN 9009 <strong>AGFA</strong> d-<strong>lab.3</strong>


Repair<br />

Printer<br />

Switching Gear SG<br />

SG_GS01 – Switching Gear Control<br />

Functional Description<br />

SG = Switching Gear<br />

Magazine drive:<br />

SG_GS01 sends the sensor signal for the<br />

measuring length (PSG, NSG) that defines the<br />

distance between two sensors for which a step<br />

number is found. It is needed for the calculation of<br />

the winding core.<br />

Position<br />

SG_GS01 is located on the fan assembly group<br />

below the assembly group SG (1).<br />

1<br />

The electrical connection is interrupted when the<br />

fan assembly group is removed.<br />

dlabr146<br />

<strong>AGFA</strong> d-<strong>lab.3</strong> 2001-01-02 /PN 9009 6.3.31


Printer<br />

Repair<br />

Layout<br />

dlabr205<br />

Voltages<br />

+ 5V Logic supply<br />

+ 24V Supply voltage<br />

+ 36V Power voltage supply<br />

Jumper<br />

J1<br />

not plugged in<br />

Only for service:<br />

plugged in<br />

Activation of the display LEDs, operating conditions can be checked<br />

LED Display<br />

D1 LED red Lights when SPI Controller is Reset<br />

D12 LED green Lights when +5V supply voltage is applied<br />

6.3.32 2001-01-02 /PN 9009 <strong>AGFA</strong> d-<strong>lab.3</strong>


Repair<br />

Printer<br />

Sheet Stocker SR<br />

SR = Sheet Stocker<br />

Sheet buffer (see Arrow) for paper from the RH<br />

paper magazine:<br />

After the cut, the paper is transported into the single<br />

sheet buffer and then by the sheet gear to the print<br />

engine on the same path as the paper from the LH<br />

paper magazine.<br />

dlabr007<br />

Sheet Bridge SB<br />

SB = Sheet Bridge<br />

The sheet bridge (1) is part of the transport unit<br />

(TU). It cannot be removed separately.<br />

dlabr110<br />

<strong>AGFA</strong> d-<strong>lab.3</strong> 2001-01-02 /PN 9009 6.3.33


Printer<br />

Repair<br />

Transport Unit TU<br />

Functional Description<br />

TU = Transport Unit<br />

The transport unit located in the centre of the<br />

paper drive has the following functions:<br />

− Sheet transport from the sheet bridge (SB) to the<br />

print engine (PE)<br />

− Sheet rotation through 90º for horizontally cut<br />

sizes<br />

− Sheet centring in the middle and parallel to the<br />

paper advance direction<br />

− Smooth transfer of the sheet to the print engine<br />

and smooth taking over of the sheet by the print<br />

engine<br />

− Advance of the sheet to the lane distributor (LD)<br />

Prerequisites:<br />

− Paper widths 3,25" - 12"<br />

− Shortest sheet length<br />

− before the rotation 3,25"<br />

− after the rotation 4,75"<br />

− Longest length to be handled 18"<br />

− Largest size to be turned 5x7" (13x18)<br />

dlabr068<br />

See also Block circuit diagram of the transport unit<br />

in Register 6.2 and Flowcharts / Transport unit in<br />

this Register.<br />

Parameter TU: Clock Time<br />

For a productivity of 1.700 prints of the size<br />

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

6.3.34 2001-01-02 /PN 9009 <strong>AGFA</strong> d-<strong>lab.3</strong>


Repair<br />

Printer<br />

TU_GS01 (Transport Unit Control)<br />

Functional Description<br />

Particularity:<br />

The primary logic and the power electronic are<br />

electrically separated.<br />

− Control of the TU assembly group<br />

− Communication with the Printer Mainboard<br />

PF_GS01<br />

Position: Behind the front cover of the TU<br />

dlabr068<br />

Layout<br />

dlabr206<br />

<strong>AGFA</strong> d-<strong>lab.3</strong> 2001-01-02 /PN 9009 6.3.35


Printer<br />

Repair<br />

Voltages<br />

+ 5V Logic supply<br />

+ 36V Power voltage supply<br />

Jumper<br />

ST3<br />

not plugged in<br />

Only for Service:<br />

plugged in<br />

Activation of the display LEDs, operating conditions can be checked<br />

LED Display<br />

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

Hardware Reset) switching part<br />

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

Hardware Reset) switching part<br />

Connectors<br />

ST1<br />

ST5<br />

ST24<br />

ST27<br />

assigned<br />

assigned<br />

assigned<br />

assigned<br />

6.3.36 2001-01-02 /PN 9009 <strong>AGFA</strong> d-<strong>lab.3</strong>


Repair<br />

Printer<br />

Print Engine PE<br />

Functional Description<br />

PE = Print engine<br />

− Smooth taking over of the single sheets from the<br />

transport unit TU<br />

− Exposure transport and exposure control<br />

− Transfer of the exposed single sheet to the<br />

transport unit<br />

Major assembly groups:<br />

− Supporting frame with oscillation stabilisers (1)<br />

− Laser module with guide mirror (2)<br />

− Exposure roller (3)<br />

− Belt assembly group (4)<br />

− Flaps (5)<br />

Laser module:<br />

− LA_GS01 LFB distributor (1)<br />

− LA_GS06 Red Laser diode (2)<br />

− PE_GS01 PE distributor (3)<br />

− LA_GS07 Polygonal drive (4)<br />

− LA_BE04 AOM (5)<br />

− LA_BE04 AOM (6)<br />

dlabr076<br />

dlabrx48<br />

<strong>AGFA</strong> d-<strong>lab.3</strong> 2001-01-02 /PN 9009 6.3.37


Printer<br />

Repair<br />

Laser Module<br />

Warning<br />

The cover plate must never ever be opened.<br />

dlabr158<br />

1 Laser diode (rot)<br />

2 Monitor diode (measures beam intensity)<br />

3 Polygon<br />

4 Postscan<br />

5 Image plane<br />

6 Laserbeam of the Argon ion laser<br />

7 Polarisation filter<br />

8 AOM (blue, green)<br />

9 Laser beam<br />

dlabr175<br />

6.3.38 2001-01-02 /PN 9009 <strong>AGFA</strong> d-<strong>lab.3</strong>


Repair<br />

Printer<br />

PE_GS01<br />

Functional Description<br />

The printed circuit PE_GS01 (L8060.2170.)<br />

− controls all functions of the print engine assembly<br />

group (PE) and the Laser module (LM) and<br />

− reports the corresponding sensor conditions<br />

For this, the commands on the SPI interface in the<br />

microcontroller are checked and the corresponding<br />

actions are initiated.<br />

The SPI interface implemented in the Controller is<br />

triggered by differential drivers (RS422).<br />

Polarisation filter output stages:<br />

The Controller controls the stepper motor output<br />

stages on ST7, ST8 and ST9 by applying the<br />

appropriate winding phases for the half step<br />

operation to a shift register. The windings are<br />

switched dead during the sleep phase.<br />

Flap activation:<br />

The output stage on ST10 for the flap is triggered by<br />

an additional Controller with run-up ramps.<br />

This sub-controller functions with the program of the<br />

flap control when there is zero potential on the input<br />

of the Pins 17,18,19.<br />

Print roller activation:<br />

The output stage on ST23 for the print roller is<br />

controlled by the Controller during the startup curve<br />

and is then switched to a clock defined by the quartz<br />

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

works in half-step mode.<br />

1 Printed circuit PE_GS01<br />

dlabrb48<br />

<strong>AGFA</strong> d-<strong>lab.3</strong> 2001-01-02 /PN 9009 6.3.39


Printer<br />

Repair<br />

Connection of the polygon control:<br />

The polygon drive on the Laser module receives<br />

through ST19:<br />

− the supply voltage of 24V<br />

− an On/Off signal and<br />

− a feedback signal: Required speed reached<br />

The polygon frequency is provided by the quartz<br />

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

ST19.<br />

Feed and exit roller drive (ST11):<br />

It is controlled by an electronic potentiometer set by<br />

the Controller. The corresponding actual parameter<br />

is recorded by the Controller via ST13 as rotation<br />

period of the roller. The control voltage of the 24V<br />

motor varies between 8 and 14V.<br />

Sensor signals:<br />

The signals of the connected light sensors are<br />

directly sent to the Controller. They can be traced<br />

on the male connector strip ST29.<br />

Sheet tip sensor PE_LS05 (2):<br />

The sheet tip sensor supplies via ST15 a frequency<br />

that is proportional to the light reflected by the<br />

paper. The duration of the period is checked by the<br />

Controller and serves to generate the signal BOP on<br />

ST5.<br />

Exposure start sensor PE_LS06 (1):<br />

Connection of the Laser diode control: On ST5, a<br />

differential facet sync signal is applied and a DARK<br />

signal for the Laser diode triggering is received. The<br />

generated BOP signal and the beginning-of-line<br />

signal from ST6 are sent differentially through ST5.<br />

The activation of the red Laser diode is supplied by<br />

an analogue voltage of ±9V through ST21 which is<br />

sent to the printed circuit through ST 20.<br />

1 Polygon control<br />

dlabrc48<br />

dlabr097<br />

dlabr098<br />

6.3.40 2001-01-02 /PN 9009 <strong>AGFA</strong> d-<strong>lab.3</strong>


Repair<br />

Printer<br />

Operating Voltage Supply<br />

The printed circuit E_GS01 gets its supply voltage<br />

through the SPI interface ST1 as source voltage of<br />

+6,5V. This voltage is stabilised to +5V by a linear<br />

regulator and supplies the Controller and the light<br />

sensors.<br />

The power voltages +24V and +36V are supplied<br />

through ST24. These voltages are led to circuit that<br />

serves as current limitation when the module is<br />

plugged under power.<br />

− The +24V are used to energise the feed and exit<br />

roller drive (DC motor) and the polygon drive.<br />

− The 36V supplies all stepper motor drives. This<br />

voltage is also used to derive via a switching<br />

regulator an additional +5V for the output stage<br />

supply, the supply of the sub- controller and the<br />

shift register.<br />

This way, the power unit is electrically separated by<br />

the logic part of the Controller and by this of the<br />

whore Printer. The signal transmission is ensured by<br />

corresponding optocouplers.<br />

A comparator circuit provides for a status signal of<br />

the three supply voltages.<br />

Controller Firmware Update<br />

In addition to the provided Update option via the SPI<br />

interface, the Controller can be programmed<br />

separately via ST2. The sub-controller can only be<br />

programmed on-board by means of a suitable PIN-<br />

Adapter.<br />

Debug Connection<br />

A non real time-capable RS232 monitor output is<br />

available on ST3 for Debut purposes.<br />

<strong>AGFA</strong> d-<strong>lab.3</strong> 2001-01-02 /PN 9009 6.3.41


Printer<br />

Repair<br />

PE_GS01, Layout<br />

dlabr201<br />

Voltages<br />

+ 5V Logic supply<br />

+ 6,5V Logic source voltage<br />

+ 9V Supply voltage<br />

– 9V Supply voltage<br />

+ 24V Supply voltage<br />

+ 36V Power voltage supply<br />

Jumpers<br />

ST25 not plugged in<br />

Only for service: Activation of the display LEDs, operating conditions can be checked<br />

plugged in<br />

ST3<br />

RS232 monitor for Debug purposes (19200,N,1)<br />

ST29<br />

Pin connector as test pins for sensor signals<br />

11 +5V<br />

12 GND<br />

13 PE_LS2<br />

14 LASD_OK<br />

15 PE_LS4<br />

16 PE_LS3<br />

17 PE_LS1<br />

18 PE_LS8<br />

19 PE_LS7<br />

20 f_BOP Output frequency of the BOP sensor approx. 100 Hz without paper,<br />

1 KHz with paper; a significant difference is important because the<br />

thresholds change dynamically<br />

6.3.42 2001-01-02 /PN 9009 <strong>AGFA</strong> d-<strong>lab.3</strong>


Repair<br />

Printer<br />

LED Display<br />

The contacts on ST25 must be plugged in<br />

(= LED enable)<br />

The status is displayed when the assembly group<br />

is initialised (from left to right).<br />

Power ok<br />

Reset<br />

BOP<br />

SV-SPI<br />

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

Lights when the Reset line on the SPI Interface is active<br />

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

assessment of the frequency f_BOP)<br />

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

interface<br />

Test Points<br />

MP1 +5V +5V logic supply of the 6,5V via the SPI Interface<br />

MP2 GND GND against +5V<br />

MP4 Steps Stepper motor clocks for the actuator of the flap control<br />

MP6 P5V Master frequency for the polygonal drive 1,399kHz<br />

MP7 P5V Logic supply 5V derived from 36V<br />

MP8 PGND GND against P5V<br />

MP9 — not used<br />

MP10 BOP BOP-Signal: low when no paper in front of the sensor<br />

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

Connector Assignment<br />

see PE_GS01, connector assignment in<br />

register 6.2<br />

<strong>AGFA</strong> d-<strong>lab.3</strong> 2001-01-02 /PN 9009 6.3.43


Printer<br />

Repair<br />

Circuit Diagram<br />

dlabe137<br />

6.3.44 2001-01-02 /PN 9009 <strong>AGFA</strong> d-<strong>lab.3</strong>


Repair<br />

Printer<br />

PO_GS01 (L8.8060.2200.) - Power Monitor<br />

Functional Description<br />

PO_GS01: L8.8060.2200.<br />

− Control and monitoring of the current supply of<br />

the Printer section<br />

− Control and monitoring of the Laser via the SPI<br />

command interface.<br />

All output voltages are A/D converted and can be<br />

checked. For this, the commands are checked at<br />

the SPI interface in the Microcontroller and the<br />

corresponding actions are initiated.<br />

The SPI interface implemented in the Controller is<br />

activated via differential drivers (RS422).<br />

dlabr034<br />

Remote Power Supply<br />

After the Reset of the Controller, the power<br />

voltages (24V, 36V, 22,5V) are switched off. They<br />

can be switched by the SPI command.<br />

All available output voltages of the power supply<br />

unit are checked at the Remote connection, are<br />

level-converted and are sent to the 11-input 10-Bit<br />

A/D converter.<br />

A simple instrumentation amplification circuit and<br />

their 2-pole measurement ensures that no<br />

inadmissible GND loops occur.<br />

The measuring values are constantly recorded in<br />

a program loop and compared to the reference<br />

values set by commands. The result of the<br />

monitoring is shown by the LEDs which light when<br />

the corresponding voltage is in the required range.<br />

<strong>AGFA</strong> d-<strong>lab.3</strong> 2001-01-02 /PN 9009 6.3.45


Printer<br />

Repair<br />

Laser Remote<br />

After the Reset of the Controller, the Laser is<br />

switched off. It can be switched on, off and in<br />

Standby by the SPI command.<br />

The Laser current and the Laser power are<br />

constantly recorded by the A/D converter and the<br />

result is available in the Controller for the check<br />

by commands.<br />

The reference value of the Laser power can be<br />

set by the Controller by means of an electronic<br />

potentiometer. The last current value is stored in<br />

an EEPROM and is immediately available after<br />

switch-on.<br />

Debug Connection<br />

Debug connection: A non real-time capable<br />

RS232 monitor output is available on ST3 for<br />

Debug purposes. It also supplies the measuring<br />

values of all voltages following a special SPI<br />

command.<br />

Layout<br />

dlabr202<br />

6.3.46 2001-01-02 /PN 9009 <strong>AGFA</strong> d-<strong>lab.3</strong>


Repair<br />

Printer<br />

Voltages<br />

+ 5V Logic supply<br />

+6,5V Logic source voltage<br />

+9V Supply voltage Printer<br />

- 9V Supply voltage Printer<br />

+ 15V Supply voltage Scanner<br />

- 15V Supply voltage Scanner<br />

+22,8V Lamp voltage Scanner<br />

+24V Supply voltage<br />

+ 36V Power voltage supply<br />

Jumpers<br />

Normal condition For the service: Jumper plugged in:<br />

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

connected to the lamp (independent of the Software)<br />

J2 24V_ON Not plugged in 24V power voltage switched on (independent of the<br />

Software)<br />

J3 36V_ON Not plugged in 36V power voltage switched on (independent of the<br />

Software)<br />

J4 LAS_ON Not plugged in Laser switched on (independent of the Software)<br />

LED Display<br />

On PO_GS01 at the top, from left to right<br />

D23 +24V_AOM Lights when AOM amplifier_supply in tolerance<br />

D22 +22,8V Lights when voltage in tolerance<br />

D21 C_LAS_ON Lights when Laser current ≥ 3A<br />

D20 L2 No function<br />

D19 L1 No function<br />

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

D28 +36VP Lights when power supply of the Printer in tolerance<br />

D27 +24VP Lights when power supply of the Printer in tolerance<br />

D26 +5V Lights when logic voltage in tolerance<br />

D25 -15V Lights when analogue voltage of the Scanner in tolerance<br />

D24 +15V Lights when analogue voltage of the Scanner in tolerance<br />

D18 -9V Lights when analogue voltage of the Printer in tolerance<br />

D17 +9V Lights when analogue voltage of the Printer in tolerance<br />

<strong>AGFA</strong> d-<strong>lab.3</strong> 2001-01-02 /PN 9009 6.3.47


Printer<br />

Repair<br />

Test Points<br />

MP1 +5 +5V logic supply derived from the +6,5V<br />

MP2 GND GND against +5V<br />

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

DC_DC converter from the above 5V<br />

MP4 PGND GND against +5VP<br />

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

of the laser power supply (measured against PGND)<br />

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

of the laser power supply (measured against PGND)<br />

Circuit Diagram<br />

dlabe138<br />

6.3.48 2001-01-02 /PN 9009 <strong>AGFA</strong> d-<strong>lab.3</strong>


Repair<br />

Printer<br />

LA_GS01 – Distributor Board<br />

Functional Description<br />

LA_GS01: L8.8060.2090.<br />

− Distributor board with voltage generation<br />

− Distributes the colour signals coming from the<br />

Printer control board PF_GS01. These signals<br />

are used to modulate the AOMs.<br />

dlabrf48<br />

Layout<br />

dlabr169<br />

<strong>AGFA</strong> d-<strong>lab.3</strong> 2001-01-02 /PN 9009 6.3.49


Printer<br />

Repair<br />

LA_GS05 – Red Laser Diode<br />

Functional Description<br />

− Generates the red laser beam<br />

− Ensures a constant temperature for the laser<br />

diode (temperature compensation generated on<br />

the board)<br />

dlabrg48<br />

LA_GS07 - Polygonal Drive<br />

Functional Description<br />

LA_GS07 controls/monitors the polygonal rotation.<br />

The rotation speed must be constant so that the<br />

prints are exposed without distortion.<br />

dlabrc48<br />

6.3.50 2001-01-02 /PN 9009 <strong>AGFA</strong> d-<strong>lab.3</strong>


Repair<br />

Printer<br />

LA_BE04 – AOM Amplifier, blue<br />

LA_BE04 – AOM Amplifier, green<br />

The intensity of the laser beam is influenced for<br />

each pixel in the acousto-optical modulators (AOM)<br />

as a function of the colour information:<br />

− AOM, blue (2)<br />

− AOM, green (1)<br />

dlabrd48<br />

1 AOM amplifier, green LA_BE04<br />

2 AOM amplifier, blue LA_BE04<br />

3 Red Laser diode LA_GS02<br />

<strong>AGFA</strong> d-<strong>lab.3</strong> 2001-01-02 /PN 9009 6.3.51


Printer<br />

Repair<br />

Lane Distributor LD / Sheet Transfer ST<br />

Functional Description<br />

LD = Lane Distributor<br />

ST = Sheet Transfer<br />

The lane distributor ensures the following<br />

functions:<br />

− Transport of the exposed prints from the<br />

transport unit to the Paper Processor (advance to<br />

the Sheet Transfer)<br />

− Back print<br />

− Support of the control strip box and transport of<br />

the control strip to the Paper Processor<br />

− Compensation of the mismatch between the<br />

Printer and the Paper Processor section<br />

dlabr079<br />

1 Sheet Transfer ST<br />

2 Lane Distribution<br />

3 Control strip box<br />

4 Back printer<br />

5 Transport Unit TU<br />

6 Sheet take-over from the TU<br />

7 Sheet transfer to ST<br />

dlabr176<br />

6.3.52 2001-01-02 /PN 9009 <strong>AGFA</strong> d-<strong>lab.3</strong>


Repair<br />

Printer<br />

Sheet Transfer ST<br />

The sheet transfer ST takes the sheet from the lane<br />

distributor and transports it into the DEV tank of the<br />

Paper Processor.<br />

The transfer of the exposed prints from the lane<br />

distributor to the Paper Processor is performed as a<br />

function of the paper width and length:<br />

dlabr062<br />

2 lanes 1 lane<br />

Prints aligned on front Prints offset<br />

edge<br />

Paper width max. 102 mm max. 102 mm > 102 mm<br />

Paper length max. 178 mm > 178 mm max. 256 mm<br />

See also Flowcharts Lane distributor in this<br />

Register<br />

LD Parameters: Paper Widths / Distribution<br />

The middle of the lane distributor is 40 mm closer to<br />

the Printer front edge than the middle of the Paper<br />

Processor.<br />

Paper widths in Inch 2 lanes +Y (to the back) -Y (to the front)<br />

3,25 X 120 0<br />

3,5 X 120 0<br />

3,75 X 120 0<br />

4 X 120 0<br />

4,75 40 -<br />

5 40 -<br />

6 40 -<br />

6,5 40 -<br />

7 40 -<br />

8 40 -<br />

8,25 40 -<br />

3,5 control strip - 95<br />

<strong>AGFA</strong> d-<strong>lab.3</strong> 2001-01-02 /PN 9009 6.3.53


Printer<br />

Repair<br />

LD_GS01 - Lane Distributor Control<br />

Functional Description<br />

LD_GS01: 8.8060.2100.<br />

− Control of the lane distributor assembly groups<br />

(LD)<br />

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

Paper Processor<br />

− Communication with the Printer Mainboard<br />

PF_GS01<br />

Position<br />

Lane Distributor, rear side<br />

dlabr118<br />

6.3.54 2001-01-02 /PN 9009 <strong>AGFA</strong> d-<strong>lab.3</strong>


Repair<br />

Printer<br />

Layout<br />

dlabr203<br />

Voltages<br />

+ 5V Logic supply<br />

+ 6,5V Logic source voltage<br />

+ 24V Supply voltage (required for the output stage of the magnetic coupling)<br />

+ 36V Power voltage supply<br />

Jumpers<br />

J1<br />

Not plugged in<br />

Only for Service: Activation of the display LEDs, operating conditions can be checked<br />

plugged in<br />

J3 Not plugged in (no function)<br />

LED Display<br />

D2 LED red Lights when the SPI Controller is Reset<br />

D54 LED green Lights when +5V supply voltage is applied<br />

Test Points<br />

MP1<br />

GND<br />

MP2 PGND GND against 5V derived from the +36V supply voltage<br />

<strong>AGFA</strong> d-<strong>lab.3</strong> 2001-01-02 /PN 9009 6.3.55


Printer<br />

Repair<br />

RD_GS01 - Back Printer Control<br />

Position<br />

Lane Distributor, bottom<br />

dlabr119<br />

6.3.56 2001-01-02 /PN 9009 <strong>AGFA</strong> d-<strong>lab.3</strong>


Repair<br />

Printer<br />

Laser Fundamentals<br />

Colour Laser Scanner (Beam generation, Beam processing, Beam deflection)<br />

Beam<br />

Beam processing<br />

Beam deflection<br />

generation<br />

←--------------------------------Pre-Scan ---------------------------------------------------------→←-Post-Scan--→<br />

1 Blue channel AOM.b AOM Blue<br />

2 Green channel AOM.g AOM Green<br />

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

4 LED BK.gb Beam combination Blue R, Green T<br />

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

6 Postscan lens White channel BSP.b Beam splitter Blue<br />

7 Photopaper BSP.g Beam splitter Green<br />

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

Int.b Polarisation filter<br />

LD.r Laser diode Red (685 nm)<br />

LK.gb Coupling fibre bundle<br />

PD.b Regulating photodiode Blue<br />

PD.g Regulating photodiode Green<br />

PD.r Regulating photodiode Red<br />

dlabr028<br />

<strong>AGFA</strong> d-<strong>lab.3</strong> 2001-01-02 /PN 9009 6.3.57


Printer<br />

Repair<br />

Laser Module (LA)<br />

The colour laser scanner is used to expose in the<br />

Raster scan digital image data on special laser<br />

paper by means of 3 Laser beams (red, green,<br />

blue).<br />

Main components of the laser tube:<br />

− glass bulb filled with gas<br />

(on the d-<strong>lab.3</strong> Argon)<br />

− 2 mirrors<br />

(the front one is partially transparent, the rear<br />

one is opaque)<br />

− H.V. electrodes to ignite (Ionisation) the gas<br />

1 Mirror (rear)<br />

2 High voltage generation + electrode<br />

3 Coupling + mirror (front)<br />

4 Laser beam<br />

5 Discharge<br />

dlabr147<br />

Beam Generation<br />

The electrons are excited by the applied high<br />

voltage to jump to a higher energy level. When<br />

the gas is discharged at the change to a lower<br />

energy level, light photons are generated which hit<br />

the mirrors, are reflected there and hit other<br />

charged atoms. The atoms that are hit release<br />

several light photons and this phenomenon<br />

continues (principle of a chain reaction).<br />

If the light amplifier in the active medium exceeds<br />

the losses of the waves reflected to and fro<br />

between the mirrors, the laser starts oscillating at<br />

a wave length which is characteristic for the laser<br />

material, producing a stationary wave field<br />

between the mirrors. One of the mirrors is faintly<br />

transparent to outcouple the laser beam from the<br />

resonator.<br />

Many laser materials, like Argon, can supply the<br />

amplification for a large number of different light<br />

frequencies. The Argon ion laser of the d-<strong>lab.3</strong><br />

produces the blue (458 nm) and green (514 nm)<br />

beams which are available for the colour laser<br />

bundle at the coupling point. The fibre bundle<br />

guides the laser beams into the optical module<br />

where they are separated and focused in bundles<br />

by lens systems.<br />

6.3.58 2001-01-02 /PN 9009 <strong>AGFA</strong> d-<strong>lab.3</strong>


Repair<br />

Printer<br />

Intensity of the Laser Beam / AOM<br />

The intensity of the beams is influenced by the<br />

acousto-optical modulators (AOM) for each pixel<br />

as a function of the colour information.<br />

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

the laser is oscillated by a frequency. Depending<br />

on the amplitude of the oscillation, the crystal<br />

becomes more or less translucent and by this<br />

changes the intensity of the laser beam.<br />

The intensity of the red laser diode is regulated<br />

directly by the preceding electronic.<br />

dlabrd48<br />

1 AOM LA_BE04<br />

2 AOM LA_BE04<br />

3 Red Laser diode LA_GS06<br />

Polarisation Filters<br />

The maximum density is set by means of the<br />

polarisation filters.<br />

The polarisation filters are controlled by stepper<br />

motors.<br />

Beam Focusing<br />

The beams are focused by partially transparent<br />

mirrors and are projected on the paper by the<br />

rotating polygonal mirror and a guide mirror.<br />

Start of Exposure<br />

The sheet front edge detection is defined by the<br />

sensor BOP (2), the exposure start, by the sensor<br />

BOL (1).<br />

dlabr097<br />

<strong>AGFA</strong> d-<strong>lab.3</strong> 2001-01-02 /PN 9009 6.3.59


Printer<br />

Repair<br />

Laser Sources<br />

Laser sources Wave length Power in the image<br />

plane<br />

Power at the<br />

monitor diode<br />

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

Green channel (Argon laser) 514,5 nm 320 µW ± 5% 550 µW ± 5%<br />

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

Modulation<br />

All channels can be regulated by polarisation filters (setting accuracy<br />

1,5% in the entire dynamic range.<br />

Red channel<br />

Direct current modulation of the Laser diode, definition of the time/time<br />

period (ref. BOL) for the suppression to calibrate the Feedback diode.<br />

Input signal 0-0,6 V on 50Ω<br />

Green and Blue channel<br />

Analogue AOM, input signal 0-0,6 V on 50Ω<br />

Laser Drift<br />

Gas lasers emit in general only a small<br />

percentage of their power as light, the major part<br />

is transformed to heat.<br />

Caution!<br />

The air exhaustion of the laser exhaust air at the<br />

back of the machine (5) must not be hindered<br />

because the service life of the laser tube drops if it<br />

gets too hot!<br />

6<br />

5<br />

4<br />

3<br />

1<br />

2<br />

dlabr154<br />

6.3.60 2001-01-02 /PN 9009 <strong>AGFA</strong> d-<strong>lab.3</strong>


Repair<br />

Printer<br />

Setting the Pixel Coverage<br />

The three lasers Red, Green, Blue produce three<br />

pixels of the colours Cyan, Magenta, Yellow on<br />

the paper.<br />

Requirement:<br />

The three pixels are centred on top of each other:<br />

tolerance: 1 / 8 pixel width offset with respect to<br />

each other.<br />

Experience has shown that exceeded tolerances<br />

are judged very differently. In general, deviations<br />

of more than one pixel width are regarded as<br />

quality deterioration on prints from digital sources<br />

(graphics, letters, fine lines). On prints from films,<br />

deviations of about one pixel width are not visible<br />

so often.<br />

Adjustable:<br />

The service technician can adjust the pixel<br />

position in scanning direction, i.e. each colour can<br />

be shifted at a right angle to the paper transport<br />

direction.<br />

Not adjustable:<br />

The pixel position parallel to the paper transport<br />

direction cannot be adjusted in the field; this<br />

adjustment is only possible in the factory.<br />

If deviations occur in this direction, the colour<br />

laser scanner has to be replaced!<br />

Warning!<br />

Never open colour laser scanners!<br />

Risk of injuries caused by laser beams!<br />

Adjusting the Pixel Coverage<br />

Prerequisites:<br />

− Printer started<br />

− At least one paper magazine in the Printer<br />

− Paper data loaded for the inserted paper<br />

− PPL in tolerance<br />

Magnifying glass with a 10-fold magnification<br />

Keyboard<br />

Mouse<br />

<strong>AGFA</strong> d-<strong>lab.3</strong> 2001-01-02 /PN 9009 6.3.61


Printer<br />

Repair<br />

There are 2 methods to set the pixel coverage of<br />

the 3 colours in Fast Scan direction:<br />

1. Approximate, pixelwise shift by means of the<br />

Pixel delay<br />

2. Fine shift of the colours with respect to each<br />

other with the Pixel shift in 1 / 8 pixel steps<br />

Pixels can only be shifted to the left.<br />

The pixel at the far left serves as reference for the<br />

adjustment and the other pixels are shifted to the<br />

left.<br />

− Print the test print TESTPRINT01.ARP<br />

− Assess the print, check pixel coverage faults<br />

− Set the pixel shift or delay<br />

− Repeat these adjustments until all 3 colours are<br />

centred on each other.<br />

Pixel Delay<br />

Increasing the value of one colour will shift the<br />

output of this colour to the left (holding up the<br />

beginning of the print). Values between 0 and 15<br />

are admissible.<br />

Pixel Shift<br />

The position of the colours Red, Green, Blue are<br />

described by a sequence of 4 cyclically connected<br />

ones and zeros. If one colour is to be shifted to the<br />

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

moved to the right.<br />

The 8 values to be entered in the pixel shift are<br />

calculated by adding the 3-Bit combination of<br />

the three colours.<br />

The colours are shifted by shifting the ones to the<br />

right. The ones that are pushed out on the right side<br />

are added again on the left side (cyclical rotation).<br />

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

pixels at max. can be shifted to the left.<br />

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

again.<br />

Starting position (presetting):<br />

R: 0 0 0 0 1 1 1 1 (2 0 )<br />

G: 0 0 0 0 1 1 1 1 (2 1 )<br />

B: 0 0 0 0 1 1 1 1 (2 2 )<br />

Entry: 0 0 0 0 7 7 7 7<br />

6.3.62 2001-01-02 /PN 9009 <strong>AGFA</strong> d-<strong>lab.3</strong>


Repair<br />

Printer<br />

Example:<br />

Red<br />

1 / 8 pixel to the left<br />

Green<br />

3 / 8 pixels to the left<br />

Blue remains unchanged<br />

Test of the correctness of this example:<br />

For Red 4 connected ones (and zeros), for Green 4<br />

connected zeros, for Blue 4 connected ones. All<br />

colours are described by 4 ones and 4 zeros.<br />

Incomplete quick test:<br />

The total of all digit numbers to be entered is 28.<br />

R: 1 0 0 0 0 1 1 1 (2 0 )<br />

G: 1 1 1 0 0 0 0 1 (2 1 )<br />

B: 0 0 0 0 1 1 1 1 (2 2 )<br />

Entry: 3 2 2 0 4 5 5 7<br />

Saving the new Values<br />

The Setup values for the pixel shift and the pixel<br />

delay are saved on the Mainboard PR_GS01.<br />

Checking the current Setup values<br />

− Call up in the Service Script:<br />

Script Files\scripts_dlab\setup_dat\<br />

pr_vers_setup.txt<br />

− Run the Script<br />

The Info window shows the current values (of the<br />

example) after Setup – values HAS (Byte):<br />

:<br />

PIXEL-Delay : 00 (RT), 00 (GN), 00(BL)<br />

PIXEL-Shift (hex) : 03, 02, 02, 00, 04, 05, 05, 07<br />

:<br />

:<br />

Editing the Setup values<br />

− Call up in the Service Script:<br />

Script Files\scripts_dlab\setup_dat\<br />

setup_init_pr_00117.txt<br />

This Init file exists in 2 versions<br />

− Default<br />

setup_init_pr_00000.txt<br />

− Printer-specific with SN<br />

setup_init_pr_00XXX.txt<br />

This version must contain the same Setup<br />

values that were found with the sample script;<br />

if not, the sampled values must be entered<br />

here.<br />

<strong>AGFA</strong> d-<strong>lab.3</strong> 2001-01-02 /PN 9009 6.3.63


Printer<br />

Repair<br />

− Enter new values directly into the Script at<br />

position X after ....<br />

Admissible setting range:<br />

Delay 0 ... 15<br />

Shift 0 ... 7<br />

########## Beginning of the Editing range #############<br />

:<br />

:<br />

# Pixeldelay RT (0 ...15)<br />

calc $ has_b_02 = X<br />

# Pixeldelay GN (0 ...15)<br />

calc $ has_b_02 = X<br />

# Pixeldelay BL (0 ...15)<br />

calc $ has_b_02 = X<br />

# Pixelshift 1 (0...7)<br />

calc $ has_b_05 = X<br />

# Pixelshift 2 (0...7)<br />

calc $ has_b_05 = X<br />

:<br />

:<br />

# Pixelshift 8 (0...7)<br />

calc $ has_b_05 = X<br />

− Run the Script<br />

A confirmation is requested for every modified<br />

Setup value.<br />

Caution!<br />

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

are displayed that should not be modified.<br />

Check the output of the values of file<br />

pr_vers_setup.txt and enter them in<br />

setup_init_pr_00XXX.txt.<br />

− Close Service<br />

− Close the d-<strong>lab.3</strong> program:<br />

Press the Windows key or + <br />

Double-click on Watchdog<br />

Close the Watchdog by clicking on X<br />

− Start the d-<strong>lab.3</strong> program again:<br />

Click on the d-<strong>lab.3</strong> icon on the Desktop.<br />

Only then will the modified Setup values become<br />

effective.<br />

− Check the modified values for pixel delay and<br />

pixel shift with TESTPRINT01.ARP<br />

6.3.64 2001-01-02 /PN 9009 <strong>AGFA</strong> d-<strong>lab.3</strong>


Repair<br />

Printer<br />

Quick Version to define the Pixel Delay and the Pixel Shift<br />

No backup function<br />

The above setting is an iterative process. To prevent<br />

the repeated starting and closing of the d-<strong>lab.3</strong><br />

program, a temporary Script can be used for the<br />

adjustment. Afterwards the new values have to be<br />

entered in the file setup_init_pr_00XXX.txt.<br />

− Set PBL in tolerance<br />

− Start Service<br />

− Check the current Setup values:<br />

Script Files\scripts_dlab\setup_dat\<br />

pr_vers_setup.txt<br />

− Note down Delay and Shift<br />

The shift value that is output is the result of the<br />

added 3-Bit combination of Red, Green, Blue.<br />

This result must be calculated back to the 3 single<br />

colours by subtraction (see Pixel shift).<br />

Example:<br />

Shift 32204557<br />

− Script Files\scripts_dlab\<br />

scripts_printer\data_la\<br />

pixelshift_and_pixeldelay.txt<br />

Run the Script and enter Delay and Shift in the<br />

interrogation windows.<br />

Example:<br />

Delay Red 0, Green 2, Blue 0<br />

Shift Red 10000111<br />

Green 11100001<br />

Blue 00001111<br />

− Script Files\scripts_dlab\setup_dat\<br />

testprint.txt<br />

Print the test print TESTPRINT01.ARP<br />

− Assess the print, check pixel coverage faults<br />

<strong>AGFA</strong> d-<strong>lab.3</strong> 2001-01-02 /PN 9009 6.3.65


Printer<br />

Repair<br />

− Define the pixel shift or delay and enter the new<br />

values.<br />

Script Files\scripts_dlab\<br />

scripts_printer\data_la\<br />

pixelshift_and_pixeldelay.txt<br />

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

Delay Red 0, Green 2, Blue 0<br />

Shift Red 10000111<br />

Green 11100001<br />

Blue 11100001<br />

− Print the test print TESTPRINT01.ARP Script<br />

Files\scipts_dlab\setup_dat\<br />

testprint.txt<br />

For identification, the corresponding correction<br />

should be entered as back print.<br />

− The adjustment is repeated until all 3 colours are<br />

centred on each other:<br />

− Then enter the values found:<br />

Script Files\scipts_dlab\setup_dat\<br />

setup_init_pr_00XXX.txt<br />

− Run the Script.<br />

A confirmation is requested for every modified<br />

Setup value.<br />

− Close Service<br />

− Close the d-<strong>lab.3</strong> program:<br />

Press the Windows key or + <br />

Double-click on Watchdog<br />

Close the Watchdog by clicking on X<br />

− Start the d-<strong>lab.3</strong> program again:<br />

Click on the d-<strong>lab.3</strong> icon on the Desktop.<br />

Only then will the modified Setup values become<br />

effective.<br />

− Check the modified values for pixel delay and<br />

pixel shift with TESTPRINT01.ARP<br />

■<br />

6.3.66 2001-01-02 /PN 9009 <strong>AGFA</strong> d-<strong>lab.3</strong>


Repair<br />

Printer<br />

Removal, Installation, Adjustment<br />

The repair instructions describe the individual<br />

assembly groups in the order of the paper advance.<br />

The following data / worksteps are stated for each<br />

part to be replaced:<br />

Cause for the replacement<br />

Required tool<br />

Prerequisites (if necessary)<br />

These worksteps have to be carried out prior<br />

to the removal.<br />

Removal / Installation<br />

Install the assembly groups in reverse order.<br />

The installation is only described separately<br />

if the removal instructions are not detailed<br />

enough.<br />

Adjustment (if necessary)<br />

<strong>AGFA</strong> d-<strong>lab.3</strong> 2001-01-02 /PN 9009 6.4.1


Printer<br />

Repair<br />

Mainboard Replacement (PF_GS01), Edition 3<br />

Allan key, size 3<br />

Open-end wrench, size 6<br />

The PCB PF_GS01 (1) is located behind the front<br />

panel<br />

− Switch off the Printer<br />

− To open the front door open first the upper door<br />

of the print engine<br />

− Press the button (see arrow), to open the front<br />

panel<br />

dlab2135<br />

Replacement is required in the following cases:<br />

− Communication problems with the Main<br />

Computer (read out of hardware and software<br />

versions is no longer possible).<br />

− Communication problems with the Printer<br />

assemblies (cables have been tested and were<br />

OK).<br />

The error symptoms could be similar to those<br />

generated by other units.<br />

A clear indication for problems on the Printer<br />

Mainboard is simultaneous lighting of all segments<br />

in the segment display (88).<br />

In order to check this jumper J5 must be plugged in.<br />

For the testing of the Mainboard there is a script<br />

available:<br />

scripts for service/initialisierung/<br />

pr_board_selftest.txt<br />

dlab2101<br />

6.4.2 2001-01-02 /PN 9009 <strong>AGFA</strong> d-<strong>lab.3</strong>


Repair<br />

Printer<br />

− There may be different versions of the Printer<br />

Mainboard (GS01) in the d-lab:<br />

L8.8060.2000.X only for d-<strong>lab.3</strong><br />

(X stands for a letter, no LED display)<br />

- L8.8060.2000.0 only for d-<strong>lab.3</strong><br />

- L8.8060.2340.0/1 only for d-lab.2<br />

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

How this depends on the software is described in<br />

the section Software Transmission.<br />

Save setup values (if still possible)<br />

Usually it will not be possible any more to read out<br />

the setup values.<br />

Setup values are stored in the following locations:<br />

− In the folder C:\DLAB\D-lab Version\ Logfiles,<br />

File: printer_setup_protokoll.txt<br />

− Diskette enclosed with the shipment,<br />

File: printer_setup_write.txt<br />

Attention:<br />

The original setup values have probably been<br />

changed since production start at the customers’.<br />

This was necessary if assemblies were replaced or<br />

machine parameters were optimized. If the data,<br />

changed meanwhile, have not been saved the two<br />

files still contain the original data, i.e. as they were<br />

at the time of shipment.<br />

If saving is still possible then:<br />

− Change in the program to Service GUI<br />

− Execute the script scripts for<br />

service/setup/<br />

printer_setup_backup.txt. The script<br />

printer_setup_write.txt<br />

is automatically created and saved in the same<br />

script folder. The file contains all setup values of<br />

the Printer and the AOM LUT.<br />

This script is used to restore the setup values<br />

after replacement of the GS01.<br />

<strong>AGFA</strong> d-<strong>lab.3</strong> 2001-01-02 /PN 9009 6.4.3


Printer<br />

Repair<br />

− Determine the operation times of the gas laser:<br />

Execute the following script in the Service GUI :<br />

Scripts for service\printer\laser\<br />

statistic_laser.txt<br />

Note values (number of ignition and<br />

burning time)<br />

− Document the reasons for the Printer Mainboard<br />

replacement by print examples if necessary.<br />

− Start the script Scripts for service/<br />

initialisation/Shut_down_d-lab to<br />

switch off the power supply to the Mainboard.<br />

If the execution of scripts is no longer possible<br />

due to defects, switch off the machine.<br />

Replacing the Printer Mainboard<br />

− Wear the antistatic wrist strap and ground it to<br />

protect the components.<br />

− Push the Printer Mainboard with it holder to the<br />

left, to do so loosen the Allan screws (1).<br />

− Unplug the connections on the PCB:<br />

For plug 10 a size 6 open-end wrench must be<br />

used.<br />

− Disengage the 6 cams, replace the PF_GS01<br />

and engage the new PCB again in the 6 cams.<br />

− Plug the connections back in<br />

Attention: Do not turn plug 10 too far.<br />

− Fasten the holder of the Mainboard by means of<br />

four Allan screws.<br />

Check the jumper setting:<br />

J1 - not plugged in<br />

J2 - not plugged in<br />

J3 - plugged in (J1...J3 exists only on Mainboard<br />

8.8060.2000.X)<br />

J4 not plugged in (BOOT)<br />

J5 not plugged in<br />

(LED_ON, segment display on)<br />

J6 plugged in (R_CAN)<br />

dlab2102<br />

6.4.4 2001-01-02 /PN 9009 <strong>AGFA</strong> d-<strong>lab.3</strong>


Repair<br />

Printer<br />

Transmit software and setup values to the<br />

Printer Mainboard (in this sequence)<br />

− Switch on voltages:<br />

Switch on d-lab, or execute the script Script<br />

for service/initialisation/<br />

start_up_d-lab.txt<br />

Check the software on the Printer Mainboard<br />

The following software elements are stored on the<br />

Printer Mainboard, and in case of PCB replacement<br />

they must be updated:<br />

− Firmware Printer Mainboard (prhp.hex)<br />

− Firmware XILINXS (prxi.hex)<br />

− And further:<br />

Firmware Printer – Bootloader (bl.hex).<br />

This file is not replaced during the update.<br />

− SETUP parameters of the Printer assemblies<br />

On spare PCBs from stock there is usually an<br />

unknown firmware version (also see Important<br />

note, next page).<br />

The setup values do not correspond either to the<br />

repaired machine. (Usually default values)<br />

Therefore a software check for the new Printer<br />

Mainboard must be made:<br />

− Check via Service / Firmware Version.<br />

− Compare the displayed result with the required<br />

version of the software package present in the<br />

machine:<br />

The firmware belonging to a certain software<br />

package can be determined subsequently.<br />

− Activate the Windows Explorer (via Watchdog)<br />

− Open the file label.txt. Path:<br />

C:\SoftwareVersion/PR/Install/<br />

PR_Vxxx-y/label.txt<br />

Information from <strong>Lab</strong>el.txt:<br />

Here HP stands for prhp.hex and XI for prxi.hex<br />

<strong>AGFA</strong> d-<strong>lab.3</strong> 2001-01-02 /PN 9009 6.4.5


Printer<br />

Repair<br />

Download XILINKS (prxi)<br />

(by experience rarely necessary, takes about 5 min)<br />

− Service<br />

− Firmware Download<br />

− LASER PRINTER*PR<br />

− xilinx pixel pipeline<br />

− Search file under<br />

− C:\Dlab\Dlabxxxx\Pr\Install\<br />

Pr_Vxxx-y (see Note below)<br />

− prxi.hex<br />

− Path and file name are displayed in the upper<br />

window after clicking Open<br />

− Select download<br />

After a few seconds a window opens:<br />

Downloading Printer<br />

After the download an automatic reset is executed,<br />

the voltages remain on.<br />

Note:<br />

y stands for 6,7,Z.<br />

The main software packages also include the<br />

different software versions for the different types of<br />

the Printer Mainboard in the folder<br />

SystemversionXXXXX/pr/install.<br />

Always change to the respective path:<br />

− V xxxxxx-6<br />

for d-<strong>lab.3</strong> with Mainboard 8.8060.2000.X<br />

(X = letter, PCB has no LED indication, only old<br />

machines)<br />

− V xxxxxx-7<br />

for all other d-<strong>lab.3</strong>, (PCB has an LED indication)<br />

− V xxxxxx-Z<br />

for all d-lab.2 and net-lab.12<br />

6.4.6 2001-01-02 /PN 9009 <strong>AGFA</strong> d-<strong>lab.3</strong>


Repair<br />

Printer<br />

Download Firmware (prhp.hex)<br />

(if necessary, takes about 30 min)<br />

This applies to all downloads:<br />

By all means do not interrupt the download<br />

otherwise it cannot be repeated!<br />

Important note:<br />

With the introduction of the main software 7.50x the<br />

firmware structure of the Mainboard changed as<br />

well.<br />

A wrong download would make the board useless.<br />

And in another case if a further update is required a<br />

download of firmware would no longer be possible.<br />

Therefore consider the following information:<br />

− If with Service\ Firmware Version a firmware<br />

< 1.04.xx was determined on the replaced<br />

Mainboard, load prhp_kombi.hex.<br />

− If the determined firmware on the replaced<br />

Mainboard is 1.04 and higher load prhp.hex.<br />

− Enter the following path in the Service GUI:<br />

− Firmware Download<br />

− LASER PRINTER*PR<br />

− HP printer main software+++<br />

− Search file under<br />

− C:\Dlab\Dlabxxxx\Pr\Install\<br />

Pr_Vxxx-y<br />

− prhp.hex (bzw.prhp_kombi.hex)<br />

− Path and file name are displayed in the upper<br />

window after clicking Open<br />

− Select download<br />

After a few seconds a window opens:<br />

Downloading Printer<br />

Once the window closes again the software<br />

download was successful.<br />

<strong>AGFA</strong> d-<strong>lab.3</strong> 2001-01-02 /PN 9009 6.4.7


Printer<br />

Repair<br />

Loading setup values (with AOM LUT)<br />

− If the data of the diskette enclosed in the<br />

shipment are to be loaded, copy the file<br />

printer_setup_write.txt first with the<br />

Windows Explorer to the folder Scripts/Scripts for<br />

Service.<br />

− Change to Service-GUI/Scripts/<br />

scripts for service/setup/<br />

printer_setup_write.txt<br />

− Start the script with Execute<br />

− At the end of the script answer the prompt Save<br />

with YES<br />

Attention!<br />

This script loads the AOM LUT determined with the<br />

removed PCB. If the PCB replacement was<br />

somehow connected with a trigger problem of the<br />

red laser, and/or the AOM green and blue, the AOM<br />

characteristic curves must be determined again (see<br />

respective paragraph).<br />

If the setup values are no longer available they can<br />

be ordered again through the service from the<br />

manufacturer by specifying the machine number.<br />

(usually the following file has been saved there:<br />

printer_setup_write.txt)<br />

6.4.8 2001-01-02 /PN 9009 <strong>AGFA</strong> d-<strong>lab.3</strong>


Repair<br />

Printer<br />

Adjustment of the video voltages:<br />

− Adjustment of the video voltages must be made<br />

prior to the determination of AOM characteristic<br />

curves.<br />

− Execute script Scripts/scripts for<br />

service/<br />

printer/laser/register_mode_on.txt<br />

(Answer the prompt – Switch OFF dynamic noise<br />

reduction of laser? – with YES)<br />

− Accept the suggested values (0,0,0,0,100,5000)<br />

− Connect the Multimeter at the respective point<br />

and the plug housing (GND) (Illustration lower<br />

circles)<br />

− Adjust the video voltages with the respective<br />

controls (Illustration upper circles)<br />

− Adjust the following values:<br />

red 390mV +/- 30mV<br />

green, blue 365mV +/- 30mV<br />

− Execute the script Scripts/scripts for<br />

service/<br />

printer/laser/register_mode_on.txt.<br />

(Answer the prompt – Switch OFF dynamic noise<br />

reduction of laser? – with YES)<br />

Final check and tests<br />

Checking the software versions:<br />

− Check the firmware version in the Service GUI,<br />

compare as explained in the procedure above.<br />

Check the setup values:<br />

− Start the script Scripts/scripts for<br />

service/setup/<br />

printer_setup_backup.txt.<br />

<strong>AGFA</strong> d-<strong>lab.3</strong> 2001-01-02 /PN 9009 6.4.9


Printer<br />

Repair<br />

− Print a test print.<br />

To do so execute Scripts/Scripts for<br />

service/<br />

testprints/X-print.txt.<br />

Evaluate the parameter (BOL, pixel shift, center<br />

of laser line...) and correct if necessary. (In case<br />

of correction save the SETUP values again.)<br />

− Verify that jumper J5 of the Printer Mainboard is<br />

open (risk of light reflection).<br />

− For safety execute script scripts for<br />

service/initialisierung/<br />

pr_board_selftest.txt again.<br />

− Run a communication test between the Printer<br />

Mainboard and the VIPS Board by executing the<br />

script:<br />

Script Files/scripts_Printer/<br />

printer_general/test lvds short.txt<br />

Message at the end:<br />

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

− After end of this script the machine program must<br />

be started again with the ON button.<br />

− Statistics values laser:<br />

After replacement of the Printer Mainboard the<br />

runtime statistics of the laser must be started<br />

again. To do so execute the script:<br />

Scripts for service\printer\laser<br />

statistic_laser.txt<br />

Answer the questions with YES so the values for<br />

the gas laser are reset to zero. Counting of the<br />

number of ignitions and operating hours starts<br />

again.<br />

6.4.10 2001-01-02 /PN 9009 <strong>AGFA</strong> d-<strong>lab.3</strong>


Repair<br />

Printer<br />

Replacing the Printer Power Supply Unit<br />

Replacement required:<br />

− Power supply unit defective<br />

− Fuse defective<br />

If the fuse is defective, replace the complete<br />

power supply unit.<br />

dlabr103<br />

The manufacturer warrants only full functionality on<br />

condition that the power supply unit has been<br />

revised in the manufacturer’s plant.<br />

1 <strong>Lab</strong>el (see Fig. below)<br />

2 PO_GS01<br />

Sticker<br />

dlabr104<br />

<strong>AGFA</strong> d-<strong>lab.3</strong> 2001-01-02 /PN 9009 6.4.11


Printer<br />

Repair<br />

Hexagon socket screwdriver 4,0<br />

Open the bottom side cover:<br />

− Open the LH paper magazine door<br />

− Push the button (1) to open the side cover<br />

− Remove the power supply unit:<br />

4 screws (1)<br />

dlabr029<br />

dlabr215<br />

6.4.12 2001-01-02 /PN 9009 <strong>AGFA</strong> d-<strong>lab.3</strong>


Repair<br />

Printer<br />

Replacing / adjusting the Guide Rails of the Paper Magazines,<br />

Replacing Light Sensor ML/MR_LS08 (locking detection)<br />

Replacement required:<br />

− Top / bottom guide rail damaged<br />

− Locking detection ML/MR_LS08<br />

defective<br />

Screwdriver<br />

− Remove the guide rail (4 screws)<br />

− Replace the light sensor:<br />

ML/MR_LS08 is accessible after the top guide rail<br />

has been removed.<br />

Readjust the guide rails:<br />

− Mount the right and left paper magazine fastening<br />

(Magazine Lock); do not tighten the screws<br />

− Mount the paper magazine<br />

− Adjust the guide rails in such a way that the<br />

magazine locks exactly into the drive<br />

− Tighten the screws, lacquer-seal them when<br />

necessary<br />

<strong>AGFA</strong> d-<strong>lab.3</strong> 2001-01-02 /PN 9009 6.4.13


Printer<br />

Repair<br />

Replacing the Magazine Drive ML/MR<br />

The magazine drive ensures 2 functions:<br />

1. Driving the paper magazine<br />

2. Driving the cutter unit<br />

Replacement required:<br />

The paper magazine drive or the cutter drive do not<br />

function.<br />

Cross tip screwdriver<br />

Allan key<br />

− Remove the paper magazine<br />

− Unscrew the RH (1) or the LH cutter unit (2),<br />

2 screws<br />

− Remove the detection of the paper magazine<br />

coding (2) (2 screws; disconnect 2 cables)<br />

− Disconnect the connector (3) on the magazine<br />

drive<br />

− Disconnect the connection between the drive unit<br />

and the voltage connector<br />

− MR: pull the assembly group to the right<br />

− ML: pull the assembly group to the left<br />

− Take out the RH drive unit toward the front<br />

Caution!<br />

Do not pull the LH drive unit straight to the front!<br />

− Move the assembly group to the front first with<br />

the right side and then with the left side<br />

1 Cutter unit<br />

dlabr030<br />

dlabr100<br />

6.4.14 2001-01-02 /PN 9009 <strong>AGFA</strong> d-<strong>lab.3</strong>


Repair<br />

Printer<br />

Replacing the Light Sensors of the Magazine Drive MD<br />

Light sensor defective:<br />

1. LH magazine drive<br />

− ML_LS01-06 Magazine coding<br />

− ML_LS07 Paper detection Shutter<br />

− ML_LS08 Locking detection<br />

2. RH magazine drive<br />

− MR_LS01-06 Magazine coding<br />

− MR_LS07 Paper detection Shutter<br />

− MR_LS08 Locking detection<br />

Hexagon socket screwdriver<br />

Cross tip screwdriver<br />

− If the light sensors are defective, replace GS<br />

(printed circuit):<br />

ML/MR_LS01-06 ML/MR_GS02<br />

ML/MR_LS07 ML/MR_GS03<br />

ML/MR_LS08 ML/MR_GS05<br />

<strong>AGFA</strong> d-<strong>lab.3</strong> 2001-01-02 /PN 9009 6.4.15


Printer<br />

Repair<br />

Replacing the Cutter Unit CU<br />

Cutter unit defective<br />

Cross tip screwdriver<br />

Allan key<br />

Removal:<br />

− Remove the paper magazine<br />

− Dismount the cutter unit (1)<br />

(2 screws, see next fig.):<br />

− Remove the detection of the paper magazine<br />

coding (2 screws)<br />

− Disconnect the connector (3)<br />

− Pull the drive unit a little to the other side to<br />

interrupt the connection to the voltage<br />

connector, turn it and remove it to the front<br />

− Remove the cutter unit: Unscrew 2 screws<br />

− RHS (1)<br />

− LHS (2)<br />

1 LH paper magazine compartment<br />

dlabr100<br />

Installation:<br />

− Push in the cutter unit up to the holding point<br />

− Check that the connector has locked in<br />

− Give the handle of the cutter unit a vigorous push<br />

until the unit locks in at the end stop.<br />

− If this is not possible, check whether the guide lug<br />

finger is deformed.<br />

dlabr030<br />

6.4.16 2001-01-02 /PN 9009 <strong>AGFA</strong> d-<strong>lab.3</strong>


Repair<br />

Printer<br />

Replacing the Light Sensors in the Cutter Unit CU<br />

Light sensor defective:<br />

1. LH cutter<br />

− SG_LS23 Detection home position cutter<br />

SG_LS24 Detection cutter cutting end<br />

− SG_LS21 Paper detection cutter<br />

SG_LS22 Splice detection<br />

2. RH cutter<br />

− SG_LS43 Detection home position cutter<br />

SG_LS44 Detection cutter cutting end<br />

− SG_LS41 Paper detection cutter<br />

SG_LS42 Splice detection<br />

Allan key<br />

Cross tip screwdriver<br />

− Remove the cutter unit<br />

− If the light sensors are defective, replace GS<br />

(printed circuit):<br />

Light sensors defective<br />

SG_LS21/22<br />

SG_LS23/24<br />

SG_LS41/42<br />

SG_LS43/44<br />

Replace GS<br />

SG_GS08<br />

SG_GS07<br />

SG_GS10<br />

SG_G09<br />

<strong>AGFA</strong> d-<strong>lab.3</strong> 2001-01-02 /PN 9009 6.4.17


Printer<br />

Repair<br />

Replacing the Switching Gear SG<br />

Replacement required:<br />

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

work<br />

The assembly group has to be removed from the<br />

Printer for all jobs on the SG.<br />

Allan key<br />

Removal:<br />

− Remove Switching Gear (1):<br />

Pull the left bracket vigorously as the assembly<br />

group is very tight in the guide.<br />

Installation:<br />

− When mounting the assembly group, make sure<br />

that the guides lock under the pins with the<br />

springs.<br />

− The connector for the SG is located on the fan<br />

assembly group<br />

1<br />

d<br />

labr146<br />

Replacing the Printed Circuit SG_GS02<br />

Replacement required:<br />

If the SG_GS02 is defective, the paper cannot be<br />

turned round any more.<br />

Allan key 2,5<br />

Back of SG_GS02:<br />

Unscrew 3 Allan screws 2,5<br />

Caution!<br />

Mind the code disk .SGBE of the motor upon the<br />

removal / installation!<br />

6.4.18 2001-01-02 /PN 9009 <strong>AGFA</strong> d-<strong>lab.3</strong>


Repair<br />

Printer<br />

Replacing the Motor SG_MO01<br />

Replacement required:<br />

If the motor is defective, the paper does not pass<br />

any more through the SG.<br />

The motor can only be replaced together with the<br />

sync disk.<br />

Allan key 2,0<br />

Allan key 3,0 angled<br />

Ball head screwdriver 3,0<br />

Dynamometer<br />

Removal:<br />

− Unscrew the .SGAJ cover:<br />

3 Allan screws 2,0<br />

− Cut the cable ties and unscrew the motor<br />

Installation:<br />

− Adjust the correct belt tension by shifting the<br />

motor<br />

− Screw on the motor very tight, using the angled<br />

screwdriver!<br />

Caution!<br />

When mounting the .SGAJ cover, make sure that a<br />

lock washer and a washer are used on each screw.<br />

If this is not done, the screw may damage the cable.<br />

Measure the belt tension with the dynamometer:<br />

1,0 N<br />

<strong>AGFA</strong> d-<strong>lab.3</strong> 2001-01-02 /PN 9009 6.4.19


Printer<br />

Repair<br />

Replacing the Motor SG_MO02<br />

Replacement required:<br />

If the motor is defective, the rocker does not move<br />

any more.<br />

Allan key 2,5<br />

Removal:<br />

− Open the circlip (on coupling .SGAS)<br />

− Unscrew the motor through the holes in the<br />

holding plate<br />

− Remove the motor with the code disk and the<br />

crank<br />

− Dismount the motor, the code disk and the crank<br />

Installation:<br />

− Installation in reverse order<br />

− The parts cannot be mixed up when they are<br />

mounted.<br />

The slide bearings between the crank and the<br />

coupling must point to the inside to the motor!<br />

Replacing the toothed Belt<br />

Replacement required:<br />

Toothed belt torn or damaged<br />

Allan key 3,0 angled<br />

Ball head screwdriver 3,0<br />

Dynamometer<br />

− Unscrew the motor SG_MO01 so that the belt<br />

tension slackens<br />

− Change the belt and screw down the motor<br />

Measure the belt tension with the dynamometer:<br />

1,0 N<br />

6.4.20 2001-01-02 /PN 9009 <strong>AGFA</strong> d-<strong>lab.3</strong>


Repair<br />

Printer<br />

Replacing the Transport Roller .SG11<br />

Replacement required:<br />

Transport roller damaged<br />

Allan keys 2,0 and 3,0<br />

Dynamometer<br />

Flat pliers<br />

− Remove the cover of the SG_GS04:<br />

Slacken 4 Allan screws<br />

− Remove the complete SG_GS04 with the GS<br />

support:<br />

− Remove one screw each on the left and on the<br />

right side of the GS<br />

− Disconnect the cable!<br />

− Unscrew the red handwheel<br />

− Unscrew the motor SG_MO01 so that the belt<br />

tension slackens; remove the belt<br />

− Unscrew the sync disk .SGKK and pull it off the<br />

shaft<br />

− Remove the pin from the shaft<br />

− Remove the circlip and the washer; pull out the<br />

ball bearing<br />

Other side:<br />

− Remove the circlip, pressure spring, washer<br />

− Pull out the ball bearing<br />

− Open the coupling (secured with a circlip)<br />

− Hang out the springs on the counter pressure<br />

roller .SGAQ<br />

− Use the pliers to detach the spring from the<br />

plate on the side of the motor SG_MO01<br />

− On the other side, the spring can be detached<br />

from the shaft<br />

− Remove the shaft with the transport roller<br />

Caution<br />

Make absolutely sure that the washer is between the<br />

ball bearing and the spring, otherwise the spring<br />

brushes directly on the bearing!<br />

Measure the belt tension with the dynamometer:<br />

1,0 N<br />

<strong>AGFA</strong> d-<strong>lab.3</strong> 2001-01-02 /PN 9009 6.4.21


Printer<br />

Repair<br />

Replacing the Pressure Roller .SGAG / Torsion Spring .SGKC<br />

Replacement required:<br />

− Pressure roller damaged<br />

− If the cut is not accurate, the torsion springs must<br />

be replaced to ensure the prescribed pressure<br />

force.<br />

Flat pliers<br />

Screwdriver<br />

Dynamometer 100 N<br />

− Hang out the springs on the counter pressure<br />

roller .SGAQ<br />

− Use the pliers to detach the spring from the<br />

plate on the side of the motor SG_MO01<br />

− On the other side, the spring can be detached<br />

from the shaft<br />

− Open the circlips and take out the shaft with the<br />

pressure roller<br />

− Remove the circlip and the washer in front of the<br />

pressure roller<br />

− Pull the pressure roller with the bearings off the<br />

shaft<br />

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

6.4.22 2001-01-02 /PN 9009 <strong>AGFA</strong> d-<strong>lab.3</strong>


Repair<br />

Printer<br />

Replacing the Light Sensors of the Switching Gear SG<br />

Light sensor defective:<br />

− SG_LS01 Paper detection, magazine RHS<br />

− SG_LS02 Paper detection, magazine LHS<br />

− SG_LS03 Remaining length detection, LHS<br />

− SG_LS04 Remaining length detection, RHS<br />

− SG_LS05 CU-SG-control<br />

− SG_LS06 CU-SG-control<br />

All other light sensors of the switching gear<br />

(SG_LS21-24 and SG_LS41-44) are located on the<br />

printed circuit in the Cutter Unit.<br />

To replace these light sensors, see<br />

Replace the light sensors in the cutter unit CU,<br />

earlier in register 6.4.<br />

Allen keys 2,5 angled and straight<br />

Watchmaker screwdriver<br />

− If the light sensors are defective, replace GS<br />

(printed circuit):<br />

SG_LS01 SG_GS03 (see below)<br />

SG_LS02 SG_GS04<br />

SG_LS03 SG_GS05<br />

SG_LS04 SG_GS06<br />

SG_LS05/06 SG_GS01<br />

Special case SG_LS01:<br />

Removal:<br />

The SG_GS03 can only be removed completed with<br />

the holding plate!<br />

− Turn up the guide plate .SGAF to get access to<br />

the screws.<br />

− Remove the cable FK 23 after the GS has been<br />

removed – use a screwdriver!<br />

Installation:<br />

When mounting the GS, make sure that all cables<br />

are flat inside the assembly group without loops.<br />

Extending cables may be torn off when the GS is<br />

installed in the Printer!<br />

<strong>AGFA</strong> d-<strong>lab.3</strong> 2001-01-02 /PN 9009 6.4.23


Printer<br />

Repair<br />

Sheet Bridge SB, replacing Parts<br />

The following repairs may become necessary in<br />

the Sheet Bridge area:<br />

− Replacement of the sync disk and the outer<br />

toothed belt<br />

− Replacement of the sync disk and the inside<br />

toothed belt<br />

− Replacement of the transport rollers<br />

− Replacement of the pressure rollers<br />

− Replacement of the toothed belts<br />

− Replacement of the coupling wheel<br />

Allan key 3,0<br />

dlabr008<br />

− Open the locking (1) of the transport unit TU (red<br />

fastening screw)<br />

− Pull out the TU towards you<br />

− Remove the top part of the SB:<br />

Slacken 4 Allan screws 3,0<br />

− 2 screws are accessible through the hole in<br />

the top plate<br />

− All 4 screws are secured from below and<br />

therefore cannot get lost<br />

dlaba009<br />

6.4.24 2001-01-02 /PN 9009 <strong>AGFA</strong> d-<strong>lab.3</strong>


Repair<br />

Printer<br />

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

Dynamometer<br />

Seeger circlip ring pliers 3 – 10 mm ∅<br />

− Remove the Seeger circlip ring<br />

− Replace the sync disks (1) and (3):<br />

The collar of the sync disks must be alternately<br />

on the belts. Risk of confusion!<br />

− Adjust the belt tension (2) by shifting the<br />

tensioning plate:<br />

The screw heads (4) to fasten the tensioning<br />

plate must not be on the belt side!<br />

dlabr207<br />

Measure the belt tension in position (2):<br />

1 Sync disk, flange out<br />

2 Test point of the belt tension<br />

3 Sync disk, flange in<br />

4 Screw head not on the belt side<br />

− Deflection of the toothed belt: 1,7 mm<br />

− Test load: 1,0 N<br />

<strong>AGFA</strong> d-<strong>lab.3</strong> 2001-01-02 /PN 9009 6.4.25


Printer<br />

Repair<br />

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

Allan key 3,0<br />

Dynamometer<br />

Seeger circlip ring pliers 3 – 10 mm ∅<br />

− Remove the Seeger circlip ring<br />

− Replace the sync disks (1) and (2):<br />

The collar of the sync disks must be alternately<br />

on the belts. Risk of confusion!<br />

− Adjust the belt tension (3) by shifting the<br />

tensioning plate:<br />

The screw heads to fasten the tensioning plate<br />

must not be on the belt side!<br />

dlabr208<br />

Measure the belt tension in position (3):<br />

1 Sync disk, flange out<br />

2 Sync disk, flange in<br />

3 Test point of the belt tension<br />

4 Seeger circlip ring<br />

− Deflection of the toothed belt: 1,2 mm<br />

− Test load: 1,0 N<br />

Replacing the Transport Rollers<br />

Allan key 3,0<br />

Seeger circlip ring pliers<br />

Dynamometer<br />

− Remove the sync disk<br />

− Remove the circlip from the ball bearing<br />

− Remove the transport shaft and pull out the<br />

transport roller<br />

If necessary, replace also the freewheel and the ball<br />

bearings when replacing the transport roller.<br />

Measure the belt tension in the indicated position<br />

(longest side):<br />

− Deflection of the toothed belt: 1,2 mm<br />

− Test load: 1,0 N<br />

6.4.26 2001-01-02 /PN 9009 <strong>AGFA</strong> d-<strong>lab.3</strong>


Repair<br />

Printer<br />

Replacing the Pressure Rollers<br />

Screwdriver<br />

Removal:<br />

− Open the circlips and remove the assembly group<br />

Installation:<br />

− Observe the exact position of the torsion spring<br />

when installing the assembly group!<br />

− If necessary, compare it with the mounting<br />

position in the transport unit (TU).<br />

1 Spring under the shaft<br />

2 Shaft plugged through the spring turns<br />

3 Spring rests on the shaft (behind circlip)<br />

dlabr209<br />

Replacing the Sheet Turnaround<br />

Removal:<br />

− Hold the sheet turnaround on both rods (1) and<br />

pull it out<br />

− Remove the printed circuit:<br />

It is attached to the pins in the sheet bridge.<br />

dlaba111<br />

Installation:<br />

− When mounting the sheet turnaround, push the<br />

belt back into the reference position<br />

dlaba112<br />

<strong>AGFA</strong> d-<strong>lab.3</strong> 2001-01-02 /PN 9009 6.4.27


Printer<br />

Repair<br />

Transport Unit TU, replacing Parts<br />

− Open the locking (1) of the TU (red fastening<br />

screw)<br />

− Pull out the TU towards you<br />

− The transport unit has to be removed for some<br />

repair jobs: Remove 2 screws each (1) from the<br />

two telescopic rails<br />

dlaba009<br />

dlabr110<br />

6.4.28 2001-01-02 /PN 9009 <strong>AGFA</strong> d-<strong>lab.3</strong>


Repair<br />

Printer<br />

Replacing / adjusting the toothed Belt (Switching Lug)<br />

− Replace the toothed belt<br />

Adjustment of the lateral guide elements (required<br />

when the toothed belt has to be replaced):<br />

− Slacken the screws<br />

− Fasten the lateral guide elements directly on the<br />

edge of the supporting plate<br />

− Tighten the screws<br />

− The adjustment is performed in the Service<br />

program.<br />

dlabr216<br />

Light Sensor TU_LS07<br />

Fork light sensor TU_LS07 defective (Home position<br />

sheet centring)<br />

Replace TU_LS07 (1):<br />

− Disconnect the connector<br />

Redefine the Setup value for the light sensor:<br />

− The adjustment is assisted by the Service<br />

program<br />

dlabr217<br />

<strong>AGFA</strong> d-<strong>lab.3</strong> 2001-01-02 /PN 9009 6.4.29


Printer<br />

Repair<br />

Toothed Belt<br />

Adjust the belt tension in such a way that the belt<br />

can easily be pushed to and fro on the gear at the<br />

belt turning point.<br />

Caution!<br />

The motor shaft may be overstressed and may<br />

break if the belt is too tight.<br />

dlabr216<br />

6.4.30 2001-01-02 /PN 9009 <strong>AGFA</strong> d-<strong>lab.3</strong>


Repair<br />

Printer<br />

Replacing the Centring Finger on the Sheet Centring Unit<br />

Allan keys 2,5 and 3,0<br />

Removal:<br />

− Pull out the TU<br />

− Unlock the bottom unit and fold it down<br />

− Disconnect the connectors from TU_MO11 and<br />

TU_LS07 (directly on the component, not on the<br />

printed circuit)<br />

− Unscrew the sheet centring unit .TUA0<br />

− Unscrew the rails with the centring fingers<br />

(2 Allan screws 2,5):<br />

− LH side guide 8.8060.TU27.<br />

with spring-loaded centring fingers<br />

− RH side guide 8.8060.TU28.<br />

with fixed centring fingers<br />

The centring rail with the fixed centring fingers is<br />

always located on the side of motor TU_MO04.<br />

Installation:<br />

Be sure to keep the order!<br />

− Push in the guides (1)<br />

− Put the centring rail with the fixed centring fingers<br />

(2) on the guides, push it against the stop (4) and<br />

screw it on<br />

− Put the centring rail with the spring-loaded<br />

centring fingers (3) on the guides, push it against<br />

the stop (4) and screw it on<br />

− Open and close the sheet centring unit by hand<br />

to check the correct stop:<br />

The centring rail must always be on the stop, the<br />

guide must never be at the end of the chamfered<br />

slit.<br />

− When mounting the sheet centring unit .TUA0,<br />

make sure that the assembly group is accurately<br />

inserted in the centring bolts, otherwise no<br />

correct sheet centring is guaranteed.<br />

If additional toothed belts or the motor TU_MO04<br />

are replaced, the belt tension must be adjusted<br />

before the centring rails are mounted.<br />

1 Guides<br />

2 Centring rail with fixed centring fingers<br />

3 Centring rail with mobile centring fingers<br />

4 Stop<br />

dlabr212<br />

<strong>AGFA</strong> d-<strong>lab.3</strong> 2001-01-02 /PN 9009 6.4.31


Printer<br />

Repair<br />

Replacing the Turntable<br />

Replacement required:<br />

In case of damage<br />

The turntable must be replaced together with the<br />

turntable shaft as the parts are lacquer-sealed!<br />

Allan key 3,0<br />

Seeger circlip ring pliers<br />

Removal:<br />

− Pull out the TU<br />

− Unlock the bottom unit and fold it down<br />

− Unscrew the cover of the printed circuit and<br />

disconnect all cables to drive unit 1:<br />

ST 6, 9, 10, 17, 21, 22, 23, 25<br />

− Tilt away the complete printed circuit with the<br />

carrier plate; unscrew 2 screws<br />

− Unscrew drive unit 1 and remove it towards<br />

the bottom: 5 screws (1) at the front, 3 screws<br />

at the back<br />

− Open the Seeger circlip ring and strip off the sync<br />

disk with the toothed belt<br />

Installation:<br />

Make sure that the assembly group is put exactly in<br />

the recesses when mounted, otherwise no correct<br />

paper transport can be guaranteed.<br />

1 Fastening screw (1st of 5 front)<br />

dlabr213<br />

Check the toothed belt tension<br />

6.4.32 2001-01-02 /PN 9009 <strong>AGFA</strong> d-<strong>lab.3</strong>


Repair<br />

Printer<br />

Print Engine PE, replacing Parts<br />

Replacing the Motor PE_MO01<br />

Replacement required:<br />

Motor defective<br />

Allan keys 2,5 and 3<br />

Removal:<br />

− Pull out the PE<br />

− Remove the rear cover plate<br />

− Remove the sensor PE_LS05 (BOP), integrated<br />

on PE_GS03,<br />

− Disconnect the connector of the motor (in the top<br />

frame)<br />

− Open the fastening of the clutch for the motor<br />

shaft (on the side of the motor)<br />

− Dismount the motor: Unscrew 4 Allan screws<br />

Caution!<br />

The rear screw is difficult to access. Do not damage<br />

the belt underneath; cover it if necessary.<br />

Motor PE_MO01: Printing roller drive<br />

dlabr096<br />

Installation:<br />

− Insert the new motor:<br />

Do not damage the belt (cover it)<br />

− Screw on the motor<br />

− Fasten the clutch<br />

− Install the cable and connect it<br />

− Mount the sensor<br />

− Mount the plate<br />

Test the function in the Service program<br />

<strong>AGFA</strong> d-<strong>lab.3</strong> 2001-01-02 /PN 9009 6.4.33


Printer<br />

Repair<br />

Replacing the Motor PE_MO02<br />

Replacement required:<br />

Motor defective<br />

Allan keys 1,5 and 3<br />

Screwdriver<br />

Removal:<br />

− Pull out the PE<br />

− Disconnect the cable of MO02 (at the bottom;<br />

brown)<br />

− Disconnect the sensor cable from PE_LS04<br />

− Unscrew the Allan screw 1,5 on the motor side of<br />

the clutch<br />

− Remove the motor plate with the motor and the<br />

sensor from the vibration absorbers:<br />

Unscrew 3 Allan screws<br />

− Detach the motor from the motor plate:<br />

4 slotted countersunk head screws<br />

Installation:<br />

1 Motor PE_MO02: Drive feed and exit roller PE<br />

2 Gearing<br />

dlabr099<br />

− Change the motor<br />

− Mount the motor plate:<br />

Mind the location of the vibration absorbers and<br />

the clutch; screw in the screws tight up to the<br />

stop (sleeve and rubber buffer)<br />

− Connect the motor and sensor cables<br />

Adjustment:<br />

Test the function in the Service program<br />

6.4.34 2001-01-02 /PN 9009 <strong>AGFA</strong> d-<strong>lab.3</strong>


Repair<br />

Printer<br />

Replacing the Gearing<br />

Replacement required:<br />

Leaking oil, synchronisation problems caused by the<br />

gearing<br />

Allan keys 2,5 and 3 and 4<br />

if available, a second person to help<br />

Removal:<br />

− Pull out the PE<br />

− Unscrew the rear plate with the venting slits on<br />

the exposure slit<br />

− Open the bottom set of belts<br />

− Open the fastening of the gear coupling for the<br />

print roller: 2 Allan screws<br />

− Close the bottom set of belts again<br />

− Disconnect the motor cable (in the top frame) and<br />

remove the motor<br />

− Unscrew 3 fastening screws (vibration absorbing)<br />

outside the gearing<br />

− Remove the gearing with the motor plate and the<br />

motor PE_MO02<br />

Call a second person to help: If the gearing slips out<br />

of its bearing with the roller, the RH bearing of the<br />

roller may get damaged (loss of the accurate<br />

running properties).<br />

The closed belt bridge supports the print roller only<br />

to a limited extent.<br />

dlabr099<br />

1 Motor PE_MO02: Drive feed and exit roller PE<br />

2 Gearing<br />

− On the gearing side, open the fastening of the<br />

clutch for the motor MO02 (in dismounted<br />

condition)<br />

− Remove the motor plate with the motor from the<br />

gearing: 3 x vibration absorbers<br />

Installation:<br />

− Link the new gearing with the motor, fasten the<br />

clutch<br />

− Mount the complete unit, carefully insert the roller<br />

drive shaft and lock it with screws<br />

− Screw down 3 screws of the suspension points<br />

until the sleeves in the rubber buffers feel<br />

resistance<br />

<strong>AGFA</strong> d-<strong>lab.3</strong> 2001-01-02 /PN 9009 6.4.35


Printer<br />

Repair<br />

− Fastening of the clutch for the shaft<br />

− Thread the motor cable and link it<br />

− Mount the rear plate<br />

Check the function in the Service program<br />

Replacing the Motor PE_MO03<br />

Replacement required:<br />

Motor defective<br />

The flap control on the exposure slit does not move<br />

any more<br />

Allan key 4<br />

Service cables L9.8060.9001.1 and L9.8060.9002.1<br />

Removal:<br />

− Pull out the PE<br />

− Detach the spring (4)<br />

− Disconnect the connector (2) of MO03 (1)<br />

− Unscrew MO03 and remove it:<br />

2 fastening screws (5)<br />

Installation:<br />

− Screw on the new motor:<br />

Make sure that it does not rest on the holding<br />

plate cutout (distortion)<br />

The spring is attached again only after the check /<br />

adjustment.<br />

− Connect the service cable<br />

− Call up the service program and execute:<br />

Scripts/Scripts_printer/data_pe/klappe_ini.txt<br />

− Check the actuator function by means of Scripts:<br />

klappe_auf.txt and klappe_zu.txt<br />

In position "Flap open " (not init) push up the<br />

toggle without the spring. The actuator piston<br />

must not touch the toggle yet in this position<br />

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

holder of MO03 as appropriate by means of the<br />

screws (6).<br />

− Hang in the spring<br />

1 PE_MO03: Flap control<br />

2 Connector<br />

3 Toggle<br />

4 Spring<br />

5 Fastening screws<br />

6 Motor holder fastening screws<br />

dlabr197<br />

6.4.36 2001-01-02 /PN 9009 <strong>AGFA</strong> d-<strong>lab.3</strong>


Repair<br />

Printer<br />

Replacing the Light Sensors PE_LS05 (BOP)<br />

Replacement required:<br />

Light sensor (integrated on PE_GS03; sensor sheet<br />

tip; transmitter/receiver LS) defective<br />

Allan key 3<br />

Cross tip screwdriver<br />

Service cables L9.8060.9001.1 and L9.8060.9002.1<br />

Removal:<br />

− Pull out the PE<br />

− Remove the rear cover plate<br />

− Remove the holder with the sensor (2)<br />

− Disconnect the cable from PE_GS03<br />

− Unscrew PE_GS02 from the holder<br />

Installation:<br />

− Mount a new GS<br />

− Connect the cable<br />

− Mount the sensor with the holder<br />

− Mount the cover plate<br />

dlabr097<br />

1. Check the adjustment sensor<br />

− Connect the service cable<br />

− Call up the service program and execute:<br />

Scripts\printer\data_pe\<br />

Lichtschranken\pe_ls05-begin of<br />

paper-sensor.txt<br />

− No. of cycles 0: The sensor is constantly<br />

checked<br />

− Enter the paper at PE at the bottom, mind the<br />

display in the field Information<br />

− The sensor function is OK when the message<br />

BOP see Paper is displayed<br />

2. Check BOP on the print<br />

(Script for this in preparation)<br />

<strong>AGFA</strong> d-<strong>lab.3</strong> 2001-01-02 /PN 9009 6.4.37


Printer<br />

Repair<br />

Replacing the Light Sensors PE_LS06 (BOL)<br />

Replacement required:<br />

Light sensor (integrated on PE_GS02; sensor<br />

exposure start; Laser receiver part) defective<br />

Allan key 3<br />

Service cables L9.8060.9001.1 and L9.8060.9002.1<br />

Removal:<br />

− Pull out the PE<br />

− Remove the rear cover plate<br />

− Disconnect the cable from PE_GS02 (1)<br />

− Remove 4 Allan screws on the outside of the GS<br />

support, see (1) in the fig. below<br />

− Remove the GS support with the PE_GS02<br />

through the opening in the cast part<br />

− Unscrew PE_GS02 from the GS support<br />

dlabr097<br />

Installation:<br />

− Mount a new GS on the GS support<br />

− Put back the complete unit (receiver opposite the<br />

mirror) and fasten it to the cast housing<br />

− Connect the cable<br />

− Mount the cover plate<br />

1. Check the adjustment sensor<br />

Link the service cable, start the machine<br />

Observe the LED on the GS: When voltage is<br />

applied, this LED lights red; when the laser is<br />

switched on (part of the red laser is uncoupled via<br />

the mirror), the LED must turn off. It remains off<br />

during the whole operation. If the LED does not<br />

turn off (the latest when the print roller starts), the<br />

mirror position is not correct.<br />

Correction of the position by shifting the GS<br />

support in its screw-down holes. The machine<br />

can be started without the service cable, but this<br />

makes the shifting of the GS plate more difficult.<br />

2. Check the parameters of the laser array middle<br />

in the Service program (Script for this in<br />

preparation)<br />

dlabr098<br />

6.4.38 2001-01-02 /PN 9009 <strong>AGFA</strong> d-<strong>lab.3</strong>


Repair<br />

Printer<br />

Replacing the Light Sensors PE_LS01/02/03/04/07/08<br />

Replacement required:<br />

Light sensor defective<br />

PE_LS01 LS before printing roller<br />

(on PE_GS04)<br />

PE_LS02 Flap control (fork light sensor)<br />

PE_LS03 LS behind printing roller<br />

(on PE_GS05)<br />

PE_LS04 Speed control for motor PE_MO02<br />

PE_LS07 Paper detection inlet PE<br />

(on PE_GS06)<br />

PE_LS08 Printing roller rotation control dlabr299<br />

<strong>AGFA</strong> d-<strong>lab.3</strong> 2001-01-02 /PN 9009 6.4.39


Printer<br />

Repair<br />

Replacing the Set of Belts at the bottom<br />

Replacement required:<br />

Belts or rollers damaged by a paper jam<br />

Allan keys 3 and 4<br />

Screwdriver<br />

Spanners 13 and 9<br />

Removal:<br />

− Pull out the PE<br />

− Open the set of belts<br />

− Remove the locking lever on the left side:<br />

Remove the safety spring (1)<br />

− Remove the sensor holder (2) with sensor<br />

PE_LS02<br />

− Detach the spring (3) on the actuator<br />

− Open the circlip (4) on the toggle, push in<br />

actuator piston<br />

− Remove the toggle (5)<br />

− Dismount the sensor PE_GS03 (6) with the<br />

holder<br />

− Unscrew the Allan screws (7) (key size 13) on<br />

both sides of the cast frame:<br />

The set of belts only hangs on 1 supporting screw<br />

(8) on either side<br />

− Remove the supporting screw on the right side,<br />

only slacken it on the left side until the set of belts<br />

is free<br />

− Remove the set of belts<br />

dlabr289<br />

Installation:<br />

− Put the new set of belts in the supporting screws<br />

first, tighten the screws<br />

− Mount 2 Allan screws on either side<br />

− Check the belt mounting position<br />

− Mount sensor PE_GS03<br />

− Mount the toggle:<br />

Do not unscrew the eccentric screw (lacquersealed,<br />

specific gap dimension)!<br />

− Mount the sensor holder with sensor PE_LS02<br />

− Hang in the spring<br />

− Mount the locking lever<br />

− Close the set of belts<br />

dlabr290<br />

6.4.40 2001-01-02 /PN 9009 <strong>AGFA</strong> d-<strong>lab.3</strong>


Repair<br />

Printer<br />

Adjust the belt tension<br />

− Turn the tensioning screws (1) at the ends of the<br />

belt bridge (accessible through the holes) ccw<br />

until it can be felt that the belt is not in mesh any<br />

more. From this point, turn cw until no spring<br />

force is felt any more.<br />

Do not check on the outer rollers as they have a<br />

larger diameter.<br />

− Count the turns between the two positions<br />

(approx. 6) and turn ccw half the number of turns<br />

dlabr298<br />

<strong>AGFA</strong> d-<strong>lab.3</strong> 2001-01-02 /PN 9009 6.4.41


Printer<br />

Repair<br />

Replacing the Set of Belts at the top<br />

Set of belts at the top 9.8060.PEC0.0<br />

Replacement required:<br />

Belts and rollers damaged by a paper jam<br />

Removal/installation in case of scratches caused by<br />

the edge of the slit.<br />

Allan keys 3 and 4<br />

Screwdriver<br />

Do not slacken the eccentric of the toggle upon the<br />

removal, do not shift the actuators. In this case,<br />

reliable functioning would not be ensured any more!<br />

Removal<br />

− Pull out the PE<br />

− Remove the top guide plate<br />

− Push in the piston on the actuator PE_MO03 (1)<br />

(stiff!)<br />

− Remove the sensor holder (above 4) with sensor<br />

PE_LS02<br />

− Detach the tension spring (4)<br />

− Open the circlip (2)<br />

− Remove the toggle (3)<br />

− Detach the cable from the cable holder<br />

− Remove the sensor plate (6):<br />

Unscrew 2 screws at the front, remove the plate<br />

to the front<br />

− Unscrew 2 screws (below the cable collar) on the<br />

set of belts (5) and pull out the assembly group<br />

with the plate (cable holder) towards the front<br />

− Removal because of scratches:<br />

Check the front edge of the part, if necessary pull<br />

it off a little and clean it<br />

dlabr256<br />

Installation:<br />

Put a sheet of photographic paper 20x30 over the<br />

print roller, clamp the sheet on the left side under<br />

the set of belts: Absolutely necessary, otherwise the<br />

belts may slip off the belt rollers when the assembly<br />

group is mounted!<br />

6.4.42 2001-01-02 /PN 9009 <strong>AGFA</strong> d-<strong>lab.3</strong>


Repair<br />

Printer<br />

− Move the set of belts to the back as far as<br />

possible (supporting it with your right hand,<br />

removed guide plate) and lower it:<br />

− The ball pins lock into the guide holes at the<br />

back<br />

− At the front, the pin must be in the plate (cable<br />

holder)<br />

− Fasten the plate and by this the whole assembly<br />

group<br />

− Check the correct belt position, if necessary, turn<br />

the belts to position them correctly<br />

− Mount the sensor plate and screw it on without<br />

shifting the belts off the rollers!<br />

− Mount the toggle:<br />

Push the bottom set of belts together a little to<br />

make the insertion easier and ensure that it locks<br />

correctly in the toggle.<br />

− Mount the sensor PE_LS02<br />

− Click in the cable<br />

− Mount the cover plate<br />

− Mount the guide plate<br />

− Remove the photographic paper from the print<br />

roller, drive the print roller by turning the clutch.<br />

Never pull out the sheet because of the belt<br />

pressure! The belts may be relocated.<br />

The belt tension is set in the same way as on the<br />

bottom set of rollers.<br />

As the rear screw is not accessible, it should be<br />

checked before mounting a new assembly group<br />

that the two clamping screws lift the rail with the<br />

rollers off the side parts by approx. 2-3 turns.<br />

<strong>AGFA</strong> d-<strong>lab.3</strong> 2001-01-02 /PN 9009 6.4.43


Printer<br />

Repair<br />

Replacing the complete Print Engine PE<br />

Replacement required:<br />

Printing roller damaged<br />

A second person is needed to replace the Print<br />

Engine as it weights approx. 50 kg.<br />

− Disconnect the Laser cable from the Laser:<br />

− Pull out the PE<br />

− Pull out the TU if necessary<br />

− Unscrew the cover from the Laser<br />

− Unscrew the locking screws on the cable<br />

− Strip off the Laser cable<br />

− Disconnect the power supply cable from the<br />

power supply unit<br />

− Disconnect the data cable from the SPI-GS<br />

− Remove the cable from the drag chain<br />

− Unscrew 4 fastening screws each on the<br />

telescopic rails:<br />

Push the PE in the machine, pushing the<br />

mounting hole of the telescopic rail over the 3 rd<br />

and then over the 4 th screw.<br />

− Hold the PE on the inner frame and lift it out, or<br />

push a mounting table under the PE so that the<br />

PE can sit on it<br />

− Push in the telescopic rails<br />

Height-adjust the TU, see Print Engine: Checking<br />

the Height Dimension in Register 10<br />

Make sure after the installation that the two cables<br />

on the laser diode lock correctly in the holder.<br />

dlabr145<br />

6.4.44 2001-01-02 /PN 9009 <strong>AGFA</strong> d-<strong>lab.3</strong>


Repair<br />

Printer<br />

Replacing the Laser Module / Laser<br />

Warning!<br />

A laser beam of class 3B may be accessible after<br />

the removal of covers.<br />

Be sure to keep the mechanical laser shutter on<br />

the fibre coupling closed when working on the<br />

laser.<br />

Looking directly into lasers of class 3B is<br />

dangerous and can always hurt the eyes.<br />

Make sure during maintenance and repair work that<br />

the laser beam is not reflected into the eyes by parts<br />

or tools.<br />

Caution!<br />

The assembly group should never be opened. The<br />

Laser fibre cable is rigidly coupled with the Laser<br />

module. It must only be disconnected on the laser<br />

head itself.<br />

The following parts can be replaced:<br />

− Laser module 4.4150.1000<br />

− Laser<br />

7.8060.LUD0<br />

− Laser power supply unit 7.8060.LUC1<br />

− PE_GS01 (3) Distributor board 8.8060.2170<br />

− LA_GS07 Polygon drive (4) 7.4150.1558<br />

− LA_BE04 AOM green (5) 8.4150.1330<br />

− LA_BE04 AOM blue (6) 8.4150.1330<br />

Not replaceable:<br />

− LA_GS06 (1)<br />

− LA_GS05 (2)<br />

dlabrx48<br />

<strong>AGFA</strong> d-<strong>lab.3</strong> 2001-01-02 /PN 9009 6.4.45


Printer<br />

Repair<br />

Replacing the Laser Module<br />

Cross tip screwdriver<br />

Allan keys 5,0 and 3,0<br />

− Disconnect the Laser cable from the Laser:<br />

− Pull out the PE<br />

− Pull out the TU and remove it<br />

− Unscrew the Laser cover<br />

− Unscrew the locking screws on the cable<br />

− Strip off the cable<br />

− Remove the cable from the drag chain<br />

− Take off the mirror cover:<br />

4 Allan screws<br />

− Disconnect the connectors<br />

− Unscrew the fastening screws on the Laser<br />

module: 4 Allan screws<br />

− Disconnect the connectors<br />

− Lift the Laser module up and out, holding it by the<br />

handles<br />

1 Carrier frame<br />

2 Laser module<br />

dlabr076<br />

6.4.46 2001-01-02 /PN 9009 <strong>AGFA</strong> d-<strong>lab.3</strong>


Repair<br />

Printer<br />

Replacing the Laser Head and adjusting the Fibre Coupling<br />

The Fibre can not be uncoupled from the module,<br />

but only from the Laser head.<br />

Purpose of the adjustment:<br />

Optimising the laser capacity by adjusting the fibre<br />

coupling on the laser head.<br />

Elements of the adjustment unit:<br />

− Fibre holder (1): Tube into which the fibre end is<br />

put<br />

− Adjustment screws (2):<br />

4 knurled screws, Allan screws (size 2)<br />

Always 2 screws are used for the horizontal and<br />

the vertical direction. The screws are locked with<br />

spring-loaded knurled nuts. The lock nuts should<br />

be tightened slightly for the adjustment so that<br />

the adjustment screws are pretensioned.<br />

Caution: Fine thread<br />

− Pressure screws (3):<br />

2 screws with a flat head and a spring-loaded<br />

Nylon tip are used for the fastening of the fibre in<br />

the adjustment unit. The screw on the laser side<br />

holds the fibre holder in the adjusted lateral<br />

position, the screw on the exit side fastens the<br />

lengthwise position of the fibre holder.<br />

− Fastening ring (4, no fig.) for the polarisation<br />

adjustment (must not be unscrewed!)<br />

− Allan screw (5), size 2<br />

dlabr107<br />

dlabr155<br />

<strong>AGFA</strong> d-<strong>lab.3</strong> 2001-01-02 /PN 9009 6.4.47


Printer<br />

Repair<br />

Caution!<br />

Use only the rear black screw (3) on the fibre<br />

coupling to remove / insert the fibres upon the<br />

replacement of the laser or the laser module.<br />

If the 4 knurled screws (2) are slackened, the<br />

preadjustment (transmission of at least 40%) of the<br />

fibres is not given any more and the fibre<br />

transmission may be zero.<br />

Caution!<br />

The laser must be switched off when the fibre is<br />

replaced as otherwise laser radiation may occur.<br />

dlabx157<br />

Laser replacement:<br />

− Switch off the laser on the laser power supply unit<br />

dlabr105<br />

6.4.48 2001-01-02 /PN 9009 <strong>AGFA</strong> d-<strong>lab.3</strong>


Repair<br />

Printer<br />

Fibre (1)<br />

General view<br />

Front view<br />

dlabr107<br />

Top plan view<br />

dlabr157<br />

dlabr155<br />

Power meter (e.g. Ophir Nova with filter or monitor<br />

diode in the laser scanning module)<br />

2 Allan keys, size 2<br />

− Completely unscrew the small Allan screw (5)<br />

− Slacken the pressure screw on the laser side until<br />

the fibre can be pulled out<br />

− Slacken the pressure screw on the exit side until<br />

the fibre holder can be pulled out<br />

− Put the fibre in the fibre holder in such a way that<br />

the pin on the fastening ring (4, no fig.) fits in the<br />

corresponding recess in the fibre holder<br />

− Mount the fibre holder with the fibre in the new<br />

laser<br />

− Tighten the pressure screws:<br />

1. Up to the stop position<br />

2. Slacken one turn<br />

dlabr156<br />

<strong>AGFA</strong> d-<strong>lab.3</strong> 2001-01-02 /PN 9009 6.4.49


Printer<br />

Repair<br />

− The tip of the pressure screw on the exit side<br />

must engage in the nut of the fibre holder<br />

− Tighten the Allan screw (5) again<br />

− Switch on the laser<br />

Allan key size 2<br />

Adjustment of the vertical and horizontal position of<br />

the fibre:<br />

− Unscrew the lock nuts<br />

− Adjust the adjustment screws on the exit side in<br />

such a way that the maximum power of the laser<br />

light transmitted through the fibre is reached<br />

(check with the monitor diode)<br />

− Find the optimum fibre position by horizontal and<br />

vertical parallel shifting of the fibre:<br />

Optimise the adjustment of the two planes<br />

separately (check by means of the voltage on the<br />

monitor diode). For this, shift the fibres in one<br />

plane by means of the adjustment screws<br />

alternately on the laser side and on the exit side<br />

until the maximum transmission is reached.<br />

Caution!<br />

Make absolutely sure that the maximum possible<br />

transmission is reached as otherwise power<br />

fluctuations may occur due to temperature drifts.<br />

Tighten the lock nuts:<br />

The voltage value must not change.<br />

6.4.50 2001-01-02 /PN 9009 <strong>AGFA</strong> d-<strong>lab.3</strong>


Repair<br />

Printer<br />

Replacing the Laser Power Supply Unit<br />

Allan key 3,0<br />

Dismount the laser power supply unit:<br />

− Disconnect the cables:<br />

1. Power cable for the laser 220 V on the right<br />

side of the Printer power supply unit<br />

(2 screws)<br />

2. Cable on the power supply unit<br />

3. Remote on PO_GS01<br />

− Unscrew the laser power supply unit (4 screws)<br />

and remove it<br />

dlabr170<br />

Replacing LA_GS01 LFB-Distributor<br />

LFB = Laser Feedback<br />

− Remove LA_GS01 (1):<br />

The GS is held at the back in 2 holders and is<br />

only locked in at the front.<br />

dlabrf48<br />

Replacing LA_GS07 Polygon Drive<br />

− Remove the GS: 4 screws<br />

Make sure that the screws do not fall into the<br />

printing roller!<br />

dlabrc48<br />

<strong>AGFA</strong> d-<strong>lab.3</strong> 2001-01-02 /PN 9009 6.4.51


Printer<br />

Repair<br />

Replacing the AOM Amplifier<br />

AOM = acoustooptical Modulator<br />

Replacement required:<br />

AOM defective<br />

The d-<strong>lab.3</strong> is equipped with an AOM amplifier each<br />

for the blue and the green laser beam:<br />

− LA_BE04 (1), blue<br />

− LA_BE04 (2), green<br />

Watchmaker screwdriver<br />

Allan key<br />

Replacement:<br />

− Pull out the PE<br />

− Draw the power plug<br />

− Unscrew the top screw (3), slacken the bottoms<br />

screw; do not disconnect the data cable (4)<br />

− Remove the AOM, disconnect the data cable (4)<br />

− LA_BE04 (1)<br />

− LA_BE04 (2)<br />

− Connect the new AOM to the data cable and the<br />

power supply:<br />

Adjust the AOM before screwing it down.<br />

− Find a new characteristic curve (adjustment by<br />

means of the Service program):<br />

For this, move an additional monitor diode into<br />

the light path<br />

− Screw down the AOM<br />

− Restart the d-<strong>lab.3</strong><br />

dlabre48<br />

dlabr173<br />

6.4.52 2001-01-02 /PN 9009 <strong>AGFA</strong> d-<strong>lab.3</strong>


Repair<br />

Printer<br />

Adjustment of the AOM Driver Electronic<br />

Adjust the potentiometers:<br />

− Bias Offset<br />

− Power<br />

− Move the 4 th monitor diode into the light path<br />

(green or blue) for the following adjustments and<br />

the recalibration<br />

− At 0 V input voltage, adjust the Bias such that the<br />

laser power is minimum<br />

− At 0,6 V input voltage, maximise the power with<br />

the potentiometer and turn it back approx. 5%<br />

− Recalibration in the Service program<br />

<strong>AGFA</strong> d-<strong>lab.3</strong> 2001-01-02 /PN 9009 6.4.53


Printer<br />

Repair<br />

Lane Distributor LD, replacing Parts<br />

− Pull the lane distributor to the front on the<br />

telescopic rails<br />

− If required (for some components), dismount the<br />

lane distributor:<br />

− Screw 4 bolts into the lane distributor from<br />

below so that it can be deposited correctly<br />

− Lift the lane distributor off the telescopic rails<br />

dlabr039<br />

Replacing the Motors LD_MO01 to LD_MO05<br />

Replacement required:<br />

Motor defective<br />

LD_MO01: Drive takeover section LD<br />

LD_MO02 Drive sheet distribution vertical<br />

LD_MO03 Drive sheet distribution horizontal<br />

LD_MO04 Drive exit station, 2 lanes<br />

LD_MO05 Drive back printer<br />

Position MO01 to MO04: See Fig. on the next page<br />

Allan key 3<br />

Dynamometer<br />

Service cables L9.8060.9001.1 and L9.8060.9002.1<br />

Removal:<br />

− Disconnect the motor connecting cables<br />

− Unscrew the motors 01, 02, 04;<br />

Slacken motor 03 first: Open the two belt<br />

tensioners on the opposite side<br />

− Remove the sync disk (circlip)<br />

Installation:<br />

− Mount the sync disk on the new motor<br />

− Mount the new motor<br />

− Connect the cables<br />

6.4.54 2001-01-02 /PN 9009 <strong>AGFA</strong> d-<strong>lab.3</strong>


Repair<br />

Printer<br />

Adjust the belt tension:<br />

− Push the motor in tensioning direction (except<br />

MO03) and fasten it at the following tensioning<br />

torque (the weight of the motors has been<br />

considered):<br />

− Motor 01<br />

− Motor 02<br />

− Motor 03<br />

35 N<br />

6 N<br />

6 N<br />

− Motor MO04 is only mounted:<br />

The belt tension is set on the clamping pieces on<br />

the opposite side. Both belts (5) and (6) for MO03<br />

must be tensioned at 27 N.<br />

− Functional check of the motors with the Scripts:<br />

MO01.txt, MO02.txt, MO03test.txt, MO04.txt<br />

Connect the service cable and call up the above<br />

Script under:<br />

Scripts/scripts_printer/data_ld/motors<br />

− The cycle number to be entered in the Scripts<br />

defines the number of possible new starts at one<br />

call. The motor is running permanently until<br />

STOP is pressed.<br />

− In the Script MO03text.txt the sledge is held in<br />

the middle after an initialisation. After the value to<br />

be measured has been confirmed, the motor runs<br />

permanently with short halts until the operator<br />

presses the STOP key.<br />

dlabr291<br />

1 Belt tensioner<br />

R1 16 N<br />

R3 12 N<br />

<strong>AGFA</strong> d-<strong>lab.3</strong> 2001-01-02 /PN 9009 6.4.55


Printer<br />

Repair<br />

Replacing the LD_GS01 (Lane Distributor Control)<br />

Replacement required:<br />

Faults due to a defective GS<br />

Allan key 2,5<br />

Removal:<br />

− Check the program version prior to the removal:<br />

Run Script and note down the version for<br />

prld.hex:<br />

Scripts/scripts_dlab/pr_vers_setup.txt<br />

− Remove the cover (3):<br />

− Slacken the screw (2)<br />

− Remove the screws (1)<br />

− Remove LD_GS01:<br />

Unscrew 4 screws (1) and remove the printed<br />

circuit towards the top (the printed circuit is only<br />

attached at the bottom)<br />

dlabr117<br />

Installation:<br />

− Mount the new GS:<br />

Installation in reverse order<br />

dlabr118<br />

Check:<br />

− Run the Script again, compare the version<br />

− If the version differs, load the appropriate file of<br />

the Software package with Service GUI /<br />

firmware_download<br />

6.4.56 2001-01-02 /PN 9009 <strong>AGFA</strong> d-<strong>lab.3</strong>


Repair<br />

Printer<br />

Replacing Light Sensors<br />

Replacement required:<br />

LS defective<br />

LS<br />

LS01<br />

LS02<br />

LS04<br />

LS05<br />

LS06<br />

LS07<br />

LS08<br />

LS10<br />

on LD_GS:<br />

GS09<br />

GS07<br />

without GS<br />

GS05<br />

GS04<br />

GS03<br />

GS02<br />

GS08<br />

Allan keys 2,5 and 4<br />

Cross tip screwdriver<br />

Removal:<br />

− Remove the GS with the defective LS:<br />

Disconnect the connector<br />

− For GS04, GS05, GS07, GS08, unlock the<br />

guide plate and the rear guide before.<br />

− For GS09 dismount the printer first.<br />

Installation:<br />

− Mount a new LS, connect the connector<br />

− For GS07 first unscrew the lateral screws used to<br />

fasten the guide plate so as not to damage the<br />

paper guide when moved in<br />

dlabr297<br />

Check:<br />

− Check the light sensors in the service program:<br />

Scripts/scriptes_printer/data_ld/<br />

ld_lichtschranken/ld_lsxx.txt<br />

− Start the Script: Status off/on is displayed<br />

− When the LS is covered, O.K. must be pushed<br />

again and the new status is displayed<br />

<strong>AGFA</strong> d-<strong>lab.3</strong> 2001-01-02 /PN 9009 6.4.57


Printer<br />

Repair<br />

Replacing toothed Belts<br />

Replacement required:<br />

Toothed belt damaged<br />

Allan keys 3 and 2,5<br />

Dynamometer<br />

Removal:<br />

− Unscrew the clamping piece or the motor for the<br />

respective belt, for the belts (5) and (6) open in<br />

addition the connection to the distributor slider<br />

− Remove the belts<br />

Installation:<br />

− Mount new belts<br />

− For the belts (5) and (6) make the connection to<br />

the slider again<br />

Adjust the belt tension:<br />

− The setting values described already under<br />

Changing the motor hold for the belts on the<br />

motors:<br />

− Motor 01 35 N<br />

− Motor 02 6 N<br />

− Motor 03 6 N<br />

− Motor 04 only mounted<br />

− Tension both belts (5 and 6) for MO03 at 27 N.<br />

− Setting values for the other belts:<br />

− R3<br />

12 N<br />

− R1<br />

16 N<br />

dlabr291<br />

6.4.58 2001-01-02 /PN 9009 <strong>AGFA</strong> d-<strong>lab.3</strong>


Repair<br />

Printer<br />

Back Printer, replacing the Print Head<br />

Replacement required:<br />

Back Printer defective<br />

Allan keys 4; 2; 2,5 and 1,5<br />

Cross tip screwdriver<br />

Service cables L9.8060.9001.1 and L9.8060.9002.1<br />

Removal:<br />

− Replace the complete printer<br />

− Disconnect the cable to the GS<br />

FK29, KA107<br />

− Unscrew 2 Allan screws on either side<br />

− Remove the assembly group to the bottom<br />

− Replace the print head<br />

− Remove the ink ribbon cartridge (1)<br />

− Disconnect the flat cable<br />

− Unscrew 2 cross tip screws<br />

− Remove the print head (2)<br />

− Replace the printer belt drive motor (3)<br />

− Remove the ink ribbon cartridge<br />

− Disconnect the motor connections<br />

− Remove the driver on the belt drive (screwed<br />

on with an Allan screw)<br />

− Unscrew 4 Allan screws<br />

− Remove the motor<br />

dalbr134<br />

Installation:<br />

− Always in reverse direction<br />

1 Back printer ink ribbon magazine<br />

2 Print head paper feed<br />

3 Drive motor<br />

Check the print quality:<br />

− Connect the service cable<br />

− Call up the following Script under Service:<br />

Scripts/scripts_printer/data_ld/4x6fast.txt,<br />

D102x152.txt, D203x305.txt<br />

<strong>AGFA</strong> d-<strong>lab.3</strong> 2001-01-02 /PN 9009 6.4.59


Printer<br />

Repair<br />

Readjust the print head counter plate:<br />

− Unscrew the stud bolts far enough so that the<br />

print head counter plate is fully on the top paper<br />

guide (up) when the two fastening screws are<br />

screwed on<br />

− Turn the stud bolts to the stop with respect to the<br />

top paper guide<br />

− Slacken the fastening screws<br />

Screw in the 4 stud bolts 0,5 turn<br />

The print head counter plate must have a distance<br />

of > 0,4 mm with respect to the bottom paper guide.<br />

Replacing RD_GS01 Back Printer Control<br />

Replacement required:<br />

Faults due to a defective GS<br />

Removal:<br />

− Check the program version prior to the removal:<br />

Run Script and note down the version for<br />

prrd.hex:<br />

Scripts/scripts_dlab/pr_vers_setup.txt<br />

− Disconnect all connectors from RD_GS01<br />

− Pull RD_GS01 off the 4 clamping pieces<br />

Installation:<br />

− Mount the new GS<br />

− Connect the connector<br />

dlabr119<br />

Check:<br />

− Run Script again, compare the version<br />

− If the version differs, load the appropriate file of<br />

the Software package with Service GUI /<br />

firmware_download<br />

6.4.60 2001-01-02 /PN 9009 <strong>AGFA</strong> d-<strong>lab.3</strong>


Repair<br />

Printer<br />

Functional Check after the Replacement of Parts<br />

If parts are replaced on an assembly group which<br />

also influence the paper transport, a functional test<br />

with paper should be performed in the Service<br />

program.<br />

For this, the assembly group has to be pulled out<br />

and operated via the service cables.<br />

There are other Scripts available, besides the<br />

indicated ones:<br />

Scripts/scripts_printer/data_ld/allgemein/4x6slow.txt<br />

Scripts/scripts_printer/data_ld/allgemein/dplfast.txt<br />

Scripts/scripts_printer/data_ld/allgemein/ldls_prf.txt<br />

Scripts/scripts_printer/data_ld/allgemein/LD_vers.txt<br />

Scripts/scripts_printer/data_ld/allgemein/kontrollstreifen<br />

/cfast_go.txt<br />

Scripts/scripts_printer/data_ld/allgemein/kontrollstreifen<br />

/cslow_go.txt<br />

Scripts/scripts_printer/data_ld/motore/MO04kupl.txt<br />

Size 4x6 slow, without pressure, roller<br />

adjustment<br />

Size 4x6 with pressure by LD<br />

Light sensor test<br />

Version check LD and RSD<br />

Control strip test, quick<br />

Control strip test, slow<br />

Test magnetic clutch<br />

<strong>AGFA</strong> d-<strong>lab.3</strong> 2001-01-02 /PN 9009 6.4.61


Printer<br />

Repair<br />

Sheet Transfer ST, replacing Parts<br />

− Slacken 1 screw (1)<br />

− Pull ST to the front<br />

dlabr062<br />

Replacing the Motor ST_MO01<br />

Replacement required:<br />

Motor defective<br />

Allan key 1,5<br />

Removal:<br />

− Dismount the hand wheel (1):<br />

2 Allan screws on the shaft<br />

− Unscrew the metal bracket with handle (2)<br />

− Disconnect the connector (3)<br />

− Detach the motor from the clutch / the sync disk<br />

(4):<br />

2 Allan screws<br />

− Slacken the belt by unscrewing the motor plate:<br />

2 tensioning screw, 1 screw inside<br />

− Remove the motor plate<br />

− Unscrew the motor from the motor plate<br />

Installation:<br />

In reverse order<br />

− Tension the belt by shifting the motor plate<br />

− Install the assembly group and check the motor<br />

function in the Service program:<br />

Scripts/scripts_printer/data_ld/ST sheet<br />

Transfer<br />

dlabr293<br />

6.4.62 2001-01-02 /PN 9009 <strong>AGFA</strong> d-<strong>lab.3</strong>


Repair<br />

Printer<br />

Replacing the toothed Belt<br />

Replacement required:<br />

Belt defective<br />

Allan key 1,5<br />

Cross tip screwdriver<br />

Removal:<br />

− Work steps as described under Replace motor<br />

ST_MO01 on the previous page<br />

− In addition:<br />

− Open the belt tensioner (1)<br />

− Remove the belt to be replaced<br />

Installation:<br />

− In reverse order<br />

Tension the belt:<br />

− Shift the motor plate and the belt tensioner<br />

dlabr294<br />

Replacing the flat Belts<br />

Replacement required:<br />

Belt defective<br />

Cross tip screwdriver<br />

Removal:<br />

− Unscrew the belt tensioner (1) of the larger<br />

toothed belt<br />

− Detach the spring (2) of the top guide shaft<br />

− Remove 3 circlips (3) from the guide roller and<br />

the large transport roller on the connector side (if<br />

necessary, unscrew the connector holder)<br />

− Remove the bearings of all 4 shafts and push the<br />

shafts towards the motor<br />

− Remove the flat belts (4)<br />

Installation:<br />

− Thread new toothed belts<br />

− Mount in reverse order<br />

− Tension the toothed belts, hang in the springs<br />

− Functional check: The belts run between the<br />

spacer rollers of the guide shafts<br />

dlabr295<br />

<strong>AGFA</strong> d-<strong>lab.3</strong> 2001-01-02 /PN 9009 6.4.63


Printer<br />

Repair<br />

■<br />

6.4.64 2001-01-02 /PN 9009 <strong>AGFA</strong> d-<strong>lab.3</strong>


Repair<br />

Paper Processor<br />

Contents<br />

General Overview .................................................................................................................................... 7.1.1<br />

Sensors and Loads in the Paper Processor....................................................................................... 7.1.1<br />

Block Circuit Diagrams........................................................................................................................... 7.1.3<br />

General System.................................................................................................................................. 7.1.3<br />

PCBs .................................................................................................................................................. 7.1.4<br />

Signal Lists .............................................................................................................................................. 7.2.1<br />

Sensors / Loads ................................................................................................................................. 7.2.1<br />

Overview of the Connectors............................................................................................................... 7.2.4<br />

Functional Description ........................................................................................................................... 7.3.1<br />

Mechanical Structure.......................................................................................................................... 7.3.1<br />

Electrical Structure ............................................................................................................................. 7.3.3<br />

Paper Processor Control.................................................................................................................... 7.3.5<br />

AC/DC Power Supply ......................................................................................................................... 7.3.7<br />

Other PCBs ...................................................................................................................................... 7.3.10<br />

Repair ....................................................................................................................................................... 7.4.1<br />

Replacement of the Densitometer...................................................................................................... 7.4.1<br />

Replacing Printed Circuits .................................................................................................................. 7.4.3<br />

Replacing Relays ............................................................................................................................... 7.4.4<br />

Temperature Switch Dryer ................................................................................................................. 7.4.5<br />

<strong>AGFA</strong> d-<strong>lab.3</strong> 2001-01-02 /PN 9009 7.i


Paper Processor<br />

Repair<br />

■<br />

7.ii 2001-01-02 /PN 9009 <strong>AGFA</strong> d-<strong>lab.3</strong>


Repair<br />

Paper Processor<br />

General Overview<br />

Sensors and Loads in the Paper Processor<br />

Processor Block (PP)<br />

FA1PPP<br />

Cooling fan for DEV<br />

FA2PPP, FA3PPP Cooling fan for BF<br />

FA4PPP<br />

Cooling fan for STB<br />

FA5PPP<br />

Cooling fan for Processor block<br />

FA6PPP<br />

Cooling fan for transport motor<br />

FA7PPP<br />

Cooling fan for DEV circulation pump<br />

FS1PET - FS3PET Level switch effluent tanks<br />

FS1PRT - FS3PRT Level switch replenishment tanks<br />

FS1PRW<br />

Level switch water replenishment tanks<br />

FS2PRW<br />

Level switch evaporation measuring tanks<br />

FS1PTK - FS5PTK Level switch temperature control tanks<br />

HS1PCT - HS3PCT Temperature sensors control tanks<br />

HT1PCT<br />

Heater DEV<br />

HT2PCT<br />

Heater BF<br />

HT3PCT - HT5PCT Heater STB<br />

LS1PRD<br />

Mixer motor rotation control<br />

MO1PPD<br />

Main drive<br />

MO1PPP<br />

Circulation pump for DEV<br />

MO2PPP<br />

Circulation pump for BF<br />

MO3PPP - MO5PPP Circulation pump for STB1-3<br />

MO1PRD<br />

Replenisher Mixer<br />

MO1PRP<br />

Replenisher pump DEV<br />

MO2PRP<br />

Replenisher pump BF<br />

MO3PRP<br />

Replenisher pump STB<br />

MO1PRW<br />

Pump DEV water replenishment<br />

MO2PRW<br />

Pump BF water replenishment<br />

MO3PRW<br />

Pump STB 3 water replenishment<br />

MO4PRW<br />

Water pump evaporation compensation tank<br />

MO6PRW<br />

Pump STB 2 water replenishment<br />

MO7PRW<br />

Pump STB 1 water replenishment<br />

MS1PTK<br />

Switch of the Processor cover<br />

MS2PTK<br />

Switch of the BF replenisher tank cover<br />

MS3PTK<br />

Processor drive interrupt, when MS1PTK activated<br />

MS4PTK<br />

Switch of the DEV replenisher tank cover<br />

MS5PTK<br />

Switch of the STB replenisher tank cover<br />

Dryer (DH)<br />

LS1PDH Dryer fan control FA1PDH<br />

FA1PDH Dryer fan<br />

FA2PDH Dryer cooling fan<br />

FA3PDH Cooling fan for dryer block<br />

FA4PDH Cooling fan for FA1PIR<br />

FA5PDH Cooling fan for FA2PIR<br />

FU1PDH Temp fuse<br />

HS1PDR Temp sensor dryer<br />

HT1PDH Dryer heater 1<br />

HT2PDH Dryer heater 2<br />

MS1PDH Dryer cover switch<br />

MS2PDH Dryer interrupt when MS1PDH is actuated<br />

TH1PDH Thermostat<br />

IR dryer (IR)<br />

HT1PIR IR dryer top<br />

HT2PIR IR dryer bottom<br />

FA1PIR Dryer fan top<br />

FA2PIR Dryer fan bottom<br />

LS1PIR Dryer fan control FA1PIR<br />

LS2PIR Paper detection<br />

LS3PIR Paper detection<br />

LS4PIR Paper detection<br />

LS5PIR Paper detection<br />

LS6PIR IR dryer control<br />

LSAPIR Dryer fan control FA2PIR<br />

TH1PIR Thermostat<br />

Paper output (PO)<br />

FA1PPO Cooling fan of the densitometer<br />

LS1PPO Paper detection 1<br />

LS2PPO Paper detection 2<br />

LS3PPO Paper detection 3<br />

LS4PPO Paper detection 4<br />

MG1PPO Pressure solenoid of the densitometer<br />

MO1PPO Drive paper exit 1<br />

MO2PPO Drive paper exit 2<br />

MG2PPO Transport direction switch-over<br />

Lane Shifter (LS)<br />

LS1PLS Detection Lane Shifter in reference position<br />

LS2PLS Detection flap in reference position<br />

MO1PLS Lane Shifter drive motor<br />

MO2PLS Flap movement<br />

Sorter (SO)<br />

LS1PSO Detection Sorter in reference position<br />

MO1PSO Sorter drive<br />

MS1PSO Sorter closed detection<br />

dlabr12<br />

<strong>AGFA</strong> d-<strong>lab.3</strong> 2001-01-02 /PN 9009 7.1.1


Repair<br />

Paper Processor<br />

Block Circuit Diagrams<br />

General System<br />

dlabr030<br />

<strong>AGFA</strong> d-<strong>lab.3</strong> 2001-01-02 /PN 9009 7.1.3


Paper Processor<br />

Repair<br />

PCBs<br />

55P-CPU<br />

dlabr170<br />

■<br />

7.1.4 2001-01-02 /PN 9009 <strong>AGFA</strong> d-<strong>lab.3</strong>


Repair<br />

Paper Processor<br />

Signal Lists<br />

Sensors / Loads<br />

Paper Processor Block (PP)<br />

Designation<br />

Function<br />

FA1PPP<br />

Cooling fan for DEV<br />

FA2PPP, FA3PPP Cooling fan for BF<br />

FA4PPP<br />

Cooling fan for STB<br />

FA5PPP<br />

Cooling fan for Processor block<br />

FA6PPP<br />

Cooling fan for transport motor<br />

FA7PPP<br />

Cooling fan for DEV circulation pump<br />

FS1PET - FS3PET Level switch of the effluent tanks<br />

FS1PRT - FS3PRT Level switch of the replenisher tanks<br />

FS1PRW<br />

Level switch of the water replenishing tanks<br />

FS2PRW<br />

Level switch of the evaporation measurement water tank<br />

FS1PTK - FS5PTK Level switch of the temperature control tanks<br />

HS1PCT - HS3PCT Temperature sensor of the control tanks<br />

HT1PCT<br />

Heater DEV<br />

HT2PCT<br />

Heater BF<br />

HT3PCT - HT5PCT Heaters STB<br />

LS1PRD<br />

Turning monitoring of the mixer motor<br />

MO1PPD<br />

Main drive<br />

MO1PPP<br />

Circulation pump for DEV<br />

MO2PPP<br />

Circulation pump for BF<br />

MO3PPP - MO5PPP Circulation pump for STB tanks 1-3<br />

MO1PRD<br />

Replenisher mixer<br />

MO1PRP<br />

Replenishing pump DEV<br />

MO2PRP<br />

Replenishing pump BF<br />

MO3PRP<br />

Replenishing pump STB<br />

MO1PRW<br />

Pump of the water replenishment DEV<br />

MO2PRW<br />

Pump of the water replenishment BF<br />

MO3PRW Pump of the water replenishment STB 3<br />

MO4PRW<br />

Water pump of the evaporation measuring tank<br />

MO6PRW Pump of the water replenishment STB 2<br />

MO7PRW Pump of the water replenishment STB 1<br />

MS1PTK<br />

Switch for the Processor cover<br />

MS2PTK<br />

Switch for the cover of the BF replenisher tank<br />

MS3PTK<br />

Interrupt of the Processor drive when MS1PTK is operated<br />

MS4PTK<br />

Switch for the cover of the DEV replenisher tank<br />

MS5PTK<br />

Switch for the cover of the STB replenisher tank<br />

<strong>AGFA</strong> d-<strong>lab.3</strong> 2001-01-02 /PN 9009 7.2.1


Paper Processor<br />

Repair<br />

Dryer DH<br />

Designation<br />

Function<br />

LS1PDH Dryer fan monitoring FA1PDH<br />

FA1PDH Dryer fan<br />

FA2PDH Cooling fan for the dryer<br />

FA3PDH Cooling fan for the dryer block<br />

FA4PDH Cooling fan for FA1PIR<br />

FA5PDH Cooling fan for FA2PIR<br />

FU1PDH Temp fuse<br />

HS1PDR Temp sensor dryer<br />

HT1PDH Dryer heater 1<br />

HT2PDH Dryer heater 2<br />

MS1PDH Switch for the dryer cover<br />

MS2PDH Interrupt of the dryer drive when MS1PDH is operated<br />

TH1PDH Thermostat<br />

IR Dryer IR<br />

Designation<br />

HT1PIR<br />

HT2PIR<br />

FA1PIR<br />

FA2PIR<br />

LS1PIR<br />

LS2PIR<br />

LS3PIR<br />

LS4PIR<br />

LS5PIR<br />

LS6PIR<br />

LSAPIR<br />

TH1PIR<br />

Function<br />

IR dryer up<br />

IR dryer down<br />

Dryer fan up<br />

Dryer fan down<br />

Dryer fan monitoring FA1PIR<br />

Paper detection<br />

Paper detection<br />

Paper detection<br />

Paper detection<br />

IR dryer monitoring<br />

Dryer fan monitoring FA2PIR<br />

Thermostat<br />

7.2.2 2001-01-02 /PN 9009 <strong>AGFA</strong> d-<strong>lab.3</strong>


Repair<br />

Paper Processor<br />

Paper Exit PO<br />

Designation<br />

Function<br />

FA1PPO Cooling fan for densitometer<br />

LS1PPO Paper detection 1<br />

LS2PPO Paper detection 2<br />

LS3PPO Paper detection 3<br />

LS4PPO Paper detection 4<br />

MG1PPO Pressure magnet of the integrated densitometer<br />

MO1PPO Drive paper output 1<br />

MO2PPO Drive paper output 2<br />

MG2PPO Transport direction change-over<br />

Lane Shifter LS<br />

Designation<br />

LS1PLS<br />

LS2PLS<br />

MO1PLS<br />

MO2PLS<br />

Function<br />

Detection Lane Shifter in reference position<br />

Detection flap in reference position<br />

Lane Shifter drive motor<br />

Flap movement<br />

Sorter SO<br />

Designation<br />

LS1PSO<br />

MO1PSO<br />

MS1PSO<br />

Function<br />

Detection Sorter in reference position<br />

Sorter drive<br />

Detection Sorter closed<br />

<strong>AGFA</strong> d-<strong>lab.3</strong> 2001-01-02 /PN 9009 7.2.3


Paper Processor<br />

Repair<br />

Overview of the Connectors<br />

Source<br />

0701..<br />

Destination Connector Description<br />

CN 1 Fan FA1AMF<br />

55A-PWF CN 2 Pilot +8 V<br />

CN 2 55A-CPU CN 3<br />

55P-SSR<br />

CN 3 DC power supply Power supply units<br />

CN 4 Vacuum pump VP1AVC 100V<br />

Socket outlet<br />

200V<br />

CN 5 55P-CPU CN 7<br />

CN 6 SSR 2 Dryer fan<br />

Dryer heater<br />

SSR 3<br />

IRC CN 9<br />

CN 7 DC power supply SSRs, relay control<br />

CN 8 DC power supply 200 V<br />

CN 9 55A-MDV CN 1 +5 V, +8 V Pilot<br />

52A-MAD CN 1<br />

55A-CPU CN 1<br />

CN 10 <strong>AGFA</strong> CN 1, CN 3 +5 V, +/- 15 V,<br />

22,8 V Lamp voltage<br />

Sens line lamp<br />

Lamp thermostat<br />

CN 11 52A-MAD CN 1, 2 PA +24 V, PB +36 V<br />

55A-IFB CN 9 +24 V<br />

<strong>AGFA</strong> CN 2 FD +24 V<br />

CN 12 55P-MDV CN 2<br />

55P-IRC CN 14<br />

CN 14 Thermostat dryer<br />

55P-IRC CN 12 + 24 V<br />

55P-MDV CN 3<br />

CN 15 <strong>AGFA</strong> CN 7 200 V (switch-off of the print lamp when the cover is<br />

removed)<br />

CN 16 55A-IFB CN 18<br />

7.2.4 2001-01-02 /PN 9009 <strong>AGFA</strong> d-<strong>lab.3</strong>


Repair<br />

Paper Processor<br />

Connections of GS 55A-CNR (Distributor Board)<br />

Connector Sensors Function<br />

CN1 FS1PTK Level switch of the DEV temperature control tank<br />

CN4 FS2PTK Level switch of the BF temperature control tank<br />

CN8 FS3PTK Level switch of the STB1 temperature control tank<br />

CN11 FS4PTK Level switch of the STB2 temperature control tank<br />

CN14 FS5PTK Level switch of the STB3 temperature control tank<br />

CN18 FS1PRW Level switch of the water replenishment tank<br />

CN20 FS2PRW Level switch of the water evaporation measurement tank<br />

CN2 FS1PRT Level switch of the DEV replenishment tank<br />

CN5 FS2PRT Level switch of the BF replenishment tank<br />

CN9 FS3PRT Level switch of the STB replenishment tank<br />

CN12 FS1PET Level switch of the DEV effluent tank<br />

CN15 FS2PET Level switch of the BF effluent tank<br />

CN17 FS3PET Level switch of the STB effluent tank<br />

CN19 MS4PTK Cover switch of the DEV replenishment tank<br />

CN21 MS2PTK Cover switch of the BF replenishment tank<br />

CN3 MS5PTK Cover switch of the STB replenishment tank<br />

CN6 MS1PTK Cover switch of the Processor<br />

CN10 MS1PDH Cover switch of the dryer<br />

CN16 FS1AST Level switch of the ASTOR system (not used)<br />

CN22 HS1PCT Temperature sensor of the DEV control tank<br />

CN24 HS2PCT Temperature sensor of the BF control tank<br />

CN25 HS3PCT Temperature sensor of the STB control tank<br />

<strong>AGFA</strong> d-<strong>lab.3</strong> 2001-01-02 /PN 9009 7.2.5


Paper Processor<br />

Repair<br />

■<br />

7.2.6 2001-01-02 /PN 9009 <strong>AGFA</strong> d-<strong>lab.3</strong>


Repair<br />

Paper Processor<br />

Functional Description<br />

Mechanical Structure<br />

The assembly groups of the Paper Processor are<br />

exchangeable thanks to clearly defined mechanical<br />

and electrical interfaces.<br />

dlabr041<br />

1 Processor tanks / racks: DEV, BF, STB1-3 13 Water replenishment tank<br />

2 Outlet Unit 14 Water replenishment: DEV, BF, STB3<br />

3 Shifter 15 Water replenishment measuring tank<br />

4 Preheating (IR heater) 16 Temperature control tanks (heater / temperature sensor)<br />

5 Dryer 17 Effluent tank: DEV, BF, STB<br />

6 Circulation pumps: DEV, BF, STB1-3 18 Fan<br />

7 Replenishing pumps: DEV, BF, STB 19 Mixer motor (replenisher tanks)<br />

8 Water replenishment: STB2, STB1 20 Dryer fan<br />

9 Main power supply unit 1) 21 Dryer rack<br />

10 Replenisher tanks: DEV, BF, STB 22 Dryer heater<br />

11 Effluent tank (valve): DEV, BF, STB 23 Main drive motor of the Paper Processor<br />

12 Processor tank (valve): DEV, BF, STB1-3<br />

1)<br />

AC supply transformer / 56A-FUR / 55A-PWF<br />

RY relay (1, 2, 3), SSR relay (2)<br />

DC supply PS1, 55A-PWD, RY relay (4)<br />

<strong>AGFA</strong> d-<strong>lab.3</strong> 2001-01-02 /PN 9009 7.3.1


Paper Processor<br />

Repair<br />

Switches<br />

1 Main switch<br />

2 RCD device<br />

dlabr125<br />

7.3.2 2001-01-02 /PN 9009 <strong>AGFA</strong> d-<strong>lab.3</strong>


Repair<br />

Paper Processor<br />

Electrical Structure<br />

PCBs / Power Supply<br />

dlabr160<br />

1 ⎯ Densitometer board 2)<br />

2 55P-MDV Driver board for<br />

- Motors<br />

- Lane Shifter<br />

- Outlet Unit<br />

- Pressure solenoid of the densitometer measuring head<br />

- 24V DC fan<br />

3 SSR2 Activation of the dryer fan (connection on CL8) 1)<br />

4 SSR3 Activation of the IR dryer 1)<br />

5 56P-SDR Control of the water replenishment<br />

6 55P-CPU Main processor of the Paper Processor<br />

7 55P-IRC Control of the IR dryer (IR heater / IR dryer fan)<br />

8 55P-SSR Board with the Solid State Relays for the activation of the<br />

- Solution heaters<br />

- Pumps<br />

- Main drive motor<br />

- AC motor 3)<br />

9 55A-PWD Voltage control<br />

10 ⎯ Power supply<br />

11 56A-FUR Fuse board<br />

1) Both Solid State Relays are behind the 55P-CPU<br />

2) Replace the densitometer board only together with the measuring head<br />

3) The SSR for the dryer heater (SSR1) is located in the AC power supply<br />

A<br />

B<br />

Paper Processor electronic<br />

AC/DC power supply<br />

<strong>AGFA</strong> d-<strong>lab.3</strong> 2001-01-02 /PN 9009 7.3.3


Paper Processor<br />

Repair<br />

Fuses<br />

dlabr164<br />

1 CP2, CP3, CP4<br />

CP1<br />

Safety cut-outs for the Printer<br />

Safety cut out main transformer<br />

2 F4-F6 Fine-wire fuse for the Paper Processor<br />

7.3.4 2001-01-02 /PN 9009 <strong>AGFA</strong> d-<strong>lab.3</strong>


Repair<br />

Paper Processor<br />

Paper Processor Control<br />

1 55P-CPU<br />

2 56P-SDR<br />

3 55P-IRC<br />

4 55P-SSR<br />

dlabr016<br />

55P-CPU<br />

LEDs on 55P-CPU<br />

LED no..<br />

D1<br />

D2<br />

55P-CPU<br />

Fast flashing (100 ms): download in process<br />

Slow flashing (1 s): normal operation<br />

Dryer ON/OFF<br />

DIP switches on 55P-CPU<br />

DIP switch 55P-CPU<br />

1 normal operation<br />

2 normal operation<br />

3 normal operation<br />

4 deleting the Flash-ROMs<br />

<strong>AGFA</strong> d-<strong>lab.3</strong> 2001-01-02 /PN 9009 7.3.5


Paper Processor<br />

Repair<br />

55P-SSR<br />

Fuses and LEDs:<br />

Fuse SSR no. Load LED<br />

F1 (250 V/2,5 A) U1 DEV heater HT1PCT D1<br />

F2 (250 V/2,5 A) U2 BF heater HT2PCT D2<br />

F3 (250 V/2,5 A) U3 STB 1 heater HT3PCT<br />

F4 (250 V/2,5 A) U4 STB 2 heater HT4PCT D3<br />

F5 (250 V/2,5 A) U5 STB 3 heater HT5PCT<br />

F6 (250 V/5 A) U6 Main drive motor MO1PPD<br />

F7 (250 V/2,5 A) U7 Driver motor of the sorter MO1PSO<br />

F8 (250 V/2,5 A) U8 Circulation pumps DEV, BF and STB MO1PPP<br />

:<br />

:<br />

MO5PPP<br />

F9 (250 V/1 A) U9 DEV replenishing pump MO1PRP<br />

U10 BF replenishing pump MO2PRP<br />

U11 STB replenishing pump MO3PRP<br />

F10 (250 V/2 A) U16 Mixer of replenishment chemicals (CW) MO1PRD<br />

U17 Mixer of replenishment chemicals (ACW) MO1PRD<br />

F11 (250 V/5A) U 18 not used<br />

F12 (250 V/1 A) U12 DEV water replenishing pump MO1PRW<br />

U13 BF water replenishing pump MO2PRW<br />

U14 STB water replenishing pump MO3PRW<br />

U15 Water replenishing pump of the<br />

measuring tanks<br />

U19 ASTOR pump (not used)<br />

7.3.6 2001-01-02 /PN 9009 <strong>AGFA</strong> d-<strong>lab.3</strong>


Repair<br />

Paper Processor<br />

AC/DC Power Supply<br />

1 Cover Paper Processor control<br />

2 Main switch<br />

3 RCD device<br />

4 AC power supply<br />

5 DC power supply<br />

6 Remove screws to open the cover<br />

dlabr165<br />

If necessary, the AC and DC power supply can be<br />

removed separately.<br />

DC Power Supply<br />

1 Power supply PS1<br />

- 24 V Power supply Scanner<br />

- 5 V Main power supply Printer<br />

- 5,2 V Densitometer power supply -<br />

24 V / 8 V Pilot power supply (Timer)<br />

2 55A-PWD<br />

dlabr166<br />

55A-PWD<br />

LEDs on 55A-PWD<br />

LED<br />

Function<br />

CD +5 V LED ON: faultless<br />

PA 24 V LED OFF: fault<br />

PB 36 V<br />

PB 36 V overvoltage LED ON: Supply voltage too high<br />

LED OFF: Supply voltage correct<br />

<strong>AGFA</strong> d-<strong>lab.3</strong> 2001-01-02 /PN 9009 7.3.7


Paper Processor<br />

Repair<br />

55A-PWD<br />

DC/DC converter to generate the supply voltage<br />

(±12V) of the AD converter of the 55P-CPU (temperature<br />

measurement). The test pins +12 V and<br />

-12 V for the check of the AD converter supply<br />

voltage are located on the 55P-CPU.<br />

dlabr300<br />

7.3.8 2001-01-02 /PN 9009 <strong>AGFA</strong> d-<strong>lab.3</strong>


Repair<br />

Paper Processor<br />

AC Power Supply<br />

AC power supply:<br />

1 55A-FUR Fuse board<br />

2 RY1 Relay AC 200 V / AC 100 V<br />

3 RY2 Relay AC 200 V / AC 100 V<br />

4 RY3 Relay AC 200 V / AC 100 V<br />

5 Main transformer 100 V power supply<br />

6 SSR1 Dryer heater 200 V On/Off<br />

7 SSR4 Main transformer On/Off<br />

8 CP 1 (10A) Fuse of the primary winding<br />

of the main transformer<br />

dlabr301<br />

55A-FUR<br />

Fuses on 55A-FUR<br />

Fuses max. current Use<br />

F1 T 2A Voltage control (mains) of GS 55A-PWF<br />

F2 T 2A Vacuum pump AC 100 V<br />

F3 T 5A Socket outlet AC 200 V<br />

F4 T 6,3A IR heater AC 200 V<br />

F5 T 6,3A IR heater AC 200 V<br />

F6 T 5A Fan-heater AC 200 V<br />

F7, F8, F9 T 6,3A not used<br />

<strong>AGFA</strong> d-<strong>lab.3</strong> 2001-01-02 /PN 9009 7.3.9


Paper Processor<br />

Repair<br />

Other PCBs<br />

55P-MDV<br />

55P-MDV (1)<br />

dlabr168<br />

Densitometer Board<br />

Densitometer board (1)<br />

dlabr167<br />

7.3.10 2001-01-02 /PN 9009 <strong>AGFA</strong> d-<strong>lab.3</strong>


Repair<br />

Paper Processor<br />

Densitometer, integrated<br />

The integrated densitometer should allow an<br />

automatic Setup routine for MBL, PBL and CBL.<br />

The routine is repeated upon the Auto-Setup until<br />

the test print values are in tolerance with the aim<br />

densities.<br />

The measuring values are compatible with those of<br />

the DENS1, provided the calibration has been<br />

performed with the same measuring plate.<br />

Procedure:<br />

A zeroing to D=0,10 in Y, M, C is performed<br />

immediately before each measurement. For this, the<br />

measuring head is pressed on the reference plate.<br />

The actual measuring procedure is triggered by the<br />

paper tip of the test print. The measuring head is<br />

pressed on the test print, the measuring lamp is<br />

switched on after 1 s and the preceding black/white<br />

pattern is expected (only for MBL, PBL, CBL) prior<br />

to the test print. If the pattern is not recognised after<br />

15 s the latest, an error message is displayed.<br />

After the correct detection of the preceding pattern,<br />

the measuring phase starts. One measurement<br />

each is performed in cycles every 20 ms for Y, M, C<br />

until the end of the measuring field is reached. The<br />

maximum value is calculated for each colour.<br />

Measuring values differing by more than 0,4 from<br />

the maximum value are eliminated; the remaining<br />

values are used to calculate the mean value.<br />

After the measurement, the measuring lamp is<br />

switched off and the measuring head is lifted.<br />

An error message appears if the measuring lamp<br />

fails.<br />

dlabr069<br />

Climatic Conditions Densitometer<br />

Temperature min. 20 ºC max. 20 ºC<br />

Relative humidity min. 15%<br />

Standby max. 85% at 35 ºC 90% at 30 ºC<br />

Operation max. 30% at 60 ºC<br />

<strong>AGFA</strong> d-<strong>lab.3</strong> 2001-01-02 /PN 9009 7.3.11


Paper Processor<br />

Repair<br />

7-Segment Display<br />

Calibration:<br />

A Measuring phase calibration<br />

d Calculation phase calibration<br />

- Wait until the measuring head is lifted<br />

Test print MBL, PBL, CBL:<br />

- Standby mode<br />

- After receipt of the Paper Top signal<br />

(LS1PPO/LS2PPO have detected the test<br />

print)<br />

0 After a lead time of 1 s<br />

2 After detected black/white length<br />

3 After detected minimum white length (10 mm)<br />

F Measuring phase<br />

- End of measurement, check<br />

Test print:<br />

- After receipt of the Paper Top signal<br />

(LS1PPO/LS2PPO have detected the test<br />

print)<br />

1..C Detected field number in Hex code (see Table<br />

below)<br />

- Wait until LS1PPO/LS2PPO are free again<br />

Field<br />

number<br />

Hex<br />

code<br />

Code<br />

(test print)<br />

12 C M<br />

11 B L<br />

10 A K<br />

9 9 J<br />

8 8 I<br />

7 7 H<br />

6 6 G<br />

5 5 F<br />

4 4 E<br />

3 3 D<br />

2 2 C<br />

1 1 B<br />

0 0 A<br />

■<br />

7.3.12 2001-01-02 /PN 9009 <strong>AGFA</strong> d-<strong>lab.3</strong>


Repair<br />

Paper Processor<br />

Repair<br />

Replacement of the Densitometer<br />

Order no. 8506/600<br />

ABC-Code B9GPC<br />

Replacement of the densitometer:<br />

− Densitometer lamp defective<br />

− Electronic defective<br />

− Internal calculation error in the densitometer<br />

As the measuring head and the processor board<br />

are tuned, they must only be replaced together.<br />

See also Procedure between customers and the<br />

Agfa subsidiary in this register<br />

Uncovering the Densitometer board<br />

− Remove the covers from the dryer in the given<br />

order / direction<br />

dens17<br />

− Unscrew the cover of the densitometer board<br />

dens18<br />

<strong>AGFA</strong> d-<strong>lab.3</strong> 2001-01-02 /PN 9009 7.4.1


Paper Processor<br />

Repair<br />

Procedure between Customers and the Agfa Subsidiary<br />

Return of the complete densitometer:<br />

− Control board (1) and<br />

− Measuring head (2)<br />

75% of the new price are credited for the returned<br />

densitometer. So, the customer has to pay 25% of<br />

the new price for the replacement densitometer.<br />

dlabr161<br />

7.4.2 2001-01-02 /PN 9009 <strong>AGFA</strong> d-<strong>lab.3</strong>


Repair<br />

Paper Processor<br />

Replacing Printed Circuits<br />

1. 55P-MDV<br />

2. Densitometer board<br />

PP electronic<br />

1. 56P-SSR<br />

2. 55P-CPU<br />

3. 55P-IRC<br />

4. 55P-SSR<br />

In the DC power supply:<br />

1. 55A-FUR<br />

2. 55A-PWD<br />

In the AC power supply:<br />

1. Fuse board<br />

<strong>AGFA</strong> d-<strong>lab.3</strong> 2001-01-02 /PN 9009 7.4.3


Paper Processor<br />

Repair<br />

Replacing Relays<br />

Dismount the AC power supply:<br />

− Remove 2 fastening screws (1)<br />

− Unscrew the cables: (2) turn cw<br />

− Pull the cables approx. 10 cm inside<br />

− Disconnect 4 connectors<br />

− Pull the unit approx. 10 cm to the front:<br />

Run the cables on the left side behind the unit<br />

Mind the cables on the left side when pushing in<br />

the unit: Run the cables again to the front and put<br />

them on the unit.<br />

7.4.4 2001-01-02 /PN 9009 <strong>AGFA</strong> d-<strong>lab.3</strong>


Repair<br />

Paper Processor<br />

Temperature Switch Dryer<br />

Reset the temperature switch dryer:<br />

Press (1)<br />

dlabr124<br />

<strong>AGFA</strong> d-<strong>lab.3</strong> 2001-01-02 /PN 9009 7.4.5


Paper Processor<br />

Repair<br />

■<br />

7.4.6 2001-01-02 /PN 9009 <strong>AGFA</strong> d-<strong>lab.3</strong>


Repair<br />

Software<br />

Contents<br />

Software Structure ..................................................................................................................................... 8.1<br />

Hardware Connection............................................................................................................................ 8.1<br />

Software Levels..................................................................................................................................... 8.2<br />

Software Structure of the Controller...................................................................................................... 8.3<br />

FL Controller ............................................................................................................................... 8.3<br />

Algorithms/Interface Controller ................................................................................................... 8.3<br />

CG Controller .............................................................................................................................. 8.3<br />

Image Management .............................................................................................................................. 8.4<br />

<strong>AGFA</strong> d-<strong>lab.3</strong> 2001-01-02 /PN 9009 8.i


Software<br />

Repair<br />

■<br />

8.ii 2001-01-02 /PN 9009 <strong>AGFA</strong> d-<strong>lab.3</strong>


Repair<br />

Software<br />

Software Structure<br />

The Main-PC controls all higher-ranking procedures.<br />

The Software responsible for the Hardware ensures<br />

the direct connection to the individual components<br />

of the Hardware, like loads and sensors.<br />

Hardware Connection<br />

rep140e<br />

<strong>AGFA</strong> d-<strong>lab.3</strong> 2001-01-02 /PN 9009 8.1


Software<br />

Repair<br />

Software Levels<br />

The Software is split up into 4 levels in charge of<br />

special functions:<br />

1. Hardware functions:<br />

Hardware-related functions operating only<br />

one sensor or load. This also includes the<br />

initialisation of registers.<br />

2. Basic functions:<br />

Functions combining several Hardware<br />

functions. This includes initialisation functions<br />

and certain Hardware-related procedures,<br />

e.g. the execution of an exposure.<br />

3. Dispatcher or Main:<br />

Distributes the commands sent by the Main-<br />

PC to basic or Hardware functions.<br />

4. Interface:<br />

Software for the communication via a RS232<br />

interface or the CAN-Bus. This also includes the<br />

respect of certain error handling protocols.<br />

8.2 2001-01-02 /PN 9009 <strong>AGFA</strong> d-<strong>lab.3</strong>


Repair<br />

Software<br />

Software Structure of the Controller<br />

The CG Controller and the FL Controller have to<br />

perform different functions. For this reason, the<br />

Software structure is different, above all as<br />

concerns the Interface and the Dispatcher.<br />

FL Controller<br />

Several functions have to be performed at the<br />

same time:<br />

− Interpreting arriving telegrams and responding to<br />

them<br />

− Sending CAN commands and assessing /<br />

transmitting the related acknowledgements<br />

− Performing basic functions simultaneously for<br />

several loads<br />

The Software on the FL Controller checks<br />

conditions in an endless cycle, responds to events<br />

and triggers the required action. This main loop<br />

(main function) runs through within 1-2 ms.<br />

Time-dependent actions are executed in<br />

Interrupts:<br />

− Response to telegrams from the RS232 interface<br />

− Response to telegrams from the CAN-Bus<br />

− Output of telegrams<br />

− Control of the motors via the PWM or CC mode<br />

Algorithms/Interface Controller<br />

Like the FL-Controller, commands are received<br />

and performed in a main loop. Besides this,<br />

Interrupt routines are running for time-dependent<br />

actions.<br />

CG Controller<br />

The CG Controller receives commands, confirms<br />

and executes them sequentially.<br />

After receipt of a telegram from the CAN-Bus, an<br />

appropriate function is called up by the Dispatcher.<br />

After it has been executed, a feedback message is<br />

sent via the CAN-Bus.<br />

Only the motors are controlled in Interrupts.<br />

<strong>AGFA</strong> d-<strong>lab.3</strong> 2001-01-02 /PN 9009 8.3


Software<br />

Repair<br />

Image Management<br />

Order 501 Order 500 Order 499<br />

dlabr141<br />

8.4 2001-01-02 /PN 9009 <strong>AGFA</strong> d-<strong>lab.3</strong><br />


Repair<br />

Maintenance<br />

Contents<br />

Maintenance Schedule and Maintenance Intervals ................................................................................ 9.1<br />

Maintenance Jobs performed by the Service Technician, yearly.......................................................... 9.3<br />

Whole Machine ..................................................................................................................................... 9.3<br />

Clean the inside Compartments..................................................................................................9.3<br />

Lubricate the plastic Gears ......................................................................................................... 9.3<br />

Scanner ................................................................................................................................................. 9.4<br />

Oil the Scanner Carriage ............................................................................................................ 9.4<br />

Negative Carrier: Lubricate the toothed Belts / Shafts (if required) ............................................ 9.4<br />

Negative Carrier: Clean the Roller Sets...................................................................................... 9.4<br />

Negative Mask: Lubricate the Pawl / the Holes (if required) ....................................................... 9.5<br />

Optical Area, clean...................................................................................................................... 9.5<br />

Transport Unit and Lane Distributor............................................................................................ 9.6<br />

Paper Processor ................................................................................................................................... 9.7<br />

Whole Machine ........................................................................................................................... 9.7<br />

Processing Racks ....................................................................................................................... 9.7<br />

Wet Section................................................................................................................................. 9.8<br />

Automatic Water Replenishment ................................................................................................ 9.8<br />

Cleaning the Evaporation Measuring Recipient.......................................................................... 9.9<br />

Dryer Rack .................................................................................................................................. 9.9<br />

Transport Belt ............................................................................................................................. 9.9<br />

Print Chute (if required)............................................................................................................... 9.9<br />

Inlet Rollers in front of the IR Dryer........................................................................................... 9.10<br />

IR Dryer (if required) ................................................................................................................. 9.10<br />

Outlet Unit ................................................................................................................................. 9.10<br />

Densitometer Area (Outlet Unit)................................................................................................9.10<br />

Paper Magazine Area left and right........................................................................................... 9.11<br />

Maintenance Jobs performed by the Service Technician, every 2 Years........................................... 9.12<br />

Replace the Laser ............................................................................................................................... 9.12<br />

End of the Maintenance Jobs.................................................................................................................. 9.12<br />

Check the Machine Functions............................................................................................................. 9.12<br />

Consumables / Cleaning Agents / Lubricants / Tools .......................................................................... 9.13<br />

Consumables ...................................................................................................................................... 9.13<br />

Cleaning Agents .................................................................................................................................. 9.13<br />

Lubricants............................................................................................................................................ 9.14<br />

Tools.................................................................................................................................................... 9.14<br />

<strong>AGFA</strong> d-<strong>lab.3</strong> 2001-01-02 /PN 9009 9.i


Maintenance<br />

Repair<br />

■<br />

9.ii 2001-01-02 /PN 9009 <strong>AGFA</strong> d-<strong>lab.3</strong>


Repair<br />

Maintenance<br />

Maintenance Schedule and Maintenance Intervals<br />

yearly<br />

x<br />

x<br />

x<br />

x<br />

x<br />

x<br />

x<br />

x<br />

x<br />

x<br />

x<br />

x<br />

x<br />

x<br />

x<br />

x<br />

x<br />

x<br />

x<br />

x<br />

x<br />

x<br />

x<br />

x<br />

x<br />

x<br />

x<br />

x<br />

x<br />

x<br />

x<br />

x<br />

x<br />

x<br />

x<br />

x<br />

x<br />

x<br />

every<br />

2 years<br />

Technician required<br />

Entire machine<br />

Clean the inner compartments<br />

Clean and grease all chains, gears and bearings<br />

Scanner<br />

Oil the scanner carriage<br />

Negative carrier: lubricate the toothed belt and the shafts<br />

Negative carrier: clean 2 roller sets<br />

Negative mask: lubricate the pawl / the holes in the bearing plate<br />

Optical area<br />

Clean the lamphouse area<br />

Clean the exposure filters<br />

Check / replace the mirror<br />

Check / replace the prism disk (mirror box)<br />

Clean the mirror box inside<br />

Clean the paper filter on the scanner carriage<br />

Clean the Zoom lens<br />

Printer: Transport Unit and Lane Distributor<br />

Check / replace the plastic bearings at the motor<br />

Check / replace the springs<br />

Toothed belt drive: Check / adjust the tension<br />

Clean the shifter shafts<br />

Clean the side plates<br />

Grease the bearing points<br />

Clean the rubber rollers<br />

Paper Processor, general<br />

Clean and grease all chains, gears, bearings<br />

Check circulation pumps, replenishing pumps, fans, hose fittings for tight<br />

seating/correct functioning<br />

Wet section, processing racks<br />

Clean the racks, check for smooth movement<br />

Check the slide bearings, roller shafts, springs, gears<br />

Check the backlash of the spring rollers;<br />

if necessary replace the bottom rollers and squeeze rollers<br />

Replace all sponge rubber rollers (squeeze area)<br />

Clean the bearing points and remove all crystals<br />

Lubricate the shaft bearing points<br />

Wet section, general<br />

Check the replenisher valves and replace them if necessary<br />

If required: Replace the circulation pumps<br />

Lubricate the mixer of chemistry<br />

<strong>AGFA</strong> d-<strong>lab.3</strong> 2001-01-02 /PN 9009 9.1


Maintenance<br />

Repair<br />

yearly<br />

x<br />

x<br />

x<br />

x<br />

x<br />

x<br />

x<br />

x<br />

x<br />

x<br />

x<br />

x<br />

x<br />

x<br />

x<br />

x<br />

x<br />

x<br />

x<br />

x<br />

x<br />

x<br />

x<br />

x<br />

x<br />

x<br />

x<br />

x<br />

x<br />

x<br />

x<br />

x<br />

x<br />

every<br />

2 years<br />

Technician required<br />

Automatic water replenishment / Evaporation measuring recipient<br />

Clean the water tank and remove lime deposits, if necessary<br />

Clean evaporation measuring recipient<br />

Dryer rack<br />

Check the foam plastic rollers, replace if necessary<br />

Clean the removable rollers and the goffered plate<br />

Clean the large plastic roller<br />

Check the bearing blocks and replace them if necessary<br />

Check the chain tension, retention if necessary<br />

Lubricate the continuous drive chain<br />

Lubricate the (outer) gears<br />

Transport belt<br />

Check the transport belt, retention if necessary<br />

Print chute<br />

If required lubricate the gears and<br />

the bearing points of the rocker<br />

Inlet roller in front of the IR dryer<br />

Clean the inlet roller<br />

Lubricate the gears<br />

IR dryer<br />

Clean the rollers<br />

Clean and lubricate the continuous chain<br />

Clean and lubricate the plastic gears<br />

Outlet Unit<br />

Clean the Outlet Unit<br />

Check the rollers, if necessary, lubricate the plastic bearings and the bearing<br />

points of the mobile guide elements<br />

Replace the plastic gears if they are worn, otherwise lubricate them<br />

Densi area in the Outlet Unit<br />

Clean the densitometer area and the densitometer head<br />

Check the pressure mechanism<br />

Paper magazine area left and right<br />

Check the coupling, replace if necessary<br />

Check the closing lever<br />

Laser<br />

x x Replace the laser<br />

x<br />

End of the maintenance jobs<br />

x<br />

Check the machine functions<br />

x<br />

Check the perfect condition of the safety devices<br />

9.2 2001-01-02 /PN 9009 <strong>AGFA</strong> d-<strong>lab.3</strong>


Repair<br />

Maintenance<br />

Maintenance Jobs performed by the Service Technician, yearly<br />

Maintenance by the service technician:<br />

once a year:<br />

− Replacement of expendable parts<br />

− Preventive replacement of parts<br />

− Greasing / lubrication of parts<br />

The Safety prescriptions on all machine stickers<br />

and in register 1 of this folder must be observed.<br />

Whole Machine<br />

Clean the inside Compartments<br />

− Remove the covers<br />

− Blow out the inside compartments including the<br />

air shafts<br />

− Clean the suction area of the cooling fans:<br />

− Grid<br />

− Fan blades<br />

− Cooling ribs of the heat exchanger<br />

Lubricate the plastic Gears<br />

Plastic gears:<br />

Lubricate the plastic gears with Klüberplex if they<br />

are noisy<br />

<strong>AGFA</strong> d-<strong>lab.3</strong> 2001-01-02 /PN 9009 9.3


Maintenance<br />

Repair<br />

Scanner<br />

Oil the Scanner Carriage<br />

Oil the shaft on both sides of the 2 sinter bearings<br />

(1) with Constant OY 220, moving the<br />

scanner carriage to and fro<br />

dlabr161<br />

Negative Carrier: Lubricate the toothed Belts / Shafts (if required)<br />

Remove the negative carrier (4 screws)<br />

Unscrew the film supply<br />

Lubricate the toothed belt inside with Isoflex<br />

Topas NB 52<br />

Lubricate the shafts with Isoflex Topas NB 52<br />

Caution!<br />

Do not touch the red lacquered screw - bottom<br />

centre. Remove only the safety washers, push the<br />

little rollers to the front as shown in the magnified<br />

illustrations and grease the shafts.<br />

sp02<br />

Negative Carrier: Clean the Roller Sets<br />

Clean the 2 roller sets TR4 and TR5 and<br />

replace them if necessary<br />

− Replace the roller with ball bearings:<br />

CM+7.8506.5015.1 x 2<br />

CM+7.0371.0072.1 x 2<br />

dlabr066<br />

9.4 2001-01-02 /PN 9009 <strong>AGFA</strong> d-<strong>lab.3</strong>


Repair<br />

Maintenance<br />

Negative Mask: Lubricate the Pawl / the Holes (if required)<br />

Lubricate the pawl and the holes in the bearing<br />

plate with Isoflex Topas NB 52<br />

sp04<br />

Optical Area, clean<br />

Caution!<br />

Be sure to switch off the lamp as otherwise the<br />

prism disk will burn.<br />

When cleaning the fragile glasses of the exposure<br />

filters with an optic cleaning cloth, slightly support<br />

the filter paddles from below as otherwise they<br />

might break.<br />

Carefully clean the lamphouse area (blow it<br />

out).<br />

Use optic pads for the following cleaning jobs.<br />

Clean the exposure filters<br />

Check the guide mirrors for damage and<br />

replace them if necessary<br />

Check the prism disk on the mirror box for dark<br />

spots (overheating) and replace it if<br />

necessary<br />

Open the frosted glass in the mirror box in the<br />

service mode (by means of the mirror box<br />

motor M01MB): Blow out the mirror box or<br />

clean it very carefully with optic pads<br />

Use optic pads for the following cleaning jobs.<br />

Open the shutter in the service mode<br />

(DS_MO01)<br />

Clean the paper filter on the scanner carriage<br />

Clean the viewing mirror<br />

Clean the top class of the Zoom lens<br />

Exit the service mode:<br />

This automatically resets the dust shutter (only<br />

in prototypes; will be omitted)<br />

dlabr060<br />

<strong>AGFA</strong> d-<strong>lab.3</strong> 2001-01-02 /PN 9009 9.5


Maintenance<br />

Repair<br />

Transport Unit and Lane Distributor<br />

Check the plastic bearings of the motor and replace<br />

them if necessary<br />

Check the springs and replace them if<br />

necessary<br />

Check the tension of the toothed belt and adjust<br />

if necessary<br />

Clean the shafts and apply a very thin film of<br />

Constant OY 220<br />

Clean the slide plates with Agfa Cleaner<br />

Grease the bearing points with Constant OY<br />

220<br />

Clean the rubber roller with Lixtop plastic cleaner<br />

dlabr068<br />

dlabr079<br />

9.6 2001-01-02 /PN 9009 <strong>AGFA</strong> d-<strong>lab.3</strong>


Repair<br />

Maintenance<br />

Paper Processor<br />

Whole Machine<br />

− Clean all chains, gears and bearings and grease<br />

them with Klübersynth<br />

Processing Racks<br />

Clean the racks and check them for smooth<br />

movement (25-60 Ncm)<br />

On all racks including the squeegee unit over<br />

the STB3 rack:<br />

Check the gears, roller shafts, slide bearings<br />

and springs for damage / wear and replace<br />

them if necessary<br />

Check the position of the slide bearings: The<br />

nipple points to the inside (see figure)<br />

− Two squeeze rollers are the most critical points<br />

in all racks (see arrows in figure above). The<br />

stress is the strongest in the CD racks because<br />

they are very close to the liquid level:<br />

− Check the backlash of the squeeze rollers<br />

with <strong>AGFA</strong> Prestige paper or similar<br />

− If necessary, replace the bottom rollers<br />

(P3-E5146) and the squeeze rollers<br />

(P3-86682)<br />

− Replace all sponge rubber rollers for STB in the<br />

squeegee area<br />

− Clean the bearing points and remove the crystals<br />

in this area<br />

− To protect the dry running bearing points (above<br />

the liquid level) from the penetration of chemistry<br />

(crystals) and keep the rack torque small<br />

at the same time, the chemical-resistant<br />

Klüberplex (sealing grease) is recommended:<br />

Apply an evenly thin film on the shaft bearing<br />

points (take out the bearings and grease the inside).<br />

roll_02<br />

<strong>AGFA</strong> d-<strong>lab.3</strong> 2001-01-02 /PN 9009 9.7


Maintenance<br />

Repair<br />

After mounting the unit, a small amount of the<br />

same grease can be applied to the rack inside<br />

while the rack is turned by hand in order to produce<br />

an even covering film (see arrow)<br />

sp14<br />

Wet Section<br />

If required replace the replenishment valves<br />

and the bellows of the pumps:<br />

CL+P4-3805(1/1) bellow<br />

CL+P4-1119(4/1) valve (PDM)<br />

CL+P4-6110(2/1) valve for STB (Teflon, lasts<br />

longer)<br />

If required (running noise) convert the pump:<br />

Pump type MD6<br />

Mixer of chemistry: Lubricate all belt<br />

turnaround pulleys and belt tensioners with<br />

Constant OY 220<br />

sp17<br />

Automatic Water Replenishment<br />

Depending on the water hardness, lime may deposit<br />

in the tray and/or on the floater switches and<br />

impair the correct functioning of the water supply<br />

(evaporation compensation).<br />

Carefully remove lime residues from the water<br />

tanks, especially from the tank inside borders<br />

as the water creeps out there through the lime<br />

rests (capillary effect). As a result,<br />

the tank is emptied prematurely<br />

the water replenishment is increased<br />

the tank chemistry is diluted<br />

Clean the floater switches: They must move<br />

freely as otherwise the automatic water replenishment<br />

does not function correctly.<br />

sp31<br />

9.8 2001-01-02 /PN 9009 <strong>AGFA</strong> d-<strong>lab.3</strong>


Repair<br />

Maintenance<br />

Cleaning the Evaporation Measuring Recipient<br />

Open the replenisher tank lid<br />

Check the black evaporation measuring recipient<br />

(see arrow) for lime deposits, remove<br />

the deposits, if any<br />

dlabr015<br />

Dryer Rack<br />

Remove the dryer rack<br />

Check the foam plastic rollers for wear and replace<br />

them if necessary<br />

Thoroughly clean the large plastic roller underneath<br />

the removable rollers<br />

Check the bearing blocks and replace them if<br />

necessary<br />

Check the gears and replace them if necessary<br />

Check the chain tension and tension it if necessary<br />

Lubricate the continuous drive chain with<br />

Klübersynth<br />

Lubricate alle outer gears with Klüberplex 302B002<br />

Transport Belt<br />

Check the transport belt and retention it, if required<br />

Print Chute (if required)<br />

Lubricate the rocker gears with Klüberplex, the<br />

bearing points of the rocker with Constant OY<br />

220<br />

sp09<br />

<strong>AGFA</strong> d-<strong>lab.3</strong> 2001-01-02 /PN 9009 9.9


Maintenance<br />

Repair<br />

Inlet Rollers in front of the IR Dryer<br />

Clean the inlet rollers<br />

Lubricate the gears with Klüberplex<br />

IR Dryer (if required)<br />

Move the sorter aside<br />

Remove the dryer cover: turn the screws 90º<br />

with a coin<br />

Disconnect the cable from the IR dryer (1)<br />

Loosen the knurled screw (2) of the IR dryer<br />

and remove the IR dryer<br />

Loosen 2 knurled screws (3) and take the<br />

insertion out of the IR dryer<br />

Clean the rollers:<br />

the inside light rubber rollers<br />

the black inlet and outlet rollers<br />

Clean the continuous chain and lubricate with<br />

Klübersynth<br />

Clean the plastic gears and lubricate with<br />

Klüberplex<br />

dlabr064<br />

Outlet Unit<br />

Remove the top cover of the Outlet Unit<br />

Clean the Outlet Unit<br />

Check the rollers for smooth movement and if<br />

necessary lubricate the plastic bearings and the<br />

bearing points of the mobile guide elements<br />

with Constant OY 220<br />

Replace the plastic gears if they are worn;<br />

otherwise lubricate with Klüberplex<br />

Densitometer Area (Outlet Unit)<br />

Clean the densitometer area of the Outlet Unit<br />

Carefully clean the densitometer head (Q-Tips)<br />

Check the pressure mechanism for smooth<br />

movement<br />

9.10 2001-01-02 /PN 9009 <strong>AGFA</strong> d-<strong>lab.3</strong>


Repair<br />

Maintenance<br />

Paper Magazine Area left and right<br />

Coupling (1): visual check, replace if necessary<br />

Check the locking lever (2): The actuator roller<br />

should not slant<br />

dlabr159<br />

<strong>AGFA</strong> d-<strong>lab.3</strong> 2001-01-02 /PN 9009 9.11


Maintenance<br />

Repair<br />

Maintenance Jobs performed by the Service Technician, every 2 Years<br />

Replace the Laser<br />

When the performance of the laser declines, a<br />

message on the screen informs the operator that<br />

the laser has to be replaced in a certain<br />

time.<br />

Caution!<br />

Replace the Laser by all means, otherwise the<br />

production quality will fall off.<br />

Replacement of the Laser: see Laser module / Laser,<br />

register 6.4 (Printer, Repair)<br />

End of the Maintenance Jobs<br />

Check the Machine Functions<br />

Check all functions of the machine as well as the<br />

perfect condition of the safety devices.<br />

9.12 2001-01-02 /PN 9009 <strong>AGFA</strong> d-<strong>lab.3</strong>


Repair<br />

Maintenance<br />

Consumables / Cleaning Agents / Lubricants / Tools<br />

Consumables<br />

Chemistry<br />

CD<br />

BX<br />

SB<br />

Tank kit<br />

Order no.<br />

5FPKS<br />

5FPLU<br />

5FPMW<br />

5FFYK<br />

Paper<br />

Order no.<br />

10,2 5FM4L<br />

12,7 5FM5N<br />

15,2 5FM6P<br />

20,3 5FM8T<br />

Air filter<br />

Lamp house<br />

CCD<br />

Cutter area<br />

Paper Processor (1)<br />

Paper Processor (2)<br />

Paper Processor (3)<br />

Order no.<br />

CM+7.8061.LHL4.0<br />

CM+7.8061.FEL2.0<br />

CM+7.0431.7225.0<br />

CL+P3-E0898<br />

CL+P4-3812<br />

CL+P4-3812<br />

Chemical filters + Test strips<br />

Order no.<br />

Chemical filters CD, BX, SB1, SB2, SB3 92GP5<br />

Test strips —<br />

Other<br />

Order no.<br />

Farbband Rückseitendrucker 102-01-0003<br />

Kopierlampe<br />

YMHSY<br />

Cleaning Agents<br />

Part number Designation Use<br />

CM+9.9999.9231.0 Lixtop plastic cleaner Panel parts<br />

CM+9.9999.9274.0 Compressed air spray Dust removal<br />

CG+078047-0003 Optic Pads Optical parts<br />

CP+G-003T Agfa Cleaner Prevents static charges<br />

CM+8.8506.1330.0 Cleaning strips (3 pcs) Cleaning the APS negative mask<br />

CM+8.8506.1320.0 Cleaning strips (3 pcs) +<br />

Isopropanol bottle (empty)<br />

Cleaning the APS negative mask<br />

<strong>AGFA</strong> d-<strong>lab.3</strong> 2001-01-02 /PN 9009 9.13


Maintenance<br />

Repair<br />

Lubricants<br />

Part number Designation Use<br />

CM+9.9999.9001.0 Never Seez Panelling parts: Ideal to loosen tight moving parts<br />

(alternative: graphitic agent)<br />

CM+9.9999.9247.0 Isoflex Topas NB 52 Dust removal: Heavy-duty lubricant, limited compatibility<br />

with plastic<br />

CM+9.9999.9271.0 Constant OY 220 Optical parts: Synthetic oil, universal applications,<br />

also for sinter and slide bearings<br />

CM+9.9999.9280.0 Klüberplex BE 31-503 Antistatic treatment: To oil heavy-duty friction<br />

points (chains)<br />

CM+9.9999.9281.0 Klübersynth GEM 4-460 Multifunctional oil: Special agent for heavily<br />

stressed slide surfaces (chains)<br />

Manufacturers<br />

Agfa offers these lubricants in Germany. If it is not<br />

possible to get them through Agfa in other countries,<br />

please contact directly the manufacturer's<br />

agency in your country.<br />

Product<br />

Never Seez<br />

Isoflex Topas NB 52<br />

Constant OY 220<br />

Klüberplex BE 31-503<br />

Klübersynth GEM 4-460<br />

Agfa Cleaner<br />

Manufacturer<br />

Varybond Chemie AG<br />

Klüber Lubrication<br />

Klüber Lubrication<br />

Klüber Lubrication<br />

Klüber Lubrication<br />

Agfa-Gevaert AG<br />

Tools<br />

Fork wrench<br />

Set of Allen keys with a ball head 2-8 mm<br />

Set of Allen keys 3 mm,<br />

250 mm long for the scanner adjustment<br />

Magnifying glass<br />

■<br />

9.14 2001-01-02 /PN 9009 <strong>AGFA</strong> d-<strong>lab.3</strong>


Repair<br />

General Data and Information<br />

Contents<br />

Technical Data .......................................................................................................................................... 10.1<br />

d-<strong>lab.3</strong> General System....................................................................................................................... 10.1<br />

Main-PC .............................................................................................................................................. 10.3<br />

Prescanner / Scanner ......................................................................................................................... 10.3<br />

Printer.................................................................................................................................................. 10.4<br />

Paper Processor ................................................................................................................................. 10.5<br />

Densitometer............................................................................................................................. 10.6<br />

Standardisation / Screws..................................................................................................................... 10.7<br />

Optional Accessories .......................................................................................................................... 10.8<br />

Consumables ...................................................................................................................................... 10.9<br />

Glossary .................................................................................................................................................. 10.11<br />

<strong>AGFA</strong> d-<strong>lab.3</strong> 2001-01-02 /PN 9009 10.i


General Data and Information<br />

Repair<br />

■<br />

10.ii 2001-01-02 /PN 9009 <strong>AGFA</strong> d-<strong>lab.3</strong>


Repair<br />

General Data and Information<br />

Technical Data<br />

d-<strong>lab.3</strong> General System<br />

Ambient conditions for test<br />

and operation<br />

− Ambient conditions for storage / transport:<br />

Temperature -50 °C to +60 °C<br />

Relative humidity 15% to 90%<br />

− Test conditions:<br />

Temperature +15 °C to +35 °C<br />

Relative humidity 15% to 90%<br />

− Ambient conditions for operation:<br />

Room temperature +15 °C to +35 °C<br />

Relative humidity 15% to 85%<br />

− Maximum ambient brightness:<br />

Printer / Paper Processor 10.000 Lux<br />

Paper magazines<br />

20.000 Lux<br />

Approval − Europe: EN 60950, EN 60204, EN 50082-1, EN 50081<br />

− USA / Canada: UL 122, C22.2 No. 950-M89(+D3),<br />

FCC 47 Part 15-A-C,<br />

FCC 47 Part 15-A-R<br />

Dimensions<br />

− Width PA + PP without<br />

Sorter extension: 2.260 mm<br />

− Depth: 770 mm<br />

− Height:<br />

1.730 mm<br />

− Weight:<br />

empty approx. 895 kg<br />

filled approx. 1.032 kg<br />

Electrical requirements − Installation<br />

V 200/210/230-240 1N~ V 400 3N~ 208 3~<br />

A xxx/xxx/20 A 15 xxx<br />

50/60 Hz<br />

− Datasheet<br />

1N~ 200-240 V<br />

3N~ 400 V<br />

3~ 208 V<br />

Max. 4,4 KVA<br />

50 / 60 Hz<br />

− Input voltage range: ± 10%<br />

Film and negative sizes Film size Negative size<br />

110 negatives<br />

135 negatives Full frame, half frame, Panorama (colour and B/W)<br />

135 slides Colour<br />

IX240 negatives Classic, HighVision, Panorama (colour and B/W)<br />

120 negatives 6x4,5 cm to 6x9 cm<br />

<strong>AGFA</strong> d-<strong>lab.3</strong> 2001-01-02 /PN 9009 10.1


General Data and Informations<br />

Repair<br />

Floor space for operation /<br />

service<br />

General<br />

− Right side 600 mm<br />

− Left side 1.100 mm<br />

− Front<br />

900 mm<br />

− Minimum distance to the wall:<br />

for operation 150 mm<br />

for service 600 mm<br />

<strong>Digital</strong> Minilab to print negative films, slides and images from digital<br />

sources and save digital data on digital storage media.<br />

− TFS Prescanner and high-power Main Scanner<br />

− Single sheet Printer with a digital exposure system (Laser)<br />

− Scanner and Printer integrated in one chassis<br />

− Paper Processor with Agfa-specific laser paper chemistry<br />

Interfaces<br />

− Ethernet for the data exchange and the connection of the external<br />

workstation or a lab network<br />

− External densitometer<br />

− Modem<br />

− <strong>Lab</strong>el printer for pricing<br />

Main control<br />

− Integrated Pentium-PC for the main control of the d-<strong>lab.3</strong><br />

− NT operating system<br />

− Integrated disk drive, CD-ROM, Zip<br />

− Touch screen monitor as user interface<br />

Noise level<br />

58 dB(A) Standby<br />

65 dB(A) Print mode<br />

68 dB(A) Print mode with Sorter<br />

Optional accessories − Additional table for a larger working area<br />

− External label printer for pricing<br />

− Masks for the different negative sizes and slides<br />

− Options for other print processing functions<br />

Print sizes Minimum: 82 mm x 117 mm (3,25" x 4,75") 4,75" paper<br />

Maximum: 210 mm x 305 mm (8,25" x 12") 8,25" paper<br />

Production capacity 1.700 prints/hour (eff., including Indexprint) under the following<br />

conditions:<br />

− Film size 135-24, 24 normally exposed negatives<br />

− Print size 102x152 mm<br />

− 152 mm paper width<br />

Service cycle − Frequency: 6 months (probably)<br />

− Time input: 0,5 days (probably)<br />

10.2 2000-01-02 /PN 9009 <strong>AGFA</strong> d-<strong>lab.3</strong>


Repair<br />

General Data and Information<br />

Main-PC<br />

Drives − Diskette<br />

− Zip<br />

− CD<br />

− PCM-CIA (rack for memory cards)<br />

Graphic card − Resolution: 1.024x768 pixels<br />

− Image recurrence frequency: >75Hz<br />

Hard disk capacity<br />

≥ 10 GByte<br />

Image processing card To generate the digital images<br />

Network card 1<br />

100 Mbit/sec for external network connection<br />

Network card 2<br />

10 Mbit/sec for internal communication<br />

Operating system Windows NT ≥ 4.0<br />

Timer board<br />

to control the switch-on and switch-off procedures<br />

Prescanner / Scanner<br />

Filter − Optimised filter set for negative films<br />

− Optimised filter set for slides (optional)<br />

Resolution for negative size − Prescanner: approx. 500 pixels per colour<br />

135<br />

− Main Scanner: approx. 6.000.000 pixels per colour<br />

Sensor type − Monochrome CCD sensor 2k x 3k pixels<br />

<strong>AGFA</strong> d-<strong>lab.3</strong> 2001-01-02 /PN 9009 10.3


General Data and Informations<br />

Repair<br />

Printer<br />

Laser recorder<br />

− Exposure by a Laser recorder<br />

− Paper transport speed<br />

− Laser wavelength:<br />

Blue<br />

Green<br />

Red<br />

100 mm/s<br />

458 nm<br />

514 nm<br />

680 nm<br />

− Scanning width 8,25"<br />

− Resolution<br />

400 dpi<br />

Paper magazines − Paper length 176 m<br />

Paper transport<br />

− Paper width<br />

3¼ - 8¼ Inch<br />

− Single-sheet transport on one lane, paper cut prior to the<br />

exposure,<br />

distance between 2 single sheets 25 mm<br />

− 2 paper magazines<br />

− Sheet rotation<br />

− Sheet centring<br />

− Lane distributor to supply 2 lanes in the Paper Processor<br />

10.4 2000-01-02 /PN 9009 <strong>AGFA</strong> d-<strong>lab.3</strong>


Repair<br />

General Data and Information<br />

Paper Processor<br />

Floor space − Width: 770 mm (Processor)<br />

Floor space for operation /<br />

service<br />

Process capacity<br />

Processor type<br />

− Length:<br />

1.102 mm (without the Sorter extension)<br />

− Height:<br />

1.732 mm<br />

− Right side: 600 mm<br />

− Distance to the wall: 150 mm / 600 mm<br />

− 1.700 prints/hr<br />

− Two-lane stand-alone Paper Processor<br />

− Replenishing system<br />

− Rinse<br />

− 1 CD, 1 BX and 3 SB tanks<br />

− Integrated print sorter<br />

15 order buckets<br />

All print sizes can be sorted and deposited.<br />

− Integrated densitometer<br />

Process specifications<br />

Solution CD BX SB<br />

Process time (in sec.) 27 27 3 x 18<br />

Temperature (in ºC) 40 35 3 x 35<br />

Replenishment rate (ml/m²) 90 120 240<br />

Tank<br />

− Automatic mixing for the replenishment<br />

− Automatic water replenishment<br />

Tank capacity in litres CD BX SB<br />

Processing tank 18,4 18,4 3 x 13,2<br />

Replenisher tank 10 10 20<br />

Effluent tank 5 5 5<br />

Transport system<br />

− Two-lane transport by means of rollers<br />

− Single sheet:<br />

Minimum length<br />

117 mm<br />

Maximum width<br />

210 mm<br />

− Lane distributor:<br />

2 lanes up to 102 mm<br />

1 lane up to 210 mm<br />

− Transport speed: 2.969 mm/min (50/60 Hz)<br />

Dryer<br />

− Preheating by means of an IR dryer<br />

− Main heater with hot air<br />

<strong>AGFA</strong> d-<strong>lab.3</strong> 2001-01-02 /PN 9009 10.5


General Data and Informations<br />

Repair<br />

Densitometer<br />

Calibration Automatic prior to every measurement to D=0,10 (Y, M, C)<br />

Data rate 1.200 Baud: Print mode / factory-set<br />

(Jumper 1 and 2 not set)<br />

9.600 Baud: Test mode<br />

Interfaces<br />

Connector 3 (data interface acc. to RS232)<br />

Type: Sub-D 9 poles<br />

Jumper settings Jumper position Mode Baud rate<br />

Normal 1.200<br />

Machine selection<br />

Measuring characteristics<br />

Transport speed<br />

Normal: The Jumpers have no impact<br />

on the densitometer function in this<br />

position<br />

Do not set! Only for the assembly !<br />

Densitometer may get damaged<br />

1.200<br />

Selection by means of soldering bridge Br1:<br />

Br1 open<br />

When Br1 is open, the transport speed can be selected with Br2<br />

Measuring range<br />

Reflection D=0,00 to 2,55 (minus the basic density)<br />

Measuring accuracy under the particular climatic conditions<br />

− Linearity, reproducibility:<br />

- to density 1,30 ± D=0,01<br />

- to density 2,00 ± D=0,02<br />

- to density 2,55 ± D=0,03<br />

Selection by means of soldering bridge Br2 (Br1 must be open):<br />

Br2 short-circuited V = 1.400 mm/min d-<strong>lab.3</strong> Process<br />

—<br />

10.6 2000-01-02 /PN 9009 <strong>AGFA</strong> d-<strong>lab.3</strong>


Repair<br />

General Data and Information<br />

Standardisation / Screws<br />

Flat head screws<br />

DIN 912 (inside the machine)<br />

− Thread: M3, M4, M6, M8<br />

− Length: 5, 8, 12, 16 mm<br />

− Surface: Zn<br />

Recessed countersunk head screws DIN 965<br />

− Thread: M3, M4<br />

− Length: 4, 6, 10 mm<br />

− Surface: Zn<br />

Cross recessed countersunk head<br />

screws<br />

DIN 7985 (fastenings visible on the outside of the machine)<br />

− Thread: M4<br />

− Length: 10 mm<br />

− Surface: Zn<br />

<strong>AGFA</strong> d-<strong>lab.3</strong> 2001-01-02 /PN 9009 10.7


General Data and Informations<br />

Repair<br />

Optional Accessories<br />

Type Order no.<br />

Additional paper magazines 8508/115 5BQVM<br />

Film mask 135H 8506/136 B72N5<br />

Film mask 135P 8506/137 B72O7<br />

Film mask 135HV 8506/138 B72PA<br />

Film mask 110 8506/139 B72QC<br />

Mirror box 120 8508/131 5AB7C<br />

Film mask 120 6x4,5 *** 8506/165 B72TJ<br />

Film mask 120 6x6 *** 8506/166 B72UL<br />

Film mask 120 6x7 *** 8506/167 B72VN<br />

Film mask 120 6x8 *** 8506/168 B72WP<br />

Film mask 120 6x9 *** 8506/169 B72XR<br />

Smart Media Card Adapter 9975/213 5DSFF<br />

<strong>Compact</strong> Flash Card Adapter 9975/214 5DSGH<br />

Air exhaustion adapter 125 mm 8060/350 5GVP2<br />

* Universal lens delivered instead of the standard lens (8060/305, 5FLMF)<br />

** LCD monitor delivered instead of the CRT monitor (8060/340, 5FLOK)<br />

*** Only in combination with the universal lens<br />

10.8 2000-01-02 /PN 9009 <strong>AGFA</strong> d-<strong>lab.3</strong>


Repair<br />

General Data and Information<br />

Consumables<br />

Chemistry<br />

CD<br />

BX<br />

SB<br />

Tank kit<br />

Order no.<br />

5FPKS<br />

5FPLU<br />

5FPMW<br />

5FFYK<br />

Paper<br />

Order no.<br />

10,2 5FM4L<br />

12,7 5FM5N<br />

15,2 5FM6P<br />

20,3 5FM8T<br />

Air filter<br />

Lamp house<br />

CCD<br />

Cutter area<br />

Paper Processor (1)<br />

Paper Processor (2)<br />

Paper Processor (3)<br />

Order no.<br />

CM+7.8061.LHL4.0<br />

CM+7.8061.FEL2.0<br />

CM+7.0431.7225.0<br />

CL+P3-E0898<br />

CL+P4-3812<br />

CL+P4-3812<br />

Chemical filters + Test strips<br />

Order no.<br />

Chemical filters CD, BX, SB1, SB2, SB3 92GP5<br />

Test strips —<br />

Other<br />

Order no.<br />

Farbband Rückseitendrucker 102-01-0003<br />

Kopierlampe<br />

YMHSY<br />

<strong>AGFA</strong> d-<strong>lab.3</strong> 2001-01-02 /PN 9009 10.9


General Data and Informations<br />

Repair<br />

10.10 2000-01-02 /PN 9009 <strong>AGFA</strong> d-<strong>lab.3</strong>


Repair<br />

General Data and Information<br />

Glossary<br />

Acousto-optic<br />

AOM amplifier<br />

(acoustooptical<br />

Modulator)<br />

AVR Controller<br />

Banding<br />

Blemish<br />

BOL (begin of line)<br />

BOP (begin of paper)<br />

CC Mode<br />

(capture compare)<br />

CDS process<br />

(Correlated Double<br />

Sampling)<br />

Colour gradations<br />

Checks the interactions between high-frequency Ultrasonic and Hypersonic<br />

waves and electromagnetic waves. The occurring refractive and diffractive<br />

effects are used for the construction of light deflectors, light modulators, light<br />

switches and other acousto-optical components.<br />

The d-<strong>lab.3</strong> features an AOM amplifier each for the blue and the green<br />

Laser beam.<br />

Upon a replacement, the characteristic curve has to be recreated<br />

(adjustment assisted by the service program). To create the characteristic<br />

curve, the service technician moves an additional monitor diode into the light<br />

path.<br />

Controller circuit (AVR = registered trademark)<br />

Caused by variations of the transport speed; cause: Irregular running of the<br />

motor, bumps against the exposure unit.<br />

Most clearly visible for the human eye at 0,7lp/mm<br />

Those pixels are considered as Blemish whose correction data exceeds the<br />

available storage range.<br />

Start of exposure<br />

Paper tip detection<br />

Interrupt routine (FL-Controller) for the motor control:<br />

A counter is active in the CC mode that triggers an Interrupt after a given<br />

time. The Port Pin must then be set explicitly in the Interrupt (see also PWM<br />

mode).<br />

Motors: Feeder motor (film width), film transport in the Feeder, Scanner<br />

sledge<br />

Improves the noise distance by means of the CDS method: Each pixel not<br />

only holds the actual pixel value, but also has a Dark Reference which<br />

accounts for local differences of the PRNU. The output signal is used to form<br />

the difference between these two signals.<br />

The two signals are found by a special CDS chip which exists separately for<br />

each quadrant.<br />

The CCD chip contains 6 additional arrays for each quadrant whose pixels<br />

are not active electrically. The average value of their content can be used as<br />

parameter to check the temperature and the dark current (Trigger to repeat<br />

the pixel correction in case the given tolerances are exceeded).<br />

1.024 gradations per colour<br />

Gradations per pixel = RxGxB = 1024x1024x1024 = 1.073.824<br />

DFÜ<br />

Remove data transmission for RDS (Remote Diagnose Service)<br />

Density gradations 1.024<br />

min. density 0,1<br />

max. density 2,1<br />

Differences are easier to discern for the human eye at low densities than at<br />

high densities.<br />

Laser power curve: Smallest gradations for lower densities.<br />

dpi (dots per inch)<br />

FAF (FIFO almost full)<br />

Resolution of digital images<br />

Buffer for the image data (FIFO) almost full<br />

<strong>AGFA</strong> d-<strong>lab.3</strong> 2001-01-02 /PN 9009 10.11


General Data and Informations<br />

Repair<br />

FIFO (first in, first out)<br />

FPGA (field<br />

programmable gate<br />

array)<br />

GUI (graphic user<br />

interface)<br />

Laser<br />

Laser diode<br />

Laser pixel size<br />

LFB<br />

LUT (look up table)<br />

LVDS Interface<br />

Piko<br />

Polarisation filter<br />

Polygon<br />

PRNU<br />

PWM mode<br />

(pulse width<br />

modulation)<br />

RS232<br />

SPI Module<br />

UM<br />

Buffer for image data<br />

After the AD conversion, the image data is preprocessed in the FPGA,<br />

multiplexed (4:1) and sent to the image processing card in the Main-PC.<br />

Operator surface<br />

English shortcut for Light amplification by stimulated emission of radiation<br />

A semiconductor diode working in the near Infrared range in which the<br />

recombination of electrons and spaces at the p-n transition between a p and<br />

an n-conductive semiconductor material is used to generate and amplify light<br />

(see Semiconductor laser).<br />

0,06325 mm<br />

Laser Feedback<br />

The adjustment of the density-proportional image data to the paper to be<br />

exposed is performed in the LUTs, taking into account the laser properties and<br />

the transmission characteristic curves of the AOM amplifier.<br />

The memory of the Printer Mainboard can save LUTs for 2 paper types at the<br />

same time.<br />

Image data interface (differential pairs of lines) between the CG-Controller and<br />

the image processing board in the Main-PC.<br />

The pixel correction (Piko) is used to level the individual pixels of the CCD<br />

chip so that the black value (dark current) and the white value (sensitivity)<br />

are identical / reproducible for the subsequent signal processing.<br />

Light filter to alter the intensity of the spectral composition by using the<br />

polarisation condition of the light<br />

Rotating mirror to deflect the beam into the exposure unit PE<br />

CCD pixels: The dark current rises beyond a constant but pixel-dependent<br />

dark current rate linear with the scanning time. Owing to the sampling<br />

process, additional pixel-dependent voltage differences occur which are not<br />

time- and light-dependent (so-called PRNU).<br />

Interrupt routine (FL-Controller) for the motor control:<br />

The Controller can generate PWM by itself. In this case, the Controller gets an<br />

Interrupt whenever a new pulse is generated. However, not all IO-Pins of the<br />

Controller can be operated in this mode. The other Ports have to be controlled<br />

in the CC mode.<br />

Motors (FL-Controller): Filter wheel negative, KG filter paddles, wheel of the<br />

auxiliary shutter, film drive<br />

Motor (CG Controller): Shutter<br />

Serial interface between the Motherboard and the Main PC.<br />

The SPI module (Serial Peripheral Interface) controls the magazine drive.<br />

<strong>Digital</strong> Mask<br />

■<br />

10.12 2000-01-02 /PN 9009 <strong>AGFA</strong> d-<strong>lab.3</strong>


Repair<br />

Index<br />

Index<br />

A<br />

Additional Air / Exhaust Air .....................................2.4<br />

Algorithm/Interface Board..................................4.1.16<br />

Algorithm/Interface Controller............................4.3.28<br />

Ambient conditions for test and operation............10.1<br />

AOM...................................................................6.3.59<br />

AOM Amplifier....................................................6.3.51<br />

AOM Amplifier, replacing...................................6.4.52<br />

Approval................................................................10.1<br />

APS Magnetic Decoder .........................4.1.18, 4.3.30<br />

Assembly Groups ...................................................2.7<br />

Assembly Groups, allocation..................................2.5<br />

Assembly Groups, Scanner.................................4.2.1<br />

Auxiliary Shutter.................................................4.3.11<br />

B<br />

Back Printer, replacing the Print Head ..............6.4.59<br />

BIOS Settings .........................................................5.7<br />

Block Circuit Diagrams, Paper Processor ...........7.1.3<br />

Block Circuit Diagrams, Scanner.........................4.1.3<br />

Boards, replacing...............................................4.4.22<br />

C<br />

Calibration, Prescanner.....................................4.4.30<br />

Calibration, Scanner ..........................................4.4.27<br />

CAN Bus ............................................................4.3.34<br />

CCD ...................................................................4.3.18<br />

CCD Board ........................................................4.1.21<br />

CCD Group CG, signal list...................................4.2.4<br />

CCD Signal Processing.....................................4.3.22<br />

CG Controller.........................................4.1.19, 4.3.31<br />

Chemical containers ...............................................1.6<br />

Chemicals, storage.................................................1.9<br />

Circuit Diagrams ...................................................2.13<br />

Cleaning agents....................................................9.13<br />

Cleaning agents, tank cleaning ..............................1.6<br />

Commands .............................................................3.3<br />

Components, Scanner.........................................4.3.2<br />

Connectors, Paper Processor .............................7.2.4<br />

Consumables...............................................9.13, 10.9<br />

Copyright ................................................................1.3<br />

D<br />

Densitometer ........................................................10.6<br />

Densitometer, integrated ...................................7.3.11<br />

Densitometer, replacement .................................7.4.1<br />

Dimensions...........................................................10.1<br />

Disposal ..................................................................1.4<br />

Disposal, liquid residues.........................................1.6<br />

Disposal, spent processing solutions .....................1.5<br />

Driver Sensor Board ............................................4.1.9<br />

Drives.............................................................5.3, 10.3<br />

Drives, jumper settings ...........................................5.8<br />

Dryer .....................................................................10.5<br />

Dryer DH, signal list.............................................7.2.2<br />

Dust Shutter, repair .............................................4.4.6<br />

E<br />

Electrical requirements .........................................10.1<br />

Electrical Structure, basic machine ........................2.3<br />

Electrical Structure, Paper Processor .................7.3.3<br />

Electrical structure, Printer ..................................6.1.4<br />

Electrical Structure, Scanner...............................4.3.1<br />

End of the Maintenance Jobs...............................9.12<br />

Ethernet .............................................................4.3.34<br />

Ethernet Boards......................................................5.3<br />

Exposure Filters, replacing ..................................4.4.5<br />

Exposure Path ...........................................4.3.4, 4.3.6<br />

F<br />

FD/SD Output Stage..............................4.1.13, 4.3.25<br />

Film and negative sizes ........................................10.1<br />

Film Drive, components.....................................4.3.19<br />

Film Feeder FF, signal list ...................................4.2.3<br />

Film Guide, Adjustment .......................................4.4.9<br />

Film Guide, coarse Adjustment ...........................4.4.8<br />

Film stop key........................................................4.3.2<br />

Filter Wheel, replacing.........................................4.4.4<br />

FL Controller ..........................................4.1.14, 4.3.25<br />

Floor space ...........................................................10.5<br />

Floor space for operation / service .......................10.2<br />

Flow chart, main scan................................4.3.4, 4.3.5<br />

Flowcharts, Printer...............................................6.3.5<br />

G<br />

Glossary..............................................................10.11<br />

Graphic card .........................................................10.3<br />

Graphic Card ..........................................................5.3<br />

Guide Rails of the Paper Magazines, replacing 6.4.13<br />

H<br />

Hard disk.................................................................5.3<br />

I<br />

I 2 C Bus...............................................................4.3.35<br />

Image processing board .........................................5.6<br />

Image processing card .........................................10.3<br />

Interfaces ..............................................................10.2<br />

IR Dryer IR, signal list..........................................7.2.2<br />

K<br />

KG Filter Wheel ...................................................4.3.8<br />

KG Segment, repair.............................................4.4.1<br />

L<br />

Lamphouse LH, signal list ...................................4.2.2<br />

Lane Distributor Control.....................................6.3.54<br />

Lane Distributor LD............................................6.3.52<br />

Lane Distributor LD, List of Signals .....................6.2.9<br />

Lane Distributor LD, replacing Parts .................6.4.54<br />

Lane Shifter LS, signal list ...................................7.2.3<br />

Laser beam, safety precautions .............................1.8<br />

Laser Diode, red ................................................6.3.50<br />

<strong>AGFA</strong> d-<strong>lab.3</strong> 2001-01-02 /PN 9009 11.1


Index<br />

Repair<br />

L (cont.)<br />

Laser Fundamentals ......................................... 6.3.57<br />

Laser Module .................................................... 6.3.38<br />

Laser Module / Laser, replacing ....................... 6.4.45<br />

Laser Module LA, List of Signals ........................ 6.2.8<br />

Laser Power Supply Unit, replacing.................. 6.4.51<br />

Laser recorder...................................................... 10.4<br />

Laser Unit LU, List of Signals ............................. 6.2.8<br />

Legal situation........................................................ 1.3<br />

Lens Group LG, signal list .................................. 4.2.3<br />

Lenses............................................................... 4.3.17<br />

LH Output Stage ................................... 4.1.12, 4.3.24<br />

Log files.................................................................. 3.3<br />

Log Files................................................................. 3.2<br />

Lubricants ............................................................ 9.14<br />

LVDS................................................................. 4.3.34<br />

M<br />

Magazine Drive MD .......................................... 6.3.26<br />

Magazine Drive ML/MR, replacing.................... 6.4.14<br />

Main control ......................................................... 10.2<br />

Main PC, Interfaces / Connections ........................ 5.1<br />

Main switch ......................................................... 7.3.2<br />

Main-PC ................................................................. 5.1<br />

Maintenance schedule........................................... 9.1<br />

Major assembly groups.......................................... 2.1<br />

Major assembly groups, Printer .......................... 6.3.1<br />

Mechanical structure, basic machine .................... 2.2<br />

Mechanical Structure, Paper Processor ............. 7.3.1<br />

Mechanical structure, Printer .............................. 6.1.3<br />

Mechanical Structure, Scanner........................... 4.3.1<br />

Mirror Box.......................................................... 4.3.10<br />

Mirror Box MB, signal list .................................... 4.2.3<br />

N<br />

Negative Carrier NC, signal list........................... 4.2.4<br />

Negative Carrier, Adjustments.......................... 4.4.20<br />

Negative Carrier, repair..................................... 4.4.14<br />

Negative Carrier: Lubricate the toothed<br />

Belts / Shafts...................................................... 9.4<br />

Negative Mask .................................................. 4.3.12<br />

Negative Masks Coding.................................... 4.3.12<br />

Network card........................................................ 10.3<br />

Noise level............................................................ 10.2<br />

O<br />

ON key ................................................................ 4.3.2<br />

Operating system................................................. 10.3<br />

Operating System .................................................. 5.9<br />

Optional Accessories ........................................... 10.8<br />

Options................................................................. 10.2<br />

P<br />

Paper Exit PO, signal list .................................... 7.2.3<br />

Paper Magazine Control ..................................... 6.1.7<br />

Paper Magazine, List of Signals ............... 6.2.3, 6.2.4<br />

Paper Processor Block, signal lists..................... 7.2.1<br />

Paper Processor Control .................................... 7.3.5<br />

Paper transport .................................................... 10.4<br />

P (cont.)<br />

Parts Functions .................................................... 2.11<br />

PC Mainboard Connections................................... 5.5<br />

PCBs, Paper Processor...................................... 7.3.3<br />

PC-Mainboard........................................................ 5.4<br />

PE_GS01, Connector Assignment ................... 6.2.22<br />

PF_GS01, replacing............................................ 6.4.2<br />

Photochemicals, Legal regulations .........................1.5<br />

Photographic paper, storage ................................. 1.9<br />

Pixel Correction................................................. 4.3.22<br />

Pixel Correction (Piko) ...................................... 4.4.28<br />

Pixel coverage, setting...................................... 6.3.61<br />

Pixel delay......................................................... 6.3.62<br />

Pixel delay / Pixel shift (quick version).............. 6.3.65<br />

Pixel shift........................................................... 6.3.62<br />

Polygonal Drive................................................. 6.3.50<br />

Power Monitor................................................... 6.3.45<br />

Precanner Adjustment ...................................... 4.4.23<br />

Prescanner............................................ 4.1.23, 4.3.14<br />

Prescanner SC, signal list................................... 4.2.4<br />

Print Engine PE................................................. 6.3.37<br />

Print Engine PE, List of Signals .......................... 6.2.7<br />

Print Engine PE, replacement........................... 6.4.44<br />

Print Engine PE, replacing Parts ...................... 6.4.33<br />

Print sizes............................................................. 10.2<br />

Printer Mainboard ................................. 6.2.11, 6.3.15<br />

Printer Mainboard PF, List of Signals ................. 6.2.2<br />

Printer Mainboard, Connector Allocation.......... 6.2.18<br />

Printer Mainboard, Technical Data ................... 6.3.24<br />

Process capacity.................................................. 10.5<br />

Process specifications ......................................... 10.5<br />

Processor type ..................................................... 10.5<br />

Production capacity.............................................. 10.2<br />

R<br />

Radio Shielding...................................................... 5.9<br />

RCD device......................................................... 7.3.2<br />

RDS functions ........................................................ 3.4<br />

Remote Diagnosis.................................................. 3.4<br />

Replacing the cutter Unit CU ............................ 6.4.16<br />

Replacing the Printer power supply unit ........... 6.4.11<br />

Resolution, main scan......................................... 4.3.4<br />

RS232 ............................................................... 4.3.34<br />

S<br />

Safety devices........................................................ 1.3<br />

Safety Instructions ................................................. 1.2<br />

Safety precautions for the handling of chemicals .. 1.6<br />

Safety Prescriptions ............................................... 1.3<br />

Scanner Carriage, oiling ........................................ 9.4<br />

Scanner Motherboard ............................. 4.1.6, 4.3.23<br />

Scanner SC, signal list........................................ 4.2.2<br />

Script Language daisy ........................................... 3.5<br />

Scripts .................................................................... 3.3<br />

Sensors / loads (list) scanner ............................. 4.2.1<br />

Sensors / Loads (lists), Paper Processor ........... 7.2.1<br />

Sensors / Loads in the Scanner.......................... 4.1.1<br />

Sensors and Loads, Paper Processor................ 7.1.1<br />

Sensors and Loads, Printer ................................ 6.2.1<br />

11.2 2001-01-02 /PN 9009 <strong>AGFA</strong> d-<strong>lab.3</strong>


Repair<br />

Index<br />

S (cont.)<br />

Service Functions ...................................................3.1<br />

Service, every 2 Years .........................................9.12<br />

Service, yearly ........................................................9.3<br />

Sheet Bridge SB ................................................6.3.33<br />

Sheet Bridge SB, List of Signals..........................6.2.6<br />

Sheet Bridge SB, replacing Parts......................6.4.24<br />

Sheet Gear SG, List of Signals............................6.2.5<br />

Sheet Stocker SR ..............................................6.3.33<br />

Sheet Transfer ST .............................................6.3.52<br />

Sheet Transfer ST, List of Signals.....................6.2.10<br />

Sheet Transfer ST, replacing Parts ...................6.4.62<br />

Shutter, repair......................................................4.4.3<br />

Signals ..................................................................2.12<br />

Silver recovery........................................................1.6<br />

Software Structure..................................................8.1<br />

Sorter SO, signal list............................................7.2.3<br />

Standardisation / Screws......................................10.7<br />

Stepper Motor, Scanner ......................................4.2.5<br />

Switching Gear SG ............................................6.3.31<br />

Switching Gear SG, replacing ...........................6.4.18<br />

Symbols ..................................................................1.2<br />

T<br />

Tank capacity........................................................10.5<br />

Technical Data......................................................10.1<br />

Technical Documentation, structure.......................1.1<br />

Technical Documentation, use ...............................1.1<br />

Temperature Switch Dryer...................................7.4.5<br />

Text Styles ..............................................................1.2<br />

Timer board ...................................................5.6, 10.3<br />

Tools, Service Technician ....................................9.14<br />

Transport system..................................................10.5<br />

Transport Unit TU ..............................................6.3.34<br />

Transport Unit TU, List of Signals........................6.2.6<br />

Transport Unit TU, replacing Parts....................6.4.28<br />

W<br />

Water endangering class 1.....................................1.5<br />

Water Replenishment .............................................9.8<br />

Z<br />

Zoom / Fixed Focus Lens, replacing .................4.4.21<br />

<strong>AGFA</strong> d-<strong>lab.3</strong> 2001-01-02 /PN 9009 11.3


Index<br />

Repair<br />

■<br />

11.4 2001-01-02 /PN 9009 <strong>AGFA</strong> d-<strong>lab.3</strong>

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