Service Manual Mako Series

8/19/2019 Service Manual Mako Series

1/94

ECRM Imaging Systems

554 Clark Rd.

Tewksbury, MA 01876

Phone (978) 851-0207 Fax - (978) 851-7016 AG11902 Rev. 5

Reference Manual

MAKO

RETURN


2/94

MAKO Reference Manual

This manual reflects the MAKO as of February, 2000.

© copyright ECRM Incorporated 2000

Information on ordering additional copies of this manual may be obtained by writing or calling:

ECRM Order Processing

554 Clark Road

Tewksbury, MA 01876

Phone No. (US) - (978) 851-0207 — Fax (US) - (978)-851-7016

Phone No. (UK) - (44) 1923-218255 — Fax (UK) (44) 1923-218256

Phone No. (Hong Kong) - 852-2-564-8989 — Fax (Hong Kong) 852-2-564-8821

Proprietary Notice

The information contained within this guide is the property of ECRM Incorporated. No transmission, reproduc- tion, transcription, storage in a retrieval system, translation into any language, or other use is permitted inwhole or in part in any form without first obtaining written permission of ECRM Incorporated.

List of Trademarks or Registrations, ECRM ® is a registered trademark of ECRM Incorporated, PelBox ® is a registered trademark of ECRM

Incorporated, KnockOut ® 4550 is a registered trademark of ECRM Incorporated, KnockOut ® /PRF is a registered trademark of ECRM Incorpo-

rated, Marlin™ is a trademark of ECRM Incorporated.

AG11902 Rev. 5


3/94AG11902 Rev. 5 3

1 Installation and Specifications .. 7Pinch Roller Lever Installation on New Machines .. 7Installation .. 7

Site Preparation .. 7Customer Responsibilities .. 7Environmental Requirements .. 8

Mako Series Specifications .. 10SCSI Interface Specification (AG11510) .. 18

2 System Block Diagrams .. 19Introduction .. 19Description of Interlocks .. 22

3 Mako Series Replacement and Alignment Procedures .. 25

Introduction .. 25

Before you begin working on your imagesetter... .. 25Wearing a Wrist Grounding Strap .. 26Removing and Replacing the Imagesetter Cover .. 26

Removing the Imagesetter Cover .. 26Replacing the Imagesetter Cover .. 27Replacing the Front Cover Gas Shock .. 27Replacing the Cover Sensor (DA0117) .. 28

Replacing the Mako Optics Assembly .. 29Optics Removal .. 29Spinner Motor Replacement Procedure .. 30

Removing the Spinner Motor from the Old Assembly .. 30Replacing the Spinner Motor in the New Assembly .. 30

Air Bearing Optics Assembly Installation Flowchart .. 31Packaging Returned Optics .. 34

Air Bearing Spinner Motor Optics Installation .. 35Unpacking the Optics Assembly .. 36Checking the Optics Assembly Temperature .. 37Cover Removal .. 38Optics Removal .. 39Spinner Motor Replacement Procedure .. 40

Removing the Spinner Motor from the Old Assembly .. 40Replacing the Spinner Motor in the New Assembly .. 40

Optics Installation .. 41System Warm-up .. 44Calibration .. 44

Set the System for Test Pattern #4 .. 45Calibration Menu .. 45Image Centering .. 47Pel Correction .. 48Line Correction .. 49Checking Perpendicularity .. 50

Installing Shims .. 51


4/94

4 AG11902 Rev. 5

Output a Test Image .. 51Package Returned Optics .. 52

Replacing the Belts .. 53Kapton Belt Drive .. 53

Removing Belts .. 53Replacing Belts .. 53

Removing and Replacing the Drive Motor .. 55

Kapton Belt Drive Motor .. 55Removing Belts .. 55Replacing Belts .. 55

Standard Belt Drive Motor .. 55Removing Motor .. 55Replacing Motor .. 55

Cutter Assembly Removal and Replacement .. 56Adjusting the Start of Line (SOL) Laser Level .. 57System Droop Adjustment Procedures .. 59

Adjusting for Droop or Reverse Droop Occurring Separately .. 59Adjusting for Droop and Reverse Droop Occurring Together .. 59

Power Supply .. 60Removal and Replacement Procedure .. 60AC Mains, Input Module Check .. 61Power Supply Adjustment Procedure .. 61

SCSI/PelBox Interface Board (AP9992P2) .. 63Removal .. 63Replacement .. 63

Main Controller Board (AP24507P3) .. 64Control Panel Board (AP9981) .. 65Capstan Assembly Removal and Replacement .. 66Input Cassette Shelf Alignment Procedure .. 70EPROM Replacement Procedure .. 71Removing and Replacing the Drive Encoder .. 73

Removal Procedure .. 73Installation Instructions .. 73

4 Calibration, Diagnostics, and System Alignment .. 75

Introduction .. 75System Warm-up .. 75Calibration Menu .. 75

Image Centering .. 77Pel Correction .. 79Line Correction .. 80Perpendicularity .. 81

Checking Perpendicularity .. 81

Installing Shims .. 82

System Errors .. 83 /BEAMON Path .. 83Bias Control .. 83

Diagnostics .. 84Spinner Test (3600/4600 and 3625/4625 Systems (AKA Mako 36/46) .. 85


5/94

AG11902 Rev. 5 5

Spinner Test (3650, 3675, 4650, and 4675) Systems .. 86Unwinding Film and Parking the Cutter .. 87Test Patterns .. 87

System Alignment .. 89Laser Alignment .. 89Belt Alignment .. 90


6/94

6 AG11902 Rev. 5


7/94

AG11902 Rev. 5 7

1 Installation and Specifications

1.1 Pinch Roller Lever Installation on New Machines

New imagesetters are shipped with the Pinch Roller in the open position and the Pinch Roller Release Lever

removed. Before using the system, you must install the Pinch Roller Release Lever.

1. Locate the Pinch Roller Release Lever in the Accessories Bag (which also contains the power cord).

2. Lift the front door of the system to the open position.

3. Locate the slot on the left side of the input cassette compartment. Note the threaded hole in the shaft behind

the slot.

4. Install the Pinch Roller Release Lever into the threaded hole.

5. Move the shaft back and forth several times to verify smooth operation.

Figure 1-1. Installing the Pinch Lever

1.2 Installation

1.2.1 Site Preparation

The following section explains the procedures required of the customer when planning for installation of the

Recorder. The customer should follow the procedures to help ensure a trouble-free installation.

1.2.1.1 Customer Responsibilities

The customer is responsible for the following:

1. Providing the exact location of the Recorder with adequate floor space for installation and testing.

2. Meeting environmental requirements such as temperature, humidity, and lighting.

3. Providing an external power source.

installleverhere


8/948 AG11902 Rev. 5

1.2.1.2 Environmental Requirements

Floor Requirements

For Recorder

: The imagesetter should be placed on a table and in an area appropriate for is specific sizeand weight. (Refer to Section 1 - Physical Data for weights and dimensions.)

NOTE:

Mako series systems are table top designs. When choosing a table to set the system on, make sure it is

sturdy enough to support the weight of the system.

For Installation and Testing

: Add an additional 2' (61cm) on each side of the recorder to allow enough space to

remove the cover for testing.

Traffic

: Locate the recorder in a low traffic area to ensure operator comfort, machine safety and cleanliness.

Vibration

: The recorder must be located in an area that is free from vibration. Excessive vibration can cause distor-

tion of the output.

Temperature

: Refer to section one for operating temperature, relative humidity, and storage temperature.

Heat Dissipation

: 1000 BTU/hr maximum.

Ambient Light

: Normal room lighting is acceptable. Avoid areas of extreme brightness. Such areas may produce fog-

ging on the output media.

Air Quality

: The environment should be as dust free as possible. Dust will impair the optimum operation of the

optics.

System Power

: See UTILITY REQUIREMENTS:

on page 16, Auto Ranging, for system power specifications.

The Recorder may exhibit problems if subject to static electricity. Therefore the system should not be placed in a car-

peted area. Use anti-static mats as necessary.


9/94AG11902 Rev. 5 9

1.2.2 Recommended Vendor Installation Procedure

The following section covers the recommended vendor installation procedure to aid in the set-up of the Recorder sys

tem at a customer site. The procedures are suggestions to be added to your own list of installation procedures.

NOTE:

Before operating the Recorder system read the system’s Operator Guide

, which is stored in the inside

cover of this document.

The following procedure is recommended to the vendor for installing a Recorder system:

1. Unpack and inventory all items shipped.

2. Set up, clean, and level the system at the location designated by the customer.

3. Check the system off-line using test patterns 3 and 4 to determine sizing, squareness, focus, and registration

4. Check the system on-line to by installing and configuring the RIP.

5. Linearize the imagesetter to the media and chemistry used.

6. Conduct on-site training of personnel who will operate or supervise the operation of the Recorder system.

7. Provide a check list for the customer to ensure proper installation procedures have been followed.

CAUTION:

STARTUP TEMPERATURE—If the imagesetter has been stored in a low temperature environment

it must warmup to at least 62°F (17C°) before it is powered on. Powering up a cold imagesetter

may damage the temperature sensitive components that it contains.

OPERATING TEMPERATURE—The imagesetter must be used in a normal operating environment

of 62°-86°F (17°-30°C). Failure to operate within this temperature range may result in degradation

of output quality.

Protective Earth

This product is protected by a protective Earth terminal. This protective Earth terminal is the third conductor in the

appliance inlet. This product must be installed near a socket outlet (which has a protective Earth conductor) and this

socket outlet must be easily accessible. The reason for this is that the plug on the power cord is intended to serve as

the disconnect device.

Electrical Safety

There are no user serviceable parts inside this product. Refer all repairs to a properly trained service technician.

Power Cord Types

Refer to AG11320 for proper cordset selection for your area.


10/9410 AG11902 Rev. 5

1.3 Mako Series Specifications

The Mako Series imagesetter and specifications appear below.

Figure 1-2. Mako Imagesetter

Mako 3600 / 3625 / 3650 / 3675/ 36 / 36 High Speed 4600 / 4625 / 4650 / 4675/ 46 / 46 High Speed

Scan Mode:(x-axis)

Flat field, full width, laser diode raster scan.

Media Transport (y-axis):

Capstan roller, variable speed, DC motor drive, continuous feed

COMPLEMENTARY MACHINE FEATURES:

• Desktop Design

• Daylight operation• Automatic media cutting

• Automatic end of media warning signal• Adjustable start of line• Host control of resolution and speed

• Host control of full exposure range• On line processor interface

• High Capacity takeup cassette• Bulk load supply cassette


11/94AG11902 Rev. 5 11

MEDIA:

Media-Visible Red

Visible sensitive film(polyester base) or paper or *plate material - all 0.004"-0.007" thick

Media-Infrared

*not available for 3625,3675, 4625 or 4675

IR sensitive film (polyester base) or paper or *plate material - all 0.004"- 0.007"

thick.

*0.007” material may be used with an online processor or with a special take-up cassette.

Emulsion type:

**Silver Halide or Dry Silver

** Image Quality on dry silver is confined by media

Roll designation:

Emulsion in, rolled on 2" heavy duty I.D. core. Break away taped to core, 400ft.(120mm) long: O.D. - 5.7" max

Width: Shaft # 1:

460mm (18.11”)

450.85mm (17.75”)416.4mm (16.38”)406.4mm (16.00”)

400mm (15.75”)390mm (15.35”)

369mm (14.52”)355.6mm (14.00”)

338mm (13.31”)310mm (12.20”)300mm (11.80”)

Shaft # 2:

457mm (17.99)

440mm (17.32”)430mm (16.93”)420mm (16.54”)

379.98mm (14.96”)330mm (12.99”)

317mm (12.48”)

Input Cassette:

Bulkload• Darkroom loaded (green safety light). Capacity - one (1) roll, for use of media

• 400 foot cassette

Output Cassette: Standard type, take up capacity:• 25' (7.5m) film• 20' (6.6m) paper.

Processing

Manual transfer to chemical/thermal processor

• Optional: Online processor

Mako3600 / 3625 / 3650 / 3675

/ 36 / 36 High Speed4600 / 4625 / 4650 / 4675

/ 46 / 46 High Speed


12/9412 AG11902 Rev. 5

RECORDING PERFORMANCE

Media Size:

355mm (14.0") max. (Performancespecs are at all widths.)

460mm (18.11") max. (Performancespecs are at all widths.)

Exposure Width:

Full width to expose the margins.

Image Size

355mm (14.0") max. width. Outputlength is limited to output cassette

capacity.

457.2mm (18.0") max. width. Outputlength is limited to output cassette

capacity.

At 2540, different resolutions will vary due to byte count.

*Mako 4600, 4625, 4650 and 4675 only

Image Location

Adjustable within ±1/16" to ± .004" (± .1mm)

ACCURACY:

ResolutionAddressability:

ENGLISH:2400/1200; 1800; and

1000 lpi

METRIC:3556 (140 lpmm)3048/1524 (120/60 lpmm)

2540/1270 (100/50 lpmm)2032/1016 (80/40 lpmm)

1446 (57 lpmm)

Mako3600 / 3625 / 3650 / 3675

/ 36 / 36 High Speed4600 / 4625 / 4650 / 4675


IMAGE WIDTHS FOR OVERSCAN ON AND OFF.

Mako 3600/4600Overscan

OFF ON

*18" 18.0 18.15

14" 14.0 14.17

12.2" 12.14 12.23

12" 12.01 12.17


13/94AG11902 Rev. 5 13

AbsoluteDimensional

Accuracy

English: ±.003” over

14" x 18".

Metric: ±.076 mm over350 X 450 mm

English: ±.003” over

18" x 24".

Metric: ±.076 mm over450 X 600 mm

Repeatability:

English: Within +.0012" over 4 con-secutive pages of 18" length.

Metric: Within +.030mm over 4 con-secutive pages of 450mm.

Measurements are done with outputcassette initially empty and media cutafter 4 images

English: Within +.0012" over 4 con-secutive pages of 24" length.

Metric: Within +.030 mm over 4 con-secutive pages of 600mm.

Measurements are done with outputcassette initially empty and media cutafter 4 images.

Nominal Line Laydown

Rates:

Mako 3600/4600

175.0 lines per second, 10500 lines per minute. (Refer to Table 2 of the Inter-face Spec).

Mako 3625/4625

267.0 lines per second, 16000 lines per minute.

Mako 3650/4650

350.0 lines/second, 21000 lines per minute.

Mako 3675/4675

533.0 lines per second, 32000 lines per minute.

Mako3600 / 3625 / 3650 / 3675

/ 36 / 36 High Speed4600 / 4625 / 4650 / 4675



14/9414 AG11902 Rev. 5

Video Data Rates

Mako 3600/4600 Mako 3650/4650

67.2 MHz @ 3556 dpi 119.3 MHz @ 3556 dpi57.5 MHz @ 3048 dpi 114.4 MHz @ 3048 dpi

48.0 MHz @ 2540 dpi 96.0 MHz @ 2540 dpi45.3 Mhz @ 2400 dpi 90.6 Mhz @ 2400 dpi38.4 MHz @ 2032 dpi 76.8 MHz @ 2032 dpi

34.0 Mhz @ 1800 dpi 68.0 Mhz @ 1800 dpi28.8 MHz @ 1524 dpi 57.6 MHz @ 1524 dpi


22.7 Mhz @ 1200 dpi 45.4 Mhz @ 1200 dpi19.2 MHz @ 1016 dpi 38.4 MHz @ 1016 dpi18.9 Mhz @ 1000 dpi 37.8 Mhz @ 1000 dpi

Mako 3625/4625 Mako 3675/4675

101.3 MHz @ 3556 dpi 119.2 MHz @ 3556 dpi


68.5 Mhz @ 2400 dpi 120.0 Mhz @ 2400 dpi57.8 MHz @ 2032 dpi 115.8 MHz @ 2032 dpi51.3 Mhz @ 1800 dpi 102.6 Mhz @ 1800 dpi


36.1 MHz @ 1270 dpi 72.4 MHz @ 1270 dpi34.2 Mhz @ 1200 dpi 68.4 Mhz @ 1200 dpi

28.9 MHz @ 1016 dpi 57.9 MHz @ 1016 dpi

28.4 Mhz @ 1000 dpi 57.0 Mhz @ 1000 dpi

Mako3600 / 3625 / 3650 / 3675

/ 36 / 36 High Speed4600 / 4625 / 4650 / 4675



15/94AG11902 Rev. 5 15

Throughput Speed:

Mako 3600/4600 Mako 3650/4650

2.9” /min @ 3550 dpi 5.3” /min @ 3556 dpi3.4” /min @ 3048 dpi 6.9” /min @ 3048 dpi4.1" /min @ 2540 dpi 8.2" /min @ 2540 dpi

4.4" /min @ 2400 dpi 8.8" /min @ 2400 dpi 5.2" /min @ 2032 dpi 10.4" /min @ 2032 dpi

5.8" /min @ 1800 dpi 11.6" /min @ 1800 dpi 6.9" /min @ 1524 dpi 13.8" /min @ 1524 dpi 7.3" /min @ 1446 dpi 14.6" /min @ 1446 dpi


10.3" /min @ 1016 dpi 20.6" /min @ 1016 dpi10.5" /min @ 1000 dpi 21.0" /min @ 1000 dpi

Mako 3625/4625 Mako 3675/4675

4.5” /min @ 3550 dpi 5.29” /min @ 3556 dpi

5.25” /min @ 3048 dpi 7.19” /min @ 3048 dpi6.3" /min @ 2540 dpi 10.33" /min @ 2540 dpi


8.89" /min @ 1800 dpi 17.78" /min @ 1800 dpi 10.50" /min @ 1524 dpi 21.00" /min @ 1524 dpi 11.07" /min @ 1446 dpi 22.13" /min @ 1446 dpi



Fast Media Advance

35" per minute

Mako3600 / 3625 / 3650 / 3675

/ 36 / 36 High Speed4600 / 4625 / 4650 / 4675



16/9416 AG11902 Rev. 5

SCREEN CHARACTERISTICS:

Dot% Range:

5% to 95%.

Dot % Uniformity:

2.5% on any screen tint within the range

Density

3.5Dmin

OPTICAL DATA:

Light Source:Visible

10mW, visible laser diode 670nm

Light Source:

Infrared

15mW, I.R. laser diode 780nm

Spot Size:

10-35 microns, resolution dependent, as measured at the film plane

ELECTRONIC DATA:

ECRM Interface:

(See details in Interface Spec. AG11273)

SCSI Interface:

(See details in Interface Spec. AG11273/AG11510)

PHYSICAL DATA:

Dimensions:

28" wide, 40" deep, and 17" high.

Weight:

150 lbs. (68kg)

UTILITY REQUIREMENTS:

Power:

90-264v~, 3 Amps (Max.),50/60 Hz; Single Phase; 300 Watts (Max)

HEAT DISSIPATION:

1000 BTU/HR (MAX)

ENVIRONMENTAL CONDITIONS:

Operating:

62-86° F (17-30° C); Relative humidity 45 - 65% non-condensing.

Extremes in humidity will cause the output media to stretch. Low humidity

(below 45%) may cause malfunctioning due to static electricity.

Mako3600 / 3625 / 3650 / 3675

/ 36 / 36 High Speed4600 / 4625 / 4650 / 4675



17/94


18/9418 AG11902 Rev. 5

1.3.1 PelBox Interface Specification (AG11273)

Verify with Documentation Control that you have the latest version of the PelBox Interface Specification (AG11273).

1.3.2 SCSI Interface Specification (AG11510)

Verify with Documentation Control that you have the latest version of the SCSI/PelBox Interface Specification(AG11510).


19/94

AG11902 Rev. 5 19

2 System Block Diagrams

2.1 Introduction

Notes:

1 Mako = AP24507P32 Mako (visible) 24680/24525

Mako (IR) 24501/24503

3 All Mako models

4 Mako 3600/4600 (visible) = AO24707

Mako 3600/4600 (IR) = AO24708

Mako 3625/4625 (AKA Mako 36/46) = AO24707

Mako 3675/4675 (AKA Mako 36/46 with High Speed Option = AO28515

Mako 3650/4650 (visible) = AO24690

Mako 3650/4650 (IR) = AO27202

5 Mako models ONLY6 Not in VR30 (AKA Sunfish)

7 Used in place of SOL Sensor in Mako mode

PowerSupply

Interlocks

Sensors/ Switches

Main Controller Board (1)

Index (7)

Encoder

Laser Driver Board (2)Turns on the Diode

(This causes exposureof PEL (or picture ele-

ment))

ControlPanel

FilmDrive

Encoder (6) ScanLens

Laser Diode FeedbackDetector

Capstan Roller

(Advances film orphotographic paper)

OpticsAssy (4)

Deflector (3)(deflects the beamacross the media)

SpinnerMotor

Indicates Path ofLaser Beam

PhaseCLK

Index (7)Encoder

Spinner (5)Controller

BoardAP27231


20/9420 AG11902 Rev. 5

Figure 2-2 Laser Driver Block Diagram

LASER DIODE

EXPOSURE8 BITS

/BEAMON

/LASERCAL

EXPOSURESERVO

BIASCIRCUIT

/LASERENB

/FINDSOL

SLOWSTART

+


21/94AG11902 Rev. 5 21

Figure 2-3 Main Control Board Block Diagram

EEPROM CPU EPROM RAMADDRESS

DECODINGFILM

DRIVESPINNER

DRIVER

CONTROLPANEL

INTERFACE

ADDRESS

DATA

STATUS

CONTROLREGISTERS

CUTTERDRIVER

SCSI/ PELBOX

INTERFACELINE

BUFFERSYSTEMTIMING

LASER DRIVERBOARD

NOTES:

1. Mako 3650/4650 models useAP27231 spinner controller board. Mako3675/4675 (AKA Mako 36/46 with HighSpeed Option) use AP28415 SpinnerController.

2. Index Pulse used in Mako 3650/4650

models. Also Mako 3675/4675 (AKAMako 36/46 with High Speed Option).

SOL (2)AMP


22/9422 AG11902 Rev. 5

Figure 2-4 Interlock Description

2.2 Description of Interlocks

S1AMonitors status of front access panel, interrupts +24 Volts between power supply and Controller Board, removes power to

laser driver board and spinner motor.

S1BMonitors status of front access panel, hardware prevents cutter motor from being enabled, firmware turns off laser and all

motors except the spinner motor. Exception is that film drive motor is allowed to operate by pressing momentary button on

control panel.

S2Monitors status of film loading door, hardware prevents cutter motor from being enabled, firmware turns off laser and all


Switch Open Short

S1A No Operation (HW) S1B Detected, (SW) Interlock Active

(HW) Cutter Motor Interlock Active

S1B No Operation (SW) (HW) S1A (HW) Interlock Active

S2 No Operation (SW) (HW) Film Drive Roller not stopped, potential pinch hazard

only, covered in manual

S3A No Operation (HW) S3B Detected, (SW) Interlock Active

(HW) Cutter Motor Interlock Active

S3B No Operation (SW) (HW) S3A (HW)Interlock Active

S1A *S1A+24 Volts

ControllerBoard

CutterMotor

S1B *S3BS2

+24 Volts +24 Volts

LaserDriver Spinner

ControllerBoard

SpinnerMotor

Laser

CutterMotor

Cutter MotorDrive Circuit

CUTTER

/DOOR OPENCUTENABLE

Part of Controller Board circuits

PowerSupply


23/94AG11902 Rev. 5 23

control panel.

S3AMonitors status of top cover panel, interrupts +24 Volts between power supply and Controller Board, removes power to

laser driver board and spinner motor.

S3BMonitors status of top cover panel, hardware prevents cutter motor from being enabled, firmware turns off laser and all


control panel.


24/9424 AG11902 Rev. 5


25/94

AG11902 Rev. 5 25

3 Mako Series Replacement and Alignment Procedures

3.1 Introduction

NOTE: These procedures apply to 2.0.6 Firmware and above. Contact Customer Service with any questions onpreviously released firmware.

This section contains procedures to remove, replace, adjust or align the major sub assemblies of the Mako systems.

Mako Series systems do not require that you perform any board adjustments or optical alignments. This section pro-

vides the following procedures to remove, replace, adjust or align a failed sub assembly in the field.

3.2 Before you begin working on your imagesetter...

!WARNING! Static electricity may damage internal components.

You must wear a wrist grounding strap whenever you work inside the system. The wrist grounding

strap must be connected to an earth ground, such as the jack on the side of the recorder, and

worn during the opening of any packaging that contains replacement components, and during any

handling and installation of these parts. The system must be plugged into a grounded wall outlet

and turned off.

If this is not done, static discharge may damage internal components, such as the laser diode. A

damaged laser diode could result in degradation of image quality or a shortened laser diode life.

CAUTION: All procedures must be performed by a qualified service technician and they should always wear agrounded static wrist strap prior to performing any removal or replacement procedures.Whenever

a service technician performs ANY maintenance or removal and replacement procedures, it is

extremely important to perform the following:

1) Before working inside the system, first connect the laser diode shunt. The shunt location is

shown in Figure 3-1 on page 26. Connect this shunt EVERY time you remove the system cover,

unless the procedure you are performing specifically states otherwise. If you do not connect this

shunt, the laser diode assembly will be damaged.

2.Once the changes are made and all cables are reconnected, the shunt can be removed.

Systems with an AP9993 laser driver board have the shunt attached to the laser diode cable. Sys

tems with an AP24524, AP24501, or AP24680 laser driver board, have a shunt on the laser switch

board (Refer to Figure 3-1 on page 3 - 26). In earlier systems, the shunt was not provided with the

cable. Use shunt FX0030 (provided in the Tooling Kit) if your system does not have the attached shunt

Install the shunt whenever you are removing and replacing a PC Board.

CAUTIONRECORDER CONTAINS

STATIC SENSITIVE COMPONENTS


26/94

26 AG11902 Rev. 5

3.3 Wearing a Wrist Grounding Strap

The system contains static sensitive devices that can be damaged by static electricity. A wrist grounding strap must be

worn at all times while working on the imagesetter with the cover removed or handling static sensitive components. A

wrist strap is packaged with replacement components that are static sensitive. Use this wrist strap if you do not have

one available or if your wrist strap has not been checked for proper operation within the last 4 weeks.

The wrist strap must be connected to a reliable earth ground. Most imagesetters have a grounding jack on the side of

the recorder for this purpose. Make sure that the recorder is plugged into a grounded outlet before servicing. If your

recorder does not have a grounding jack or if you are using a disposable wrist grounding strap, remove the imageset-

ter cover and immediately attach the ground directly to the metal case of the power supply. Do not install or remove

the laser diode shunt until you are properly grounded.

3.4 Removing and Replacing the Imagesetter Cover

3.4.1 Removing the Imagesetter CoverBefore working on any internal components of the imagesetter you must remove its cover.

1. Power down the system. Leave the system plugged into the outlet for earth ground.2. Wear a wrist grounding strap and attach it to the jack on the side of the recorder.

3. Remove the system’s back cover by loosening the center screw in back. Lift the rear of the cover and slide it

back, then remove it.

4. Install the laser diode shunt. See Figure 3-1 for shunt locations.The shorting plug location depends on the

type of optics assembly. To install the shunt verify which system you have .

Figure 3-1 Laser Diode Shunt Locations

NOTE: These picturesdepict two different

optics assemblies.

Verify your optics

assembly before

proceeding.

Side Views

Shunted

Unshunted

Unshunted

Remove(Unshunted)

Install(Shunted)

Shunt

Shunt


27/94

AG11902 Rev. 5 27

3.4.2 Replacing the Imagesetter Cover1. Remove the laser diode shunt.

2. Install the back cover by sliding it forward and tightening the center screw in back.

3. Remove the wrist grounding strap from the system.

3.4.3 Replacing the Front Cover Gas Shock

Mako systems have a gas shock that holds up the front, top cover of the imagesetter. If this shock becomes worn, usethe following procedure to replace it.

1. Wear a wrist grounding strap as explained on page 3 - 26.

2. Remove the system back cover. (See 3.4.1 Removing the Imagesetter Cover on page 3 - 26.) Although the

gas shock is located in the front of the system, removing the rear cover makes it easier to perform this proce

dure.

3. Raise the front, top cover.

The gas shock is a retractable arm, which is connected to the chassis and the bottom, left corner of the raised

cover (Figure 3-2).

4. The Gas shock is mounted on two pins that secure it to the imagesetter. One pin is located on the top cover,

and the other pin is located on the imagesetter chassis. To remove the gas shock, use a screw driver as a leverand remove each end of the shock from the pin that secures it.

5. Install the new gas shock by pushing each end of the shock onto the appropriate pin on the top cover and on

the chassis. You may need to use a screwdriver as a lever to snap the shock onto each pin.

Figure 3-2 Replacing the Gas Shock on a Mako System

6. Replace the system cover. (See 3.4.2 Replacing the Imagesetter Cover on page 3 - 27.)

Gas Shock

Top Cover

Use a screwdriver to pop off thegas shock from the pins thathold it to the imagesetter’s

cover and chassis.


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28 AG11902 Rev. 5

3.4.4 Replacing the Cover Sensor (DA0117)The Mako series imagesetters have a cover sensor, which enables the imagesetter to know when the cover is open.


2. Remove the system back cover. (See 3.4.1 Removing the Imagesetter Cover on page 3 - 26.)

3. Open the system front cover. The cover sensor is located on the back side of the front cover (Figure 3-3).

4. The cover sensor is mounted with three screws and is attached to a wire connector. Remove the wire connec-

tor and remove the nuts from the three mounting screws to remove the cover sensor.

5. Install the new cover sensor, tighten the nuts on the three mounting screws, and attach the wire connector to

the new cover sensor.

Figure 3-3 Cover Sensor


Top Cover

Wire Connector

Mounting Screws


29/94

AG11902 Rev. 5 29

3.5 Replacing the Mako Optics Assembly

3.5.1 Optics RemovalWith the cover removed, the power turned off, and the diode shunt installed, the optics may be removed from the sys-

tem.


2. Remove the following connections from the old optics assembly:

a. Spinner cable to AP24507 P12, Main Controller PCB, if present.

b. Spinner cable to AP27231 J3, Speedring PCB.

c. Ribbon cable to P1 of the Laser Driver Board.

d. Coaxial cable to AP24507 P1, Main Controller PCB, if present.

e. Ground cable.

3. Remove the scan lens mask (if equipped) by removing the two screws and lifting the cover straight up.

CAUTION: The optics assembly is heavy. While removing the optics be very careful to support the assembly,and then pull it up and out toward you while removing it. Do not let the assembly fall down toward

you while removing it up and out of the system. Ensure that the laser driver board(s) do not hit the

base of the system.

4. Using a 9/64 allen wrench (T-handle) remove three screws from the optical bed plate. Support the optics

assembly to prevent it from falling, then remove the fourth screw (Figure 3-4).

5. Remove the optics assembly and shims.

Figure 3-4 Location of Screws Securing the Optics Assembly

Optical Bed Plate

ScrewsScrews


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30 AG11902 Rev. 5

3.5.2 Spinner Motor Replacement ProcedureWhen replacing the system optics with an assembly that does not contain a Spinner Motor, the system Spinner Motor

should be removed from the old optics and installed in the new assembly.

3.5.2.1 Removing the Spinner Motor from the Old Assembly

1. Wear a static wrist-strap and ground it to the system as directed in Section 3.3.

2. Place the new optics assembly, scan lens down, on a clean, flat surface.

3. Remove the protective plastic cap from the spinner motor hole on the new optics assembly.

Figure 3-5 Spinner Motor

NOTE: * There is no scribe mark on 3600, 3625, 4600 or 4625 Makos (AKA Mako 36/46). Use the start of line sen-sor at the image plane for a left margin reference on these systems.

4. Cut the tie wrap that holds the spinner motor cables to the optics, and with a 5/32" Allen wrench, remove 3

mounting screws from around the Spinner Motor in the old optics assembly. Support the motor with one

hand to prevent it from falling out. Set the screws and their washers and spacers aside carefully to replace

later.

5. Carefully remove the Spinner Motor by lifting it straight out, being careful to not let the mirror touch any

part of the chassis.

3.5.2.2 Replacing the Spinner Motor in the New Assembly

NOTE: Do not touch the Spinner Motor Mirror for any reason.

1. Carefully guide the Spinner Motor straight into the housing.

2. Align the scribe mark on the edge of the Spinner Motor with the scribe mark on the housing.

3. Install and torque the three mounting screws with their washers and spacers to 15 in/lb.

4. Verify that the scribe marks still line up exactly.

Mirror

Motor body

Alignment scribe*


31/94

AG11902 Rev. 5 31

3.5.3 Air Bearing Optics Assembly Installation Flowchart

Figure 3-6 Air Bearing Optics Assembly Installation Flowchart

AC24657

coax

supplied?

Air Bearing

Optics Assembly

Installation Flowchart

Begin

Yes

No Yes

No

Set Laser

Driver J6 A-B

Install shim

between pin

and channel on

side it was

taped

Install 4 screws

between pin

securing optics

to channel

Install scan

lens mask (if

removed)

Connect:

-Ground cable

-Ribbon cable

to laser driver

-Spinner cable

to AP27231

-Spinner cable

to AP24507

Remove laser

diode shunt

Yes

No

Firmware

V2.3.2 or

Higher?

Complete (warmup and calibrate)

Yes

No

Firmware

V2.3.2 or

Higher?

Remove

AC24657 Coax

Set Laser

Driver J6 A-B

Install shim

between pin

and channel on

side it was

taped

Install 4 screws

securing optics

to channel

Install cover

and turn on

power

Set front panel

/BEAMON to

RIBBON

CABLE P4

Install scan

lens mask (if

removed)

Connect:

-Ground cable

-Ribbon cable

to laser driver

-Spinner cable

to AP27231

-Spinner cable

to AP24507

Remove laser

diode shunt

Install cover

AP24507

rev. E or

higher?

Set Laser

Driver J6 B-C

Install shim

between pin

and channel onside it was

taped Install sca

lens mask

removed

Install 4 screws

securing optics

to channel Connect

-Ground ca

-Ribbon ca

to laser driv

to laser driv

-Spinner ca

to AP2723

-Spinner ca

to AP2450

-Coax cable

AP24507 P

Remove las

diode shu

Install cov

and turn o

power

Set front pa

/BEAMON

COAXIA

CABLE P

(Cal menu

AP24680

Laser Driver?

Firmware

V 2.3.5 or

higher

?

Yes

Yes

No

Set J8 to

A-B

Set J8 to

B-C

No

Install cover


32/94

32 AG11902 Rev. 5

Refer to Figure 3-7.

1. Remove the system cover. (See 3.4.1 Removing the Imagesetter Cover on page 3 - 26.)

2. Check the optics to see if an AP24680 laser driver board is installed. Note: AP24680 laser driver boards are

used on visible systems only.

If an AP24680 is installed, proceed with step 3.

If an AP24680 is not installed, proceed with step 6.

NOTE: All Mako systems contain an AP24680 laser driver board and firmware version 2.3.5 or higher.

3. If the optics has an AP24680 installed, check the version of the firmware installed on the main controller

board.

If the firmware version is V 2.3.5 or higher proceed with step 4.

If the firmware version is lower than V 2.3.5, proceed with step 5.

4. If the firmware version is V 2.3.5 or higher, set AP24680 J8 to A-B.

5. If the firmware version is lower than V 2.3.5, set AP24680 J8 to B-C.

6. Check the optics to see if they have been supplied with an AC24657 coax BEAMON cable attached to P5 of

the laser driver PCB. If the optics were not supplied with an AC24657, continue with step 7. If they were

supplied with an AC24657, proceed with step 17.

7. If the laser driver is not supplied with an AC24657 coax BEAMON cable, set jumper J6 on the laser driver

board to the A-B position. Note: This position is hard-wired on the IR systems.

8. Install shim (if provided) between the reference pin and the optics channel. The shim is attached to the optics

assembly with cellophane tape and should be installed on the same side of the optics that it is taped (e.g. a

shim taped to the left side of the optics should be installed under the left reference pin). Discard the tape.

Ensure the reference pins are seated securely against the shim or optics channel.

Figure 3-7 Shim Locations

IMPORTANT: Remove the old shims and replace them with the new shims that are shipped with the new opticsassembly. Using the old shims with the new optics assembly could cause a System Error 2. Keep

the old shims with the old optics.

CAUTION

This is a generic picture.Some details may lookdifferent on your ma-chine.

(Installed Optics Assembly Top View)

Pin

Possible

Shim Location

Possible

Shim Location

2 Mounting Screws 2 Mounting Screws

(Do not adjust)(Do not adjust)

Pin


33/94

AG11902 Rev. 5 33

9. Install the 4 screws (2 on each side) that hold the optics to the channel.

10. For IR systems if a scan lens mask was removed from the channel, replace it and tighten the 2 screws to

secure.

For visible systems, if the scan lens mask was removed from the channel, replace it with the mask provided

in the kit and tighten the two screws to secure it.

11. Connect the following cables:

a. Ground cable.

b. Ribbon cable to P1 of the Laser Driver Board.

c. Spinner cable to AP27231 J3, Speedring PCB.

d. Spinner cable to AP24507 P12, Main Controller PCB.

12. Remove the shunt from the diode on the laser diode board.

13. Check the firmware version on the AP24507. If the version is lower than 2.3.2, proceed with step 14. If it is

version 2.3.2 or higher, proceed with step 15.

14. You have finished the procedure. Replace the system’s cover (Section 3.4.2) and perform the system war-

mup and calibration procedures. (See Chapter 4 Calibration, Diagnostics, and System Alignment .)

15. Replace the system’s cover as described in Section 3.4.2 and turn the power on.

16. Enter the calibration menu by pressing the PREV and MENU front panel keys simultaneously. Press the

NEXT key until the /BEAMON PATH? menu is reached. Select RIBBON CABLE P4. Press the NEXT key

and save the settings. Proceed with system warmup and calibration.

You have finished the procedure. Replace the system’s cover (Section 3.4.2) and perform the system war-

mup and calibration procedures. (See Chapter 4 Calibration, Diagnostics, and System Alignment .).

17. If the optics assembly was supplied with an AC24657 coax BEAMON cable attached to P5 of the laser

driver PCB, check if the AP24507 firmware version is 2.3.2 or higher. If it is not version 2.3.2 or higher, pro

ceed to step 18. If the firmware version is 2.3.2 or higher, proceed with step 26.

18. If the AP24507 firmware version is lower than 2.3.2, do not use the AC24657 coax BEAMON cable.

Remove the coax cable from P5 of the laser driver board.

19. Set jumper J6 on the laser driver board to the A-B position.

20. Install shim (if provided) between the reference pin and the optics channel. The shim is attached to the opticsassembly with cellophane tape and should be installed on the same side of the optics that it is taped (e.g. a

shim taped to the left side of the optics should be installed under the left reference pin). Ensure the reference

pins are seated securely against the shim or optics channel (Figure 3-7 on page 3 - 32). Discard the tape.



secure.




a. Ground cable.



d. Spinner cable to AP24507 P12, Main Controller PCB.


25. You have finished the procedure. Replace the system’s cover (Section 3.4.2) and perform the system war-

mup and calibration procedures. (See Chapter 4 Calibration, Diagnostics, and System Alignment .)

26. Check the revision of the AP24507 Main Controller Board. If the revision is lower than E, follow steps 18-

24 for installation. If it is Rev. E or higher, continue with step 27.

27. Set jumper J6 on the laser driver board to the B-C position.


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34 AG11902 Rev. 5

28. Install shim (if provided) between the reference pin and the optics channel. The shim is attached to the optics

assembly with cellophane tape and should be installed on the same side of the optics that it is taped (e.g. a

shim taped to the left side of the optics should be installed under the left reference pin). Ensure the reference

pins are seated securely against the shim or optics channel (Figure 3-7 on page 3 - 32). Discard the tape.



secure.




a. Ground cable.



d. Spinner cable to AP24507 P12 Main Controller PCB.

e. Coaxial cable to P1 of the AP24507 P1, Main Controller PCB.


33. You have finished the procedure. Replace the system’s cover (Section 3.4.2) and perform the system warmup

and calibration procedures. (See Chapter 4 Calibration, Diagnostics, and System Alignment .)

34. Enter the calibration menu by pressing the PREV and MENU front panel keys simultaneously. Press the

NEXT key until the /BEAMON PATH? menu is reached. Select COAXIAL CABLE P1. Press the NEXT

key and save the settings. Proceed with system warmup and calibration.


36. Perform system warmup and calibration as described in Chapter 4 Calibration, Diagnostics, and System

Alignment .

3.5.4 Packaging Returned OpticsThe return optics must be properly packaged with all return information. Use the packaging from the new optics

assembly.

1. Complete the Optics Defect Tag and attach it to the return optics assembly. Complete all sections of the tag.

2. Include a sample output from the system, illustrating the problem described on the defects tag.

NOTE: Failure to provide all information on the return tag or to use the appropriate packaging for the returnedoptics may reduce your returned parts credit.

3. Wear a wrist grounding strap as described in Section 3.3.

4. Make sure the laser diode of the return optics is shunted as described in Section 3.4.1.

5. Place return optics in the antistatic bag.

6. Place the return optics in the same packaging materials that held the new optics assembly. Include any foam

or other buffer material around the optics assembly.7. Securely close all packaging.

8. Write the RMT number on the outside box containing the return optics assembly. Return optics assemblies

will not be accepted if the RMT number is not written on the outside box.

9. Return the optics to ECRM.


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AG11902 Rev. 5 35

3.6 Air Bearing Spinner Motor Optics Installation

This section contains all of the procedures necessary to replace the air bearing spinner

motor optics assemblies in Makos. It is part of a kit that includes all of the materials and

instructions you need to replace the optics, including the following materials:

• Optics assembly (with a temperature strip)

• Defects tag for the old optics assembly

• Grounding strap

• Optics mask (Mako 3650/4650 systems only)

This document is intended for trained service technicians only.

Required materials:

• HB0577Tape Plastic Black 3/4” x 66 Ft Long

• HB1467Allen Wrench Set, 12 Piece (in place of Torx driver for Encoder Housing)

• HB2131Medium Flat Blade Screwdriver, 6 inch

• HB0956 1/4” Nut Driver

• HC0576 Micrometer Torque Wrench

!!WARNING!!Do not power up a cold optics assembly

Do not install the new optics assembly unless the temperature of

the assembly is 62°F (17°C) or above. Powering up an imageset-

ter with a cold optics assembly may damage the laser diode.

!!WARNING!!Static electricity may damage diode

This optics assembly kit contains a wrist grounding strap. The

wrist grounding strap must be connected to an earth ground,

such as the jack on the side of the recorder, and worn during the

opening of the package that contains the optics, during any han-

dling of the optics, and during installation of the optics. The sys-

tem must be plugged into a grounded wall outlet and turned off.

CAUTIONRECORDER CONTAINS

STATIC SENSITIVE COMPONENTS


36/94

36 AG11902 Rev. 5

Disposable vinyl wrist straps are packaged with a container of

moisturizing lotion. Always apply lotion to your wrist before

putting on the wrist strap.

If this is not done, static discharge may cause the laser diode to

be damaged. A damaged laser diode could result in degradation

of image quality or a shortened laser diode life.

3.6.1 Unpacking the Optics Assembly

The optics assembly is shipped in a static bag, which is placed inside of a shipping con-

tainer (or containers). After you remove the optics assembly from the shipping containers,

do not open the static bag until you are wearing a wrist grounding strap.

Do not discard the packing material and shipping containers. You need them to ship the old

optics assembly back to ECRM.

The optics assembly packaging also contains a defects tag, which you must complete andreturn to ECRM along with the old optics assembly.

NOTE: Failure to provide all information on the return tag or to use the appropriate packaging for the returned

optics may reduce your returned parts credit.


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AG11902 Rev. 5 37

3.6.2 Checking the Optics Assembly Temperature

CAUTION: Shipping and storage temperatures may chill an optics assembly. Do not install a

cold optics assembly and power up the imagesetter. Powering up an imagesetter with

an optics assembly that is colder than 62°F (17°C) may cause system errors and dam-

age the laser diode.

The optics assembly must be warmed to at least 62°F (17°C) before you install it and

power up the imagesetter. The optics assembly is shipped with a temperature strip at the

top of the assembly, above the circuit board (Figure 3 - 12). When the 62°F (17°C) panel

on the temperature strip turns green, the optics assembly is ready for installation.

Figure 3-8 Checking the Optics Assembly Temperature

Check the temperature strip before you install the optics assembly and power up the imag-

esetter, to avoid damaging the optics assembly. While the optics are warming up, it is a

good time to fill out the Defects Tag that must be returned with the old optics.



88 31

86 30

84 29

82 28

80 27

78 26

76 24

74 23

72 22

70 21

68 20

66 1964 18

62 17

60 16

58 14

OpticsAssembly

Temperature Strip


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38 AG11902 Rev. 5

3.6.3 Cover Removal

Before installing the optics assembly remove the imagesetter cover.

1. Power down the system. Leave the system plugged into the outlet for earth ground.

2. Wear a wrist grounding strap and attach it to the jack on the side of the recorder. If necessary, you

may connect the wrist grounding strap to the power supply case after you remove the imagesetter

cover.3. Remove the system’s back cover by loosening the center screw in back. Lift the rear of the cover

and slide it back, then remove it.

4. If you were unable to connect your wrist grounding strap to the or banana jack on the imagesetter in

step 2, connect it to the power supply case now.

5. Install the laser diode shunt (Figure 3 - 9).

Figure 3-9 Shunt Location

Side View

Shunt

Shunted

Unshunted

Unshunted


39/94

AG11902 Rev. 5 39

3.6.4 Optics Removal

With the cover removed, the power turned off, and the shunt installed, the optics may be

removed from the system.

1. Remove the following connections from the old optics assembly:

a. Spinner cable to AP24507 P12, Main Controller PCB, (21K/32K systems.)

b. Spinner cable to AP999P2/AP24507 P15, main controller PCB. (10.5K/16K systems.)

c. Spinner cable to AP27231/AP28495 J3, Speedring PCB, if present.

d. Ribbon cable to P1 of the Laser Driver Board.

e. Coaxial cable to AP24507 P1, Main Controller PCB, if present.

f. Ground cable.

2. Remove the scan lens mask (if equipped) by removing the two screws and lifting the cover straight

up.

CAUTION: The optics assembly is heavy. While removing the optics be very careful to support

the assembly, and then pull it up and out toward you while removing it. Do not let the

assembly fall down toward you while removing it up and out of the system. Ensurethat the laser driver board(s) do not hit the base of the system.

3. Using a 9/64 allen wrench (T-handle) remove three screws from the optical bed plate. Support the

optics assembly to prevent it from falling, then remove the fourth screw (Figure 3 - 4).

4. Remove the optics assembly and shims.

Figure 3-10 Location of Screws Securing the Optics Assembly

Optical Bed Plate

ScrewsScrews


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40 AG11902 Rev. 5

3.6.5 Spinner Motor Replacement Procedure

When replacing the system optics with an assembly that does not contain a Spinner Motor,

the system Spinner Motor should be removed from the old optics and installed in the new

assembly.

3.6.5.1 Removing the Spinner Motor from the Old Assembly

1. Wear a static wrist-strap and ground it to the system as directed in Section 3.6.1.

2. Place the new optics assembly, scan lens down, on a clean, flat surface.

3. Remove the protective plastic cap from the spinner motor hole on the new optics assembly.

Figure 3-11 Spinner Motor

4. With a 5/32" Allen wrench, remove 3 mounting screws from around the Spinner Motor in

the old optics assembly. Support the motor with one hand to prevent it from falling out. Set

the screws and their washers and spacers aside carefully to replace later.

5. Carefully remove the Spinner Motor by lifting it straight out, being careful to not let the

mirror touch any part of the chassis.

3.6.5.2 Replacing the Spinner Motor in the New Assembly

NOTE: Do not touch the Spinner Motor Mirror for any reason.

1. Carefully guide the Spinner Motor straight into the housing.

2. Align the scribe mark on the edge of the Spinner Motor with the scribe mark on the hous-

ing.

3. Install and torque the three mounting screws with their washers and spacers to 15 in/lb.

4. Verify that the scribe marks still line up exactly.

Mirror

Motor body

Alignment scribe


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AG11902 Rev. 5 41

3.6.6 Optics Installation

Figure 3-12 High Speed Optics Assembly Installation Flowchart

5

AC24657

coax

supplied?

High Speed

Optics Assembly

Installation Flowchart

NOTE: Complete shaded blocks

only if necessary.

Begin

Yes

No Yes

No

6

Set Laser

Driver J6 A-B

7

Install shim

between pin

and channel on

side it was

taped

8

Install 4 screws

between pin

securing optics

to channel

9

Install scan

lens mask (if

removed)

10

Connect:

-Ground cable

-Ribbon cable

to laser driver

-Spinner cables

11

Perform spinner

motor encoder

cleaning

12

Remove laser

diode shunt

Yes

No

13

Firmware

V2.3.2 or

Higher?

Complete (warmup and calibrate)

Yes

No

17Firmware

V2.3.2 or

Higher?

18

Remove

AC24657 Coax

19Set Laser

Driver J6 A-B

20

Install shim

between pin

and channel on

side it was

taped

21

Install 4 screws

securing optics

to channel

15

Install cover

and turn on

power

16

Set front panel

/BEAMON to

RIBBON

CABLE P4

22

Install scan

lens mask (if

removed)

23

Connect:

-Ground cable

-Ribbon cable

to laser driver

-Spinner cables

24

Perform spinner

motor encoder

cleaning

33

Perform spinner

motor encoder

cleaning

25Remove laser

diode shunt

26

Install cover

27

AP24507

rev. E or

higher?28

Set Laser

Driver J6 B-C

29

Install shim

between pin

and channel onside it was

taped31

Install scan

lens mask (if

removed)

30

Install 4 screws

securing optics

to channel

32

Connect:

-Ground cable

-Ribbon cable

to laser driver

to laser driver

-Spinner cables

34

Remove laser

diode shunt

35

Install cover

and turn on

power

36

Set front panel

/BEAMON to

COAXIAL

CABLE P1

(Cal menu)

1

AP24680

Laser Driver?

2

Firmware

V 2.3.5 or

higher

?

Yes

Yes

No

3

Set J8 to

A-B

4

Set J8 to

B-C

No

14

Install cover


42/94

42 AG11902 Rev. 5

Refer to Figure 3 - 13.

1. Check the optics to see if an AP24680 laser driver board is installed. Note: AP24680 laser driver

boards are used on visible systems only.

If an AP24680 is installed, proceed with step 2.

If an AP246860 is not installed, proceed with step 5.

2. If the optics has an AP24680 installed, check the version of the firmware installed on the main con-troller board.

If the firmware version is V 2.3.5 or higher proceed with step 3. If the firmware version is lower

than V 2.3.5, proceed with step 4.

3. If the firmware version is V 2.3.5 or higher, set AP24680 J8 to A-B.

4. If the firmware version is lower than V 2.3.5, set AP24680 J8 to B-C.

5. Check the optics to see if they have been supplied with an AC24657 coax BEAMON cable attached

to P5 of the laser driver PCB. If the optics were not supplied with an AC24657, continue with step

7. If they were supplied with an AC24657, proceed with step 17.

6. If the laser driver is not supplied with an AC24657 coax BEAMON cable, set jumper J6 on the laser

driver board to the A-B position. Note: This position is hard-wired on the IR systems.

7. Install shim (if provided) between the reference pin and the optics channel. The shim is attached tothe optics assembly with cellophane tape and should be installed on the same side of the optics that

it is taped (e.g. a shim taped to the left side of the optics should be installed under the left reference

pin). Discard the tape. Ensure the reference pins are seated securely against the shim or optics chan-

nel.

IMPORTANT: Remove the old shims and replace them with the new shims that are shipped with

the new optics assembly. Using the old shims with the new optics assembly could

cause a System Error 2. Keep the old shims with the old optics.

Figure 3-13 Shim Locations

CAUTION

This is a generic pic-ture. Some detailsmay look differenton your machine.


PinPin

PossibleShim Location

Possible

Shim Location

2 Mounting Screws 2 Mounting Scre

(Do not adjust)(Do not adjust)

mask

2” (see text)


43/94

AG11902 Rev. 5 43


9. For IR systems if a scan lens mask was removed from the channel, replace it and tighten the 2

screws to secure.

10. For visible systems, if the scan lens mask was removed from the channel and the mask IS NOT a 2

inch mask (see Figure 3 - 13), replace it with the mask provided in the kit and tighten the two

screws to secure it.


12. Ground cable.

13. Ribbon cable to P1 of the Laser Driver Board.

14. Spinner cable to AP27231/AP28495 J3, Speedring PCB, if present.

15. Spinner cable to AP24507 P12, Main Controller PCB. (21K/32K systems.)

16. Spinner cable to AP999P2/AP24507 P15 main controller PCB (10.5K/16K systems).


18. Check the firmware version on the AP24507. If the version is lower than 2.3.2, proceed with step

14. If it is version 2.3.2 or higher, proceed with step 15.

19. You have finished the procedure. Replace the system’s cover (Section 3.4.2) and perform the sys-

tem warmup (Section 3.6.7) and calibration (Section 3.6.8) procedures.

20. Replace the system’s cover as described in Section 3.4.2 and turn the power on.

21. Enter the calibration menu by pressing the PREV and MENU front panel keys simultaneously.

Press the NEXT key until the /BEAMON PATH? menu is reached. Select RIBBON CABLE P4.

Press the NEXT key and save the settings. Proceed with system warmup and calibration.



23. If the optics assembly was supplied with an AC24657 coax BEAMON cable attached to P5 of the

laser driver PCB, check if the AP24507 firmware version is 2.3.2 or higher. If it is not version 2.3.2

or higher, proceed to step 18. If the firmware version is 2.3.2 or higher, proceed with step 26.

24. If the AP24507 firmware version is lower than 2.3.2, do not use the AC24657 coax BEAMON

cable. Remove the coax cable from P5 of the laser driver board.

25. Set jumper J6 on the laser driver board to the A-B position.

26. Install shim (if provided) between the reference pin and the optics channel. The shim is attached tothe optics assembly with cellophane tape and should be installed on the same side of the optics that


pin). Ensure the reference pins are seated securely against the shim or optics channel (Figure 3-13

on page 3 - 42). Discard the tape.



screws to secure.

29. For visible systems, if the scan lens mask was removed from the channel and the mask IS NOT a 2”

mask (see Figure 3 - 13), replace it with the mask provided in the kit and tighten the two screws to

secure it.


31. Ground cable.

32. Ribbon cable to P1 of the Laser Driver Board.

33. Spinner cable to AP27231/AP28495 J3, Speedring PCB, if present.

34. Spinner cable to AP24507 P12, Main Controller PCB. (21K/32K systems.)

35. Spinner cable to AP991/AP24507 P15 main controller PCB (10.5K/16K systems).


37. Replace the cover as described in Section 3.4.2 and verify operation.

You have finished the procedure. Replace the system’s cover (Section 3.4.2) and perform the sys-



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44 AG11902 Rev. 5

38. Check the revision of the AP24507 Main Controller Board. If the Rev. is lower than E, follow steps

18-24 for installation. If it is Rev. E or higher, continue with step 27.

39. Set jumper J6 on the laser driver board to the B-C position.

40. Install shim (if provided) between the reference pin and the optics channel. The shim is attached to

the optics assembly with cellophane tape and should be installed on the same side of the optics that


pin). Ensure the reference pins are seated securely against the shim or optics channel (Figure 3-13

on page 3 - 42). Discard the tape.41. Install the 4 screws (2 on each side) that hold the optics to the channel.


screws to secure.

For visible systems, if the scan lens mask was removed from the channel and the mask IS NOT a 2”

mask (see Figure 3 - 13), replace it with the mask provided in the kit and tighten the two screws to

secure it.


a. Ground cable.


c. Spinner cable to AP27231/AP28495 J3, Speedring PCB, if present.

d. Spinner cable to AP24507 P12 Main Controller PCB. (21K/32K systems.)

e. Spinner cable to AP999P2/AP24507 P15 main controller PCB (10.5K/16K systems.)

f. Coaxial cable to P1 of the AP24507 P1, Main Controller PCB.




46. Enter the calibration menu by pressing the PREV and MENU front panel keys simultaneously.

Press the NEXT key until the /BEAMON PATH? menu is reached. Select COAXIAL CABLE P1.

Press the NEXT key and save the settings. Proceed with system warmup and calibration.

3.6.7 System Warm-up

Now that the optics have been installed, the system must be warmed up to operating tem-

perature before calibration.

1. Ensure that the power cord is firmly attached to the system and that it is plugged into an appropriate

outlet, then turn on the system power.

2. Allow the system to warm up for at least 30 minutes before proceeding.

NOTE: If a System Error 2 occurs, power down, attach a wrist grounding strap, remove the cover, check the optics

assembly cable connections, and make sure the shunt is removed. Also ensure that the proper shims have

been installed. If the System Error 2 continues, contact ECRM Customer Service.

NOTE: If the first image output is blank, attach the wrist grounding strap, remove the cover, and make sure the

diode is not shunted.

3.6.8 Calibration

After a 30 minute warm-up period the system is ready to be calibrated for the new optics

assembly. Test pattern #4 will be used for calibration measurements. The Calibration

Menu will be used to adjust Image Centering, Pel Correction, and Line Correction.


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AG11902 Rev. 5 45

3.6.8.1 Set the System for Test Pattern #4

Use the keypad to access Test pattern #4 as follows:

1. Press MENU.

2. Press SELECT until “USER SETUP” appears on the bottom line.

3. Press NEXT. “INTERFACE MODE” should appear.

4. Press SELECT until bottom line reads “TEST PATTERNS”.

5. Press NEXT.

6. Press SELECT until “TEST PATTERN #4” appears.

7. Press NEXT key.

8. Set “EXPOSURE VALUE” to 210. This value may need to be adjusted depending on the

type of media used. If the test pattern is too light, increase the exposure. If the test pattern

is too dark, decrease the exposure.

9. Press NEXT key until “Save user” “Setup” is displayed.

10. Press NEXT.

3.6.8.2 Calibration Menu

The Calibration menu provides the service technician with procedures for calibrating the

Image Centering, Pel Correction and Line Correction. To enter the Calibration Menu,

from the Online or Offline window, press and hold the Prev Key and then press the Menu

Key. The Calibration Menu will appear. Refer to the Calibration Menu Map (Figure 3 -

14) for the following procedure.

When you enter values from the keypad, PREV and NEXT move the cursor left and right

respectively, and SELECT changes the value of a selected field.

NOTE: The calibration measurements in this document appear in metric units. In the System Setup menu, change

the measuring units to “Metric” before proceeding with the instructions in the following sections.

If necessary, change the units to Metric in the System Setup menu as follows:

1. At the “Online” prompt, press MENU to access the System Setup menu.

2. Press NEXT to view the “English/Metric” display, which is the first System Setup menu

option.

3. Press SELECT to enter “Metric”.

4. Keep pressing NEXT until the “Save System Setup?” prompt appears.

5. Press SELECT to enter “Yes”.

6. Press NEXT to exit the System Setup menu: “Online” appears in the display.

Remember to change the units back to English when you are finished working on the system.

NOTE: All values on the display screen appear in hundredths of a millimeter (.01mm), so that you can enter values

as whole integers without adding a decimal place. For example, a value of 27.35mm appears as 2735 on

the display.


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gure 3-14 Calibration Menu

30000

ONLINE/OFFLINE

IMAGE CENTERING

SHIFT RIGHT

IMAGE CENTERING

SHIFT LEFT

IMAGE CENTERING

VALUE IN 0.01 mmIMAGE CENTERING

VALUE IN 0.01 mm

SHIFT RIGHT

BY (0-4064):####

SHIFT LEFT

BY (0-4064):####

PEL CORRECTION

VALUE IN 0.01mm

EXPECTED VALUE

45000

ACTUAL VALUE

#####

LINE CORRECTION VALUE

IN 0.01mm

EXPECTED VALUE

60000

ACTUAL VALUE

#####

IGNORE SYSTEM ERRORS?

NO

IGNORE SYSTEM ERRORS?

YES

/BEAMON PATH?

COAXIAL CABLE P1

/BEAMON PATH?

RIBBON CABLE P4

LASER DIODE BIAS

% (0-100): 100

SAVE CALIBRATION SETUP?

NOSAVE CALIBRATION SETUP?

YES

ONLINE/OFFLINE

CALIBRATION DEFAULT VALUES IN METRIC

WINDOWS

Mako 36XX Mako 46XX

IMAGE CENTERING SHIFT RIGHT 762 4064

IMAGE CENTERING SHIFT LEFT 762 4064

PEL CORRECTION VALUE .. ..

EXPECTED VALUE 35000 45000

ACTUAL VALUE * *

LINE CORRECTION VALUE .. ..

EXPECTED VALUE 45000 60000

ACTUAL VALUE * *

USE SPOT DOUBLER .. ..

IGNORE SYSTEM ERRORS YES/NO YES/NO

SAVE CALIBRATION YES/NO YES/NO

*Actual values are calculated from the measured values when running test

patterns.

**Example values in the chart are for Mako 4650 only.

OTE: To access

he Calibration menu,

om the Online/

ffline window:

Press and hold the

REV key.

Then press the

MENU key.

he Image Centering

indow appears.

PREV

NEXT

SELECT

NEXT

SELECT

NEXT

NEXT

NEXT

NEXT

SELECT

SELECT

PREV

NEXT

NEXT

NEXT

NEXT

NEXT

NEXT

NEXT

NEXT

NEXT

NEXT


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3.6.8.3 Image Centering

Refer to the Calibration Menu Map (Figure 3 - 14) for the following procedure. When you enter

values from the keypad, PREV and NEXT move the cursor left and right respectively, and SELECT

changes the value of a selected field.

To set the image centering, output a test pattern and measure the distance from the edge of the test

pattern to the edge of the media.

1. Press the SELECT key to start test pattern #4. The system should display “Recording

Image”.

2. Wait 60 seconds and then press the STOP key.

3. Cut and process the image.

4. If the test pattern is cut off on the left or right side of the output, make an initial centering

adjustment as described below and output the test pattern again (make all measurements in

millimeters):

a. Calculate: X = ((Film Width - Expected grid width)/2) * 100

b. Measure: Y = existing margin*100.

c. Calculate: Y-X. This is the initial adjustment value.

d. See whether “Image Centering” is “Shift Left” or “Shift Right”.

e. Apply the initial value to the current “Image Centering” value.

For Example, if “Shift Left” is selected and the image is too far to the left, subtract

from the “Shift Left” value. If “Shift Right” is selected and the image is too far to the

left, add to the “Shift Right” value. See the example in Figure 3 - 15.

Figure 3-15 Example Values for Initial Centering Adjustment

NOTE: For a Mako 36 the film width is usually 355mm, and the grid width is usually 350mm. For a Mako 46 the

film width is usually 460mm, and the grid width is usually 450mm.

*Example values:Film width = 310mm

Expected grid width = 300mm

Existing margin = 20mm

X = ((310 - 300)/2) * 100 = 500

Y = 20 * 100 = 2000

Initial Correction = Y - X = 1500

Current centering value = “Shift Right” by “1900”.

This grid must shift right.

Make “Shift Right” value = “3400”.

(Note: If this example grid was off the film to the right, you

would set “Shift Right” value = “400”.)

Expected grid width

Existing margin

Emulsion Up

Trailing Edge


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This initial adjustment results in an image that appears entirely on the film and requires a

minimal adjustment to become perfectly centered. When the entire test pattern appears

between the left and right sides of the output, complete the following steps to center the

image.

5. Measure the distance between the left edge of the film and the left edge of the test pattern

in millimeters.

6. Measure the distance between the right side of the film and the right side of the test pattern

in millimeters.

7. Calculate the difference between these two values and divide by 2, then multiply by 100.

Apply any initial adjustment. This is the image centering value.

8. Use the calibration menu map in Figure 3 - 14 to access the current “Image Centering”

value.

9. Apply the image centering value to the current “Shift Left” or “Shift Right” value, as

required to center the grid on the film. For Example, if “Shift Left” is selected and the

image is too far to the left, subtract from the “Shift Left” value. If “Shift Right” is selected

and the image is too far to the left, add to the “Shift Right” value.

Figure 3-16 Adjusting Image Centering

10. Save the calibration setup as described on the menu map in Figure 3 - 14.

11. Output the test pattern and measure the image centering value again. If the new image cen-

tering value is greater than 1.0mm, repeat this procedure and add or subtract as needed the

correction value to the existing image centering value.

3.6.8.4 Pel Correction

Pel correction adjusts the width of the image. Using the centered output from Section 3.6.8.3, per-

form the following:

1. Measure the width of the test pattern 4 grid.

2. Calculate the error by finding the difference between the test pattern width and the

expected width of the test pattern (Figure 3 - 17). The pel correction value is the measured

error in millimeters, multiplied by 100.

3. Apply the pel correction value to the current “Pel Correction” “ACTUAL VALUE”.

Trailing edge,emulsion side up

Smaller distance Greater distance

greater distance - smaller distance

2* 100 + initial recorder setting = image centering value{ }

Image Centering Value (measurements in millimeters)


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AG11902 Rev. 5 49

If the grid is too narrow, subtract the pel correction value from the “ACTUAL VALUE”. If the grid is too

add the pel correction value to the “ACTUAL VALUE”

Figure 3-17 Pel Correction

3.6.8.5 Line Correction

Line correction adjusts the length of the image. Make sure the Pel correction is within specification before

adjusting the line correction.

1. Press the SELECT key to run test pattern 4. Wait until the test pattern is complete and the display no lo

indicates “RECORDING IMAGE”.

2. Calculate the error by finding the difference between the test pattern length and the expected length of

pattern (Figure 3 - 18). The line correction value is the measured error in millimeters, multiplied by 10

3. Apply the line correction value to the current “Line Correction” “ACTUAL VALUE”.

If the grid is shorter than the expected value, subtract the line correction value from the “ACTUAL VALU

the grid is longer than the expected value, add the line correction value to the “ACTUAL VALUE”.

Figure 3-18 Line Correction

Pel CorrectionACTUAL VALUE

Line CorrectionACTUAL VALUE


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3.6.8.6 Checking Perpendicularity

Optics shims are used to adjust the perpendicularity.

1. Press SELECT key to run test pattern 4. Wait until the test pattern is complete and

the display no longer indicates “RECORDING IMAGE”.

Figure 3-19 Adjusting Perpendicularity

2. Place the image on a flat surface, emulsion up with the trailer toward you.

3. Measure diagonally in both directions across the image.

4. Find the difference between the two measurements (long diagonal - short diago-

nal).

5. If the measurement is greater than 0.19mm use shims to raise the side of the

optics indicated in Figure 3 - 19, as described in Section 3.6.8.7.

Emulsion up! Emulsion up!

shim NON power supply side shim power supply side

trailer


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3.6.8.7 Installing Shims

Use a shim whose thickness equals the perpendicularity measurement difference, or use multiple shims whose

total thickness equals the perpendicularity measurement difference. Shims should only be required on one side

the optics.

1. See Section 3.6.3 for instructions on removing the imagesetter cover.

2. Use a 9/64 allen wrench (T-handle) to loosen the four screws on the optical bed plate, which

secure the optics assembly to the rail bracket of the imagesetter. Do not remove.3. Place the shim(s) between the pin of the optics assembly and the optics channel

Figure 3-20 Shim Placement

4. Tighten the four mounting screws on the optical bed plate.

5. Replace the cover onto the imagesetter as described in Section 3.4.2.

6. Output test pattern 4 again and recalculate the perpendicularity value. If the new perpendicu

ity value is greater than .19mm, repeat this procedure.

3.6.9 Output a Test Image

Now that the machine is calibrated, return the machine to the appropriate interface mode and output a

Test image.

1. Press MENU key.

2. Press SELECT until “User Setup” appears on the bottom line.

3. Press NEXT. “Interface Mode” should appear.

4. Select appropriate interface mode for the host (remote or serial).

5. Press STOP and save the setup.

6. Calibrate the system and output an image to verify the operation of the system.

CAUTION

This is a generic pic-ture. Some detailsmay look differenton your machine.


PinPin



2 Mounting Screws 2 Mounting Screws

(Do not adjust)

(Do not adjust)


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3.6.10 Package Returned Optics

The return optics must be properly packaged with all return information. Use packaging

from the new optics assembly.

1. Complete Optics Defect Tag and attach it to the return optics assembly. Complete all sections of the

tag.

2. Include a sample output from the system, illustrating the problem described on the defects tag.



3. Wear a wrist grounding strap as described in Section 3.6.1.

4. Make sure the laser diode of the return optics is shunted as described in Section 3.6.3.

5. Place return optics in the antistatic bag.

6. Place the return optics in the same packaging materials that held the new optics assembly. Include

any foam or other buffer material around the optics assembly.

7. Securely close all packaging.

8. Write the RMA number on the outside box containing the return optics assembly. Return optics

assemblies will not be accepted if the RMA number is not written on the outside box.9. Return the optics to ECRM.


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3.7 Replacing the Belts

3.7.1 Kapton Belt Drive

NOTE: Replacing either one of the belts or both, require the same procedure.

3.7.1.1 Removing Belts

1. Remove the cover. (See 3.4.1 Removing the Imagesetter Cover on page 3 - 26.)

2. Release three screws holding the drive motor bracket to the drive (Figure 3-21), and slide the whole motor

assembly up.

Figure 3-21 Kapton Drive Belts

3. Release 2 screws through the holes in the pulley and slide the whole assembly to the left.

4. Remove the slow belt first and the fast belt next, if necessary.

3.7.1.2 Replacing Belts

1. Replace the Fast belt first and the Slow belt last.

2. Tighten the slow belt to10 to 15 lbs by sliding the pulley assembly to the right and tightening the two screws

through the holes. Use belt tension gage AX0073 to verify tension.

3. Tighten the fast belt to 10 to 15 lbs by sliding the drive motor assembly down and tighten the three screws.Use belt tension gage AX0065 to verify tension.

Drive Motor Screws

Slow belt Pulley Assembly screw holes (2 places)

Screws (3 Places)

Fast belt


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4. Check that the slow belt is centered on the pulley. If necessary, slide the pulley on its shaft by releasing 4 set

screws and retighten in the centered position.

Figure 3-22 Kapton Belt Drive Tension Gauges (AX0073/AX0065)

5. Power up and run the drive motor. Press the PREV, NEXT, AND MENU buttons simultaneously to access

the “System Alignment” menu. Press SELECT for Belt Alignment, then press NEXT. The “Hit Advance

Start Film” window will be displayed. Press the ADVANCE key and the Drive motor will run until you press

the STOP key. This is done to check that the fast belt is centered on the large pulley. If necessary, adjustscrews while running until the belt is centered and stable.

6. Replace the cover when belt replacement is complete. (See 3.4.2 Replacing the Imagesetter Cover on page 3

- 27).

Fast Belt

Idler Pulley

Slow Belt

Screws behind these twoholes hold the idler pulleyin place

Belt gauge AX0073

The spring in the AX0065 ten-sion gauge sets the propertension for the belt.

The indent is visible whenthe tension is correct.


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3.8 Removing and Replacing the Drive Motor

3.8.1 Kapton Belt Drive Motor

3.8.1.1 Removing Belts

1. Remove cover (See 3.4.1 Removing the Imagesetter Cover on page 3 - 26).

2. Disconnect connector (P14) on the Main Controller board. Take the fast Belt, out of the way. Refer to

Figure 3-21 Kapton Drive Belts. Release 2 screws and slide the whole motor assembly to the left.

3. Remove 3 screws to the drive motor

Service Manual Mako Series

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