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MAKO

Reference Manual

RETURN

ECRM Imaging Systems


554 Clark Rd.
Tewksbury, MA 01876
Phone (978) 851-0207 Fax - (978) 851-7016 AG11902 Rev. 5
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 in
whole 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
1 Installation and Specifications .. 7
Pinch Roller Lever Installation on New Machines .. 7
Installation .. 7
Site Preparation .. 7
Customer Responsibilities .. 7
Environmental Requirements .. 8
Mako Series Specifications .. 10
SCSI Interface Specification (AG11510) .. 18

2 System Block Diagrams .. 19


Introduction .. 19
Description of Interlocks .. 22

3 Mako Series Replacement and Alignment Procedures .. 25


Introduction .. 25
Before you begin working on your imagesetter... .. 25
Wearing a Wrist Grounding Strap .. 26
Removing and Replacing the Imagesetter Cover .. 26
Removing the Imagesetter Cover .. 26
Replacing the Imagesetter Cover .. 27
Replacing the Front Cover Gas Shock .. 27
Replacing the Cover Sensor (DA0117) .. 28
Replacing the Mako Optics Assembly .. 29
Optics Removal .. 29
Spinner Motor Replacement Procedure .. 30
Removing the Spinner Motor from the Old Assembly .. 30
Replacing the Spinner Motor in the New Assembly .. 30
Air Bearing Optics Assembly Installation Flowchart .. 31
Packaging Returned Optics .. 34
Air Bearing Spinner Motor Optics Installation .. 35
Unpacking the Optics Assembly .. 36
Checking the Optics Assembly Temperature .. 37
Cover Removal .. 38
Optics Removal .. 39
Spinner Motor Replacement Procedure .. 40
Removing the Spinner Motor from the Old Assembly .. 40
Replacing the Spinner Motor in the New Assembly .. 40
Optics Installation .. 41
System Warm-up .. 44
Calibration .. 44
Set the System for Test Pattern #4 .. 45
Calibration Menu .. 45
Image Centering .. 47
Pel Correction .. 48
Line Correction .. 49
Checking Perpendicularity .. 50
Installing Shims .. 51

AG11902 Rev. 5 3
Output a Test Image .. 51
Package Returned Optics .. 52
Replacing the Belts .. 53
Kapton Belt Drive .. 53
Removing Belts .. 53
Replacing Belts .. 53
Removing and Replacing the Drive Motor .. 55
Kapton Belt Drive Motor .. 55
Removing Belts .. 55
Replacing Belts .. 55
Standard Belt Drive Motor .. 55
Removing Motor .. 55
Replacing Motor .. 55
Cutter Assembly Removal and Replacement .. 56
Adjusting the Start of Line (SOL) Laser Level .. 57
System Droop Adjustment Procedures .. 59
Adjusting for Droop or Reverse Droop Occurring Separately .. 59
Adjusting for Droop and Reverse Droop Occurring Together .. 59
Power Supply .. 60
Removal and Replacement Procedure .. 60
AC Mains, Input Module Check .. 61
Power Supply Adjustment Procedure .. 61
SCSI/PelBox Interface Board (AP9992P2) .. 63
Removal .. 63
Replacement .. 63
Main Controller Board (AP24507P3) .. 64
Control Panel Board (AP9981) .. 65
Capstan Assembly Removal and Replacement .. 66
Input Cassette Shelf Alignment Procedure .. 70
EPROM Replacement Procedure .. 71
Removing and Replacing the Drive Encoder .. 73
Removal Procedure .. 73
Installation Instructions .. 73

4 Calibration, Diagnostics, and System Alignment .. 75


Introduction .. 75
System Warm-up .. 75
Calibration Menu .. 75
Image Centering .. 77
Pel Correction .. 79
Line Correction .. 80
Perpendicularity .. 81
Checking Perpendicularity .. 81
Installing Shims .. 82
System Errors .. 83
/BEAMON Path .. 83
Bias Control .. 83
Diagnostics .. 84
Spinner Test (3600/4600 and 3625/4625 Systems (AKA Mako 36/46) .. 85
4 AG11902 Rev. 5
Spinner Test (3650, 3675, 4650, and 4675) Systems .. 86
Unwinding Film and Parking the Cutter .. 87
Test Patterns .. 87
System Alignment .. 89
Laser Alignment .. 89
Belt Alignment .. 90

AG11902 Rev. 5 5
6 AG11902 Rev. 5
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.

install
lever
here

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.

AG11902 Rev. 5 7
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 size
and 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.

8 AG11902 Rev. 5
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.

AG11902 Rev. 5 9
1.3 Mako Series Specifications
The Mako Series imagesetter and specifications appear below.

Figure 1-2. Mako Imagesetter

3600 / 3625 / 3650 / 3675 4600 / 4625 / 4650 / 4675


Mako
/ 36 / 36 High Speed / 46 / 46 High Speed

Scan Mode: Flat field, full width, laser diode raster scan.
(x-axis)

Media Transport Capstan roller, variable speed, DC motor drive, continuous feed
(y-axis):

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

10 AG11902 Rev. 5
3600 / 3625 / 3650 / 3675 4600 / 4625 / 4650 / 4675
Mako
/ 36 / 36 High Speed / 46 / 46 High Speed

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

Media-Infrared IR sensitive film (polyester base) or paper or *plate material - all 0.004"- 0.007"
thick.
*not available for 3625,
3675, 4625 or 4675 *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: Shaft # 2:


460mm (18.11”) 457mm (17.99)
450.85mm (17.75”) 440mm (17.32”)
416.4mm (16.38”) 430mm (16.93”)
406.4mm (16.00”) 420mm (16.54”)
400mm (15.75”) 379.98mm (14.96”)
390mm (15.35”) 330mm (12.99”)
369mm (14.52”) 317mm (12.48”)
355.6mm (14.00”)
338mm (13.31”)
310mm (12.20”)
300mm (11.80”)

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

AG11902 Rev. 5 11
3600 / 3625 / 3650 / 3675 4600 / 4625 / 4650 / 4675
Mako
/ 36 / 36 High Speed / 46 / 46 High Speed

RECORDING PERFORMANCE
Media Size: 355mm (14.0") max. (Performance 460mm (18.11") max. (Performance
specs are at all widths.) specs are at all widths.)

Exposure Width: Full width to expose the margins.

Image Size 355mm (14.0") max. width. Output 457.2mm (18.0") max. width. Output
length is limited to output cassette length is limited to output cassette
capacity. capacity.
At 2540, different resolutions will vary due to byte count.
IMAGE WIDTHS FOR OVERSCAN ON AND OFF.

Mako 3600/4600
Overscan
OFF ON

*18" 18.0 18.15

14" 14.0 14.17

12.2" 12.14 12.23

12" 12.01 12.17

*Mako 4600, 4625, 4650 and 4675 only

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

ACCURACY:
ENGLISH:
Resolution 2400/1200; 1800; and
Addressability: 1000 lpi

METRIC:
3556 (140 lpmm)
3048/1524 (120/60 lpmm)
2540/1270 (100/50 lpmm)
2032/1016 (80/40 lpmm)
1446 (57 lpmm)

12 AG11902 Rev. 5
3600 / 3625 / 3650 / 3675 4600 / 4625 / 4650 / 4675
Mako
/ 36 / 36 High Speed / 46 / 46 High Speed
Absolute English: ±.003” over English: ±.003” over
Dimensional 14" x 18". 18" x 24".
Accuracy Metric: ±.076 mm over Metric: ±.076 mm over
350 X 450 mm 450 X 600 mm

Repeatability: English: Within +.0012" over 4 con- English: Within +.0012" over 4 con-
secutive pages of 18" length. secutive pages of 24" length.
Metric: Within +.030mm over 4 con- Metric: Within +.030 mm over 4 con-
secutive pages of 450mm. secutive pages of 600mm.
Measurements are done with output Measurements are done with output
cassette initially empty and media cut cassette initially empty and media cut
after 4 images after 4 images.

Nominal Line Laydown Mako 3600/4600


Rates: 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.

AG11902 Rev. 5 13
3600 / 3625 / 3650 / 3675 4600 / 4625 / 4650 / 4675
Mako
/ 36 / 36 High Speed / 46 / 46 High Speed
Video Data Rates Mako 3600/4600 Mako 3650/4650

67.2 MHz @ 3556 dpi 119.3 MHz @ 3556 dpi


57.5 MHz @ 3048 dpi 114.4 MHz @ 3048 dpi
48.0 MHz @ 2540 dpi 96.0 MHz @ 2540 dpi
45.3 Mhz @ 2400 dpi 90.6 Mhz @ 2400 dpi
38.4 MHz @ 2032 dpi 76.8 MHz @ 2032 dpi
34.0 Mhz @ 1800 dpi 68.0 Mhz @ 1800 dpi
28.8 MHz @ 1524 dpi 57.6 MHz @ 1524 dpi
27.3 MHz @ 1446 dpi 54.6 MHz @ 1446 dpi
24.0 MHz @ 1270 dpi 48.0 MHz @ 1270 dpi
22.7 Mhz @ 1200 dpi 45.4 Mhz @ 1200 dpi
19.2 MHz @ 1016 dpi 38.4 MHz @ 1016 dpi
18.9 Mhz @ 1000 dpi 37.8 Mhz @ 1000 dpi

Mako 3625/4625 Mako 3675/4675


101.3 MHz @ 3556 dpi 119.2 MHz @ 3556 dpi
86.9 MHz @ 3048 dpi 119.0 MHz @ 3048 dpi
72.3 MHz @ 2540 dpi 118.7 MHz @ 2540 dpi
68.5 Mhz @ 2400 dpi 120.0 Mhz @ 2400 dpi
57.8 MHz @ 2032 dpi 115.8 MHz @ 2032 dpi
51.3 Mhz @ 1800 dpi 102.6 Mhz @ 1800 dpi
43.5 MHz @ 1524 dpi 86.9 MHz @ 1524 dpi
41.3 MHz @ 1446 dpi 82.4 MHz @ 1446 dpi
36.1 MHz @ 1270 dpi 72.4 MHz @ 1270 dpi
34.2 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

14 AG11902 Rev. 5
3600 / 3625 / 3650 / 3675 4600 / 4625 / 4650 / 4675
Mako
/ 36 / 36 High Speed / 46 / 46 High Speed
Throughput Speed: Mako 3600/4600 Mako 3650/4650

2.9” /min @ 3550 dpi 5.3” /min @ 3556 dpi


3.4” /min @ 3048 dpi 6.9” /min @ 3048 dpi
4.1" /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
8.3" /min @ 1270 dpi 16.6" /min @ 1270 dpi
8.7" /min @ 1200 dpi 17.4" /min @ 1200 dpi
10.3" /min @ 1016 dpi 20.6" /min @ 1016 dpi
10.5" /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 dpi
6.3" /min @ 2540 dpi 10.33" /min @ 2540 dpi
6.67" /min @ 2400 dpi 11.70" /min @ 2400 dpi
7.87" /min @ 2032 dpi 15.75" /min @ 2032 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
12.6" /min @ 1270 dpi 25.20" /min @ 1270 dpi
13.33" /min @ 1200 dpi 26.67" /min @ 1200 dpi
15.75" /min @ 1016 dpi 31.50" /min @ 1016 dpi
16.0" /min @ 1000 dpi 32.00" /min @ 1000 dpi

Fast Media Advance 35" per minute

AG11902 Rev. 5 15
3600 / 3625 / 3650 / 3675 4600 / 4625 / 4650 / 4675
Mako
/ 36 / 36 High Speed / 46 / 46 High Speed

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: 10mW, visible laser diode 670nm
Visible

Light Source: 15mW, I.R. laser diode 780nm


Infrared

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.

16 AG11902 Rev. 5
3600 / 3625 / 3650 / 3675 4600 / 4625 / 4650 / 4675
Mako
/ 36 / 36 High Speed / 46 / 46 High Speed
Storage: 0 to 130°F (-18 to 54° C) DELTA temp. not to exceed 25° per hour (14° C per
hour)

Relative humidity NOT over 65% with NO condensation.

SAFETY REGULATIONS:
CSA C22.2 No. 950-95
TÜV EN 60 950:95, EN 60825-1:1994
FCC VOL II, Part 15, Subpart J, Class A
DOC CRC c.1374
EMC EN55022:1994 Class A, EN50082-1:1992

AG11902 Rev. 5 17
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).

18 AG11902 Rev. 5
2 System Block Diagrams

2.1 Introduction
Power Interlocks
Supply
Index (7)
Encoder

Sensors/
Switches Main Controller Board (1)

Control
Laser Driver Board (2) Panel
Turns on the Diode
(This causes exposure
of PEL (or picture ele-
ment))

Film Laser Diode Feedback


Drive Detector

Encoder (6) Scan Deflector (3)


Lens (deflects the beam
across the media)

Spinner
Optics Motor
Capstan Roller Assy (4)
(Advances film or
photographic paper)
Encoder
Index (7)

Spinner (5)
Controller
Board
Indicates Path of AP27231
Laser Beam
PhaseCLK

Notes:
1 Mako = AP24507P3 5 Mako models ONLY
2 Mako (visible) 24680/24525 6 Not in VR30 (AKA Sunfish)
Mako (IR) 24501/24503 7 Used in place of SOL Sensor in Mako models
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

AG11902 Rev. 5 19
SLOW
START

EXPOSURE
8 BITS
/LASERENB
/BEAMON EXPOSURE BIAS
SERVO CIRCUIT /FINDSOL
/LASERCAL

LASER DIODE

Figure 2-2 Laser Driver Block Diagram

20 AG11902 Rev. 5
SOL (2)
AMP

EEPROM CPU EPROM ADDRESS FILM SPINNER (1)


RAM DECODING DRIVE DRIVER

CONTROL ADDRESS
PANEL
INTERFACE DATA
CONTROL CUTTER
REGISTERS DRIVER
STATUS

SCSI/
PELBOX LINE SYSTEM
INTERFACE BUFFER TIMING
NOTES:

1. Mako 3650/4650 models use


AP27231 spinner controller board. Mako
3675/4675 (AKA Mako 36/46 with High
Speed Option) use AP28415 Spinner
Controller.
LASER DRIVER
BOARD 2. Index Pulse used in Mako 3650/4650
models. Also Mako 3675/4675 (AKA
Mako 36/46 with High Speed Option).

Figure 2-3 Main Control Board Block Diagram

AG11902 Rev. 5 21
S1A *S1A
+24 Volts
Power
Supply
Controller Cutter
Board Motor

S1B S2 *S3B

+24 Volts +24 Volts

Laser
Driver Spinner
Controller
Board

Laser
Spinner
Motor

CUTTER
CUTENABLE Cutter Motor Cutter
/DOOR OPEN Drive Circuit Motor

Part of Controller Board circuits

Figure 2-4 Interlock Description

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

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

22 AG11902 Rev. 5
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
motors except the spinner motor. Exception is that film drive motor is allowed to operate by pressing momentary button on
control panel.

AG11902 Rev. 5 23
24 AG11902 Rev. 5
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 on
previously 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...

CAUTION
RECORDER CONTAINS
STATIC SENSITIVE COMPONENTS

!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 a
grounded 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.

AG11902 Rev. 5 25
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 Cover


Before 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.

Side Views

NOTE: These pictures


depict two different
optics assemblies.
Verify your optics
Shunt assembly before
proceeding.

Shunt

Shunted

Unshunted
Remove Install
(Unshunted) (Shunted)

Unshunted

Figure 3-1 Laser Diode Shunt Locations

26 AG11902 Rev. 5
3.4.2 Replacing the Imagesetter Cover
1. 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, use
the 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 lever
and 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.

Use a screwdriver to pop off the


gas shock from the pins that
Top Cover
hold it to the imagesetter’s
cover and chassis.

Gas Shock

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.)

AG11902 Rev. 5 27
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.

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.)
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.

Wire Connector

Top Cover

Mounting Screws

Figure 3-3 Cover Sensor

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

28 AG11902 Rev. 5
3.5 Replacing the Mako Optics Assembly

3.5.1 Optics Removal


With the cover removed, the power turned off, and the diode shunt installed, the optics may be removed from the sys-
tem.

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


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.

Optical Bed Plate

Screws Screws

Figure 3-4 Location of Screws Securing the Optics Assembly

AG11902 Rev. 5 29
3.5.2 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.

3.5.2.1 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.

Motor body

Mirror
Alignment scribe*

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.

30 AG11902 Rev. 5
3.5.3 Air Bearing Optics Assembly Installation Flowchart
Air Bearing
Begin Optics Assembly
Installation Flowchart
AC24657 Yes
coax
supplied?
AP24680 No
Laser Driver
? No Firmware Yes
V2.3.2 or
Yes Set Laser Higher?
Driver J6 A-B
No AP24507 Yes
Firmware No
rev. E or
V 2.3.5 or Set J8 to higher?
B-C Install shim
higher
between pin
? Set Laser
and channel on
No Driver J6 B-C
Yes side it was
taped
Remove
Set J8 to AC24657 Coax
A-B Install shim
between pin
Install 4 screws and channel on
between pin side it was
Set Laser
securing optics taped
Driver J6 A-B Install scan
to channel
lens mask (if
removed)

Install shim Install 4 screws


Install scan
between pin securing optics
lens mask (if
and channel on to channel Connect:
removed)
side it was -Ground cable
taped -Ribbon cable
to laser driver
Connect: Install scan to laser driver
-Ground cable lens mask (if -Spinner cable
-Ribbon cable Install 4 screws removed) to AP27231
to laser driver securing optics -Spinner cable
-Spinner cable to channel to AP24507
to AP27231 -Coax cable to
-Spinner cable AP24507 P1
Connect:
to AP24507
-Ground cable
-Ribbon cable
to laser driver
-Spinner cable
to AP27231 Remove laser
-Spinner cable diode shunt
Remove laser to AP24507
diode shunt

Install cover
Install cover
and turn on
and turn on
Firmware Yes power
power
V2.3.2 or
Higher? Remove laser
diode shunt
Set front panel
No Set front panel /BEAMON to
/BEAMON to COAXIAL
RIBBON CABLE P1
Install cover Install cover
CABLE P4 (Cal menu)

Complete (warmup and calibrate)

Figure 3-6 Air Bearing Optics Assembly Installation Flowchart

AG11902 Rev. 5 31
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.

Pin Pin
Possible Possible
Shim Location Shim Location

2 Mounting Screws This is a generic picture. 2 Mounting Screws


Some details may look
different on your ma-
chine. (Do not adjust)
(Do not adjust) CAUTION

(Installed Optics Assembly Top View)


Figure 3-7 Shim Locations

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.

32 AG11902 Rev. 5
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 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.
21. Install the 4 screws (2 on each side) that hold the optics to the channel.
22. 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.
23. 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.
24. Remove the shunt from the diode on the laser diode board.
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.

AG11902 Rev. 5 33
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.
29. Install the 4 screws (2 on each side) that hold the optics to the channel.
30. 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.
31. 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.
e. Coaxial cable to P1 of the AP24507 P1, Main Controller PCB.
32. Remove the shunt from the diode on the laser diode board.
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.
35. Replace the system cover. (See 3.4.2 Replacing the Imagesetter Cover on page 3 - 27.)
36. Perform system warmup and calibration as described in Chapter 4 Calibration, Diagnostics, and System
Alignment.

3.5.4 Packaging Returned Optics


The 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 returned
optics 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.

34 AG11902 Rev. 5
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.

CAUTION
RECORDER CONTAINS
STATIC SENSITIVE COMPONENTS

!!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.
AG11902 Rev. 5 35
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 and
return 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.

36 AG11902 Rev. 5
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.

88 31
86 30
84 29
Temperature Strip 82 28
80 27
78 26
76 24
74 23
72 22
70 21
68 20
Optics
Assembly 66 19
64 18
62 17
60 16
58 14

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.

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.

AG11902 Rev. 5 37
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).

Side View

Shunt

Shunted

Unshunted

Unshunted

Figure 3-9 Shunt Location

38 AG11902 Rev. 5
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. Ensure
that 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.

Optical Bed Plate

Screws Screws

Figure 3-10 Location of Screws Securing the Optics Assembly

AG11902 Rev. 5 39
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.

Motor body

Mirror

Alignment scribe
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.

40 AG11902 Rev. 5
3.6.6 Optics Installation
High Speed
Begin Optics Assembly
5 Installation Flowchart
AC24657 Yes
coax
1 supplied? NOTE: Complete shaded blocks
AP24680 No only if necessary.
Laser Driver 17
? No Firmware Yes
6 V2.3.2 or
Yes Set Laser Higher?
Driver J6 A-B
27
2 No AP24507
No Yes
Firmware 4 rev. E or
Set J8 to 7
V 2.3.5 or higher?
B-C Install shim
higher 28
between pin
? Set Laser
and channel on
No Driver J6 B-C
Yes side it was
taped 18
3 Remove
Set J8 to AC24657 Coax 29
A-B Install shim
8 between pin
Install 4 screws and channel on
19
between pin side it was
Set Laser 31
securing optics taped
Driver J6 A-B Install scan
to channel
lens mask (if
removed)
20 30
9
Install shim Install 4 screws
Install scan
between pin securing optics
lens mask (if
and channel on to channel
removed)
side it was
32
taped
Connect:
22 -Ground cable
10 Install scan -Ribbon cable
Connect: 21 lens mask (if to laser driver
-Ground cable Install 4 screws removed) to laser driver
-Ribbon cable securing optics
-Spinner cables
to laser driver to channel
-Spinner cables

23
Connect:
-Ground cable 33
11
-Ribbon cable Perform spinner
Perform spinner
to laser driver motor encoder
motor encoder
-Spinner cables cleaning
cleaning

12 34
Remove laser Remove laser
diode shunt 24 diode shunt
Perform spinner
15
motor encoder
Install cover 35
13 cleaning
Yes and turn on Install cover
Firmware
power and turn on
V2.3.2 or 25
Higher? power
Remove laser
diode shunt
16 36
No
Set front panel Set front panel
/BEAMON to /BEAMON to
14 26
RIBBON COAXIAL
Install cover Install cover
CABLE P4 CABLE P1
(Cal menu)

Complete (warmup and calibrate)

Figure 3-12 High Speed Optics Assembly Installation Flowchart

AG11902 Rev. 5 41
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 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 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.
mask

Possible
Shim Location
Pin
Pin

Possible 2” (see text)


Shim Location

2 Mounting Screws 2 Mounting Screw


This is a generic pic-
ture. Some details
may look different
(Do not adjust)
on your machine. (Do not adjust)
CAUTION

(Installed Optics Assembly Top View)

Figure 3-13 Shim Locations

42 AG11902 Rev. 5
8. Install the 4 screws (2 on each side) that hold the optics to the channel.
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.
11. Connect the following cables:
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).
17. Remove the shunt from the diode on the laser diode board.
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.
22. 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.
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 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 3-13
on page 3 - 42). Discard the tape.
27. Install the 4 screws (2 on each side) that hold the optics to the channel.
28. For IR systems if a scan lens mask was removed from the channel, replace it and tighten the 2
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.
30. Connect the following cables:
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).
36. Remove the shunt from the diode on the laser diode board.
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-
tem warmup (Section 3.6.7) and calibration (Section 3.6.8) procedures.

AG11902 Rev. 5 43
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
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 3-13
on page 3 - 42). Discard the tape.
41. Install the 4 screws (2 on each side) that hold the optics to the channel.
42. 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 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.
43. Connect the following cables:
a. Ground cable.
b. Ribbon cable to P1 of the Laser Driver Board.
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.
44. Remove the shunt from the diode on the laser diode board.
45. 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.
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.

44 AG11902 Rev. 5
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.

AG11902 Rev. 5 45
ONLINE/OFFLINE
NOTE: To access
the Calibration menu,
SELECT
from the Online/ PREV IMAGE CENTERING IMAGE CENTERING
SHIFT RIGHT SHIFT LEFT
Offline window:
NEXT NEXT
1. Press and hold the IMAGE CENTERING IMAGE CENTERING
VALUE IN 0.01 mm
PREV key. VALUE IN 0.01 mm

2. Then press the SHIFT RIGHT SHIFT LEFT


BY (0-4064):#### BY (0-4064):####
MENU key.
NEXT NEXT

The Image Centering PEL CORRECTION


window appears. VALUE IN 0.01mm

CALIBRATION DEFAULT VALUES IN METRIC


PREV
EXPECTED VALUE WINDOWS
45000 Mako 36XX Mako 46XX
NEXT
IMAGE CENTERING SHIFT RIGHT 762 4064
ACTUAL VALUE IMAGE CENTERING SHIFT LEFT 762 4064
##### PEL CORRECTION VALUE .. ..
EXPECTED VALUE 35000 45000
NEXT ACTUAL VALUE * *
30000
LINE CORRECTION VALUE LINE CORRECTION VALUE .. ..
IN 0.01mm EXPECTED VALUE 45000 60000
ACTUAL VALUE * *
NEXT USE SPOT DOUBLER .. ..
IGNORE SYSTEM ERRORS YES/NO YES/NO
EXPECTED VALUE
SAVE CALIBRATION YES/NO YES/NO
60000

NEXT *Actual values are calculated from the measured values when running test
patterns.
ACTUAL VALUE **Example values in the chart are for Mako 4650 only.
#####

NEXT

IGNORE SYSTEM ERRORS? IGNORE SYSTEM ERRORS?


NO SELECT YES

NEXT NEXT

/BEAMON PATH? /BEAMON PATH?


COAXIAL CABLE P1 RIBBON CABLE P4
SELECT
NEXT
NEXT
LASER DIODE BIAS
% (0-100): 100

NEXT

SAVE CALIBRATION SETUP? SAVE CALIBRATION SETUP?


NO SELECT YES

NEXT NEXT

ONLINE/OFFLINE

Figure 3-14 Calibration Menu

46 AG11902 Rev. 5
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.

*Example values:
Film width = 310mm Existing margin
Expected grid width = 300mm
Existing margin = 20mm

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


Y = 20 * 100 = 2000
Initial Correction = Y - X = 1500
Emulsion Up
Current centering value = “Shift Right” by “1900”. Trailing Edge
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

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.

AG11902 Rev. 5 47
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.

Smaller distance Greater distance

Trailing edge,
emulsion side up

Image Centering Value (measurements in millimeters)

{
greater distance - smaller distance

2
} * 100 + initial recorder setting = image centering 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”.

48 AG11902 Rev. 5
If the grid is too narrow, subtract the pel correction value from the “ACTUAL VALUE”. If the grid is too wide,
add the pel correction value to the “ACTUAL VALUE”

Pel Correction
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 longer
indicates “RECORDING IMAGE”.
2. Calculate the error by finding the difference between the test pattern length and the expected length of the test
pattern (Figure 3 - 18). The line correction value is the measured error in millimeters, multiplied by 100.
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 VALUE”. If
the grid is longer than the expected value, add the line correction value to the “ACTUAL VALUE”.

Line Correction
ACTUAL VALUE

Figure 3-18 Line Correction

AG11902 Rev. 5 49
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”.

Emulsion up! Emulsion up!


trailer

shim NON power supply side shim power supply side

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.

50 AG11902 Rev. 5
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 of
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

Pin Pin

Possible Possible
Shim Location Shim Location

2 Mounting Screws 2 Mounting Screws


This is a generic pic-
ture. Some details
may look different
(Do not adjust) on your machine.
CAUTION
(Do not adjust)

(Installed Optics Assembly Top View)

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 perpendicular-
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.

AG11902 Rev. 5 51
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.

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.
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.

52 AG11902 Rev. 5
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.

Slow belt Fast belt Pulley Assembly screw holes (2 places)

Screws (3 Places) Drive Motor Screws

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.

AG11902 Rev. 5 53
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.

Slow Belt

The indent is visible when


the tension is correct.
Belt gauge AX0073

Idler Pulley Screws behind these two


holes hold the idler pulley
in place

The spring in the AX0065 ten-


sion gauge sets the proper
tension for the belt.

Fast Belt

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, adjust
screws 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).

54 AG11902 Rev. 5
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 bracket. Carefully remove motor with bracket.
4. Remove the four screws to the drive motor (Figure 3-21 Kapton Drive Belts). Remove the motor.

3.8.1.2 Replacing Belts


1. Replace with new motor. Reconnect P14 on the Main Controller board.
2. Refer to 3.7 Replacing the Belts on page 3 - 53 (Step 3 and Step 4) to tighten and align the Fast Belt.
3. Replace cover (See 3.4.2 Replacing the Imagesetter Cover on page 3 - 27.)

3.8.2 Standard Belt Drive Motor

3.8.2.1 Removing Motor


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 (See Figure 3-
22 Kapton Belt Drive Tension Gauges (AX0073/AX0065)). Release 2 screws and slide the whole motor
assembly to the left.
3. Remove 2 screws to the drive motor bracket. Carefully remove motor with bracket.
4. Remove the four screws to the drive motor. Remove the motor.

3.8.2.2 Replacing Motor


1. Replace with new motor. Reconnect P14 on the Main Controller board.
2. Refer to section Section 3.7.1.2 on page 3 - 53 to tighten and align the Fast Belt.
3. Replace cover (See 3.4.2 Replacing the Imagesetter Cover on page 3 - 27.)

AG11902 Rev. 5 55
3.9 Cutter Assembly Removal and Replacement
1. Remove the cover (Refer to 3.4.1 Removing the Imagesetter Cover on page 3 - 26).
2. Pull off the plastic cutter shield from the front of the cutter assembly. A hook-and-loop fastener strip holds
the cutter shield in place.
3. Disconnect the two sensor connectors (Figure 3-23).
4. Disconnect the two wires on the cutter motor.
5. Loosen (do not remove) the 4 screws in the cutter assembly.
6. Slide the cutter assembly to the left and pull it out of the system.
7. Install the new cutter assembly.
8. Tighten the 4 screws holding the cutter assembly in place.
9. Reconnect the sensor connectors to the cutter assembly.
10. Reconnect the two wires onto the cutter motor.
11. Attach the plastic cutter shield to the front of the cutter motor.
12. Replace the cover (Refer to 3.4.2 Replacing the Imagesetter Cover on page 3 - 27).

Screws (4 places)

Cutter Motor
Connectors

Sensor Connectors

Figure 3-23 Cutter Assembly

56 AG11902 Rev. 5
3.10 Adjusting the Start of Line (SOL) Laser Level
NOTE: Section 3.16 on page 3 - 66, step 8(c) describes the removal and replacement of the SOL detector.

CAUTION: The start of line adjustment for standard speed optics is performed at ECRM and should not be necessary in
the field. DO NOT ADJUST SOL unless you are installing a filter kit or changing the laser pre-bias.

This procedure applies only to Mako 3600, 3625, 4600, and 4625 systems (AKA Mako 36/46). There is no SOL adjustment for
Mako 3650, 3675, 4650 and 4675 systems (AKA Mako 36/46 with High Speed Option).

CAUTION: This procedure requires an oscilloscope. Adjusting SOL without an oscilloscope may damage the laser diode.

Required materials:

• Wrist grounding strap


• Oscilloscope
• HB0523 Tweeker, Large 3/32
The optics assembly must be at least 62°F (17°C) before you perform this procedure (See !WARNING! on page 9).

CAUTION: Failure to allow optics temperature to stabilize or machine to warm up may cause SYSTEM ERROR #2, jitter,
or displaced data in image.

1. Wear a wrist grounding strap (see Section 3.3)


2. Turn off power and remove cover (see Section 3.4.1).

NOTE: Do not install the Laser Diode Shunt..

3. Connect Channel #1 of the Oscilloscope to:


AP24507 - TP11
4. Connect Channel #2 of the Oscilloscope to:
AP24507 - TP12
5. Set scope sensitivity to 1V/DIV for both channels, time base to 2 microseconds/DIV, internal trigger to Channel #1, and
trigger on the positive edge.
6. Install media and output cassettes.
7. Defeat interlocks with SW0212 key.
8. Power on the system.
9. If a SYSTEM ERROR #2 is displayed, adjust Laser Driver pot R33 one revolution CCW and press PREV to restart.
10. Repeat step 6 until SYSTEM ERROR #2 is no longer displayed. If SYSTEM ERROR #2 cannot be cleared, the Laser
Diode may be defective. Make sure the diode is not shunted.
11. Leave system turned on and allow it to warm up for 30 minutes.
12. Under the USER SETUP menu, select TEST PATTERNS and select TEST PATTERN 0.
13. Press STOP. Machine responds SAVE SETUP YES/NO.
14. Press STOP. Machine responds OFFLINE.

AG11902 Rev. 5 57
15. Press SELECT to start Test Pattern 0. The machine responds RECORDING IMAGE / FILM COUNT n.n.

Channel #1

Channel #2

Figure 3-24 Channel Readings

16. Adjust laser Driver pot R33 until the peak voltage on Channel #1 is 4V +/- 0.1V for IR machines, and 2V+/-
0.1V for visible machines. See Figure 3-24. Never allow voltage on Channel #1 to exceed 10 V or damage
to the diode may occur.
17. Verify the presence of a pulse on Channel #2. See Figure 3-24.
18. Press STOP to terminate Test Pattern 0.
19. Turn power off.
20. Remove Oscilloscope leads.
21. Reinstall the cover.

58 AG11902 Rev. 5
3.11 System Droop Adjustment Procedures

3.11.1 Adjusting for Droop or Reverse Droop Occurring Separately


1. Allow the machine to be powered on for at least 30 minutes before making the following adjustments.
2. Run the standard droop test. For field use, run Test Pattern #2.
3. Ensure that you are properly grounded using the wrist strap. Power down the system.
4. Remove the top cover. Defeat the interlocks with SW0212. Power up the system.
5. If reverse droop is detected, rotate R41 CW one turn (Figure 3-25). If normal droop is present, rotate R41
one turn CCW.

50% tint

Normal Droop
50% tint

Reverse Droop

Figure 3-25 Droop Examples

6. Repeat steps 2 to 5 until the reverse droop or normal droop is at an acceptable level.
7. Power down the system, remove the interlocks, and replace the cover as described in 3.4.2 Replacing the
Imagesetter Cover on page 3 - 27.

3.11.2 Adjusting for Droop and Reverse Droop Occurring Together


NOTE: This procedure is performed at ECRM and should not be necessary in the field.

1. Power on the machine for at least 30 minutes before making the following adjustments.
2. Run the standard droop test (For field use, run TEST PATTERN #2.)
3. Ensure that you are appropriately grounded using the wrist strap.
4. Power down the system. Remove the top cover. Defeat the interlocks with SW0212. Power up the system.
5. Under the DIAGNOSTIC menu, set the machine to LASER ALIGNMENT.
6. Place positive probe of a DVM onto TP1. Place the ground probe on ground of the Laser Driver board.
7. Record the initial settings at TP1.
8. Adjust R43 CCW to increase the voltage at TP1 by 0.1 Volts.
9. Run the Droop Test Image.
10. Repeat steps 8 and 9 until the droop is at the acceptable. If you cannot get the droop to reach an acceptable
level call Customer Service.

AG11902 Rev. 5 59
3.12 Power Supply

3.12.1 Removal and Replacement Procedure


Remove and replace the power supply (PS0105) as follows:

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


2. Remove cover (See 3.4.1 Removing the Imagesetter Cover on page 3 - 26.). Unplug the AC cable from the
side of the power supply.

P25 Connector
(to AC21721 power for
SCSI/Pel Board)

P1 Connector P24 Connector


(to Controller Board) (to Interlock Cabling)

Figure 3-26 Power Supply Rear View

3. Install the laser diode shunt (See Figure 3-1 on page 26.)
4. Disconnect the P1 connector from the controller board.
5. Disconnect the P24 connector from the interlock cabling. If the system is a non- interlock system, save the
shorting plug for reinstallation on new power supply assembly.
6. Disconnect P25 from AC21721 SCSI/Pel power cable (If present).
7. Remove and set aside the 4 nuts from bottom of assembly (Figure 3-27).

4 Nuts
(At the base of the
power supply.)

Figure 3-27 Power Supply, Top View

8. Lift the power supply assembly out of the system.


9. Set the new power supply assembly in system.
10. Replace the 4 nuts.
11. Reconnect the P1 connector to the controller board.
12. Reconnect P24 to Interlock cable (on a non-interlock system, reinstall shorting plug to P24).

60 AG11902 Rev. 5
13. Reconnect P25 to AC21721, SCSI/Pel power cable (If present).
14. Plug in AC Cable. Remove the laser diode shunt.
15. Remove the laser diode shunt.
16. Replace cover. (See 3.4.2 Replacing the Imagesetter Cover on page 3 - 27.).

3.12.2 AC Mains, Input Module Check


1. Prior to powering the imagesetter, Use a DMM to check the following:
With the power switch off, there should be No continuity between any two terminals of the AC mains input.
2. Check for continuity between the ground terminal of the AC mains input and any exposed metal of the imag-
esetter Base Tray. There should be no more than 0.50Ω.
3. Turn the power switch on. There should be a high impedance between the Hot and Neutral terminals; mini-
mum of 700kΩ. Also, insure there is no continuity between the Ground terminal and either the Hot and Neu-
tral terminal.
4. Turn power switch off.

3.12.3 Power Supply Adjustment Procedure


Necessary tools: HB1425.

See Figure 3-28 for power supply adjustment locations. Specifications for each voltage are in Table 4-1.

Table 3-1: Voltage Specifications

Voltage P1 Connector Tolerance


+5BV PIN 1,2 +0.25V/-0V
+24V PIN 5 +1.2V

+15V PIN 7 +0.45V

-15V PIN 9 +0.45V

GND PIN 3, 4, 6, 8, 12

1. With the power supply installed and connected to the system, turn on the power.
2. Turn the rear adjustment POT until 5V is within the specified range.
3. Verify that 24V is within the specified range. If it is not, turn the rear adjustment POT until both 5V and 24V
are within the specified range.

NOTE: Turning the rear adjustment POT adjusts both 5V and 24V. After adjusting one it is necessary to check the
other to ensure that it is still within the range specified.

AG11902 Rev. 5 61
-15 Adjust
+15 Adjust

5 Volt/24 Volt Adjustment


(sets 5 volts located on
rear of power supply)

Figure 3-28 Power Supply Adjustments

4. Place the adjustment tool HB1425 through the lower hole on the side of the power supply and engage the
lower POT on the power supply PC board. Turn the adjustment POT until +15V is within the range specified.
5. Place the adjustment tool HB1425 through the upper hole on the side of the power supply and engage the
upper POT on the power supply PC board. Turn the adjustment POT until -15V is within the range specified.

62 AG11902 Rev. 5
3.13 SCSI/PelBox Interface Board (AP9992P2)
The following procedure describes the steps necessary to remove and replace the AP9992P2 SCSI/PelBox Interface
Board.

3.13.1 Removal
1. Wear a wrist grounding strap as explained on page 3 - 26.
2. Remove cover. (See 3.4.1 Removing the Imagesetter Cover on page 3 - 26.)
3. Install the laser diode shunt.
4. Remove main controller cable to AP9992P2-P2.
5. Remove PelBox cable to AP9992P2-P1.
6. Remove SCSI cable to AP9992P2-P3.
7. Remove power cable to AP9992P2-P6.
8. Remove the six screws securing the AP9992P2 to the standoffs and remove the board.

3.13.2 Replacement
1. Ensure that all necessary cabling, firmware, etc. is installed on the main controller board before installation
of the AP9992P2.
2. Place the AP9992P2 board on the standoffs with P1 and P2 toward the rear of the machine.
3. Connect main controller cable from AP24507-P3 to AP9992P2-P2.
4. Connect PelBox cable to AP9992P2-P1.
5. Connect SCSI cable to AP9992P2-P3.
6. Connect power cable from AP24507 P17 to AP9992P2-P6.
7. Remove laser diode shunt.
8. Install cover. (See 3.4.2 Replacing the Imagesetter Cover on page 3 - 27.).

AP9992 Board

Figure 3-29 AP9992 Board Location

AG11902 Rev. 5 63
3.14 Main Controller Board (AP24507P3)

CAUTION: Service Technicians should always wear a grounded static wrist strap prior to performing any
removal, replacement or alignment procedures.

1. Remove cover. (See 3.4.1 Removing the Imagesetter Cover on page 3 - 26).
2. Install laser Diode Shunt.
3. Remove AP9992 SCSI/PelBox Interface Board (Refer to 3.13 SCSI/PelBox Interface Board (AP9992P2) on
page 3 - 63).
4. Remove connector P4 from main controller board first. (This will reduce the possibility of static damage to
the laser diode.)
5. Remove the remaining connectors leaving P10 connector for last.
6. Remove and set aside the screws that fasten the board to the optics housing.
7. Noting the orientation of the board, lift and remove the main controller board from the PelBox.
8. If the three standoffs shown in Figure 3 - 30 exist, put black electrical tape over the three standoffs indicated
to prevent electrical shorts.

3 Standoffs

Figure 3-30 Standoff Location

NOTE: This type of controller is not used in the Mako series.

9. Use the screws removed in step 4 to install the new board.


10. Reconnect the P10 Power Supply connector first. Reconnect the rest of the connectors, reconnecting the P4
connector last.
11. Select the appropriate EPROMs and install in the U301 and U302 locations, as described in the EPROM
replacement procedure enclosed with the new controller board.
12. Remove laser diode shunt.
13. LCD Display Adjustment:
a. Power up the imagesetter

NOTE: If EPROM error is displayed, press Previous to restart.

b. Observe the control panel display and adjust R21 of the 9991 (R17 of the AP24507P3) for the best con-
trast with a minimal amount of black background.
c. Power down.
14. Replace cover. (See 3.4.2 Replacing the Imagesetter Cover on page 3 - 27.)

CAUTION: DO NOT REMOVE LASER DIODE SHORTING PLUG WITH POWER ON

64 AG11902 Rev. 5
3.15 Control Panel Board (AP9981)
1. Remove cover. (See 3.4.1 Removing the Imagesetter Cover on page 3 - 26.)
2. On visible laser systems remove the light shield
3. Unplug connector P1 and P2 from back of control panel board.
4. Remove 3 screws retaining control panel board in place.
5. Remove control panel board.
6. Place new control panel board, replace 3 screws.
7. Plug in connector P1 and P2 into back of control panel assembly.
8. Replace cover. (See 3.4.2 Replacing the Imagesetter Cover on page 3 - 27.)

NOTE: If the LCD display requires an intensity adjustment, refer to Section 3.14, step 13. LCD Display Adjust-
ment:

AG11902 Rev. 5 65
3.16 Capstan Assembly Removal and Replacement
1. Remove the cover. (See 3.4.1 Removing the Imagesetter Cover on page 3 - 26.)
2. Remove the screws connecting the cables to the cover, so the cover hangs fully open. This step makes it eas-
ier to perform the rest of the procedure.
3. Remove the cutter. (See Section 3.9 on page 3 - 56.)
4. Remove the input cassette shelf.
a. Remove the knob from the pinch roller handle.
b. Remove ground strap from the shelf to the chassis.
c. Use a marker to index the locations of the four screws retaining the input cassette shelf.
d. Remove the four screws locating the input cassette shelf on the drive roller assembly.
e. Remove the EOM senor connector from the EOM sensor assembly (on the underside of the input cas-
sette shelf) and remove the input cassette shelf from the imagesetter.
5. Loosen the drive motor:
a. Loosen the three screws on the drive motor bracket, but do not remove them.
b. Slide the motor up and loosen the Kapton belt. Let the Kapton belt and the drive motor hang loosely in
place.
6. Remove the belts and pulleys:
a. Vertically line up the two holes in the idler pulley and loosen the tension on the idler pulley by loosening
the two screws visible through the holes.

Drive pulley Black belt


Screws behind these
two holes hold the
idler pulley in place

Idler pulley

Motor bracket screws


Kapton belt

Bracket with motor

Figure 3-31 Capstan Assembly

b. Remove both belts.


c. Remove the screw and washer from the end of the idler pulley shaft.
d. Loosen the two hub set screws and remove the idler pulley and wave washer from its shaft. Save the
wave washer.
e. Remove the left and right laser shields from the drive assembly.
f. Remove the two screws securing the idler bearing with shaft and remove them from the drive.
g. Remove the four hub set screws that hold the drive pulley to the drive assembly and remove the drive
pulley. Two hub set screws are located on either side of the drive pulley.
7. Remove the drive motor:
a. Remove the drove motor cable from P14 of the controller board.

66 AG11902 Rev. 5
b. Remove the 3 screws holding the drive motor bracket to the drive.
c. Remove the drive motor and its attached bracket.
8. Remove the drive roller assembly.
a. Remove the ground strap from the drive roller assembly.
b. Remove the outside encoder connector P2 from the main controller board.
c. On standard speed systems, remove the bolt holding the SOL detector to the drive assembly and remove
the SOL detector (Figure 3-32). Note that the SOL detector is pushed against the side of the drive
assembly and must be replaced like this. (There is no SOL sensor on high speed systems.) Note that on
Mako 3600 systems the SOL detector is mounted to the right of other systems. It must be replaced by
using the Alignment block (FX0919) that is found in the tool kit. To replace the SOL on the Mako
3600s, place the SOL under the drive cross bar (Figure 3-33) and loosely attach it with the SOL detector
mounting screw. Then place the Alignment block (FX0919) under the drive cross bar and SOL, and
position it on the edge of the drive cross bar. Then tighten the SOL detector mounting screw until it is
firmly in place. Place the Alignment block in the tool box.

SOL detector pushed


against the side of the SOL detector mounting screw
drive while the mounting
screw is tightened.

Drive encoder ribbon cable

Figure 3-32 SOL Detector

Alignment Block SOL detector mounting screw

Drive encoder ribbon cable

Figure 3-33 SOL Detector for the Mako 3600 and Mako 3625 (AKA Mako 36)

d. Hold the drive assembly while you remove the four bolts that secure it onto the channel (two on top and
two in front). Hold the drive assembly while you remove the bolts so the assembly doesn’t fall out. Lift

AG11902 Rev. 5 67
the drive assembly out of the channel (Figure 3-34).

Remove these four bolts

Channel

Figure 3-34 Drive Assembly

9. Install the new drive roller assembly into the imagesetter:


a. Place the new drive into the channel and install the four mounting bolts very loosely, not tight enough to
grip the drive in any way. Make sure the drive contacts the channel evenly on the front and top.

Top Cross Bar

Mounting screws
(both sides)

Tighten these screws first

Figure 3-35 Drive Assembly and Channel

b. Carefully tighten the two front mounting bolts, making sure that the top cross bar does not lift off of the
channel.
c. Tighten the two top bolts securing the drive to the channel, ensuring that the drive does not show any
signs of warping. Note: If you experience any difficulty tightening the two top bolts, if they bind or if
the drive or any part of it visibly bends during the tightening, call ECRM Customer Service.
d. On standard speed systems, replace the SOL sensor assembly and the screw that holds it to the left side
of the drive assembly. (There is no SOL sensor assembly on high speed systems.)
e. Connect the outside encoder connector J2 to P2 of the Main Controller board.
f. Connect the ground strap to the drive roller assembly.
g. Take the four mounting bolts from the front of the old drive and install them onto the new drive. These
bolts hold the cutter assembly when you attach it in step 14.
10. Replace the drive motor:
a. Attach the drive motor and bracket to the drive and loosely insert the three screws that secure the
bracket.

68 AG11902 Rev. 5
b. Connect the drive motor cable to P14 of the main controller board.
11. Replace the pulleys:
a. Mount the idler bearing with shaft onto the new drive assembly and loosely install the two screws into it
(Figure 3-31).
b. Install the wave washer and then the idler pulley onto the idler pulley shaft. Align the shaft flats with the
two hub set screws on the idler pulley, while you push the idler pulley onto the shaft. Compress the
wave washer 2/3 to 3/4 and tighten the two hub set screws.
c. Install the screw and washer onto the end of the idler pulley shaft.
d. Install the drive pulley on the roller shaft of the new drive assembly. Set the drive pulley just clear of the
idler pulley, align the flats of the roller shaft with the hub set screws, and tighten the hub set screws.Two
hub set screws are located on either side of the drive pulley
e. Reinstall drive belts and align them per Section 3.7 on page 3 - 53.
12. Reinstall the laser shields on the left and right sides of the drive assembly.
13. Reinstall the input cassette shelf:
a. Place the input cassette shelf onto the system.
b. Attach the EOM sensor connector to the EOM assembly on the rear of the shelf.
c. Connect the four screws that hold the input cassette shelf to the drive roller assembly. Make sure the
four screws line up with the indexes you made in step 4c.
d. Connect the ground strap from the chassis to the input cassette shelf.
e. Attach the pinch roller handle knob.
f. For a Mako series imagesetter with a slotted input cassette shelf, align the shelf as described in section
3.17 Input Cassette Shelf Alignment Procedure on page 3 - 70.
14. Reinstall the cutter assembly. (Refer to the cutter replacement procedure Section 3.9 on page 3 - 56.)
15. Reconnect the cables to the left and right sides of the cover.
16. Replace the cover. (See 3.4.2 Replacing the Imagesetter Cover on page 3 - 27.)

AG11902 Rev. 5 69
3.17 Input Cassette Shelf Alignment Procedure
This procedure describes how to align the input cassette shelf on a Mako imagesetter with a slotted shelf. To align the
input cassette shelf, use two shelf alignment tools to make sure the input cassette shelf is straight before you tighten it,
as described below:

1. Remove the imagesetter cover. (See 3.4.1 Removing the Imagesetter Cover on page 3 - 26).
2. Remove the screws connecting the cables to the cover, so the cover hangs fully open. This step makes it eas-
ier to perform the rest of the procedure.
3. Remove the cutter. (See Section 3.9 on page 3 - 56.)
4. Remove the two top screws that hold the cutter assembly to the imagesetter.
5. Remove all four screws from the input cassette shelf.
6. Insert one shelf alignment tool (AX0094) on the left side of the cassette shelf so that its pin fits inside the
left-most reference slot on the cassette shelf. Make sure the left screw hole on the tool aligns with the top
screw hole on the film drive side plates.

Shelf alignment tool


AX0094
Align the hole in the shelf
Reference slot alignment tool with the
screw hole in the film drive
side plate

Film drive side plate

Figure 3-36 Inserting shelf alignment tools

7. Insert the other shelf alignment tool (AX0094) on the right side of the cassette shelf so that its pin fits in the
right-most reference slot on the cassette shelf. Make sure the right screw hole on the tool aligns with the top
screw hole on the film drive side plate.
8. Insert a cutter assembly screw into each of the shelf alignment tools, to secure them to the input cassette
shelf. As you tighten the shelf alignment tools in place the input cassette shelf becomes perfectly positioned
in the imagesetter.
9. Insert screws into the two accessible screw holes on the cassette shelf. Only the top screw holes are accessi-
ble because the lower holes are covered by the shelf alignment tools.
10. Remove the cutter assembly screws from the shelf alignment tools and remove the tools from the cassette
shelf.
11. Insert the two cutter assembly screws back into the top holes of the film drive side plates.
12. Insert the remaining two screws into the bottom holes of the input cassette shelf.
13. Replace the cutter. (See Section 3.9 on page 3 - 56.)
14. Replace the screws connecting the cables to the cover.
15. Replace the imagesetter cover. (See 3.4.1 Removing the Imagesetter Cover on page 3 - 26).

70 AG11902 Rev. 5
3.18 EPROM Replacement Procedure
This section describes how to change a Mako Series system EPROM.

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

1. Turn on the power to your imagesetter.


2. Refer to Section 4, Menu Operation, in the Mako Series Operator Guide, AG11792, for instructions on how
to use the Calibration menu, System Setup Menu, and User Setup menu. Record the current values for the
menu options listed below:

Table 3-2: Menu Selections to Verify

Calibration Menu System Setup Menu User Setup Menu


1. Image Centering (direction and 1. English/Metric 1. Interface Mode
value) 2. Media Type 2. Resolution
2. Pel Correction 3. Line Spacing 3. Media Width
3. Line Correction 4. Film Advance After Cut 4. Overscan
4. Spinner Type 5. Maximum Cassette Length 5. Counter Display
5. Ignore System Errors 6. Cut Trailer Length
6. BEAMON Path 7. Image Offset
8. Spinner Timeout

6. Turn OFF the power to your imagesetter.


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

CAUTION: Failure to wear a ground strap can result in damage to sensitive electronics in your imagesetter.
Do not attempt to complete this procedure without doing so.

Failure to install the laser diode shunt during this operation can result in damage to the laser diode.

8. Remove the AP9992 SCSI/PelBox Interface Board (Refer to Section 3.13 SCSI/PelBox Interface Board
(AP9992P2) on page 3 - 63.

AG11902 Rev. 5 71
9. Using an IC extractor tool, locate and remove the EPROM’s from their sockets on the Main Controller
Board. Table 1 lists the EPROM part number and Main Controller Board reference designator for each sys-
tem type.

Table 3-3: Mako Series EPROM Identification*

Imagesetter EPROM Part


PCB Part Number Reference
Series Number
Mako 3600 AP24507P3 U-302 JA1032
U-301 JA1033

Mako 3625 AP24507P3 U-302 JA1053


(AKA Mako 36) U-301 JA1033

Mako 3650 AP24507P3 U-302 JA1035


U-301 JA1037

Mako 3675 AP24507P3 U-302 JA1053


(AKA Mako 36 with High U-301 JA1037
Speed Option)

Mako 4600 AP24507P3 U-302 JA1032


U-301 JA1034

Mako 4625 AP24507P3 U-302 JA1053


(AKA Mako 46) U-301 JA1034

Mako 4650 AP24507P3 U-302 JA1035


U-301 JA1036

Mako 4675 AP24507P3 U-302 JA1053


(AKA Mako 46 with High U-301 JA1036
Speed Option)

* Language EPROM not included in older systems.

10. Install the Updated EPROM into the appropriate socket, paying close attention that the 'u' notch on the
replacement EPROM is aligned with the 'u' notch on printed circuit board mask.
11. Replace the AP9992 SCSI/PelBox Interface Board (Refer to 3.13 SCSI/PelBox Interface Board (AP9992P2)
on page 3 - 63).
12. Refer to Section 3.4.2 Replacing the Imagesetter Cover on page 3 - 27.
13. Upon power up, a message "EPROM ERROR #n Press PREV to continue" is displayed. (The imagesetter
system calibration and set-up data need to be reinitialized.) Press the PREV key to re-initialize the imageset-
ter.
14. Refer to Chapter 4 Calibration, Diagnostics, and System Alignment for instructions to access the Calibrating
menu. The EPROM Installation is Complete.

72 AG11902 Rev. 5
3.19 Removing and Replacing the Drive Encoder
This section describes how to remove and replace the Drive Encoder.

3.19.1 Removal Procedure


1. Remove cover.
2. Loosen mounting hardware, do not remove.
3. Loosen setscrew in hub.
4. Pull centering slide to out position.
5. Remove mounting hardware.
6. Remove encoder.
7. Do not restore centering slide into encoder housing. This may result in damage to encoder disk.

3.19.2 Installation Instructions

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

Set up the unit as follows before beginning installation.

1. Verify that the unit is set up as follows prior to beginning installation.

CAUTION: Static precautions must be observed during this entire procedure.

• With two fingers, front and back, rotate Hub until setscrew aligns with slot in PC board. This
allows the allen wrench to fit into the setscrew without touching the PC board. (Slide lock
mechanism needs to be pushed in slightly, but not all the way, to allow hub to rotate freely.)
• Pull Slide Lock Mechanism out to fully extended position to lock the Hub in the correct posi-
tion. Refer to Figure 2.

Slide Lock pull out


mechanism
setscrew
mounting holes (2)
slot

setscrew to slot
alignment

PC board

Hub

Figure 3-37 Hub Position

AG11902 Rev. 5 73
2. Verify encoder mount FA21415 is Rev 2 or later (Figure 3-38). Change the encoder mount assembly
(AO21572) if necessary.

.65 to .74 Max for Non-thru Shaft


If the Encoder Mount looks like this,
.75 min for Thru Shaft
install a new Encoder Mount Assembly

3/8

Encoder Mount
(FA21415)

Figure 3-38 Checking the Encoder Mount

3. Align Hub with Shaft and gently push Hub onto Shaft until Encoder is resting on mounting surface. Push on
Hub only, not on the PC board or the Encoder Body.
4. Align Encoder with threaded holes and install mounting hardware.
5. Maintain pressure on Hub to insure it is seated in centering mechanism and secure Hub to Shaft by rotating
setscrew clockwise, using long leg of allen wrench, until setscrew makes contact with Shaft. Note: The flat
on the shaft must be lined up with the set screw in the hub before tightening.
6. Note the position of the short leg of the allen wrench and rotate an additional 1/4 turn clockwise to apply
approximately 20 oz-in torque.
7. Push Slide Lock Mechanism in completely.
8. INSPECTION: Verify that a gap exists between the disk and the mask by inserting a .010” plastic shim in
gap on the underside of the PC board (see Figure 3). Rotate roller slowly one revolution, gently moving
.010” shim (or equivalent) to verify no binding exists. If a .010” minimum gap does not exist, remove and re-
install the Encoder.

CAUTION: Do not rotate roller without first verifying the gap between mask and disk. Any disk contact with
mask may result in disk/mask damage and encoder replacement.

9. Install Cover. If Cover has through-hole option, align mylar seal with Shaft and slide Cover over Encoder
body until the tabs on the base engage with the locking features in the cover. Care must be taken when
installing through-hole cover onto a stepped shaft.

Hub
PC board

disk
mask
base insert .010 shim
in this gap

Figure 3-39 Checking the Gap

74 AG11902 Rev. 5
4 Calibration, Diagnostics, and System
Alignment
4.1 Introduction
This section provides the menu maps for service calibration, diagnostics and system alignment. All calibration, diag-
nostics or system alignment procedures must be performed by a qualified technician.

4.2 System Warm-up


The system must be warmed up to operating temperature before calibration.

1. Ensure that the power cord is firmly attached to the system and 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.

4.3 Calibration Menu


The Calibration menu (see Figure 4-1) allows service technicians to calibrate 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 appears. Refer to the Calibration Menu Map (Figure 4-1)
for the following procedures.

When you enter values with the keypad, PREV and NEXT move the cursor left and right respectively, and SELECT
changes the value of a selected field.

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.

AG11902 Rev. 5 75
Calibration Menu To access the Calibration menu, from the Online/Offline window:

1. Press and hold the PREV key.

ONLINE/OFFLINE
2. Then press the MENU key.

SELECT
PREV IMAGE CENTERING IMAGE CENTERING
SHIFT RIGHT SHIFT LEFT

NEXT NEXT
IMAGE CENTERING IMAGE CENTERING
VALUE IN 0.01 mm VALUE IN 0.01 mm

SHIFT RIGHT SHIFT LEFT


BY (0-762):#### BY (0-762):####

NEXT NEXT

PEL CORRECTION
VALUE IN 0.01mm

CALIBRATION DEFAULT VALUES IN METRIC


PREV
EXPECTED VALUE WINDOWS
(see table) Mako 36xx Mako 46xx
NEXT
IMAGE CENTERING SHIFT RIGHT 762 4064
ACTUAL VALUE IMAGE CENTERING SHIFT LEFT 762 4064
##### PEL CORRECTION VALUE .. .
EXPECTED VALUE 35000 45000
NEXT ACTUAL VALUE * *
LINE CORRECTION LINE CORRECTION VALUE .. ..
VALUE IN 0.01mm EXPECTED VALUE 45000 60000
ACTUAL VALUE * *
NEXT IGNORE SYSTEM ERRORS YES/NO YES/NO
SAVE CALIBRATION YES/NO YES/NO
EXPECTED VALUE
(see table)
*Actual values are calculated from the measured values when running test patterns.
NEXT
ACTUAL VALUE
#####

NEXT

IGNORE SYSTEM ERRORS? IGNORE SYSTEM ERRORS?


NO SELECT YES

NEXT NEXT

/BEAMON PATH? /BEAMON PATH?


COAXIAL CABLE P1 RIBBON CABLE P4
SELECT
NEXT
NEXT
LASER BIAS Level
% (0-100): 100

NEXT

SAVE CALIBRATION SETUP? SAVE CALIBRATION SETUP?


NO SELECT YES

NEXT NEXT

ONLINE/OFFLINE

Figure 4-1 Calibration Menu

76 AG11902 Rev. 5
4.3.1 Image Centering
Refer to the Calibration Menu Map (Figure 4-1) for the following procedure. When you enter val-
ues 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 4-2.

*Example values:
Film width = 310mm Existing margin
Expected grid width = 300mm
Existing margin = 20mm

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


Y = 20 * 100 = 2000
Initial Correction = Y - X = 1500
Emulsion Up
Current centering value = “Shift Right” by “1900”. Trailing Edge
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

Figure 4-2 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.

AG11902 Rev. 5 77
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 pat-
tern 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 4-1 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.

Smaller distance Greater distance

Trailing edge,
emulsion side up

Image Centering Value (measurements in millimeters)

{
greater distance - smaller distance

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

Figure 4-3 Adjusting Image Centering

10. Save the calibration setup as described on the menu map in Figure 4-1.
11. Output the test pattern and measure the image centering value again. If the new image
centering value is greater than 1.0mm, repeat this procedure and add or subtract as needed
the correction value to the existing image centering value.

78 AG11902 Rev. 5
4.3.2 Pel Correction
Pel correction adjusts the width of the image. Using the centered output from Section 4.3.1, perform 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 4-4). 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”.
If the grid is too narrow, subtract the pel correction value from the “ACTUAL VALUE”. If the grid is too
wide, add the pel correction value to the “ACTUAL VALUE”.

Pel Correction
ACTUAL VALUE

Figure 4-4 Pel Correction

AG11902 Rev. 5 79
4.3.3 Line Correction
Line correction adjusts the length of the image. Make sure the Pel correction is within specification before adjusting
the line correction.

NOTE: As of firmware release 2.3.5 there are two independent line corrections available: One for when 4mil
media type is selected from the System Setup menu and another for when 8mil media type is selected.

1. Press the SELECT key to run test pattern 4. Wait until the test pattern is complete and the display no longer
indicates “RECORDING IMAGE”.
2. Calculate the error by finding the difference between the test pattern length and the expected length of the
test pattern (Figure 4-5). The line correction value is the measured error in millimeters, multiplied by 100.
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
VALUE”. If the grid is longer than the expected value, add the line correction value to the “ACTUAL
VALUE”.

Line Correction
ACTUAL VALUE

Figure 4-5 Line Correction

80 AG11902 Rev. 5
4.3.4 Perpendicularity
Optics shims are used to adjust the perpendicularity.

4.3.4.1 Checking Perpendicularity


1. Press SELECT key to run test pattern 4. Wait until the test pattern is complete and the display no longer indi-
cates “RECORDING IMAGE”.

Emulsion up! Emulsion up!


trailer

shim NON power supply side shim power supply side

Figure 4-6 Adjusting Perpendicularity

2. Lay the film out with the emulsion up and the trailer toward you.
3. Measure diagonally in both directions across the image.
4. Find the difference between the two measurements (long diagonal - short diagonal).
5. If the measurement is greater than 0.19mm use shims to raise the side of the optics, as shown in Figure 4-6
and as explained in Section 4.3.4.2.

AG11902 Rev. 5 81
4.3.4.2 Installing Shims
If the perpendicularity measurement is greater than .19mm install the required shims as shown in Figure 4-6. Use a
shim whose thickness equals the perpendicularity measurement, or use multiple shims whose total thickness equals
the perpendicularity measurement. Shims should only be required on one side of 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

Pin Pin

Possible Possible
Shim Location Shim Location

2 Mounting Screws 2 Mounting Screws


This is a generic pic-
ture. Some details
may look different
(Do not adjust) on your machine.
CAUTION
(Do not adjust)

(Installed Optics Assembly Top View)

Figure 4-7 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 perpendicularity value is
greater than .19mm, repeat this procedure.

82 AG11902 Rev. 5
4.3.5 System Errors
1. Press and hold PREV and press MENU to access the Calibration menu.
2. Press NEXT until the Ignore System Errors? window appears.
3. Press SELECT to choose either No or Yes.

4.3.6 /BEAMON Path


The /BEAMON Path? window allows the selection of the correct /BEAMON path for the cable being used. Refer to
3.6.3 to identify the configuration.

NOTE: The factory setting needs to be changed only if the optics are changed. Only qualified service technicians
should change this default. An incorrect setting results in all black output.

1. Press and hold PREV and press MENU to access the Calibration menu.
2. Press NEXT until the /BEAMON Path? window appears.
3. Press SELECT to choose the correct /BEAMON cable selection for the system.

4.3.7 Bias Control


The Bias Control window controls the percent of maximum Laser Bias Level applied when imaging. The default
value is 100%. The percent value can be lowered to reduce background fog on sensitive media. This feature is only
available on systems having 2.3.5 firmware or above and AO24690/AO24691 optics assemblies. Refer to the calibra-
tion menu in Figure 4-1.

NOTE: This window has no effect unless used with the AP24680 Laser Driver Board.

1. Output an exposure sweep from the RIP.


2. Cut and process the image and check it for background fog. Background fog is a change in density between
the white area on the header before the exposure sweep and the area to the left of the exposure sweep.
3. If background fog is present reduce the bias percent as follows:
a. Hold down PREV and press Menu to access the Calibration menu.
b. Press PREV. The Laser Bias Level window appears. On Mako systems you can also access the Laser
Bias Level window with the System Setup menu, as described in the system’s Operator Guide.
c. Make the numerical selection as explained in 4.3 Calibration Menu on page 4 - 75. The amount of
adjustment necessary depends on the media type being used.
4. Repeat these steps until the exposure sweep appears without background fog.

NOTE: Reduce the bias only enough to eliminate the background fog. Overadjusting the bias may result in the loss
of vertical line width.

5. Linearize the imagesetter as described in the RIP Operator Guide.

AG11902 Rev. 5 83
4.4 Diagnostics
To access the Diagnostics menu from the ONLINE/OFFLINE prompt Press
MENU to access the Menu Options User Setup. Press SELECT to access the
MENU OPTIONS Menu Options System Setup. Keep pressing SELECT until Menu Options
DIAGNOSTICS Diagnostics appears.
NEXT

SELECT SELECT SELECT


DIAGNOSTICS DIAGNOSTICS DIAGNOSTICS DIAGNOSTICS
UNWIND FILM SPINNER TEST PARK CUTTER EPROM VERSION

NEXT NEXT NEXT


NEXT
STOP

HIT ADVANCE TO HIT SELECT TO START EPROM VERSION


UNWIND FILM AVERAGING JAxxxx x.x.x

Advance ABOUT 5 SECONDS


Pressed SELECT

ADVANCING MEDIA EPROM VERSION


UNWIND FILM AVERAGING
JAxxxx x.x.x
Advance ABOUT 5 SECONDS
Released ABOUT 40 SECONDS

AVERAGE VALUE =
######

NEXT

MINIMUM VALUE =
######

NEXT

MAXIMUM VALUE =
######

NEXT

VARIANCE TESTING
HIT STOP TO END

STOP

MINIMUM VALUE =
######

NEXT

MAXIMUM VALUE =
######

NEXT

VARIANCE = 0
#

NEXT *

SELECT SELECT TO REDO


*Variance increments from 0 to
STOP TO FINISH
11 as NEXT is pressed. After
STOP Variance=4, # should always = 0.

ONLINE/OFFLINE
NO CASSETTE

Figure 4-8 Diagnostic Menu


84 AG11902 Rev. 5
4.4.1 Spinner Test (3600/4600 and 3625/4625 Systems (AKA Mako 36/46)
This test runs the Spinner Motor while counting clock pulses from each Start Of Line (SOL) signal to the next SOL
signal. A running average of clock pulses is maintained and variations from this average are stored in counting loca-
tions in memory called “bins”. Each bin keeps a tally of how many variations from the average clock pulse count
occurred during the approximately 40 second test. There are eleven bins corresponding to variations from the average
of 0 (right on the average) to 11 (11 counts and higher above or below the average clock pulse count). If there were 5
occurrences of clock pulse counts that were 3 counts above or below the average, then bin 3 would contain a total of
5. During the test, the bin containing the tally of clock pulse counts that were 3 counts above or below the average is
reported as VARIANCE=3 0005 (the number of occurrences).

NOTES:
1) The spinner test is a diagnostic tool that is used to verify the existence of a faulty spinner motor. It can-
not be used to prove the quality of a good spinner motor.

2) Start-Of-Line signal must be within specifications prior to running this test.

3) This test is done for spinner motor speed fluctuation (jitter) only.

The following diagnostic aids the service technician in determining whether the average speed fluctuation of the
Spinner motor is within the range for acceptable output. This procedure must be performed by a qualified technician.

NOTE: This test is done for spinner motor speed fluctuation (jitter) only.

1. To access the DIAGNOSTICS MENU from the ONLINE?OFFLINE window perform the following steps:
Press Menu. Press SELECT until Menu Options Diagnostics appears. Press NEXT. Press SELECT until
Diagnostics Spinner Test appears.
2. Press NEXT. The PRESS SELECT TO START AVERAGING window will appear. Press SELECT again.
The AVERAGING window will appear. Wait a minimum of 15 minutes for the spinner motor to warm up.
Press the NEXT Key to start averaging the spinner. Approximately 40 seconds after you press NEXT, an
average will be displayed. (for example: AVERAGE VALUE=182670). This number represents the average-
period of a revolution (of the spinner) computed over a number of revolutions. When you press NEXT, the
MINIMUM VALUE=nnnnn is displayed. Press NEXT again and the MAXIMUM VALUE=nnnnn is dis-
played. The differences between the average and the minimum and the average and the maximum should be
+ 6.
3. Press NEXT again. VARIANCE TESTING STOP TO END window will be displayed. Press Stop. The
MAXIMUM VALUE will be displayed, then press NEXT and the MINIMUM VALUE will be displayed.
Then press NEXT.
Variance=0
####
will appear. Each time you press NEXT, the Variance will increase by 1.
Variance=1
####
Variance=2
####
up to ...
Variance>=11
####
4. The variance refers to speed variations of the spinner motor. Once the VARIANCE=7 window appears, the
number displayed should be 0. Press NEXT. The SELECT TO REDO AND STOP TO FINISH window is
displayed. Press SELECT to redo. From this point on, every time you press NEXT, the number displayed
should be 0. Press NEXT to STOP the Spinner Motor test. Run this test 4 more times, each time exiting the
SPINNER TEST menu.

AG11902 Rev. 5 85
NOTE: Failure to exit the test properly or using the REDO feature may cause erroneous results.

If numbers appear after VARIANCE=7 or above during the testing on any one of the 5 times that the Spinner Motor
test was run, this is not a problem, however if more than 1 Spinner Motor test shows Variance=7 or above, then con-
tact Customer Service.

To verify this, cycle machine power and repeat test. If jitter is no longer present, the spinner controller board may be
bad.

NOTE: Test Pattern #4 (Figure 4-9) should be used to determine jitter acceptability.

Run output with Test Pattern #4. The grid should meet the acceptance criteria. If unacceptable jitter appears
on the SOL side of the grid, the Spinner motor may need to be replaced.

.075mm Measure jitter here


Start-of-line side

Test Pattern #4

.05mm Trailer
Figure 4-9 Measuring Jitter Using Test Pattern # 4

4.4.2 Spinner Test (3650, 3675, 4650, and 4675) Systems


This test runs the Spinner Motor while counting clock pulses per revolution. A running average of clock pulses is
maintained and variations from this average are stored in counting locations in memory called “bins”. Each bin keeps
a tally of how many variations from the average clock pulse count occurred during the approximately 40 second test.
There are eleven bins corresponding to variations from the average of 0 (right on the average) to 11 (11 counts and
higher above or below the average clock pulse count). If there were 5 occurrences of clock pulse counts that were 3
counts above or below the average, then bin 3 would contain a total of 5. During the test, the bin containing the tally
of clock pulse counts that were 3 counts above or below the average is reported as VARIANCE=3 0005 (the number
of occurrences).

NOTES:
1) The spinner test is a diagnostic tool that is used to verify the existence of a faulty spinner motor. It can-
not be used to prove the quality of a good spinner motor.

2) This test is done for spinner motor speed fluctuation (jitter) only.

The following diagnostic aids the service technician in determining whether the average speed fluctuation of the
Spinner motor is within the range for acceptable output. This procedure must be performed by a qualified technician.

NOTE: This test is done for spinner motor speed fluctuation (jitter) only.

86 AG11902 Rev. 5
1. To access the DIAGNOSTICS MENU from the ONLINE?OFFLINE window perform the following steps:
Press Menu. Press SELECT until Menu Options Diagnostics appears. Press NEXT. Press SELECT until
Diagnostics Spinner Test appears.
2. Press NEXT. The PRESS SELECT TO START AVERAGING window will appear. Press SELECT again.
The AVERAGING window will appear. Wait a minimum of 15 minutes for the spinner motor to warm up.
Press the NEXT Key to start averaging the spinner. Approximately 40 seconds after you press NEXT, an
average will be displayed. (for example: AVERAGE VALUE=182670). This number represents the average-
period of a revolution (of the spinner) computed over a number of revolutions. When you press NEXT, the
MINIMUM VALUE=nnnnn is displayed. Press NEXT again and the MAXIMUM VALUE=nnnnn is dis-
played. The differences between the average and the minimum and the average and the maximum should be
+ 1.
3. Press NEXT again. VARIANCE TESTING STOP TO END window will be displayed. Press Stop. The
MAXIMUM VALUE will be displayed, then press NEXT and the MINIMUM VALUE will be displayed.
Then press NEXT.
Variance=0
####
will appear. Each time you press NEXT, the Variance will increase by 1.
Variance=1
####
Variance=2
####
up to ...
Variance>=11
####
4. The variance refers to speed variations of the spinner motor. Once the VARIANCE=2 window appears, the
number displayed should be 0. Press NEXT. The SELECT TO REDO AND STOP TO FINISH window is
displayed. Press SELECT to redo. From this point on, every time you press NEXT, the number displayed
should be 0. Press NEXT to STOP the Spinner Motor test. Run this test 4 more times, each time exiting the
SPINNER TEST menu.

NOTE: Failure to exit the test properly or using the REDO feature may cause erroneous results.

If numbers appear after VARIANCE=2 or above during the testing on any one of the 5 times that the Spinner Motor
test was run, this is not a problem, however if more than 1 Spinner Motor test shows VARIANCE=2 or above, then
contact Customer Service.

To verify this, cycle machine power and repeat test. If jitter is no longer present, the spinner controller board may be
bad.

NOTE: Test Pattern #4 (Figure 4-9) should be used to determine jitter acceptability.

Run output with Test Pattern #4. The grid should meet the acceptance criteria. If unacceptable jitter appears
on the Start Of Line side of the grid, the Spinner motor may need to be replaced.

4.4.3 Unwinding Film and Parking the Cutter


Unwind Film and Park Cutter procedures are found in Section 4.3 Installing Media of Mako systems: Mako Series
Operator Guide, AG11792

4.4.4 Test Patterns


To access the offline test patterns on the PelBox system, go to the Test Patterns window:

1. Press the Menu Button. Select Menu Options USER SETUP. Then Press NEXT. The Interface mode window
appears. Press SELECT until INTERFACE MODE TEST PATTERNS appears.

AG11902 Rev. 5 87
2. Press NEXT then SELECT to access the Test Patterns 0, 1, 2, 3 and 4. Choose the desired Test Pattern:

NOTE: If you run the Test Patterns with OVERSCAN on, the grid pattern may show a line down the side at the
beginning of the image.

Pattern #0 outputs the following:


A repeating 1 line pattern of white/black in successive 1/4th image widths. (This pattern does not start the
film drive motor.)
Pattern #1 outputs the following:
A repeating 2 line pattern with:
line 1 - the first 2/3rds black, then the last 1/3rd a pattern of four pels on/four pels off.
line 2 - the first 2/3rds white, then the last 1/3rd a pattern of four pels on/four pels off.
Pattern #2 outputs the following:
A repeating pattern which gives a series of black or white horizontal bars across 3/4ths of the line. The last
1/4th of each bar is a 50% checkerboard with a square dot dimension of 8 pels. Each horizontal bar is
repeated for 1/2 inch.
Pattern #3 outputs the following:
A 50% square dot (checkerboard) patterns. The dot's dimension is:
8 pels/lines for resolution <1016 dpi.
16 pels/lines for resolutions, 1016 <= pel resolution <=1800dpi. 32 pels/lines for resolutions, 1800
<= pel resolution <=2540dpi.
Pattern #4 outputs the following:
This generates a grid that can be used to size the machine. The test pattern is run at 2540dpi with Overscan
on, widest media width possible. It generates 25mm x 25mm grid covering an area that is model specific:
Mako 36xx = 350mm x 350mm
Mako 46xx = 450mm x 450mm
Grid size is firmware dependent.
To generate a Test Pattern, perform the following:

1. Select the desired Test Pattern #.


2. Press the NEXT Button. The Exposure window will appear. Press Stop. SAVE SETUP will appear. Select
SAVE SETUP YES. Press NEXT. The OFFLINE window will appear. Press the SELECT button. The Test
Pattern will start. For Test Pattern 4, the test Pattern continues to run until it stops automatically. All the
other Test Patterns run until you press the Stop Button.
3. After you press Stop, cut and process the output.
4. Repeat this process for any desired Test Pattern.

88 AG11902 Rev. 5
4.5 System Alignment
The Laser Alignment option (Figure 4-10) is used to test the exposure values (0-255) for the laser. The BELT
ALIGNMENT option is used to keep the motor running while adjusting the belt. After the adjustment has been made,
the motor can be shut off.

ONLINE/OFFLINE

To access the System Alignment Menu, from the Online/Offline window:


Hold down the PREV key.
Hold down the NEXT key.
Press the MENU key.
The System Alignment window appears.

SELECT
SYSTEM ALIGNMENT SYSTEM ALIGNMENT
LASER ALIGNMENT BELT ALIGNMENT

NEXT NEXT

ADVANCE
EXPOSURE HIT ADVANCE TO ADVANCING MEDIA
VALUE (0-255) START FILM FILM COUNT: XXX STOP
STOP STOP

ONLINE/OFFLINE

Figure 4-10 System Alignment Menu Map

4.5.1 Laser Alignment


The following procedure allows the service technician to look at a test point on the Laser Driver to verify that the
laser diode is functional. This procedure must be performed by a qualified technician.

1. From the ONLINE/OFFLINE window, press and hold the PREV Key, press and hold the NEXT key, then
press the Menu key. The System Alignment menu is displayed.
2. Press the NEXT key. The Exposure Value (0-255) ### window is displayed. Set the Exposure Value to 255.
Press NEXT until the cursor wraps around under the left most position to ensure the exposure is set (e.g.
255).
3. With a Digital Volt Meter, measure TP5 on the Laser Driver board. If the voltage is above 10VDC, the diode
needs to be replaced. Refer to Section 6 for optics assembly replacement.
4. Press the Stop key. You will be returned to the ONLINE/OFFLINE window.

AG11902 Rev. 5 89
4.5.2 Belt Alignment
1. From the ONLINE/OFFLINE window, press and hold the PREV key, press and hold the NEXT key, then
press the Menu key. SYSTEM ALIGNMENT LASER ALIGNMENT is displayed.
2. Press the SELECT key. The SYSTEM ALIGNMENT BELT ALIGNMENT window appears. Press NEXT.
Hit Advance to Start Film window is displayed. Press the ADVANCE button to start the motor. Adjust the
belt.
3. When the adjustment is complete. Press the Stop key twice. The motor will shut off. You will be returned to
the ONLINE/OFFLINE window.

90 AG11902 Rev. 5
A drive roller assembly .. 67
drive, Capstan .. 66
droop .. 59
AC24657 .. 32, 42
dust .. 8
accuracy .. 12
adjusting SOL .. 57
air quality .. 8
alignment, belt .. 90
E
alignment, laser .. 89 earth ground .. 9
antistatic bag .. 34, 52 electronic data .. 16
AP9981 board .. 65 electrostatic warning .. 25
assembly, cutter .. 56 emulsion types .. 11
encoder, drive .. 73

B English/metric .. 45
environmental requirements .. 8
EPROM replacement .. 71
BEAMON cable .. 32, 42
Error Two .. 44, 75
belt alignment .. 90
belt tension gage AX0065 .. 53
belt tension gage AX0073 .. 53
belt, standard .. 55
F
block diagrams .. 19 film unwinding .. 87
board control panel, AP9981 .. 65 firmware version .. 33, 43
floor requirements .. 8

C G
cable, BEAMON .. 32, 42
calibration .. 44 gage, belt tension AX0065 .. 53
Calibration menu .. 45, 75 gage, belt tension AX0073 .. 53
Capstan drive .. 66 gas shock .. 27
centering adjustment, initial .. 47, 77 grid, test pattern four .. 45
centering, image .. 47, 77 ground .. 9
channel readings .. 58 grounding .. 25, 26, 35
control panel board (AP9981) .. 65 grounding strap .. 35
correcting Line .. 49, 80
correcting Pel .. 48, 79
cover removal .. 38
H
cover sensor .. 28 heat dissipation .. 8
customer responsibilities .. 7
cutter assembly .. 56
cutter parking .. 87 I
Ignore System Errors .. 83
D image centering .. 47, 77
image, test .. 51
data, electronic .. 16 infrared media .. 11
data, optical .. 16 initial centering adjustment .. 47, 77
data, physical .. 16 installation .. 7, 9
defect tag .. 34 installing shims .. 51, 82
defects tag .. 36, 52 interface specification .. 18
Diagnostics menu .. 84 interlock description .. 22
dimensions .. 16
diode shunt locations .. 38
discharge, static .. 25, 26 J
discharging static .. 35 jitter .. 85, 86
display values .. 45, 75
drive encoder .. 73
drive motor .. 55 K
drive motor, Kapton belt .. 55
Kapton belt drive motor .. 55
drive motor, standard belt .. 55

AG11902 Rev. 5 91
L R
laser alignment .. 89 recording performance .. 12
laser diode .. 38 regulations, safety .. 17
laser diode damage .. 35, 37 release lever .. 7
laser driver block diagram .. 20 removing the cover .. 38
lighting .. 8 removing the optics .. 29, 39
Line correction .. 49, 80 replacing the spinner motor .. 30, 40
locating pins .. 32, 42 return optics .. 34, 52
lotion .. 36 RMA number .. 34, 52

M S
machine features .. 10 safety regulations .. 17
main control board block diagram .. 21 sample output .. 34, 52
maintenance procedures .. 25 sensor, cover .. 28
Mako specifications .. 10 shim placement .. 32, 42, 51, 82
material, packing .. 36 shims .. 50, 81
measuring values .. 45, 75 shock, gas .. 27
media types .. 11 shunt locations .. 26, 38
menu, Calibration .. 45, 75 shunt removal .. 27
metric units .. 45 site preparation .. 7
moisturizing lotion .. 36 SOL adjustment .. 57
motor, drive .. 55 specifications, interface .. 18
motor, spinner .. 85, 86 specifications, Mako .. 10
motor, standard belt .. 55 spinner motor .. 85, 86
spinner motor replacement .. 30, 40
O spinner test (standard) .. 85, 86
standard belt drive motor .. 55
offline test patterns .. 87 Start of Line adjustment .. 57
operating temperature .. 9 startup temperature .. 9
optical data .. 16 static bag .. 36
Optics Defect tag .. 34 static wrist strap .. 25, 26, 35
optics defect tag .. 52 system alignment .. 89
optics removal .. 29, 39 system block diagrams .. 19
optics returns .. 34, 52 System Error Two .. 44, 75
optics temperature .. 35, 37 system power .. 8
oscilloscope .. 57, 58 system warmup .. 44, 75
output, sample .. 34, 52
T
P tag, defects .. 36, 52
packing material .. 36 tag, Optics Defect .. 34
park cutter .. 87 temperature .. 35, 37
patterns test .. 87 temperature at startup .. 9
Pel correction .. 48, 79 temperature for operating .. 9
performance .. 12 tension gage, belt AX0065 .. 53
perpendicularity adjustment .. 50, 81 tension gage, belt AX0073 .. 53
physical data .. 16 test image .. 51
pinch roller .. 7 test pattern # four .. 45
power cord types .. 9 Test Pattern 0 (zero) .. 58
power requirements .. 16 test patterns, offline .. 87
power supply .. 60
power supply adjustment .. 61 U
units of measurement .. 45
unwind film .. 87

92 AG11902 Rev. 5
utility requirements .. 16

V
values, measuring .. 45, 75
version, firmware .. 33, 43
vibration .. 8
visible media .. 11
voltage specifications .. 61

W
warmup, system .. 44, 75
wrist grounding strap .. 25, 26, 35
wrist grounding strap connections .. 26, 38

AG11902 Rev. 5 93
94 AG11902 Rev. 5