AccuSet Service Manual

ABC Publication Number 580011-002

AccuSet
Service Manual

This document discloses subject matter in which

Agfa Division, Bayer Corporation. has proprietary
rights. Neither receipt nor possession thereof
confers or transfers any right to reproduce or disclose
the document any part thereof, any information
contained therein, or any physical article or
device, or to practice any method or process,
except by written permission from or written
agreement with Agfa Division, Bayer Corporation.

COPYRIGHT 1997
Agfa Division, Bayer Corporation.

Prepared by
Customer Documentation
200 Ballardvale Street
Wilmington, MA 01887

Printed in the U.S.A.

Trademarks
AGFA and the Agfa Rhombus are registered
trademarks of Agfa-Gevaert. AccuSet is a
trademark of Bayer Corporation.

Publication Number
580011-002
Table of Contents

TABLE OF CONTENTS

CHAPTER ONE: INSTALLATION

1.1 Product Overview ........................................................................................ 1-1

1.2 Laser Safety................................................................................................... 1-1
1.3 Technical Equipment Specifications ........................................................... 1-2
1.4 Installation Procedures ................................................................................ 1-3
1.4.1 Customer Pre-installation Responsibilities ........................................ 1-3
1.4.2 Pre-installation Checks....................................................................... 1-4
1.4.3 System Installation.............................................................................. 1-4
1.4.4 Customer Application Training.......................................................... 1-6

CHAPTER TWO: OPERATIONS

2.1 Introduction.................................................................................................. 2-1

2.2 About the User Guide.................................................................................. 2-1

CHAPTER THREE: FUNCTIONAL ANALYSIS

3.1 Introduction.................................................................................................. 3-1

3.2 Scanner (Spin Motor) Drive......................................................................... 3-1
3.3 Media Transport (or Leading) System......................................................... 3-3
3.3.1 Elements of Media Transport System ................................................ 3-3
3.3.2 Optical Encoder Signals..................................................................... 3-5
3.3.3 Block Diagrams of Take-up and Supply Servos............................... 3-6
3.3.4 Block Diagram of Capstan Servo ...................................................... 3-8
3.3.5 Page Length Correction ..................................................................... 3-9
3.3.6 Stop/Backup/Restart Operation ........................................................ 3-10
3.4 Pixel-Clock Phase-Lock Loop...................................................................... 3-11
3.5 Laser Diode Driver....................................................................................... 3-15
3.5.1 Characteristics of Laser Diode Module ............................................. 3-15
3.5.2 Laser-Diode Driver Circuit ................................................................. 3-16
3.5.3 Image Density Feedback Control Loop ............................................ 3-18
3.5.4 Protection of Laser Diode .................................................................. 3-19

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AccuSet Service Manual

CHAPTER FOUR: DIAGNOSTICS

4.1 Introduction.................................................................................................. 4-1

4.2 Modes of Operation..................................................................................... 4-1
4.3 Core Testing ................................................................................................. 4-3
4.3.1 ROM CRC............................................................................................ 4-3
4.3.2 8KB System Memory.......................................................................... 4-3
4.3.3 Interrupt Controller Register.............................................................. 4-3
4.3.4 80188 Internal Timer Register............................................................ 4-4
4.3.5 80188 Internal Timer 2 SYNC ............................................................ 4-4
4.3.6 80188 Internal Timer 0 and 1 ............................................................ 4-4
4.3.7 Invalid Op-Code................................................................................. 4-4
4.3.8 32K System Ram................................................................................. 4-4
4.3.9 8530 Serial Communication Controllers............................................ 4-4
4.3.10 Operator Control Panel Loopback .................................................. 4-5
4.3.11 Spin Motor Power Up Test .............................................................. 4-5
4.4 Sub-system Tests .......................................................................................... 4-6
4.4.1 128KB Flash EEPROM........................................................................ 4-6
4.4.2 32K Image Buffer Memory ................................................................ 4-6
4.4.3 Non-Volatile RAM ............................................................................... 4-6
4.4.4 SBR to Engine..................................................................................... 4-7
4.4.5 Index Frequency ................................................................................ 4-7
4.4.6 Encoder............................................................................................... 4-8
4.4.7 Leading and Tension Motors ............................................................. 4-8
4.4.8 Take-Up and Supply Motor Tests...................................................... 4-9
4.4.9 Filter Motor ......................................................................................... 4-10
4.4.10 Laser Driver Module......................................................................... 4-10
4.4.11 Video Feedback Test........................................................................ 4-11
4.5 Selectable Tests ............................................................................................ 4-11
4.5.1 CGEN Loopback Test......................................................................... 4-11
4.5.2 Power Cutter Test............................................................................... 4-12
4.6 Error Reporting............................................................................................. 4-13
4.6.1 NVRAM Error Log............................................................................... 4-13
4.6.2 Error/Status Messages ........................................................................ 4-16
4.7 System Wiring ............................................................................................. 4-21
4.7.1 System Interconnect Diagram............................................................ 4-22
4.7.2 Cabling and Connectors..................................................................... 4-23

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Table of Contents

CHAPTER FIVE: PUP

5.1 Module Overview ........................................................................................ 5-1

5.2 Constraints/Limitations................................................................................. 5-1
5.2.1 Constraints .......................................................................................... 5-1
5.2.2 Limitations .......................................................................................... 5-1
5.3 Functional Requirements ............................................................................. 5-2
5.3.1 Image Quality Test Patterns............................................................... 5-2
5.3.2 Alignment Routines ............................................................................ 5-2
5.3.3 Shared Code ....................................................................................... 5-2
5.4 User Interface Requirements ....................................................................... 5-2
5.4.1 Entering Commands........................................................................... 5-2
5.4.2 Keypad................................................................................................ 5-3
5.4.3 Invoking the PUP ............................................................................... 5-4
5.5 PUP Main Menu ........................................................................................... 5-5
5.5.1 Align.................................................................................................... 5-6
5.5.2 W Density ........................................................................................... 5-6
5.5.3 V-Lines ................................................................................................ 5-6
5.5.4 Load Params ....................................................................................... 5-7
5.5.5 Filter Mtr ............................................................................................. 5-7
5.5.6 Laser Diode......................................................................................... 5-8
5.5.7 Leading Mtr......................................................................................... 5-8
5.5.8 Spinner Mtr ......................................................................................... 5-8
5.5.9 Exit ...................................................................................................... 5-8
5.6 Patterns ......................................................................................................... 5-8
5.6.1 CF File................................................................................................. 5-8
5.6.2 Pat ....................................................................................................... 5-9
5.6.3 Resolution ........................................................................................... 5-9
5.6.4 No Media Load ................................................................................... 5-9
5.6.5 Burn-in Once...................................................................................... 5-9
5.6.6 B-List ................................................................................................... 5-9
5.6.7 Exit ...................................................................................................... 5-9

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AccuSet Service Manual

5.7 Params .......................................................................................................... 5-10

5.7.1 Exp. Start, Inc ..................................................................................... 5-10
5.7.2 Date..................................................................................................... 5-10
5.7.3 Set/Disp. Params ................................................................................ 5-10
5.7.4 F2C0P START...................................................................................... 5-10
5.7.4 Serial No. ............................................................................................ 5-14
5.8 Errs................................................................................................................ 5-14
5.8.1 Abort Imaging..................................................................................... 5-14
5.8.2 Display Errors ..................................................................................... 5-14
5.8.3 Clear Errors......................................................................................... 5-14
5.9 Pattern Description ...................................................................................... 5-14
5.9.1 Exposure............................................................................................. 5-15
5.9.2 HOR & VERT Rulings......................................................................... 5-15
5.9.3 Incremental Leading........................................................................... 5-15
5.9.4 Halftone Screens ................................................................................ 5-15
5.9.5 HOR & VERT Lines ............................................................................ 5-15
5.9.6 Vertical Modulation Transfer Function .............................................. 5-16
5.9.7 Horizontal Modulation Transfer Function......................................... 5-16
5.9.8 Fog Test .............................................................................................. 5-16
5.9.9 Checkerboard Squares ....................................................................... 5-16
5.9.10 Square Dots ...................................................................................... 5-16
5.9.11 One Inch Grid with Targets............................................................. 5-16
5.9.12 One Inch Grid with Patterns ........................................................... 5-17
5.10 Command File List ..................................................................................... 5-17
5.11 PAT Commands .......................................................................................... 5-19
5.12 PUP Pause Functions ................................................................................. 5-20

CHAPTER SIX: PROCEDURES

6.1 Introduction.................................................................................................. 6-1

6.2 Removal/Replacement Procedures ............................................................. 6-1
6.2.1 Front, Left and Right Cover ............................................................... 6-1
6.2.2 Rear Panel (Electronic Enclosure) ..................................................... 6-1
6.2.3 Top Cover Assembly .......................................................................... 6-2
6.2.4 Tensioner Assembly ........................................................................... 6-2
6.2.5 Tensioner Potentiometers/PCB.......................................................... 6-3

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Table of Contents

6.2.6 Driven Nip Roller/Door and Cutter Cover as Single Unit................ 6-5
6.2.7 Driven Nip Roller/Door Assembly .................................................... 6-5
6.2.8 Driver Nip Roller ................................................................................ 6-5
6.2.9 Take-Up Motor ................................................................................... 6-6
6.2.10 Cutter Motor ..................................................................................... 6-6
6.2.11 Platen Assembly ............................................................................... 6-7
6.2.12 Cutter Assembly................................................................................ 6-8
6.2.13 Cutter Sensor .................................................................................... 6-8
6.2.14 Cassette Sensor ................................................................................. 6-8
6.2.15 Supply Motor .................................................................................... 6-9
6.2.16 Imager Fan........................................................................................ 6-9
6.2.17 Imager ............................................................................................... 6-10
6.2.18 Capstan Motors and Encoders ......................................................... 6-11
6.2.18.1 Heidenhain Capstan Encoder ............................................ 6-11
6.2.18.2 Heidenhain Capstan Motor................................................ 6-11
6.2.18.3 COPS Encoder and Motor.................................................. 6-12
6.2.19 Capstan Roller .................................................................................. 6-13
6.2.22 Imbedded Engine Controller (IEC) ................................................. 6-14
6.2.23 Control Panel.................................................................................... 6-17
6.2.24 Line Length Correction..................................................................... 6-17
6.2.25 Job Depth Correction....................................................................... 6-17
6.2.26 AccuSet 1200 Hard Drive................................................................. 6-18
6.2.27 RIP PCB............................................................................................. 6-19
6.2.28 Vacuum Pump Assembly ................................................................. 6-20
6.3 Electronic Alignment Procedures ................................................................ 6-22
6.3.1 Tensioner Adjustments (Mechanical Positioning)............................. 6-22
6.3.2 Tensioner Alignment (Electrical) ....................................................... 6-23
6.3.3 Capstan Servo Alignment................................................................... 6-24
6.4 Firmware Download Procedure for Systems with External
Agfa Single Board RIPs............................................................................... 6-30
6.5 Firmware Download Procedure for Systems with Internal
Agfa Single Board RIPs............................................................................... 6-31

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AccuSet Service Manual

CHAPTER SEVEN: PREVENTIVE MAINTENANCE

7.1 Introduction.................................................................................................. 7-1

7.2 Pre-inspection Procedures........................................................................... 7-1
7.3 Inspection Procedures ................................................................................. 7-1
7.3.1 Mechanical Inspection ....................................................................... 7-1
7.3.2 Motor Maintenance for cleaning DC brushless tension motors....... 7-2
7.3.3 Operational Inspection ...................................................................... 7-2

CHAPTER EIGHT: PARTS LIST

8.1 Field Replaceable Units (FRU) .................................................................... 8-1

8.1.1 Cables ................................................................................................. 8-2
8.2 Options (Piece Parts) ................................................................................... 8-3
8.3 Hardware Diagnostic Tool Kit..................................................................... 8-3

APPENDIX A: THE ACCUSET 1500

A.1 Product Overview ...................................................................................... A-1

A.2 Vacuum System .......................................................................................... A-2
A.3 The New IEC .............................................................................................. A-4

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Installation

CHAPTER ONE: INSTALLATION

1.1 PRODUCT OVERVIEW

The AccuSet is a laser based typesetter capable of exposing red sensitive media to
produce high quality PostScript text and graphics at screen ruling of up to 175
lines per inch with 256 shades of gray.

NOTE: See Appendix A for an overview of the AccuSet 1500 and

changes to the Accuset Service Manual.

Resolution in Media Speed in

Dots per inch (DPI) Inches Per Minute (IPM)
AccuSet 800 1000 1500
600 15.00 30.0 *
1200 7.50 15.0 22.50
1800 5.00 10.0 15.00
2400 3.75 7.5 11.25
3000 * 6.0 9.00
* This model does not produce this resolution.

Maximum line length is 82 picas. The depth of job is limited by the image control
system.

The input media supply cassette will support daylight and bulk reloadable media on
100 and 250 foot rolls with 2 inch cores, in widths of 10, 11, 12, 13.3 and 14 inches.

The system is capable of exposing red sensitive (670 10 nm) paper, film and Z plate
materials.

At 600 dpi the system produces a 35 micron spot; all other resolutions produce a
20 micron spot.

The system interfaces with the front end through an internal or external hardware RIP
or an external software RIP.

1.2 LASER SAFETY

WARNING 1: The laser is as a class one device and is harmless to the

operator when contained with the AccuSet system. However,
when the covers are removed, the laser is a class 3B laser
and can be harmful to the eyes if caution is not used.

WARNING 2: Looking directly into the laser beam or laser beam reflection
can cause permanent eye damage. To avoid this danger,
observe the following safety rules:
The laser presents no danger when the covers are installed.
Never look directly at the laser beam.
Use caution with tools and reflective surfaces to prevent laser reflection.
Keep the work area well lighted.

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AccuSet Service Manual

Follow the assembly/disassembly procedures (Chapter 6) precisely. No

short cuts.
Promptly report any actual or suspected accident.
Never operate the laser with the covers removed from the AccuSet system.
The Service Engineer must report immediately to a medical facility if any
of the following eye symptoms are experienced:
A visual halo effect
A change in tearing
A change in color perception

1.3 TECHNICAL EQUIPMENT SPECIFICATIONS

Table 1-1 Electrical

AC Power Range 110 19 VAC

218 38 VAC

Auto-ranging LVPS 90 to 256 VAC

AC Plug Type (NEMA) 5-15 R 2 Pole

AC Plug Type (Int.) EU-258 IPCEA

Dimensions (H x W x D) 38 3/4 x 32 x 29

Weight 350 lbs.

Max. Draw Amps 3.75 Amps at 90 VAC

Nominal Draw Amps 3.0 Amps at 115 VAC, 1.5 Amps at 230 VAC

Watts Max. 220 Watts

BTU Rating 754 BTU/Hr.

Plumbing Requirements N/A

Agfa Media Information ZHN Film - 10",11,12",13.3",14"

ZHN Paper
ZHN Plate
5 mil Thickness (Max.)

The power supply used in the AccuSet is a switching supply. Power consumption
is calculated by multiplying the volts and amps times the 0.6 power factor.

Table 1-2 Environmental Limitations

Temperature Range 65 to 85 degrees F

Humidity Range 35% to 85% non-condensing

Altitude Range

Operation To 8,000 feet

Shipping To 35,000 feet
Storage To 14,000 feet

1-2
Installation

Shipping and Storage

Temperature 30 to 160 degrees F

Humidity 10% to 95%

Table 1-3 Color Separation Environmental Specifications

Temperature 70 3 degrees F

Humidity 55% 5%

NOTE: Closer tolerances are required when running color separations, as

environmental conditions will affect repeatability.

1.4 INSTALLATION PROCEDURES

There are four steps to the installation procedure that must be performed in
sequence. They are:

1.4.1 Customer Pre-installation Responsibilities

1.4.2 Agfa Pre-installation Checks
1.4.3 System Installation
1.4.4 Customer Application Training

1.4.1 CUSTOMER PRE-INSTALLATION RESPONSIBILITIES

The customer is responsible for the following on-site preparations before the
Service Engineer can install the equipment.

Electrical

The customer must provide a dedicated three wire electrical power line
from the power box to the wall receptacle, with the third wire connected
to earth ground.
The electrical wire may be run in conduit, but the conduit may not serve
as the ground.
The receptacle must be the isolated ground type as specified in Table 1-1.

Environmental

The customer should follow the environmental specifications, as stated in the

equipment installation handbook, to provide the proper operating environment,
for the AccuSet system. Refer to Tables 1-2 and 1-3.

Work Space Allocation

The AccuSet is a floor standing unit on omni-directional casters.

The Raster Image Processor (RIP) will either be located within the unit or
in a separate external enclosure.
The AccuSet must be located in a clean area that provides sufficient clear-
ance for the servicing of the equipment

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AccuSet Service Manual

Shipment Delivery and Inspection

Upon the delivery of the equipment, the customer should verify that the
number of packages received agrees with the number called out on the
shippers bill of lading.
Packages should be checked for damage prior to signing the carrier
release form.
Should any package be found damaged or missing, this should be noted
on the carriers bill of lading and the Traffic Department at Agfa should be
notified.
Have the carrier locate the equipment in the area where the system is to
be installed.
Agfa personnel are not responsible for the unloading or moving of equip-
ment.

1.4.2 PRE-INSTALLATION CHECKS

Prior to unpacking, inspecting or installing the equipment the Service Engineer

must verify that the following pre-requisites have been met.

A dedicated line exists

The dedicated line is earth grounded
15 Amp fuse or circuit breaker is installed for the dedicated line
A NEMA 5-15 R receptacle/EU-258 IPCEA is installed
Correct voltage and grounding at the receptacle
Sufficient environmental controls are present, as to meet the environmen-
tal levels specified in Table 1-2 and 1-3.
Once the above items have been verified the Service Engineer can install the sys-
tem as outlined in 1.4.3.

1.4.3 SYSTEM INSTALLATION

Unpack and Inventory

Open all cartons, remove the contents and check the items received
against the order forms, invoices and shipping documents.
Record any back order, missing or incorrect items on the service report
and notify the Regional or Area office of any discrepancies.
Refer to unpacking procedures.

Inspection

Visually inspect each item for damage.

Notify the Regional or Area office if damage is discovered

1-4
Installation

Initial Testing

1. Check the power range switch on the power supply (115/230V). Systems
are shipped with the switch in the 230V position.

CAUTION: Power supply damage will result if 230 VAC is applied to

the system when the switch is in the 115V position.

2. Plug the line cord into the wall receptacle and turn the system on.

3. Check system cooling fans for proper operation.

4. Observe the systems basic confidence checks (BCC) and system diagnos-
tics. Refer to chapter 4.

5. Refer to chapter 4 for mode selections.

6. Load the supply cassette with media and install the media in the system.
Refer to chapter 2. Instruct the user at this time.

7. Set the DMax for the output media user test pages (3.7-3.9 film/1.6-1.8
paper/4.0 -4.2 Alliance). Refer to Chapter 6: Exposure Tests in the
AccuSet User Guide.
8. Enter the Photo Unit Processor (PUP).

a. Place the system in the off-line mode.

b. Press the test key and use the arrow key to move to the sub-menu.

c. Enter the Service password (777).

d. Using the arrow key, move the cursor to the upper menu and press
the enter key. The Application ROM revision will be displayed.

e. Press the clear key to display the PUP main menu. It appears eventu-
ally if you press no key.

f. Press the right arrow key to move the cursor to the pattern field and
press enter.

g. Press the select key to move to the burn-in list.

h. Press the right arrow key to move to the submenu.

i. Using the numerical keypad to enter each Command File (CF) num-
ber shown in Table-4. Press the enter key to run the CF.

For your information, the full list of CF numbers starts on page 5-15.

j. Using the arrow key to move the cursor to the upper menu and press
enter.

k. Press the on-line key to change the menu to burn-in once and press
enter.

l. Upon the completion of the burn-in files, process and evaluate. Refer
to chapter 5 for test file specifications.

m. Correct any mis-alignments using procedures found in chapter 6.

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AccuSet Service Manual

9. Install the interface cables from the front end to the RIP and queue a job
to test for proper system operation.

10. Accurately complete any and all paperwork.

Table 1-4

Installation
Test Description

CF 19 Horizontal lines 1 x 2-1/2", Vertical lines 1 x 4 for 1/2", Checkerboard

squares 6 x 6-1/2", and full black 1/2".

CF 28 One inch grid with patterns that runs at 1200 and 2400 dpi. Four
sections or one inch bands filled with 1 x 2 horizontal lines,
1 x 4 vertical lines, and a 50% and 100% tint.

CF 16 95% tint for 18 inches with 10 second stops every 1/2 inch. This pattern
runs at 1200 dpi. only.

CF 21 95% tint for 18 inches with 10 second stops every 1/2 inch. This pattern
runs at 2400 dpi. only.

1.4.4 CUSTOMER APPLICATION TRAINING

1. Instruct the customer on the functionality of the control panel.

2. Demonstrate the media loading and unloading procedures.

3. Explain density and calibration procedures.

4. Ensure the customer fully understands the system operation, thereby

reducing unnecessary service calls.

1-6
Operations

CHAPTER TWO: OPERATIONS

2.1 INTRODUCTION

This chapter contains a summary of the information in the AccuSet User Guide. In
this document, operations refers to how the customer uses the system.

2.2 ABOUT THE USER GUIDE

The user guide describes how to operate the AccuSet. It is written for operators
who use the AccuSet regularly as a production tool. It assumes that they are famil-
iar with the following:

Operation of the front end computer.

Operation of the programs in use on the front end computer.
Operation of the RIP that drives the AccuSet.
The AccuSet User Guide deals only with the AccuSet and refers customers to other
sources for information about the different parts of imaging systems.

Read the following to become acquainted with the contents of the guide.

Chapter 1: Getting Acquainted

Describes the features and parts of the AccuSet imagesetter. Also contains impor-
tant safety instructions and laser safety information.

Chapter 2: Operating the AccuSet

Describes the basic operating procedures: starting up the AccuSet, using the con-
trol panel, loading media, imaging a job. Also includes shut down and reset pro-
cedures.

Chapter 3: Status Messages

Lists the messages that appear on the AccuSet control panel message display.
Describes the meaning and corrective action.

Chapter 4: Set Up Cassettes and Options

Describes cassette parameters and how to set them up. Also describes the features
controlled through the OPTION key on the control panel.

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AccuSet Service Manual

Chapter 5: Installation
Describes site and environmental requirements for best operation of the AccuSet.
Contains procedures for setting up your AccuSet including how to connect the
imagesetter to your imaging system, how to test the imagesetter after it is connect-
ed, and how to set up the AccuSet operating software.

Chapter 6: Exposure Tests

Provides information about the photographic processes at work when you use the
AccuSet imagesetter. Describes how to use and evaluate the exposure tests that
are part of the AccuSet software.

Chapter 7: Left Margin Setup

Describes how to use and evaluate a test that helps you calculate adjustments for
the left margin position on the AccuSet.

2-2
Functional Analysis

CHAPTER THREE: FUNCTIONAL ANALYSIS

3.1 INTRODUCTION

This chapter presents a functional description of the operation of the AccuSet

Imagesetter. The major elements of the imagesetter that are described are as fol-
lows:

Photographic media transport system (or leading system)

Pixel-Clock Phase-Lock Loop
Laser Diode Driver Circuitry
This chapter does not include a discussion of the processing of the imagery data
nor the architecture of the computer.

3.2 SCANNER (SPIN MOTOR) DRIVE

This module, shown in Figure 3-1, provides the electrical drive for the 3-phase
scanner (or spin) motor. The motor delivers 3-phase Hall-sensor signals that sense
motor shaft angle. These Hall-sensor signals are converted in the decoder logic to
form the commands for the motor power amplifier (Power amp). These com-
mands activate VMOS transistors in the power amplifier, controlling it to generate
appropriate 3-phase motor voltages to drive the motor in the proper direction.

The switching power supply is a variable DC power source for the power amp.
Motor speed is controlled by varying the command to the switching power supply
which varies the supply voltage. Motor current is sensed and used to close a cur-
rent feedback loop around the switching power supply. The integral comparator
(integral comp.) has an integral network, that produces high steady-state loop
gain, to achieve accurate control of motor current and motor torque.

An optical encoder mounted on the motor shaft delivers a square wave with 1200
cycles per revolution. At the operating scan rate, 300 (450 for AccuSet 1500) rev-
olutions per second, the frequency of the encoder square wave is 360 (540 for
AccuSet 1500) KHz. The pulse rate is measured to generate a voltage proportion-
al to motor speed. This is used as a velocity feedback signal for the velocity feed-
back loop and is fed to a 4800:1 counter.

The counter generates a 75 (112.5 for AccuSet 1500) Hz. square wave that the
phase detector compares with command signal formed by counting down the
crystal-oscillator clock signal of the computer. The phase difference between these
two square waves is the position error signal for the phase-lock position loop.
The phase-lock loop uses a frequency-phase detector. When combined with a
position-loop integral network, this detector allows the position loop to achieve
phase lock-on in spite of large initial errors in frequency. The position-loop inte-
gral network also minimizes the steady-state phase error. The frequency-phase
detector is discussed further in the description of the capstan servo in Paragraph
3.3.4.

3-1
AccuSet Service Manual

Position Command
from Crystal Oscillator
75 /112.5 Hz

+ Phase
Detector
4800:1
Count Down Position Feedback
75 /112.5 Hz

Integral
Phase-Lock Network
Position
Loop Switch

To servos +
Pulse Rate Velocity Feedback Signal +
Detector Velocity
Command
+
Encoder Pulses Motor Current Loop
360/540 KHz
----------------------
(1200 cycles per Velocity
scanner revolution) Loop

Integral
Integral
Comparator
Comp.

Decoder Power Switching

Logic Amplifier Power Supply

Hall signals Motor

3-phase

Encoder

Figure 3-1 Scanner/Spin Motor Block Diagram

3-2
Functional Analysis

To start the motor spinning, the position loop is opened by opening the switch,
and a velocity command voltage drives the velocity loop. The velocity feedback
loop commands the motor to accelerate until the motor velocity feedback voltage
is nearly equal to the velocity command voltage. Then the switch is closed, and
the position loop phase-locks the motor velocity to the 75 (112.5 for AccuSet
1500) Hz command derived from the crystal oscillator.

The scanner motor air bearings suffer high wear when the motor is rotating slow-
ly. To minimize this wear, acceleration and deceleration are very high at low
speeds. During initial acceleration, an 8-amp surge of current is applied to the
motor. During deceleration, the motor windings are shorted together. The reverse
emf provides high dynamic braking torque. The power supply for the braking
control has long-term voltage storage, to ensure that the motor is rapidly deceler-
ated in case of power failure.

AccuSet 1500 Only

Through the vacuum sensing switch the IEC board detects the strength of the vac-
uum. The switch closes when the vacuum falls below six (6) inches of mercury. If
the IEC detects a vacuum loss during normal spin motor operation, it displays an
error but allows the AccuSet 1500 to continue operation.

Greater air bearing damage happens when the AccuSet 1500 spin motor is started
up or turned off while a vacuum is present. This damage is minimized by the fol-
lowing control functions:

Before the spin motor can turn on, the IEC checks the vacuum switch. If
a vacuum is detected, an error message is displayed and the spin motor is
disabled.
Before the spin motor can turn off, the Accuset 1500 vacuum pump and
solenoid are turned off, which quickly bleeds-off the vacuum. After the
vacuum is purged and the vacuum switch closes, the IEC allows the spin
motor to turn off, as described in the paragraph above.

3.3 MEDIA TRANSPORT (OR LEADING) SYSTEM

3.3.1 ELEMENTS OF MEDIA TRANSPORT SYSTEM

The media transport system (also called the leading system) transports the pho-
tographic media from the supply canister, across the capstan roller, where it is
exposed, and then stores it in the take-up canister.

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AccuSet Service Manual

Figure 3-2 shows the mechanical components of the AccuSet media path. The
supply, capstan, and take up servos comprise the media transport system. The
capstan roller and servo motion are synchronized with the spinner motor to pro-
duce precise imaging on the media. Media tension is measured and applied by the
take-up rollers and spring loaded arms. The supply servo responds to the take-up
signal to move media into and out of the supply canister. The take-up pinch (or
nip) rollers and servo motor anchors the end of the media and feeds the exposed
media into the cutter, take-up canister, or media buffer.

Potentiometers

(B) (C)
Supply +8 Volt Take-up
Servo Servo
Take-up
Tension
Arm
Supply Take-up
Roll of Tension
Photo Media Pinch Take-up
Arm Rollers
Springs Canister

Capstan
Flywheel Motor
Motor

Supply Encoder
Canister
Motor (A) Scanner/Spinner
Friction Capstan Encoder Pulses
Drive 360/540 KHz
Servo (From Fig. 3-1)
Wheel

Figure 3-2 Elements of the Media Transport System

Potentiometers on the supply and take-up tension arms provide the position error
voltage that controls the supply and take-up servos. The supply servo feeds the
media from the supply canister at the proper rate to keep the supply tension arm
nearly at a fixed position, thereby keeping nearly constant media tension on the
supply side of the capstan. Similarly, the take-up servo drives the pinch rollers at
the proper rate to keep the take-up tension arm nearly at a fixed position, thereby
keeping nearly constant media tension on the take-up side of the capstan.

The tension in the media is kept nearly the same on both sides of the capstan,
and variations of media tension are kept small. This minimizes load torques on
the capstan, thereby allowing the capstan to position the media accurately as it is
being exposed.

3-4
Functional Analysis

3.3.2 OPTICAL ENCODER SIGNALS

Coupled to the capstan motor shaft is an optical encoder with 3750 line-pairs per
revolution (3750 black lines and 3750 clear lines). Three types of control signals
are derived from the signals of this encoder:

1. A signal proportional to velocity, used for velocity feedback;

2. A square wave, with 4 times 3750 (or 15,000) cycles per revolution, used
in a phase-lock loop to control capstan position during printing.

3. Up/down encoder pulses, with a resolution of 15,000 pulses per revolu-

tion, used to control capstan position during the stop, backup, restart
mode. Coupled to the motor shafts of the take-up and supply servos are
optical encoders with 200 line-pairs per revolution. Velocity feedback sig-
nals are derived from the signals of these encoders.
An optical encoder typically generates two analog signals, called A and B, which
are approximately cosine and sine functions of the shaft angle, multiplied by the
number of line pairs per revolution (3750 for the capstan servo or 200 for the
take-up and supply servos). To generate a velocity signal, analog signals A and B,
and their negatives, are differentiated. Appropriate segments of these four deriva-
tives are selected to generate a continuous dc signal, which (except for ripple) is
proportional to velocity.

In the capstan servo, the analog A and B signals are processed to form digital sig-
nals for position control. During normal printing operation, a square wave with
15,000 cycles per revolution is derived from these analog signals, where the rising
edges of the square wave occur at the zero crossings of the A and B signals. This
is called the capstan encoder feedback signal, which is used as the feedback sig-
nal of a phase-lock loop that synchronizes capstan motion with scanner rotation.
When the imagesetter runs out of imagery data, the capstan stops and backs up
and then restarts when the new data is available, achieving operating speed at the
next printed line. During this stop/backup/restart operation, the relative motion of
the capstan is measured by counting up/down pulses derived from the encoder
analog A and B signals. An up or down pulse is generated at each zero crossing
of an A or B signal. The direction of a count (up or down) is determined by com-
paring the slope at each zero crossing (positive or negative) with the sign (posi-
tive or negative) of the other (A or B) signal.

3-5
AccuSet Service Manual

3.3.3 BLOCK DIAGRAMS OF TAKE-UP AND SUPPLY SERVOS

Figure 3-3 is the block diagram of the take-up servo. The servo motor shaft is cou-
pled directly to one of the take-up pinch rollers. Since the servo delivers torque in
one direction (to advance the media), a simple power amplifier drives the motor,
which applies voltage and delivers current of one polarity. A resistor in series with
the motor provides a voltage proportional to motor current, which is used to close
a current feedback loop around the power amplifier.

Tension
Command
Signal (From the IEC)
+
Integral + + Power Motor
Network Amplifier

Current
Motor Sense
Current
Motor
Velocity

Velocity
+8 Vdc Sense

Potientiometer Encoder
Position (Tension)
Take-up
Feedback Tension
Arm

Supply Take-up
Canister Canister

Take-up
Pinch
Capstan Rollers

Figure 3-3 Take-up Servo Block Diagram

The A and B analog signals from the optical encoder coupled to the motor shaft
are processed to generate a DC voltage proportional to motor velocity. This is
used to close a velocity feedback loop.

3-6
Functional Analysis

The take-up tension arm is spring loaded to exert tension on the photographic
media. A potentiometer coupled to the arm delivers a signal proportional to the
position of the tension-arm roller. Since the torque from the spring changes with
roller position, this potentiometer signal is also proportional to spring torque and
hence to the tension of the media. The potentiometer signal provides the tension
(or position) feedback signal for the tension (or position) feedback loop.

A tension command voltage is derived from the computer. The tension feedback
signal from the potentiometer is subtracted from this to form the tension error sig-
nal. This error signal is proportional to the error in roller position (or tension) and
is used to close the position feedback loop. An integral network provides high
steady-state gain in this loop, so that steady-state tension is accurately controlled.

The supply servo, which applies torque on the roll of photographic media in the
supply canister, has nearly the same block diagram as the take-up servo. The shaft
of the supply servo motor (which is external to the supply canister) is coupled to
a friction roller. The friction roller is forced against a flywheel mounted on bear-
ings inside the supply canister. By this means the motor applies torque to the roll
of photographic media, which is fastened tightly to the flywheel.

The torque applied by the supply servo motor is opposite to the rotation of the
photographic media. The servo motor acts like a brake, keeping tension in the
media.

The supply servo is complicated by the changing radius of the media roll, which
varies by about 2 to 1. The ratio of linear speed of the media to motor angular
velocity varies by this same factor. To compensate for this, a variable gain element
(controlled by the computer) is placed in series with the velocity feedback signal
derived from the encoder. This element has four gain settings, which approxi-
mately compensate for the variation of roll radius. To determine the proper gain
setting, the computer calculates the film roll radius by comparing the digital count
rate from the supply servo encoder (which is proportional to the angular velocity
of the media roll) with the count rate from the capstan encoder (which is propor-
tional to the linear velocity of the media).

3-7
AccuSet Service Manual

3.3.4 BLOCK DIAGRAM OF CAPSTAN SERVO

Figure 3-4 is the block diagram of the capstan servo. The servo motor is driven
by a 4-quadrant power amplifier, which can deliver both polarities of voltage and
current to the motor. Motor current is sensed to provide current feedback around
the power amplifier.

1200 Spinner Encoder

Digital Pulses-per-revloution
Signal (350/540 Khz
See Fig. 3-1)
Processing
LD Bus

Velocity
Capstan Command
Command Signal
Signal

+ +
Phase Integral + + Power Motor
Detector Network Amplifier

Capstan
Encoder
Feedback
Signal Motor Current

Velocity Sense
Phase-Lock Loop
Position A/B Encoder
Loop Signals
15000 Cycle/rev
Square Wave

For position
senseing during Up/Down Encoder Capstan
start/stop/backup Counts Roller
operation.

Figure 3-4 Capstan Servo Block Diagram

The analog signals from the capstan encoder are processed to produce (1) a
velocity feedback signal, (2) a square wave with 15,000 cycles per capstan revo-
lution, called the capstan encoder feedback signal, and (3) up/down encoder
counts, which are used to measure capstan motion during stop/backup/restart
operation.

The velocity signal derived from the encoder is used to close a velocity feedback
loop around the motor. This loop is commanded by a velocity command voltage
generated by the computer. During stop/backup/restart operation, the position
loop switch is open, and the capstan motion is controlled completely by the
velocity command signal. During normal printing, the velocity command signal is
still present, in order to minimize capstan positioning error.

During printing, capstan motion is accurately controlled by means of a phase-

lock position loop. This loop phase-locks the capstan encoder feedback signal to
the capstan command signal, which is a square wave derived by counting pulses
from the scanner encoder.

3-8
Functional Analysis

The phase detector in Fig 3-4 generates a phase-error voltage proportional to the
time difference between the rising edges of the capstan command signal and the
capstan encoder feedback signal. The phase-error voltage is linear over the range
T, where T is the period of the capstan command signal. The phase-lock loop
controls the motion of the capstan to minimize the phase error voltage. The inte-
gral compensation gives high gain to the loop at low frequencies, to achieve low
steady-state phase error.

This phase detector is called a frequency-phase detector, because it allows the

phase-lock loop to correct for large frequency errors. When the command fre-
quency exceeds the feedback frequency, the phase detector delivers a sawtooth
voltage waveform having an average positive value; and it delivers a waveform
with an average negative value for the reverse condition. The integral network
integrates this average value, and thereby changes the commanded capstan speed
until the frequency of the encoder signal matches that of the command signal.
Then the loop is able to lock on in phase.

3.3.5 PAGE LENGTH CORRECTION

The capstan ideally advances the media 5 inches for every capstan revolution. To
achieve this, the capstan diameter should be [(5 in.)/ - t], where t is the thickness
of the photographic media (normally 0.0045 in. for photographic film). Hence, the
ideal capstan diameter is 1.5870 in. Because of manufacturing tolerance, the actual
capstan diameter varies somewhat from this ideal. Page-length correction involves
digital circuitry and software that compensate for the error in capstan diameter, so
that page length is accurately controlled.

Since the capstan encoder feedback signal has 15,000 cycles per revolution of the
capstan, and each revolution of the capstan ideally advances the medium by 5
inches, each period of the capstan encoder feedback signal ideally corresponds to
a motion of 1/3000 inch of the media.

When the image density is 3000 dots per inch (DPI), the desired line-to-line spac-
ing is 1/3000 inch. Hence, for an ideal capstan diameter, the capstan command
signal should have a period equal to one cycle of the scanner, or 1200 scanner
encoder pulses. The capstan phase-lock loop will then force the capstan encoder
to advance one period (which ideally corresponds to 1/3000 in.) for every cycle of
the scanner (every printed line).

For this ideal case at 3000 DPI, the capstan command signal should be a square
wave with a period of 1200 scanner encoder pulses. (It is Hi for 600 pulses, and
Low for 600 pulses.) Table 3-1 shows, in column 2, the ideal number of scanner
encoder pulses per period of the capstan command signal, for the various image
densities in DPI shown in column 1. The frequencies of these square waves vary
from 360 (540 for AccuSet 1500) Hz at 3000 DPI to 1500 Hz at 600 DPI, and so
their periods vary from 3.33 (2.22 for AccuSet 1500) to 0.67 (0.88 for AccuSet
1500) msec.

3-9
AccuSet Service Manual

Table 3-1: Ideal number of scanner encoder pulses per period of the capstan-com-
mand signal for various image densities in dots per inch, when the capstan diame-
ter is ideal, and the change of page length for a period change of 1/4 pulse.

Table 3-1

Image Density Ideal Period Change for 1/4 pulse Max Page
DPI (encoder pulses) Relative 26-inch page Error

3000 1200 0.0208% 5.4 mils 2.7 mils

2400 960 0.0260% 6.8 mils 3.4 mils

1800 720 0.0347% 9.0 mils 4.5 mils

1200 480 0.0521% 13.5 mils 6.8 mils

6001 240 0.1042% 27.1 mils 13.6 mil

1 600 DPI is unavailable on the Accuset 1500

For this ideal case, the capstan command signal could be formed by counting
pulses from the capstan encoder to generate a TTL square wave that is High for
half the specified number of pulses, and then Low for the same number.
However, when the capstan diameter is not ideal, the period of the capstan com-
mand signal must be modified to achieve the proper page length.

To achieve fine control of the page length, a signal at 4 (360 (540 for AccuSet
1500) KHz), or 1.440 (2.16 for AccuSet 1500) MHz, is formed that is phase
locked to the scanner encoder signal. Pulses from this signal are counted to form
the capstan command signal. The High and Low intervals can differ by one pulse,
and so the period of the capstan command signal can be changed in increments
equivalent to 1/4 of a scanner encoder pulse. Dividing 0.25 pulse by the pulse
periods in column 2 of Table 3-1 gives the relative change of pulse period shown
in column 3. Multiplying the values of column 3 by 26 inch gives the values in
column 4. These are the changes of length of a nominal 26-inch page produced
by changing the period of the capstan command signal by one pulse of the 1.44
(2.16 for AccuSet 1500) MHz signal.

Thus, as shown in column 4, the length of a 26-inch page can be changed in

increments of 5.4 mils at 3000 DPI. After page-length correction, the maximum
page-length error is half this value, or 2.7 mils, as shown in column 5. The maxi-
mum page length error after correction thus varies from 2.7 mils at 3000 DPI, to
6.8 mils at 1200 DPI, and to 13.6 mils at 600 DPI.

3.3.6 STOP/BACKUP/RESTART OPERATION

When the imagesetter runs out of imager data in the middle of a page, the capstan
servo stops and backs up; and then restarts when new data is available. During
this period the capstan motion is controlled by the velocity command signal gen-
erated by the computer.

3-10
Functional Analysis

The up/down encoder pulses are counted to keep track of capstan position dur-
ing this period. To achieve an unambiguous count, the system starts and ends the
counting process when moving at printing speed, at points that are not close to
rising edges of the capstan command signal. Consequently, the counter never
starts or stops near a point where an up or a down encoder count is generated.

In this process, the relative phase between the capstan command signal square
wave and the index pulse of the scanner encoder must be maintained between
the last printed line and the next line after restart. A rather complex process is
implemented in the page-length correction ASIC to achieve this condition.

3.4 PIXEL-CLOCK PHASE-LOCK LOOP

The imagery data is clocked by the pixel clock to form the on and off pixels of
light generated by the laser diode. Nominally the scan lens projects a 14-inch-wide
image onto the capstan for 45 scanner rotation, or 1/8 of a scan cycle. Since the
scan rate is 360 (450 for AccuSet 1500) Hz, 1/8 of a scan cycle occurs in 1/2400
(1/3600 for AccuSet 1500) sec. Hence the nominal scan rate is 2400 (3600 for
AccuSet 1500) inch per sec, which is 33.6 (50.4 for AccuSet 1500) inch/msec.

To achieve an image density of 3000 dots per inch (DPI), the nominal pixel clock
frequency should be (3000 dot/in.)(33.6 (50.4 for AccuSet 1500) in./msec),
which is 100.8 (151.2 for AccuSet 1500) MHz. Table 3-2 shows, in column 2, the
nominal pixel clock frequencies for the image densities in DPI given in column 1.

Table 3-2: Nominal frequencies and count-down ratios of pixel-clock phase-lock

loop for the various image densities in dots per inch (DPI)

Table 3-2
DPI Pixel Clock Frequency in KHz Count-Down Ratio
MHz MHz Oscillator Command Fixed Variable
3000 100.8 151.2* 100.8 151.2* 360 540* 2 140

2400 80.64 120.96* 80.64 120.96* 360 540* 2 112

1800 60.48 90.72* 60.48 90.72* 180 270* 2 168

1200 40.32 60.48* 80.64 120.96* 360 540* 2 112

600 20.16 60.48* 80.64 120.96* 180 270* 4 112

*Bold Numbers are for the AccuSet 1500 Only

Because of manufacturing tolerances, the focal length of the scan lens can vary by
2.5% from the nominal value. Consequently, the image line length for 45 of
scanner rotation can vary 2.5% from the nominal 14 inch width. To compensate
for this, the pixel clock frequency is varied by 2.5% from the nominal values in
column 2 of Table 3-2, to achieve the proper line length.

3-11
AccuSet Service Manual

The pixel-clock frequency is controlled by a phase-lock loop, which locks togeth-

er the oscillator and command frequencies. The command signal is produced by
the spinner encoder that generates 1200 360 (540 for AccuSet 1500) KHz square
wave pulses per revolution at the operating scan rate of 300 (450 for AccuSet
1500) Hz. Column 4 shows the two command signal frequencies. The 180 (270
for AccuSet 1500) signal is derived by dividing the spinner encoder frequency by
2:1.

The scanner encoder delivers a zero-reference pulse once per revolution, which
has the width of several encoder pulses. This pulse is used to gate the scanner
encoder signal to form the scanner index pulse as follows: (1) the rising edge of
the scanner index pulse coincides with the first rising edge of the scanner encoder
signal when the zero reference pulse is Hi, and (2) the falling edge of the scanner
index pulse coincides with the next rising edge of the scanner encoder signal.
When the 360 (540 for AccuSet 1500) KHz encoder signal is counted down to
form the 180 (270 for AccuSet 1500) KHz command signal, the phase of the
command signal is chosen to have a rising edge that coincides with the rising
edge of the scanner index pulse.

Column 3 of Table 3-2 gives the nominal oscillator frequencies for generating the
required pixel-clock frequencies. A single oscillator frequency of 80.64 (120.96
for AccuSet 1500) MHz is counted down to generate the nominal pixel-clock fre-
quencies shown in column 2.

The oscillator frequency is counted down by a fixed ratio of 2:1 or 4:1, and then
by a variable ratio of N:1 to form the feedback frequency. These fixed and vari-
able ratios for the nominal frequencies are shown in columns 5 and 6. Dividing
the oscillator frequency by the product of the fixed and variable ratios gives the
frequency of the feedback signal, which is controlled by the phase-lock loop to
be equal to that of the command signal (360 or 180 (540 or 270 for AccuSet
1500) KHz).

The variable ratio is changed to vary the pixel clock frequency. The maximum
required variation from the nominal is 2.5%. The relative value of the count-
down ratio can be changed in steps of 1/112 or 0.89% for 2400, 1200, and 600
DPI, in steps of 1/140 or 0.71% for 3000 DPI, and in steps of 1/168 or 0.60% for
1800 DPI. To achieve finer control of pixel-clock frequency, a phase-shift com-
mand waveform is applied to the phase-lock loop after the phase detector. The
rate-of-change of the commanded phase waveform changes the oscillator frequen-
cy during printing, and so provides fine tuning of the pixel-clock frequency.

Figure 3-5 is a block diagram of the pixel-clock phase-lock loop. The command
frequency is a square wave derived from the scanner encoder frequency. The
phase lock loop varies the oscillator frequency until the frequency of the feedback
signal matches that of the command frequency. The phase detector output is a
phase error voltage proportional to the time difference between the rising edges
of the command signal and the feedback signal. This error signal is linear over the
range T, where T is the period of the command signal.

3-12
Functional Analysis

Encoder Pulses
360/540 KHz
1/2 From Spinner
(See Fig. 3-1)

180 /270 KHz

Command Signal
360 or 180 KHz
/540 or /270 KHz

+
Feedback Signal Phase
Detector

Variable +
1/N Countdown Phase
Register Shift
+ Command
From the
IEC

Integral
Network

Voltage
Controlled
Oscillator

1/2 1/2

600 DPI* 1200 DPI* 3000 DPI *

2400 DPI * Pixel Clocks
1800 DPI See table 3-2
for frequencies .

Figure 3-5 Pixel Clock Phase-Lock Loop

The integral compensation gives the phase-lock loop very low steady-state phase
error. It also allows the phase detector to correct for large errors in frequency, and
thereby greatly improves the phase lock on capability (see the discussion of the
capstan servo, which uses the same kind of frequency-phase detector.). The oscil-
lator consists of two modules, one operating at 60 (90.72 for AccuSet 1500)
MHz, for the 1800 DPI pixel clock, and the other at 80 (120.96 for AccuSet
1500) and 100 (151.2 for AccuSet 1500) MHz, for the other pixel clocks.

The phase-lock loop operates with a phase offset proportional to the commanded
phase-offset voltage, which has a waveform of the general shape shown by the
solid or dashed curve in Fig 3-6. The amplitude of the waveform is determined by
a voltage command from the computer. The sloped portions of this waveform are
formed by means of an up/down counter, and the direction (up or down) of the
counter determines which of these waveforms (solid or dashed) is generated. The
print interval occurs between points B and D, and the waveform slope in this
interval determines the effective frequency shift applied to the pixel clock.

3-13
AccuSet Service Manual

The time interval between points A and E is the same as the interval between
points E and F, and is equal to 150 encoder pulses, which is 1/8 of the spinners
scan cycle (417 (278 for AccuSet 1500) sec). The phase shift command is held
constant for 3/4 of the scan cycle, between points F and A.

During factory test, the line length for a 14-inch wide page is measured using the
nominal count-down ratio in the pixel clock. From the error in line length, the
computer determines the actual count-down ratio and the parameters of the
phase-offset voltage waveform.

The location on a page of the beginning of a printed line is established by the ris-
ing edge of the BOL (beginning-of-line) pulse. That edge coincides with a rising
edge of the pixel-clock feedback signal. The location is established by the digital
parameter INDICAP stored in computer memory, which is determined during fac-
tory test. When the command frequency is 360 (540 for AccuSet 1500) KHz,
INDCAP is the number of pixel-clock feedback pulses (minus 4 pulses) measured
from the rising edge of the scanner-encoder index pulse to the rising edge of the
BOL pulse.

The BOL pulse enables the pixel clock signal to clock the imager data. The rising
edge of the BOL pulse is accurately timed to start the imager data at the beginning
of a line; the falling edge occurs well after the end of a line and is not critical.
Since the rising edge of the BOL pulse coincides with a rising edge of the pixel-
clock feedback signal, it coincides with a rising edge of the pixel clock signal, and
so accurately times the start of imager data.

The time reference for initiating the BOL pulse is derived from the scanner index
pulse, which is synchronized with the command signal of the pixel-clock phase-
lock loop. However, the actual BOL pulse is synchronized with the feedback sig-
nal of that loop. Because of the phase-shift command voltage, there is a large
varying phase shift between these feedback and command signals. The system has
logic to ensure that the BOL pulse is accurately timed despite this varying phase
shift.

The jitter in the pixel clock is very low, and the BOL pulse timing is accurately
set, thereby ensuring very small horizontal line-to-line jitter.

The oscillator frequency and the commanded time-shift waveform is always the
same for 2400, 1200, and 600 DPI. (At 600 DPI, the phase-shift voltage waveform
and the phase shift in degrees is twice as large, but the corresponding time shift in
sec is the same.) However, the commanded time-shift waveform can vary as
image density is changed from 1800 to 2400 to 3000 DPI. This can cause the loca-
tion of the left-hand margin to move as much as 21 mils, although the line length
will stay the same.

3-14
Functional Analysis

In Fig 3-6, point B on the waveforms corresponds to the left-hand margin. The
maximum phase shift at this point is equivalent to a displacement on the page of
about 10 mils. With a change in DPI, the waveform can change from the solid to
the dashed curve, and this can result in a worst-case relative displacement of the
left-hand margin from about -10 mils to +10 mils, or about 20 mils peak-to-peak.

Print
Interval

A E F
PHASE SHIFT COMMAND

B C
0
B

D
A F
E

TIME

Figure 3-6 General Shape of the Phase-Shift Command Voltage

3.5 LASER DIODE DRIVER

3.5.1 CHARACTERISTICS OF LASER DIODE MODULE

The laser diode is a Toshiba TOLD9215, rated at 10 milliwatt (mW) output optical
power with a wavelength of approximately 670 nanometers (nm). The image set-
ter operates the laser diode from a minimum optical power of 0.7 mW to a maxi-
mum of 9.25 mW.

Mounted in the same module with the laser diode is a photosensitive monitor
diode, which, when back biased, transmits a current that is proportional to the
optical power from the laser diode. The sensitivity of the monitor diode is stable
for a particular unit, but can vary from unit to unit from 2 to 12 A/mW
(microamp per milliwatt). (The monitor-diode sensitivity is specified by the manu-
facturer for each unit.) Over the normal operating range, the optical power P and
current I in the laser diode are related approximately by the following typical
characteristic:

I = 35 mA + 1.16 (mA/mW) P + 0.5 (mA/C) T

where T is the temperature rise in C above 25C (nominal room temperature).

The current change for a 10C rise in temperature is 5 mA. This current change is
equivalent to an optical power change of 4.3 mW, which is 43% of rated optical
power. Thus, the laser diode is quite sensitive to temperature changes. The laser
diode is forward biased. Its approximate impedance is a constant voltage drop of
1.75 volt in series with a resistance of 18 ohms.

3-15
AccuSet Service Manual

3.5.2 LASER-DIODE DRIVER CIRCUIT

Figure 3-7 is a simplified diagram of the circuitry for controlling the laser diode.
The laser-diode module is a 3-terminal element which contains a laser diode LD
and a photosensitive monitor diode MD. The laser-diode driver circuit is powered
by the source voltage Es delivered at the emitter of transistor Q1. Voltage Es is
about 7 volt at peak optical power (9.25 mW) and room temperature. The laser
diode LD is in series with a resistor of 91 ohms and transistor Q4. When transistor
Q4 is on, the voltage drop across Q4 is about 0.4 volt, and operating current flows
through the laser diode (about 45 mA at peak power). When transistor Q4 is off, a
smaller prebias current flows through the laser diode because of the 100-ohm
resistor across transistor Q4 (about 32 mA at peak power). At this prebias current,
the laser diode does not act as a laser, but still emits a small amount of optical
power as a light-emitting diode (about 0.2 mW when the operating laser power is
9.25 mW).

Prebias current minimizes electrical transients and thereby allows faster response
in the modulation of electrical current and optical power. However, a more impor-
tant advantage is that prebias current helps to stabilize the temperature of the
laser diode by keeping the electrical power dissipation in the diode nearly con-
stant. At maximum optical power (9.25 mW), the electrical power dissipated in the
diode at 45 mA operating current is 104 mW, and the electrical power dissipated
at 32 mA prebias current is 74 mW. Hence the power dissipated with prebias cur-
rent is 74/104 or 71% of the power dissipated with operating current.

Also connected to the source voltage Es is the compensation circuit. The transistor
Q3 in this circuit is gated on when the transistor Q4 in the laser-diode driver cir-
cuit is gated off, and vice-versa. The compensation circuit has nearly the same
impedance as the laser-diode driver circuit for both on and off states.
Consequently, the load impedance experienced by the source voltage Es does not
change appreciably as the laser diode is gated on and off. This constancy of
impedance helps to stabilize the source voltage Es.

For a constant current, the optical power output from the laser diode decreases
appreciably with increasing temperature. Consequently, after the laser diode is
gated on, the output power drops because of the temperature rise in the diode.
The drop in optical power follows a transient that can be approximated as a sum
of three exponential terms of different time constants. To compensate for this
effect, the circuit has three compensation impedances, which generate current
transients with time constants of approximately 7.5, 30, and 300 sec. The ampli-
tudes of these current transients are adjusted by means of two potentiometers,
one which sets the amplitude of the long time constant (300 sec) term, and the
second which sets (by the same amount) the amplitudes of the short time-constant
terms (7.5 and 30 sec).

3-16
Functional Analysis

Gain
Density Feedback Voltage 20 to 60 mV/mW
11
0.22 to 0.66 Volt/mW

Density Feedback Loop

AD 585 +8 VAR
Sample/Hold Circuit 2200 pf
Source Voltage

+
+
Q1
1.25
mA/V Laser Diode
Es
+ Module
MD

10K

10K
Density C
Calibrate LD
Command

Switch
Voltage
Gain and
Offset Rc
Change 91
Cc
Q3
Q4 Laser
Diode
Density ON
Potentiometer
Compensation
Digital Circuit
Density Laser Diode
Command Driver Circuit
Digital/Analog
Converter

Figure 3-7 Simplified Diagram of Circuitry for Controlling the Laser Diode

Figure 3-7 shows a compensation impedance feeding from the arm of a poten-
tiometer in the compensation circuit to the cathode of the laser diode. This con-
sists of a compensation resistor Rc in series with a compensation capacitor Cc.
The actual circuit has three such compensation circuits operating in parallel. The
product of resistance Rc times capacitance Cc is the time constant for each com-
pensation impedance. When the laser diode is turned on (Q4 on, Q3 off) a step of
voltage is applied across each impedance, and this generates a transient current,
which flows into the laser driver circuit at the anode of the laser diode. The cur-
rent in the driver circuit stays nearly constant, and so this transient current forces
the current in the laser diode to decrease by an amount approximately equal to
the transient current.

The potentiometer adjusts the amplitude of the voltage applied across the com-
pensation impedance, and thereby adjusts the amplitude of the transient current.
At room temperature, and maximum optical power (9.25 mW), the step of voltage
across the compensation impedance can vary from 0.4 volt to 4.8 volt with differ-
ent potentiometer settings. At minimum optical power (0.7 mW), this voltage step
can vary from 0.3 volt to 3.4 volt. For a given potentiometer setting, the amplitude
of a compensation current transient is nearly independent of optical power.

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AccuSet Service Manual

The values of Rc and Cc for the three compensation impedances were developed
empirically. During factory test, the two potentiometers in the compensation cir-
cuit are adjusted at an optical power level of 5 mW until the resultant waveform
of optical power (as sensed by the monitor diode) is as flat as possible. For a
series of 8 imagesetters, the average potentiometer sensitivity settings were 0.16
for the short time-constant impedances and 0.23 for the long time-constant
impedance, which resulted in voltage steps of 0.9 and 1.1 volts. The correspond-
ing average amplitudes of the compensation transients in current and optical
power are:

(a) for 7.5 sec time constant: 45 A and 39 W

(b) for 30 sec time constant: 350 A and 300 W

(c) for 300 sec time constant: 330 A and 280 W

On the other hand, for the 8 imagesetters in this series of tests, the potentiometer
settings varied widely from these average values.

3.5.3 IMAGE DENSITY FEEDBACK CONTROL LOOP

Optical power is controlled by the density feedback loop, which adjusts the
power level of the laser diode when it is on, and thereby adjusts the density of
the resultant exposed image. This feedback loop operates intermittently for a 500-
sec interval near the center of the inactive portion of each 3333 (2222 for
AccuSet 1500)-sec scan. The loop sets the value of source voltage Es that results
in the required optical power during that time interval. In the remainder of the
scan, the source voltage is held constant by means of a sample-and-hold circuit.

The density feedback loop is shown in Fig 3-7. The photosensitive monitor diode
MD, which is back biased, transmits a current that is proportional to optical power
from the laser diode LD. The laser diode gives an accurate measure of optical
power, but its sensitivity varies from unit to unit over the range: 2 to 12 A/mW (a
6:1 range). This monitor current is fed through the parallel combination of two 10
KW resistors. When the sensitivity of the monitor diode is less than 4 A/mW, the
switch in series with one of these resistors is opened, and the resistance from the
monitor-diode cathode to ground is 10 KW; otherwise the switch is closed and the
resistance is 5 KW. With this change of switch setting, the resultant voltage sensi-
tivity at the monitor diode cathode can vary over the range: 20 to 60 mV/mW (a
3:1 range).

The voltage at the monitor diode cathode is fed to an amplifier with a voltage
gain of 11 to form the density feedback voltage. Hence, the density feedback volt-
age has a sensitivity that can vary over the range 220 to 660 mV/mW, and the volt-
age at maximum power (9.25 mW) can vary over the range: 2.04 to 6.11 volt.

The power of the laser diode is set by an 8-bit digital density command in the
computer, which can vary from 0 to 255. This is fed to a digital-to-analog convert-
er, the output from which is fed through opamp circuits that provide gain and
voltage offset. This produces a voltage that varies from -0.122 volt when the digi-
tal density command is zero to +8.14 volt when the digital density command is
255 (maximum). This voltage is applied to the density potentiometer, the sensitivi-
ty of which is denoted kd. The voltage on the wiper arm of the potentiometer is
the density command voltage and is equal to 8.14 kd volt at maximum density
command.

3-18
Functional Analysis

In the input stage of the sample-and-hold circuit, the density feedback voltage is
subtracted from the density command voltage to form the density error voltage.
When the switch in that circuit is closed (which occurs during the 500-sec cali-
bration interval), a current proportional to this error voltage drives an integrating
opamp output stage, and so the rate of change of the output voltage from the
sample-and-hold circuit is proportional to the density error voltage. The propor-
tionality constant is 0.54 (volt/sec)/volt, and the maximum slew rate of the out-
put voltage is 0.43 volt/sec. A wide-band feedback amplifier is closed around the
emitter of transistor Q1, so that the source voltage Es accurately follows the out-
put voltage from the sample-and-hold circuit.

Hence, when the switch in the sample-and-hold circuit is closed, the source volt-
age Es changes at a rate proportional to the density error voltage; it changes until
the density error voltage to zero, and the density feedback voltage is equal to the
density command voltage. The effective time constant of the density feedback
loop varies from 0.35 to 1.05 sec, and the maximum slew rate of the source volt-
age Es is 0.43 volt/sec. Hence this loop can accurately correct for errors in laser
power in a small fraction of the 500 sec interval used for calibration. When the
switch is open, the charge on the feedback capacitor of the integrating opamp
cannot change, and so the sample-and-hold output voltage and the source voltage
are held constant. There is negligible droop of these voltages between calibration
intervals.

The density potentiometer is set during factory test by commanding maximum

digital density (255) and adjusting the potentiometer until the monitor diode cur-
rent corresponds to 9.25 mW of laser power. Each laser diode has a data sheet,
supplied by the manufacturer, which specifies the monitor diode current for that
unit at 10 mW of optical power. This value is used to calibrate the monitor diode
current readings. To avoid overdriving of the laser diode, the potentiometer is
adjusted for the minimum power setting, and then is changed until the correct
laser diode power is obtained. The sensitivity of the final potentiometer setting kd
may vary from 0.25 to 0.75 with different sensitivities of the monitor diode.

When the digital density command is zero, the voltage applied to the density
potentiometer is -0.122 volt, and so the density command voltage (which is -0.122
kd) can vary from -30 mV to -90 mV. This voltage is sufficiently negative to back
bias the laser diode and forward bias the monitor diode. This ensures that the
optical output power is zero when zero digital density is commanded.

3.5.4 PROTECTION OF LASER DIODE

The laser diode can be damaged in an extremely short time if it generates exces-
sive optical power, because of excessive optical power density in the laser cavity.
To guard against this possibility, the system has a protection circuit that accurately
adjusts the supply voltage (denoted +8VAR) applied to the collector of the Q1
transistor. This limits the maximum possible value of source voltage Es, and there-
by limits the maximum possible laser diode current.

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AccuSet Service Manual

As was shown in paragraph 3.5.1, the laser optical power for a given current is
critically dependent on temperature. Hence, the protection circuit has an LM35CR
temperature sensor mounted close to the laser diode, which senses the laser diode
temperature. The voltage Et from this temperature sensor is equal to:

Et = 0.250 V + 10 (mV/C) T

where T is the temperature rise above room temperature, 25C. This signal Et is
used to vary the voltage reference to an LT1065CT voltage regulator, which gener-
ates the supply voltage +8VAR applied to the collector of transistor Q1. The volt-
age +8VAR is controlled such that the optical power from the laser diode cannot
exceed the 10 mW rated optical power by a large factor, regardless of tempera-
ture.

To protect the laser diode during power start-up and shut-down, a TL7770-5 dual
power-supply supervisor is used to monitor the +5 V and the +12 V power supply
voltages. Whenever either of these power supply voltages is more than 10%
below nominal value, the supervisor shorts out the voltage reference to the
LT1065CT voltage regulator, and thereby turns off the +8VAR voltage that powers
the laser diode driver circuit. During start-up, the supervisor has a time delay,
which keeps the +8VAR voltage at ground for 0.66 sec. Also, the supervisor shorts
out the output from the sample-and-hold circuit, thereby forcing the source volt-
age Es to ground.

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Diagnostics

CHAPTER FOUR: DIAGNOSTICS

4.1 INTRODUCTION

Chapter four contains the description for: operating modes, ROM based diagnos-
tics, core testing, subsystem testing, selectable tests, error codes and the photo
unit processor (PUP).

The information contained in this chapter is used to diagnose and correct system
related problems. The Boot ROMs reside on the IEC board.

Interconnect wiring diagrams are provided to assist in troubleshooting.

4.2 MODES OF OPERATION

After the system core testing has successfully been run and prior to sub-system
testing, the operator will be prompted for an operating mode selection.

When the word CODE is displayed on the control panel, the operator has five
(5) seconds to enter the desired operating mode. The following describes the
available operating mode:

Normal load (no entry)

This is the default mode. Sub-system testing will be executed prior to jumping to
the application program. The control panel will display the sub-system under test.
When sub-system testing is completed, control will be passed to the applications
and the message ON-LINE will be displayed. Any errors detected will be dis-
played to the control panel. The user can scroll via the left and right arrow keys
should multiple errors occur.

Forced load (1)

When this key is entered, the program will execute the IEC and single board RIP
(SBR) tests and then immediately jump to the applications without executing the
remaining sub-system testing.

The ON_LINE message will be displayed. Should an error be detected during a

checksum of the EEPROM, the boot will instead jump to the EEPROM loader.

Debug Mode (2)

When this key is entered, the CLI program will be down-loaded into system mem-
ory from a PC via the serial link. The CLI program is used as an Engineering and
Manufacturing debug tool.

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AccuSet Service Manual

EEPROM load (3)

When this key is entered the user will be able to upgrade the engine Applications
ROM. Control will be passed from the diagnostics to the EEPROM loader once the
IEC and SBR tests have been completed. The SBR tests needs to be executed in
order to set the desired communication mode. When control has been passed to
the loader, LOAD PROGRAM will be displayed. Refer to chapter 6.

Selectable Tests (4)

When this key is entered the user may select a combination of any or all sub-sys-
tem tests and a desired loop count. The user will be prompted to enter the sub-
system(s) to be tested. SBR is not a valid test. Valid entries are 1,3,4,5 and 6. Any
subset (5) of these tests may be entered.

If no sub-system entry is made and the ENTER key is struck the default is to run
all tests. Refer to Table 4-2 for valid key entries and sub-system test it represents.

Next, the user will be prompted for a pass count. Valid pass counts are 1 to 9999.
If the user strikes ENTER without entering a pass count value, the loop count
will default to one.

Next, the user will select between Halt on Error or Loop on Error mode. Halt
on Error will terminate the testing at the first error encountered. Loop on Error
will ignore errors and continue testing until the pass count has decremented to
zero.

Boot Version (5)

When this key is entered the system will go through the normal test process, but
will pause briefly to display the current Boot ROM version prior to passing control
to the applications and the message On-Line will be displayed.

Debugger (6)

This debugger will be used by Engineering during the software development

cycle. There is no field use intended for this mode.

APIS Loopback (7)

When this key is entered, the boot will execute the CGEN loopback test. This test
requires an external test module. Test card p/n 204971- 501 and cable p/n 206583-
501 must be connected to the APIS port. (Field kit 2362-502)

The user will be prompted to enter the resolution of the test. The select key is
used to scroll to the selected resolution. Next, the user is prompted for a pass
count. (1 to 9999) with the default being one. The user is then prompted to select
the desired loop mode, Halt on Error or loop on Error. This test isolates faults
between the writing engine and the image control system by providing a closed
loop test capability at the engine. Refer to 4.4.5.

4-2
Diagnostics

Power Cutter (8)

When this key is pressed, the boot will execute the power cutter test. Refer to
4.5.2

4.3 CORE TESTING

The first test run in the boot sequence will be the core tests (the minimum hard-
ware required to run tests).

If any of the core tests fail, it will be considered a fatal error. The program will
halt testing, and an error will be reported via a diagnostic LED located on the IEC
module. Refer to Table 4-1.

The following items are checked during the core tests:

ROM CRC
8KB System memory
Interrupt controller register
80188 Internal timer register
80188 Internal timer 2 sync
80188 Internal timer 0 and 1
Invalid Op-Code
32K System Ram
8530 Serial Communication controllers
Operator Control Panel loopback

4.3.1 ROM CRC

A CRC of the full 32K of ROM is performed. The CRC at run time is checked
against the CRC stored in the last word of the ROM. The program romopt is
used to calculate the stored CRC.

4.3.2 8KB SYSTEM MEMORY

This test runs a BITPAT on the first 8KB of system memory. System memory refers
to the 32K bytes of read/write memory that is used for program variable and
stack.

4.3.3 INTERRUPT CONTROLLER REGISTER

This test will write and then verify a marching 1 to the interrupt mask register,
checking the read/writeable bits. Interrupt generation will be checked by the tests
that use interrupts (i.e. Timer tests).

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AccuSet Service Manual

4.3.4 80188 INTERNAL TIMER REGISTER

This test will write and then verify a marching 1 through all the internal timer reg-
isters, with the exception of the timer control registers. There are three internal
timers in the 80188. Timers 0 and 1 have three count registers and one control
register. Timer 2 has two count registers and one control register.

4.3.5 80188 INTERNAL TIMER 2 SYNC

In this test, the operation of timer 2 is checked by running the timer against the
80188 Loop instruction (16 clock cycles long). The test is set to run from 0 to
0FFFH. The timer will interrupt the CPU at the end of the count cycle. The CPU
will start the timer prior to executing the loop instruction with register CX set to 0.
When the timer interrupts the CPU, the 1s complement of the CX register will be
saved and a flag set. At the end of the loop the flag will be checked and the saved
count is verified to be 3FFFH 1.

4.3.6 80188 INTERNAL TIMER 0 AND 1

Now that timer 2 has been verified, it will be used as a pre-scaler for timers 0 and
1. Timer 2 will clock each of the other two timers and the 64k count will be veri-
fied on each. The internal priority resolution of the timer interrupt structure will
also be verified during this test.

4.3.7 INVALID OP-CODE

This test verifies that the 80188 responds with an interrupt level of 6 to all invalid
op-codes. The test attempts to execute each of the eight invalid op-codes and to
verify each as it is being executed via the invalid interrupt. When the interrupt
from the offending op-code occurs the stack is used to recover the offending op-
code which is then stored. At the end of the test the table is checked.

4.3.8 32K SYSTEM RAM

The 32K system RAM will be tested by running an address as data memory test
on the 32K of system RAM (less the first 8K).

4.3.9 8530 SERIAL COMMUNICATION CONTROLLERS

This test will first exercise the SCCs write/read registers with a walking 1 and 0
data pattern. The SCC internal register used will be the Interrupt Vector Register
(Register 2) and the time constant registers (12 and 13). This will test the data bus
to the SCC as well as the SCCs internal timers. The accuracy of the 8530 SCC
baud rate generator is verified by timing a sample amount of zero count interrupts
against the interrupt enable bit in the External/Status Interrupt Control register
(write register 15) of the SCC channel to be tested.When this bit is set, an
External/Status interrupt is generated whenever the counter in the SCCs internal
baud rate generator reaches zero. Then the SCC writes to register 12 and 13 with
the time constant for 2400 baud. The baud rate generator for the SCC channel
being tested will be enabled and an interrupt wait loop will be entered.

4-4
Diagnostics

When the first zero count interrupt is encountered, timer 1 will be enabled in the
interrupt service routine. After this and all other zero count interrupts, a zero
count interrupt counter will be incremented. When the sample count has been
reached, timer 1 will be halted and the SCC baud rate generator will be enabled in
the interrupt service routine. After reaching the sample count of zero count inter-
rupts, timer 1 will be read and matched against an expected value. Since the SCC
baud rate generator uses a 4.0 clock base, the elapsed time for timer 1 will use a
2.0 Mhz clock base. The elapsed time for the timer should be 4/2 that of the timer
constants times the sample count. If the timer 1 elapsed time does not fall within a
2% range, an error code will be posted indicating the elapsed time was either less
than or greater than the allowable range. The SCC channel A will be programmed
for internal loopback and asynchronous mode with a baud rate of 2400. An incre-
menting data pattern will be used as test data is transmitted, received and verified.
Both transmitter and receiver interrupts will be used to handle the data transfer.
This test will be repeated for Channel B and for the second SCC chip.

4.3.10 OPERATOR CONTROL PANEL LOOPBACK

The control panel test will first read the state of CARRYDETECT bit to determine if
the control panel is physically connected to the IEC. If CD is set, the second part
of this test is to send two data bytes to the control panel (85H, 8AH). The control
panel will echo the two bytes back to the SCC. The SCC will verify that the data
received back is the same as the data that was sent out.

NOTE: If the MSB of any data byte set to the control panel is set to a
1, the data byte sent will be echoed back to the SCC but
will not be processed (test feature). If this test fails a fatal
error message will be reported.

4.3.11 SPIN MOTOR POWER UP TEST

NOTE: If an AccuSet 1500 is powering up, the following spin motor

power up tests are not performed as part of core testing.
Instead, they are performed prior to the index frequency
tests, described in Paragraph 4.4.5

The spin motor will be tested approximately five seconds after power has been
applied to it. This test will count encoder pulses received during one revolution of
the spin motor. This will verify the motor turned on after the RUN bit in the spin
motor control register (port 0EH) was set. The purpose of this test is to prevent
the motor from being damaged by shutting it down in the event the motor is not
sending encoder pulses back to the IEC. Since the test is run prior to the motor
coming up to full speed, the test will only require a minimum of thirty encoder
pulses be received by the IEC. The test will use the 80188s timer 0 to count
encoder pulses. Encoder pulses are indirectly fed back to the micro-processor via
the test mux on the IEC. If thirty or more pulses are counted, it is assumed that
the motor is spinning.

If less than thirty pulses are counted, the test will reset the RUN and the BRAK-
ERES bit which will shut down the spin motor. A spin motor will not inhibit the
applications from coming up. (no core error reported) If a spin motor power error
occurs, fault isolation can be attempted via the PUP program.

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AccuSet Service Manual

4.4 SUB-SYSTEM TESTS

The sub-system tests will provide a functional test of each module in the writing
engine after successful completion of the core tests. Refer to Table 4-2.

The test philosophy for the boot diagnostics is to isolate a fault to the module
level and report the error to the control panel.

NOTE: A failure in one module may cause other modules to report

errors as the previous test failure may have occurred in an
integral area of subsequent tests (i.e. a spin motor failure will
cause recalibration and video errors as beginning and end of
line BOL and EOL are required).

The IEC sub-system test will verify the following components and data paths on
the main control module:

128KB of Flash EPROM

2KB of NVRAM
32K Scan Line Buffer Memory

4.4.1 128KB FLASH EEPROM

A check sum will be performed on the full 128K byte of flash EEPROM. The
check sum value calculated will be checked against the value stored in the upper
two locations of the EEPROM.

If a check sum error be detected, the boot will post a 10 IEC Error on the con-
trol panel and the boot executive will pass control to the EEPROM after the
remaining sub-module tests when the enter key is pressed. When this occurs, the
control panel will display the message LOAD PROGRAM.

The flash EEPROM test will also check to see if the EEPROM is blank. If the
device is blank the control panel will briefly display the message Blank EEP-
ROM.The boot will then pass control to the EEPROM loader following comple-
tion of the remaining sub-module tests.

4.4.2 32K IMAGE BUFFER MEMORY

The 32K IB memory will be tested by running an address as data test on the
entire 32K of memory.

If an error occurs, an error code 11 and IEC Error will be displayed on the
control panel.

4.4.3 NON-VOLATILE RAM

The NVRAM test will consist of both a write/read and checksum of the entire 2K
of NV RAM. The first part of the test will perform a write/read on 6 unused loca-
tions (so as not to disturb resident data). Next a checksum of the NVRAM will be
performed.The value calculated will be compared with the stored checksum
stored at the top of the NVRAM.

4-6
Diagnostics

If a checksum error occurs, the memory location containing the checksum will be
re-written with the new calculated checksum value and a 12 IEC Error message
will be displayed on the control panel.

4.4.4 SBR TO ENGINE

The SBR to engine will test the serial link between the two modules and the video
path between the SBR and the image buffer on the IEC. If an SBR is not detected
by the engine, the NVRAM location that contains the value of the communication
mode will be written with 0FFFFh and the NVRAM checksum updated.

The engine will look for an APIS diagnostic command GP90 (GET_DIAG_PARAM-
ETERS) from the SBR. The boot code will wait 55 seconds for the SBR to send the
command. If a (GP90) is not received by the engine within 40 seconds, the engine
will assume no SBR is connected to the engine, and proceed to the sub-system
test.

If a GP90 is received by the engine, it will in response, send a REPA 91000001

(the 000001 indicating Boot Mode) command back to the SBR. The SBR will
then send the engine a GP91 ( GET_SW_SETTING) command. The engine will
respond with REPA 92xxxxxx (xxxxxx is the state of the switch setting in NVRAM
at location 5000:7F0). This phase of the test will verify the serial link between the
SBR and the engine. Refer to Table 4-4.

To test the video path between the SBR and the engine, the SBR will send a (BT)
and (ET000012) commands to the engine. The SBR will send 12 scan lines of data
to the engines IB memory. The data pattern sent will yield a checksum value of
zero. The engine will then perform a checksum on the IB memory and report the
result back to the SBR. The engine will send either a REPA 93000001 for a correct
checksum or a REPA93000000 response for an incorrect checksum to the SBR.

The SBR and engine will terminate the test when the RIP sends a reset command
(SRRE) to the engine. When the engine receives this command, it will send the
SBR a RERE and exit the test.

If a checksum error should occur, an error code 20 SBR Error will be displayed
on the control panel.

NOTE: The AccuSet 1500 spin motor power up tests are performed
at this time. See Paragraph 4.3.1 for a description of the
tests.

4.4.5 INDEX FREQUENCY

The spin motor will be tested using the 80188s timer 0 to verify the motor is spin-
ning by checking for index pulses. The nominal index period is 3.33 (2.22 for
AccuSet 1500) msec. the test will verify the measured period is within a 3% (100
usec) range. The spin motors index signal is fed back into timer 0 of the 80188.
The test measures the time period between successive index pulses. The comple-
tion time allowed for this test is two seconds.

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AccuSet Service Manual

Fault Isolation

If the measured index period is outside the 3% range or if index pulses are not
detected by the 80188 timer, a read of the spin motor status port (port 186H) will
be performed. Port bit 0-2 contain the phase A, B and C sense signals sent to the
spin motor. Bits 3, 6, and 7 contain the hall sensor feedback signals. Bit 4 contains
the state of the brake flop. Initial fault isolation will determine if the hall sensors
are in 1 of 6 valid states. If they are in an invalid state, then the fault is assumed to
be with the spin motor or cabling. If not valid an error code 30 (33 for AccuSet
1500) Spin Mtr Error will be displayed on the control panel.

If the hall sensors are in a valid state, the spin motor feedback signals will be read
and compared against the Hall status bits. If the phase signals sent by the IEC to
the spin motor are incorrect, the boot will assume the problem is with the IEC
module, and an error code 30 (33 for AccuSet 1500) IEC Error will be dis-
played.

If either case does not yield an error, the spin motor or cabling problem will be
assumed. An error code 30 (33 for AccuSet 1500) Spin Mtr Error will be dis-
played on the control panel.

4.4.6 ENCODER

The 80188 timer will be used to count encoder pulses sent from the spin motor to
the IEC. Timer 0 will be set up as an event counter and will increment its internal
count value for each encoder pulse received during one revolution of the spin
motor (3.33 (22.2 for AccuSet 1500) msec). Since the previous test will verify
that the motor is spinning, this test will check the encoder and the path between
the encoder and the IEC. The completion time allowed for this test is 2 seconds.

Fault Isolation

The 80188s Timer 0 count value will contain the number of encoder pulses
received during a 3.33 (22.2 for AccuSet 1500) msec time interval. The test will
verify that the timers count values lie within a range of 1200 50. If the encoder
count is outside this range, an error code 31 (34 for AccuSet 1500) Spin Mtr
Error will be displayed on the control panel.

4.4.7 LEADING AND TENSION MOTORS

Capstan Motor Test

The test will command the motor to move forward direction while sensing
encoder pulses using the 80188s 0 timer. The IEC will enable the power to the
capstan motor, set TEN_EN, then start the capstan moving by writing to the
SERVO SPEED DIRECTION PORT (3000 dpi value). When an encoder pulse is
received, it will enable Timer 0 to count. Timer 0, upon reaching its programmed
count value (25usec) will generate an interrupt. The interrupt routine will be used
to count encoder pulses received from the capstan motor, will reset the capstan
motor flop and re-arm Timer 0. The test will terminate when 100 encoder pulses
are counted in the interrupt service routine. After completing the test, in the for-
ward direction, the test will be repeated in the reverse direction. During this test,
the tension motors will be disabled.

4-8
Diagnostics

The completion time for the test is 6 seconds (3 for each direction). If this test fails
(or a time-out occurs), an error code 40 and Leading Error message will be dis-
played on the control panel.

Fault Isolation

If an error occurs, the test will first determine if a shutdown occurred by reading
the SERVO_R_Port (302H), bit 0 (SHUTDOWN). If a shutdown occurred, bit 0 will
be high. It will be assumed the IEC shut down the capstan motor because of an
error condition on the IEC board. A 40 IEC error will be reported on the control
panel.

If SHUTDOWN is false, a read of the LEAD_FEEDBACK_REG (port 08H) will

determine if the IEC is trying to drive the capstan motor. Bits 0 and 1 are the feed-
back signals that indicate whether the IEC is driving the capstan motor. If the IEC
is driving the motor in the forward direction, bit 0 will be high. In the reverse
direction, bit 1 will be high. If an error occurs and a read of the port indicates the
IEC is not supplying power to the capstan motor, the error will be assumed to be
IEC related and an error message 40 IEC Error will be displayed on the control
panel.

If the IEC is driving the capstan motor, then the error is assumed to be off the
board (motor or cabling). In this case a 40 Leading Error will be displayed to the
control panel.

4.4.8 TAKE-UP AND SUPPLY MOTOR TESTS

The Take-up and supply side motors will be tested individually. For the take-up
side, the test will first command the motor to move. For the Take-up side, the test
will command the motor to move. Encoder pulses are fed into a readable port
SERVO_R_PORT on the IEC. Once the motor starts turning, the port is read every
3msec. When the TKUP_ENC bit changes from its previous read state, an initial
encoder count value of 5 will be decremented by 1. The motor will continue to
move until the counter is decremented to zero.

This test is repeated for the supply side motor, this time sensing changes in the
state of SUP_ENC. If either of the tests fail (or a time-out occurs, an error code
41 (take up) or 42 (supply) and Leading Error messages will be displayed to
the control panel. During these tests, the capstan will be disabled.

Fault Isolation

If an error occurs, the test will first determine if a shutdown occurred by reading
the SERVO_R_PORT (302H) bit 0 (SHUTDOWN). If a shutdown occurred, bit zero
will be high. In this case it will be assumed the IEC shut down either the take up
or supply motor because of an error condition on the IEC. If this occurs a 41 IEC
Error (take up) or a 42 IEC Error (supply) will be reported.

If SHUTDOWN is false, A read of the LEAD_FEEDBK_REG (port 08H) will deter-

mine if the IEC is trying to drive the motors. Bits 2 (take up) and 3 (supply) are
the feedback signals that determine whether the IEC is driving the motors. These
signals are active low. If an error occurs and a read of the port indicates the IEC is
not supplying power to either motor, then the error will be assumed to be IEC
related. If this occurs an error message 41 IEC Error (take up) or a 42 IEC Error
(supply) will be reported.

4-9
AccuSet Service Manual

If the IEC is driving both motors, then the error is assumed to be off the board
(motor or cabling). If this occurs, a 41 Leading Error (take up) or a 42 Leading
Error (supply) will be reported.

4.4.9 FILTER MOTOR

Home Sense Test

This test will issue step pulses (at a 100 msec step rate) that will move the stepper
motor to/off the HOME position. The IEC will continue to issue step pulses (up to
55) until it detects the filter motor is at the HOME position. After each motor step,
the HOMESENSE bit in the filter register port (182H bit 4) is read. If HOMESENSE
is false (low), the IEC will issue another step pulse. Once the filter is HOME, the
IEC will move 10 additional steps. A read of the Filter Motor Status register will
verify that HOMESENSE went false.

The completion time for the test is 9 seconds. A failure will be reported if a time-
out occurs, if the IEC does not detect HOMESENSE true within 55 motor steps or
it detects HOMESENSE false within 10 steps of HOME.

Fault Isolation

If an error occurs, the test will first determine if the IEC is supplying power to the
home sensor (SENSOR_PWR). Port 182H bit 5 will be active low if the IEC is sup-
plying power. If the bit is high the IEC is not supplying power and the error mes-
sage 50 IEC Error will be reported.

If power is being supplied, then the filter motor feedback phase pulses will be
read to determine if the IEC is supplying the proper phase signals to the motor.
Port182H bit 0-3 are the feedback signals sent to the filter motor. The IEC will
issue four additional pulses to the motor. After each on it will read the port. Bits
0-3 should contain only 4 valid phase patterns (0AH,06H,05H,09H). If the feed-
back signals are not in one of these states, then the IEC is not supplying the filter
motor with the correct phase signals and an error message 50 IEC Error will be
reported.

If the IEC is supplying power to the sensor, and the phase pulses are correct, then
it will be assumed that the filter motor or cabling is at fault and a 50 Filter Motor
will be reported.

4.4.10 LASER DRIVER MODULE

Recalibration Test

The recalibration test will command the Laser Driver board to turn the laser on
and perform a recalibration cycle for both zero and half power density values.
Following each recalibration cycle, a read of the Filter Motor Status register (port
182H) will verify that the WSENSE (bit 7) feedback signal from the Laser Driver
board, DENS_FDBK and the IEC density DACs were driven to their proper states.

The LDM will drive WSENSE low when the diode is turned off and will set it to
a high when the diode is on. The IEC will drive DENS_FDBK high when the
diode is off and drive it low when the diode is on. The completion time allowed
for this test is 2 seconds.

4-10
Diagnostics

Fault Isolation

A failure will be detected if WSENSE is in the incorrect state after either recalibra-
tion cycle. To isolate the cause of the fault, a read of the DENS_FDBK signal for
the calibration cycle will determine if the error was caused by the IEC sending an
incorrect density value to the LDM. If the density value is correct, then the failure
is assumed to be beyond the IEC Module (LDM or cabling) and an error message
60 LDM Error will be reported.

If a read of the DENS_FDBK bit indicates the IEC sent an incorrect density value
to the LDM, then the fault is assumed to be with the IEC and a 60 IEC Error will
be reported.

4.4.11 VIDEO FEEDBACK TEST

The video path from the IEC to the Laser Driver will be tested by filling a scan
lines worth of data into the IEC image buffer with a known data pattern. Once
filled the OUT_EN bit will be set and scan line buffer data will be serially shifted
out through the serialization logic. The video signal is fed indirectly back to the
timer 0 input pin on the 80188. The timer will be used to count video transitions
for the single scan line of video data. During this time the VIDOFF signal will be
set so a zero density calibration will be run prior, so as to not expose the media.
This test will be repeated for all resolutions (600 ,1200 1800,2400 and 3000 dpi).
The completion time for the test is 2 seconds.

Initially, the test will send one scan line of data (all zeros) to clear out any data
that may be in the serialization path. Then, one scan line of data, written earlier to
the scan-line buffer, will be sent out The data pattern sent out of memory will cre-
ate 3 low to high video transitions on VIDEO. After the data is sent, Timer 0s
count value will be read to verify it received 3 video transitions. If 3 transitions are
received, the test will continue on to the next resolution. Should an error occur,
the test will immediately terminate and an error message 61 IEC Error will be
reported.

When this test is run in mode 4, the control panel will post additional information
on the control panel if an error occurs. It will display the resolution that failed and
the actual video transition count it received.

Fault Isolation

If the video transition count is incorrect for any resolution an error code 61 IEC
Error will be displayed to the control panel.

4.5 SELECTABLE TESTS

4.5.1 CGEN LOOPBACK TEST

The CGEN loopback test will test the path from the APIS connector on the IEC
module to the 32K image buffer. The test card will fill the image buffer (to the
nearest scan line) with an incrementing data pattern. Once filled, the image buffer
data will be checked. Initially, the test will verify the serial link is functioning by
sending a couple of data bytes (55H, AAH) to the test card (the test card will echo
the data back to the SCC). The sending of serial data will also kick off the parallel
test by setting BRR.

4-11
AccuSet Service Manual

If the two bytes sent out are not echoed back to the SCC, an error message 70
Time-out Error will be reported.

Once the serial link is checked out, the test card will transfer the incrementing
data pattern to the image buffer. If an error is detected when the IB data is
checked, the control panel will display the following data: address in error, good
data pattern and the bad data pattern.

The CGEN Loopback test will allow all resolutions to be tested.

4.5.2 POWER CUTTER TEST

The power cutter module test will command the cutter to perform a single cut
operation and will verify that it was able to find, move away from and return to
the cutter home position. The test will first verify (or move) the cutter to the home
position, then will command the cutter to cut (one revolution of the cutter
motor). The test then verifies the cutter returned to the home position. The power
cutter cannot run in a loop mode.

The test will first enable the SENSOR POWER (Power Cutter Command register
port 6, bit 2. After a 200 msec delay, the CUT_HOME status bit in the Power
Cutter Status register (port 184 bit 1) will be read to verify the cutter is home. If
the CUT_HOME is true, the test will set CUT_EN to initiate a cut.

If the cutter is not initially home, CUT_EN will be sent and the test will wait for 3
seconds for the cutter to find home. If the cutter does not find home within 3 sec-
onds, then an error will be reported.

If a home error occurs, the Power Cutter status register will be read to determine
the source of the error (IEC or Power Cutter). If the home error was caused by the
IEC not supplying sensor power (port 184, bit 2, low), then an 80 IEC Error will
be reported.

If the IEC is supplying power (bit 2, high), then the error is assumed to be with
the Cutter module (motor or cabling) and will report an error message, 80 Power
Cutter Error.

If a home error did not occur, CUT_EN will be set (port 6, bit 0). After a 1 second
delay the test verifies that the cutter moved away from home (starting cut) by
reading the state of the CUT_HOME bit (port 184, bit1). Once CUT_HOME goes
inactive CUT_EN is disabled.

If CUT_HOME is still active one second after setting CUT_EN, the test will check if
the CUT_SENS bit (port 184, bit 0) in the power cutter status register is set. If its
set, then the IEC is issued a cut command. In this case, the error is determined to
be with the power cutter or cabling and an error message 80Pwr Cutter Error
will be reported. If CUT_SENS is not set, then it will be assumed the power cutter
did not move because the IEC did not drive the CUT_EN signal active and an
error message 80 IEC Error will be reported.

If the cutter moved away from the home position one second after CUT_EN was
set, the test will wait up to three seconds for the cutter to complete the cut com-
mand and return home (one revolution of the cutter motor). Once home
(CUT_HOME set), the test is completed.

4-12
Diagnostics

If a home error occurs, a read of the power cutter status register will determine if
the error was due to the IEC not supplying sensor power to the cutter module. If
bit 0 is not set, an 80 IEC Error will be reported. If the IEC is supplying sensor
power, then it is assumed the error is with the cutter module or cabling and an
80 Pwr Cutter Error will be reported.

4.6 ERROR REPORTING

Errors detected during the boot process will either blink the LED on the IEC
board, or will display an error code/message on the control panel.

Core errors will be displayed as a blink pattern on the LED since the SCC chip for
the control panel will not have been tested.

The left and right arrow keys are used to scroll, should multiple errors occur.

4.6.1 NVRAM ERROR LOG

The AccuSet writing engine contains an NVRAM error log that will store the 50
most recent sub-system errors detected during the boot process (excluding core
tests). The information stored is the sub-system test number which corresponds to
the test(s) that failed during the boot.

The error log is located at 5000:07C6H - 5000:07E2H. Location 5000:07C6 will

always contain the last error.

Before new data is written into the log, the first location is read to see if error
information currently exists. If the error log is blank, data is written to that first
location.

If data currently exists in the first location, the entire error array is shifted right
one memory location before the new data is entered. If the log is full, any addi-
tional entries will delete the oldest entry.

Table 4-1

Test Blink error code

CRC ROM 1

First 8K system memory 2

80188 Tests 3

System memory (8K-32K) 4

SCC 1 Test (80H-86H) 5

SCC Tests (88H-8eH) 6

Control Panel Loopback 7

4-13
AccuSet Service Manual

Table 4-2

Module Sub-system# Control Panel Display

Spin Module n/a 00

IEC Module 1 10

SBR to Engine 2* 20

Spin Motor 3 30

Leading System 4 40

Filter Motor 5 50

LDM Module 6 60

* SBR to engine test cannot be run in Mode 4.

Table 4-3

Display
Code Message Sub-system failure

10 EEPROM IEC

11 32K Image Buffer IEC

12 NVRAM IEC

20 SBR SBR

30 Spin Motor Index Test Bad spin motor

30* Spinner Wrong Incorrect spin motor

30* Vacuum Error Pump is off and vacuum is detected.
This error can be caused by a bad:
Vacuum solenoid
Vacuum switch

30 Spin motor encoder test Bad spin motor

31 Spin Mtr. Error Bad spin motor test failure

* Bold numbers are for the AccuSet 1500 Only

4-14
Diagnostics

Table 4-3 (continued)

Display
Code Message Sub-system error

32* Vacuum. Error Pump is on but no vacuum is detected

This error might be caused by a bad:
IEC or loose J20 connector
Vacuum pump/motor
Vacuum solenoid
Vacuum switch
Disconnected or cut vacuum pipe
Leaky imager assembly
Spin Motor Encoder

33* Spin Mtr. Error Spin motor index

34* Spin Mtr. Error Spin motor encoder

40 Capstan Motor Test IEC/Leading

41 Take up Motor IEC/Leading

42 Supply Motor Test IEC/Leading

50 Filter Motor Test IEC/Leading

60 Recalibration Test IEC/Laser driver

61 Video Feedback Test IEC

70 CGEN Loopback Test IEC

80 Power Cutter IEC/Power cutter

* Bold numbers are for the AccuSet 1500 Only

4-15
AccuSet Service Manual

Table 4-4

Centronics 0
Serial 1*
Test 3
Appletalk 4

* Default is Serial Mode (1)

4.6.2 ERROR/STATUS MESSAGES

This paragraph lists the different status messages that appear on the AccuSet mes-
sage display. These messages:

Tell you what the imagesetter is doing.

Let you know if there is a problem.

NOTE: Some messages in this paragraph describe RIP functions.

These messages appear only on AccuSet systems equipped
with an internal RIP. External RIP status messages are
described in the RIP Hardware User Guide.

Status Messages

The messages that appear on the control panel display show:

The machines operating status.

That a system error has occurred.
That an operator error has occurred.

NOTE: The Action instructions listed under some of the following

status messages are suggested repair actions or work-around
actions that have been provided to the user in the AccuSet
User Guide.

Aborting Job
Meaning: Appears after you press CANCEL JOB. The internal RIP is
aborting a job. If the engine has not started yet, the job will
be flushed. If the engine is imaging, both the imagesetter
and RIP are reset.

Advancing Media
Meaning: Media is being advanced.

Bad Command
Meaning: Appears when outputting reserved CFs (No associated pat-
tern) and when a CF is attempted to be run at an unsup-
ported resolution.

4-16
Diagnostics

Bridge Overrun
Meaning: The length of the job to be imaged will not fit on the
bridge to the on-line media processor.

Busy
Meaning: The system is imaging a job.

Cassette Full
Meaning: 50 feet or 15.2 meters of media have been fed into the
take-up cassette without a cut.
Action: Press CUT and remove the cassette.

Cutter Jam
Meaning: The power cutter is jammed.
Action: Take the AccuSet off line. Press OPTION, then ENTER. Use
the SELECT key to select Clear Cutter Jam function and
press ENTER to clear the jam.

Cutting Media
Meaning: The media is advancing and is then cut.

End Of Take
Meaning: The system has completed imaging the job.

Hardware Error
Meaning: The system detected a hardware error.
Action: Press CLEAR to remove the message from the display and
resend your job. If the message appears again, call Field
Service.

Illegal Mode
Meaning: Appears when an APIS CUT or FEED command is being
attempted while the AccuSet is Off-Line.

Imaging
Meaning: The system is in the process of imaging a file. The media
advance amount to the right of the message indicates the
amount completed. The system increases this amount every
tenth of a foot.

Laser Filter Err

Meaning: The system detected an error in the laser filter assembly.
Action: Reset the AccuSet. If this does not clear the error, call for
service.

4-17
AccuSet Service Manual

Load Program
Meaning: Operator selected software loading from control panel or
EPROM checksum error.

Loading Media
Meaning: Tension is being applied to the media.

Media Jam
Meaning: The media is jammed.
Action: Take the AccuSet off line. Press CLEAR to clear the mes-
sage. Clear the jam by opening the media transport covers
and internal light shield. Look for obstructions in the media
path. Make sure that the take-up cassette is seated proper-
ly. Reload the media.
If the AccuSet is on line, pressing CLEAR does not perma-
nently clear the Media Jam message. After one second, the
message reappears.

Media Low
Meaning: The media remaining in the supply cassette is less than the
amount specified through the Alarm menu.

Media Motor Err

Meaning: The system detected an error in the operation of the media
transport system.
Action: Reset the AccuSet. If this does not clear the error, call for
service.

Media Present
Meaning: You have tried to execute the motor cleaning function
without first removing the media.
Action: Remove the media and continue the motor cleaning func-
tion.

Missed Brkpoint
Meaning: The RIP sent more data than it specified.
Action: Reset the AccuSet from the control panel. Process the job
that generated the error; check to make sure that it is com-
plete. If you cannot clear the error, call for service.

No Cassette
Meaning: There is no take-up cassette in the take-up compartment.
Action: Put a take-up cassette into the take-up compartment. It
there is a take-up cassette in the compartment, make sure
that it is properly seated.

4-18
Diagnostics

No Power Cutter
Meaning: You have tried to use the power cutter and it is turned off.
Action: Either perform the cut manually, or turn the power cutter
on.

Out Of Media
Meaning: The system sensed a loss of tension on the media. This is
an indication that no media is present.
Action: Take the AccuSet off line. Press CLEAR to remove the mes-
sage, then reload media.
If the AccuSet is on line, pressing CLEAR does not perma-
nently clear the Out Of Media message. After one second,
the message reappears.

NOTE: When the AccuSet runs out of media, it automatically feeds

the end of the roll to the take-up area.

Over Current
Meaning: An over current condition was sensed by the system.
Action: Reset the system by pressing OPTION, SELECT, ENTER,
ENTER. If the message reappears, call Field Service.

Pause Pending
Meaning: You pressed ON LINE while the AccuSet was imaging a
job. When the job is done, the system will go off line.

Power Up
Meaning: You have started up the AccuSet; the imagesetter is loading
its operating software. This message appears only on sys-
tems equipped with an internal RIP.

Processing
Meaning: The AccuSet is processing a PostScript file. This message
appears only on systems equipped with an internal RIP.

Processor Error
Meaning: The optional on-line media processor is reporting an error.
The AccuSet cannot image jobs or advance media until you
clear this error.
Action: Press CLEAR to remove the message. Check your on-line
processor and correct the problem.

4-19
AccuSet Service Manual

Processor not RDY

Meaning: The optional on-line media processor is not on line.
Action: Press CLEAR to remove the message. If necessary, turn the
processor on. If your system is not equipped with an on-
line processor, turn off the Processor function under
OPTION.

Print Test Page

Meaning: The AccuSet is imaging a test page controlled by the TEST
key.

Remove Cassette
Meaning: The take-up cassette was not removed after the last cut.
Action: Remove the cassette and put in an empty take-up cassette.

RESET SYSTEM?
Meaning: You are about to reset the AccuSet. Appears after you press
OPTION SELECT.
Action: To confirm your intention to reset the imagesetter, press
ENTER two times.
To cancel the reset, press any other control panel function
key before you press ENTER the second time.

RIP Boot Error

Meaning: The internal RIP in the AccuSet did not complete its startup
sequence within 20 minutes. Normally, startup takes
approximately 5 or 10 minutes.
Action: The AccuSet is on line and can be used without the inter-
nal RIP. If communication with a RIP is required, restart the
AccuSet. If you are unable to clear the message, call for
service.

Storing Values
Meaning: The values selected in the Cassettes setup are being stored
as current values.

Unloading Media
Meaning: The media is being rewound into the supply cassette. A
small leader will extend from the cassette for later reload-
ing.

To Clear Messages

When the AccuSet is off line, press CLEAR to remove messages from the control
panel display.

4-20
Diagnostics

4.7 SYSTEM WIRING

This part of chapter 4 contains wiring information and diagrams. Paragraph 4.7.1
is an overall wiring diagram. Paragraph 4.7.2 contains pin utilization (pin-out),
color coding, and footprint information for most connectors in the AccuSet.

See Figure 6-14 to find the location of the IEC connectors.

The format of the pin-out information is as follows:

TB2-5A (9,3)

The first position contains the number of the originating connector and pin
or a signal name. Connector numbers can be looked up in Paragraph 4.7.1.
Signal names are referred to throughout this document, mostly in Chapter
3.

The second position is enclosed in parentheses (9,3). It uses the standard

resistor color code to specify the color of the wire that connects to the
pin. This color coding format is not used consistently throughout this ser-
vice manual. Some wires are labeled with a color and some non-code col-
ors are used, for example purple.

The color code is as follows:

0 Black
1 Brown
2 Red
3 Orange
4 Yellow
5 Green
6 Blue
7 Violet
8 Gray
9 White

4-21
4-22
LVPS IEC

Power
W4 TBI
Switch

W3 J-3 J-5 J 703 J 709 J 704 J-8 J-7 J-6 J-55 J-9 J-481 J-2 J-522 J-523 J-20 *
Jumper
AC SWX2 W30 R1
Capstan
Recpt Supply & Pellicle Vacuum
W5 DC - Motor
Power APIS/ Capstan Supply & Take-up User Power Laser Motor Spin Spin
W6 Take-up Cassette Supply Take-up Motor Int. Remote On-line Cutter & Drive Drive & Motor Motor - Solenoid
AC to IEC CGEN ENC - Switch
TB2/4 ENC Sense ENC Tensioner Drive (Keyed) Diag. Proc. Sense Video Int. Sense Drive Encoder
SEL
SW P-3 P-5 P703 P709 P704 P-8 P-7 P-6 P-55 P-9 P-481 P-2 P-522 P-523 P-20
Either/Or
AccuSet Service Manual

W23 W8

ENC ENC
Fan Fan
W10

Imager W13 W21 W7 J/P-4

W25 J1P1 W24 W9 W30 W12 W14 Options W15 W16 W17 W18 W19
Fan

W31 J/P-5

APIS to Take-up J/P-1

W11 Laser
Ext. RIP ENC
Cable Control
4.7.1 SYSTEM INTERCONNECT DIAGRAM

J/P-2 Module
CPSI Supply Laser Spin
RIP ENC Control Motor
J-5 P-5 J-5 P-5 Module Encoder
DC Internal DC
Pwr Pwr J/P-2
J-6 P-6 J-6 P-6
Take-up
Tension
APIS/CGEN
APIS/CGEN SCSI J/P-1 J/P-3 J/P-1 J/P-1 J/P-1
J/P20 Pellicle Spin Vacuum *
J-20 J-2 Capstan Cass Supply Control Cutter Home Switch
Tension Panel Sense Motor
P-20 P-2 ENC Sense Sense

Cutter
Supply "+" Pellicle
"+" Motor
Cutter Vacuum *
Supply "" Solenoid
W20 ""
W26

J/P1 J/P3A J/P-1

NOTES: Vacuum *
SCSI DC Pwr Capstan Motor
System will configure with one of the following: Motor
Internal RIP W27
CPSI
Take-up
APIS Cable to External RIP J1 P1 "+"

W22 Take-up
""
W28
HD
W29 Cut
Platen * Only on the
AccuSet 1500
Diagnostics

4.7.2 CABLING AND CONNECTORS

Capstan Motor Connector

P704-8 (5) This connector connects the capstan
1
(9,5) to the P704 0f the IEC board. The sup-
2 P704-7 ply and take-up motor drive signals
also share this cable.
3
4

IEC P704 Connector

1 This connects the drive signals for the
2 capstan, take up, and supply motors.
3 SUP - 2 (9,3)
4 SUP - 1 (3)
5 T/U - 1 (7)
6 T/U - 2 (9,7)
PL1 - 2 (9,5)
7
PL1 - 1 (5)
8
IEC Power P3 Connector
1 TB2-5A (4)
TB2-7 (0) This connects the low voltage power
2 supply (LVPS) to the IEC.
3 TB2-8 (6)
4 TB2-5A (4)
5 TB4-2 (0)
6 TB2-6A (0)
TB2-4 (0)
7
TB4-1B (2)
8
TB4-1B (2)
9
10 TB4-1B (2)
11 TB4-2 (0)
TBB4-2 (0)
12
13 RI (7)
RI (7)
14

4-23
AccuSet Service Manual

Disk Power Connector

TB4-1B (2) This connector supplies power to

4 the optional hard disk.
TB2-6B (0)
3
2 TB4-2B (0)

1 TB2-5A (4)

P5 RIP Power Connector

1 TB4-2B (0) This connector supplies DC power

2 TB4-2B (0) from the LVPS to the optional RIP
PCB.
3
4 TB4-1A (2)
5 TB4-1A (2)
6 TB4-1A (2)

P6 RIP Power Connector

This connector supplies DC power

1 From the LVPS. to the Optional
2 TB4-1A (2) internal RIP PCB.

3 TB2-5B (4)
4
5 TB4-2B (0)
6 TB2-6B (0)

4-24
Diagnostics

Imager Fan Connectors

7 The top illustration connects to the

1 fan that cools the interior of the
imager assembly.
2 The fan is connected to the 12 Vdc
supply and turns on with that supply.
3 8,9
The bottom illustration shows the
cable that connects the LVPS to the
upper connector. The two wires are a
twisted pair for noise suppression.
3
2
1

TB2-6 TB2-5

(9, 8) (7)

Aperture Motor Connection.

1
2 IEC filter aperture drive and sensor
3 Green connector from the imager assembly
4 Black
Blue
Motor
5
6 Red
7
8
9
10 Black Signal 3
11 Blue + 5 VDC 2
12 Red Ground 1
P2 P1

4-25
AccuSet Service Manual

IEC P523 Spin Encoder Connector

Pin Wire Color
No 1000 1500 Function
1. Black Black Ground
2. White White Z
3. Brown Orange /Z
13579 4.
5.
Shield
NC
Shield
NC
Ground
No connection
2 4 6 8 10 6.
7.
Red
NC
Red
Ground
+5Vdc
Jumpered to pin 4
8. NC NC No connection
9. Green Green /A
10. Blue Blue A

IEC P522 Spin Motor Drive Connector

Pin Wire Color
No 1000 1500 Function
1. NC NC No connection
1 2 2. Yellow Yellow +5 Hall sensor
3. Brown Brown S3 Hall sensor
3 4 4. Blue Blue S3 Hall sensor
5 6 5. Orange Brown S1 Hall sensor
6. White Violet Ground Hall sensor
7 8 7. Shield Shield Motor case
9 10 8.
9.
Red
Green
Red
Black
Phase A
Phase B
10. Black Green Phase C

IEC P703 Capstan Motor Encoder

10 9 The following shows the color of the wire that

connects to each pin.

8 7 1 Green
2 Yellow
3 Brown
6 5 4 Empty
5 Blue
6 Red
4 3 7 Empty
8 Empty
2 1 9 Black (To internal shield)
10 White

4-26
Diagnostics

Cabinet or ENC Fans

The top illustration connects to the left

and right fans that cool the rear elec-
1 (7) tronics section of the AccuSet cabinet.

2 These fans are wired to the connector

3 (9,7) in parallel and turns on with the 24
Vdc supply.
4
The bottom illustration shows the
cable that connects from the LVPS to
the upper connector. The two wires
are a twisted pair for noise suppres-
sion.

(9,7) (7)

4-27
AccuSet Service Manual

P4 and P5 Connectors
P709-13 (5)
1 These inline connectors provide
6 P709-14 (0) noise shielding for the motor encoder
2 signals.
7 P709-15 (4) The top illustration is P5, the supply
3 encoder connector.
8 P709-16 (3)
4 The bottom illustration is P4, the take-
9 up encoder connector.
P709-17 (2)
5

P709-1 (5)
1
6 P709-2 (0)
2
7 P709-3 (4)
3
8 P709-4 (3)
4
9 (2)
5 P709-5

IEC to Cutter Connections

1 PC-1 (7) The top illustration shows P55 of the

2 PC-2 (9,8) IEC.

3 J1-2 (3) The bottom illustration shows P1 that

J1-3 (9,3) connects to the cutter sensor.
4 (7)
5 J1-1 The PC-1 and PC2 are the cutter
motor drive signals. The cutter motor
connectors are not shown.

1 P55-5 (1)
2 P55-3 (2)
3 P55-4 (8)

4-28
Diagnostics

Connectors P2 and P3

1 P709-12 (5) P2 and P3 plug into the tensioner

potentiometer PCBs and connect to
2 P709-11 (4) P709 of the IEC PCB..
3 P709-9 (3)
The top illustration, shows the supply
connector.

1 P709-7 (0) The bottom illustration shows the

2 P709-8 (1) take-up connector.

3 P709-10 (2)

Cassette Sensor P1

1 P709-21 (0) This connects the cassette sensor to

2 P709-19 (3) P709 of the IEC PCB.

3 P709-20 (2)

IEC to Vacuum System

These two plugs connect the IEC to

J20-2 the vacuum system.
1 2
The top plug shows the bulkhead
J20-4 mounted connector on the vacuum
3 4 pump assembly.

J20-1 The bottom plug shows the J20 on the

IEC.
J20-3
Pins 2 and 4 are ground.
Pin 1 is the NO_VAC signal
P1-1 (4) from the vacuum switch
1 Pin-3 is the VAC_PWR drive
P1-2 (0)
2 signal for the vacuum motor
P1-3 (2) and solenoid, which are
3 wired in parallel.
P1-4 (0)
4

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AccuSet Service Manual

IEC J709 Connector

The following components connect to the IEC through P/J709:

The encoder for the supply and take-up motors

The cassette sensor
The potentiometers for the supply and take-up tensioner

P4-1 (5) P4-2 (0)

1 2
P4-3 (4) P4-4 (3)
3 4
P4-5 (2)
5 6
P2-1 (0) P2-2 (1)
7 8
P3-3 (3) P2-3 (2)
9 10
P3-2 (4) P3-1 (5)
11 12
P5-1 (5) P5-2 (0)
13 14
P5-3 (4) P5-4 (3)
15 16
P5-5 (2)
17 18
P1-2 (3) P1-3 (2)
19 20
P1-1 (0)
21 22
23 24
25 26

4-30
Diagnostics

Low Voltage Power Supply (LVPS)

The LVPS, shown below, provides the three direct current voltages that operate
the electronic and electromechanical components.

On newer models the manual line voltage select switch (SWX2) has been replaced
by an automatic select circuit.

LVPS
1 +5
TB4
2 +5 Return
SWX 2 1
2 1 Unused
3 2 Unused
3 +24
TB2 4 +24 Return
5 +12
1 Load
TB1 2 Neutral 6 +12 Return
3 Ground 7 -12 Return
8 -12

Power Line Connection

To LVPS The top illustration shows the double
TB1 pole on/off switch.

1 3
The bottom illustration shows the rear
2 4 of the line cord socket. The lower
connection (4) connects directly to
the AccuSer cabinet frame and to the
(1) (6) LVPS TB1-3 connector.

(4)

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AccuSet Service Manual

Power Select Switch

2A 1A (3)
This circuit is used with the original
model LVPS. The new LVPS model
uses an automatic circuit that senses
2 1 (9,3) the line voltage and configures the
power supply automatically.

2B 1B

To LVPS 1
SWX2
2
3
4
5

4-32
PUP

CHAPTER FIVE: PUP

5.1 MODULE OVERVIEW

The AccuSet Photo Unit Processor (PUP) program is a software tool to aid the
manufacturing or field service technician in aligning and verifying the AccuSet
writing engine. Manufacturing system burn-in of the writing engine is also sup-
ported. The PUP resides in ROM on the AccuSet engine control module and runs
with or without the RIP being present.

The PUP fulfills its functions by writing special test patterns on the media and by
providing special machine controls (such as turning the laser beam on or off).

The PUP test patterns are examined to verify image quality.

5.2 CONSTRAINTS/LIMITATIONS

The following paragraphs describe the PUPs constraints and limitations.

5.2.1 CONSTRAINTS

1. The PUP patterns do not try to emulate normal test and graphics output;
that is, no font characters or pictures are produced.

2. The AccuSet PUP will not provide the full set of patterns found in the
9800 PUP, but will provide a minimum set of patterns for image quality
measurement (see paragraph 5.9, Pattern Descriptions).

3. A line width of 108 picas (18 inches) will not be supported.

4. One of the PUP patterns must be available to the user. An entry point will
be provided so that the operating software may call the PUP when com-
manded by the control panel.

5. A RIP will not be needed to run the PUP.

5.2.2 LIMITATIONS

The AccuSet PUP has the following limitations due to limited ROM space and soft-
ware limitations.

1. No IEEE type of composite test page (one page containing many different
patterns, text, graphics and halftone photos) will be provided. A simpler
composite page is provided. See paragraph 5.9, Pattern Descriptions.

2. Any halftone pattern, with the exception of 50% and 100% tints, will not
run 1800 and 3000 dpi because stop start operation is out of the question
and full speed operation would require more buffer space than is avail-
able.

3. The screen patterns will be limited to size 6 x 12 pixels at 1200 dpi (dou-
bled at 2400).

5-1
AccuSet Service Manual

5.3 FUNCTIONAL REQUIREMENTS

The functional requirements are discussed here. See also paragraph 5.4, User
Interface Requirements, for details on executing the commands.

5.3.1 IMAGE QUALITY TEST PATTERNS

The PUP makes it simple for the user to generate test copy. The main vehicle for
generating copy is the Command File. Only two simple parameters are needed
with the command file, the file number and the resolution. The parameters associ-
ated with a pattern are fixed within the command file and cannot be specified by
the user. The user is able, through another command, to also run patterns specify-
ing the parameters.

Support commands are also provided to change various parameters and display
errors. These and other commands are described in detail in paragraph 5.4, User
Interface Requirements.

The CF number, density, date, machine serial number, and resolution are printed
with the pattern as part of the CF file. The machine serial number is kept in non-
volatile RAM; the date must be entered each time the PUP is used.

See paragraph 5.9 for a detailed description of the patterns. See paragraph 5.10 for
a list of the CF files.

5.3.2 ALIGNMENT ROUTINES

The PUP will give the user the ability to control certain machine functions in order
to align the machine. The spin clock and write beam can be turned on or off, for
example. The density register can be set to specified values.

5.3.3 SHARED CODE

The PUP runs as part of the application. The imaging code is shared. The PUP
software fills the image buffer, rather than the RIP filling the buffer via the RIP
interface hardware. The buffer is output by the same controlling software or imag-
ing code as is used during normal output of RIP data.

The application software also handles control panel input and output and vali-
dates the PUP commands.

5.4 USER INTERFACE REQUIREMENTS

5.4.1 ENTERING COMMANDS

The user enters commands and receives feedback through a control panel consist-
ing of twenty-four keys and a 16 by 2 character display.

5-2
PUP

5.4.2 KEYPAD

The keypad consists of 24 keys. The function of the keys that relate to PUP are
described below.

CASS This key is used to access 10 cassette storage areas used to define
engine parameters that are media supply cassette dependent. The
machine parameters associated with each cassette are displayed all
at once and the range of cassettes is 0 to 9. The parameters become
the current and default engine parameters if the CASS key is fol-
lowed by ENTER or the underline cursor is positioned in the
Cassette Number field and ENTER is pressed.

SELECT This key preceded by the SYSTEM key and followed by the ENTER
key will initiate a soft reset of the engine. This key is also used to
cycle through defined options in several PUP sub menus. The
ENTER key is not allowed until the cursor is placed in the upper
left-hand portion of the display. This can be accomplished with
either of the ARROW keys.

ENTER This key is used to save a value or values selected or entered via an
action or setup key. The value or values are saved as the current
and default values.

ON LINE This key puts the engine into the OFF LINE state, where the engine
will not image from a RIP. This is used to allow the user to perform
action commands such as Media Feed, Load, Unload and Setup
New Engine Parameters. The engine must be in the OFF LINE state
before PUP can be entered. While in PUP mode, this key can be
used to cycle backwards through an option field.

FEED This key is used to initiate a media advance, if followed by the

ENTER key. The operator has the option before the ENTER key to
change the default media advance amount.

CUT This key is used to initiate a Pre-cut Media advance followed by a

media cut, if followed by the ENTER key. The operator has the
option, before pressing ENTER, to change the default Pre-cut Media
advance amount.

LOAD This key, followed by ENTER, allows the user to initiate media ten-
sioning after media has been manually threaded from the supply to
the take-up cassettes.

UNLOAD This key, followed by ENTER, causes the media tension to relax,
and the media to rewind into the supply box. A small tail of media
remains extended for reloading.

TEST The PUP is entered in this command if the appropriate password is

entered in the number field. Once in PUP, this key can be used to
get back to the uppermost PUP menu from any level.

CLEAR This key is used to clear keying errors while in number fields as
well as clearing error messages from the display.

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AccuSet Service Manual

ARROWS The right and left arrow keys are used to move from field to field in
some of the action and setup messages. The underline cursor
moves with the arrow keys to indicate the current field position.

NUMBERS Some of the action and Setup commands need the ability to
increase/decrease or otherwise change a value. These can be han-
dled by the number keys.

5.4.3 INVOKING THE PUP

The procedure for invoking the PUP and entering commands is:

1. Reset the machine and wait for the Boot Tests to complete and the oper-
ating software to begin.

2. Wait for the machine to go ON LINE.

3. Press the ON LINE key to enter OFF LINE mode.

4. Press the TEST key and enter the password, 777, followed by ENTER key,
once the cursor is positioned in the upper left-most part of the display.

5. The display will show the version number. The CLEAR key can be used to
clear the display. After the version number is cleared from the display, the
upper level menu commands will be displayed (Align, Patterns, Params,
Errs and Exit).

6. Commands and parameters can now be entered as described in each

command description.
To exit the PUP:

1. Press TEST to enter the main menu. Press the ENTER key while the cursor
is positioned in the Exit field.

5-4
PUP

5.5 PUP MAIN MENU

The PUP Main Menu can be accessed at anytime via the TEST key. The entries
are: Align, Patterns, Params, Errs and Exit.

Move the cursor, using the arrow keys, to the desired entry and press ENTER.

The main menus and their sub menus are:

Align

Wr Density
V-Lines
Load Params
Filter Mtr
Laser Diode
Leading Mtr
Spinner Mtr
Exit

Patterns

CF File
Pat
Resolution
No Media Load
Burn-in Once
B-List
Exit

Params

Exp. Start, Inc

Date
Set/Disp. Params
F2C0P Start
Serial No.
Exit

Errs

Abort Imaging
Display Errors
Clear Errors
Exit

5-5
AccuSet Service Manual

5.5.1 ALIGN

This command field lets the user enter alignment mode. Alignment mode can be
entered by pressing the ENTER key while the cursor is positioned in the Align
field of the upper level menu. The alignment mode must be entered before other
alignment commands will execute. Also, the alignment mode must be exited
before other (pattern generation) commands will execute. Entering alignment
mode will turn on the write beam and enable the Calibrate signal. The resolution
is set to 1200 dpi upon entry.

All of the alignment mode commands can be cycled via the SELECT key once in
alignment mode. The commands and their parameters can be activated with the
ENTER key when the cursor is positioned in the upper left corner of the display.

5.5.2 WR DENSITY

This command writes the specified parameter values to the density register. The
value is in decimal (0 to 4095). This value is written directly to the DAC without
being converted with the System Power Number algorithm. The register is written
immediately; the value written is used for the density value for the lines drawn via
V-Lines and can be modified any time while the lines are drawn.

5.5.3 V-LINES

This command will create a vertical line pattern in the image buffer and image it
continuously until this command is selected again to disable imaging. The first
parameter contains the ENABLE and DISABLE commands which can be selected
via the SELECT key. This field is used to Enable the output of a specified vertical
line pattern until DISABLE is followed by the ENTER key. The second parameter
contains the ON OFF and OFF ON selection which is used to specify whether the
vertical pattern is an On Off or Off On bits pattern. This field is also cycled via the
SELECT key. The second and third patterns can be written with values of 0 to
65535. These fields reflect the number of On Off or Off On bits dependent upon
the selection in the second field. The pattern will be built and enabled after the
ENTER key is pressed as long as ENABLE has been selected and the display cur-
sor is position in the upper left-hand portion of the screen.

NOTE: The vertical pattern does not have to be disabled to change

the pattern. The command can be executed again after modi-
fying the second, third, and fourth parameters while keeping
ENABLE selected. Also, to output a solid line pattern, 1-ON
and 0-OFF should be the input to the pattern generator. A 0-
ON and 0-OFF is an invalid combination and will cause
undesirable results.

5-6
PUP

5.5.4 LOAD PARAMS

This command allows the user to change certain software parameters that affect
imaging. These values can be changed while the vertical line pattern is enabled.
Both the action required to update the parameters in NVRAM as well as affecting
the IEC hardware is accomplished once the ENTER key is pressed after modifying
the parameter.

Mnemonic Name Range Default

PXCLK Line Length Adjust 0 to 630 315

( 315 mils) (0 mils adjust.)
INDCAP Index to Capstan Adjust 100 to 255 100=.09 per
increment
RESV3
SPN6 System Power # for 600 DPI 0-870 870
SPN12 System Power # for 1200 DPI 0-870 870
SPN18 System Power # for 1800 DPI 0-870 870
SPN24 System Power # for 2400 DPI 0-870 870
SPN30 System Power # for 3000 DPI 0-870 870
F1COP Filter 1 Crossover Point 0-870 0
F2COP Filter 2 Crossover Point 0-870 0
TKPMIN Min DAC value for Take-up 0-255 0
SUPMIN Min DAC value for Supply 0-255 0
TKPMAX Max DAC value for Take-up 0-255 85
SUPMAX Max DAC value for Supply 0-255 85
ALEADS Phase A leads Phase B, Capstan 0-1 1
OFFS A Capstan Phase A Offset 0-255 128
OFFS B Capstan Phase B Offset 0-255 128
GAIN A Capstan Phase A Gain 0-255 170
GAIN B Capstan Phase B Gain 0-255 170
ATN A Capstan Phase A Attenuation 0-255 170
AA LAG Capstan Phase A Lag 0-255 28

5.5.5 FILTER MTR

This command, followed by ENTER, rotates the filter motor to one of four possi-
ble positions depending on which position was selected from the parameter field
(FILTER1, NO FILTER, FILTER2, or APERTURE) via the SELECT key. If the filter
motor is already in the position selected, the motor will not seek that position
again.

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AccuSet Service Manual

5.5.6 LASER DIODE

This command, followed by ENTER, turns the writing beam on or off depending
on which parameter was selected (ON or OFF).

5.5.7 LEADING MTR

This command, followed by ENTER, moves the Capstan motor to one of three
possible directions depending on which direction was selected from the parame-
ter field (FWD XXX, REV, or STP) via the SELECT key. The FWD direction has 10
possible selections. The first 5 run the capstan motor in lockstep with the spin
motor encoder signals at all of the five resolution speeds (FWD 600 LOCKED,
FWD 1200 LOCKED, FWD 1800 LOCKED, FWD 2400 LOCKED, FWD 3000
LOCKED). The second 5 FWD speeds run the Capstan motor with only the veloci-
ty loop at all of the five Resolution speeds (FWD 600, FWD 1200, FWD 1800,
FWD 2400, FWD 3000).

5.5.8 SPIN MTR

This command, followed by ENTER, turns the spin motor on or off depending on
which parameter was selected (ON or OFF).

NOTE: The spin motor will not stop immediately when the bit is
turned off. The motor will gradually coast to a stop.

5.5.9 EXIT

This command, followed by ENTER, exits alignment mode, turning off the refer-
ence and write beams, and returns to the upper PUP menu. Pressing the TEST
Key while in alignment mode will initiate the same action.

5.6 PATTERNS

The Pattern commands are used to produce copy. These commands can be
accessed by pressing the ENTER key while the cursor is positioned in the Pattern
field of the upper level PUP menu and then pressing the SELECT or ON LINE keys
to step through the selections.

5.6.1 CF FILE

This command executes a command file in order to print a diagnostic pattern. The
command files are numbered from 0 to 99 and are described in paragraph 5.10.
The CF number is entered in the first field using the number keys. The Resolution
is selected in the second field using the SELECT key. Printing commences after
pressing the ENTER key with the cursor positioned in the upper left corner of the
display. Paragraph 5.10 contains a list of the patterns and their parameters. A mes-
sage, CF:DN, is displayed on the Control Panel when the file is done imaging and
a CF:LOW when done imaging with a media amount in the Supply box that is less
than the ALARM amount.

5-8
PUP

5.6.2 PAT

This command allows the user to print a pattern with a list of parameters (usually,
this command is contained in a Command file). This command has five parameter
fields and their use differs from pattern to pattern. Imaging will commence after
the parameters have been entered and the ENTER key is pressed while the cursor
is in the upper left corner of the display. An audible tone signifies the pattern has
been completed. Also the IMAGING LED on the Control Panel is solid ON while
imaging and BLINKING when not. Paragraph 5.11 contains a list of the patterns
and their parameters.

5.6.3 RESOLUTION

This command sets the engine resolution. The resolution can be 600, 1200, 1800,
2400 or 3000 dpi. The resolution can be changed by pressing the SELECT key in
the parameter field to select 600, 1200, 1800, 2400, or 3000, then pressing ENTER
while the cursor is in the upper left portion of the display. The default setting is
1200 dpi.

NOTE: The CF files override the resolution set by this command.

5.6.4 NO MEDIA LOAD

This command allows the user to put power to the capstan, so that files can be
run without media loaded. The command can be activated by pressing ENTER.
The command must be re-executed before each run.

5.6.5 BURN-IN ONCE

This command runs a series of Command files, specified with the B-List com-
mand, that are imaged once. This command is activated upon pressing the ENTER
key.

5.6.6 B-LIST

This command allows the user to enter a list of burn-in files.

Press the ENTER key. The display now shows the list number (Bl, B2, etc.), the CF
number and the CF resolution. Press SELECT under the list position to go to the
next entry. Use the number keys to enter CF numbers, and use the SELECT key to
select resolutions. Press the ENTER key with the cursor in the upper left corner to
enter the file in the burn-in list. Up to five CF numbers and their resolutions can
be entered. If less than five numbers are being entered, then the last number
should be 255 to act as an end-of-list marker. Note that the CF numbers are 0-
99.

The list entered is used in subsequent burn-in commands. Exiting and re-entering
PUP will reset the list to the default values.

5.6.7 EXIT

This command followed by ENTER exits the Pattern menu and returns to the
upper PUP menu. Pressing the TEST key while in the Pattern menu will initiate
the same action.

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AccuSet Service Manual

5.7 PARAMS

The Params Menu contains commands that are used to alter default parameters
used in printing patterns such as Exposure Start and Increment. This menu can be
entered by pressing ENTER while the cursor is positioned under Params in the
upper PUP menu. The SELECT and ON LINE keys are used to cycle through the
command selections.

5.7.1 EXP. START, INC

This command sets the array of 24 trial exposure values used in the exposure pat-
terns (exposure flag on). Any pattern, except numbers 6, 9, and 11, can be printed
with the exposure array density values. Some CF files set the exposure flag for the
user or the flag can be turned on via the Set Parameter command. See paragraphs
5.10 and 5.11 for the CF file numbers or Pattern numbers.

The first parameter field is the first exposure value. The second parameter field
specifies the increment. For example, the two numbers 25 and 10 will produce
copy exposed at the 24 densities 25, 35, 45 of the display. Remember that valid
exposure values are 0 to 255. An increment that increases the exposure value to a
number greater than 255 will result in an exposure value of 255, the maximum.
The exposure array default setting is 100 with an increment of 3. These numbers
should bracket the mid-point density of 128 when running the 8 inch exposure
CF, CF 1, which does 16 bands.

5.7.2 DATE

This command enters the date that is printed with a CF file. The date is not stored
in non-volatile RAM. It must be entered each time the machine is turned on. The
date can be entered via the 3 parameter fields which are the Month, Day and
Year, in that order. The numbers are entered in decimal and can be stored by
pressing ENTER while the cursor is in the upper left portion of the display.

5.7.3 SET/DISP. PARAMS

These commands allow the user to display and/or change certain software param-
eters. Exiting and re-entering PUP will restore the default values for the parame-
ters that do not get saved in NVRAM.

NOTE 1: The values input by the user are not checked; invalid values
will cause unpredictable results.
NOTE 2: An NV for a default value indicates that the default is stored
in Non-Volatile RAM and is, therefore, the last value set by
the user.

5.7.4 F2C0P START

This function enables you to select the number of band pairs (F2C0P Start and
Dec). For example, a Start of 10 and a Dec of 1, produces a file with the first band
pair starting with the F2C0P 10 increments higher than the current set in NV RAM
with each consecutive band decrementing the F2C0P by a value of 1. The
eleventh band pair has the F2C0P equal to the current setting followed by 10
band pairs decrementing down from the current setting. A total of 21 band pairs
are created.

5-10
PUP

Mnemonic Name Range Default

rsv1 Reserved
rsv2 Reserved
pf Pause function 0-2 0
err Imager internal error code
prch Front Porch (in bytes) based on 600 DPI 14
(14 = approx. .188")
lwid Line Width based on 600 DPI 8100
nold Leading OFF Flag 0 = leading on, 1 = off 0
ll Light Leak Delay 1 unit = .1 hours 10
pflag Pause Flag 1 = on, 0 = off 0
lfunc Line Function 0-2 0
c1 Pause Constant C1 Starting n for lines 10
c2 Pause Constant C2 Starting n for pauses 10
exflg Exposure Flag 1 = Run exp. array val. 0
0 = normal exposure
exlin Exposure segment in Lines based on 600 DPI 600
c3 Pause Constant C3 Constant for lines 0
c4 Pause Constant C4 Constant for pauses 0
pport PUP Port 0 = off, 1 = on 0
dmode Diagnostic Mode 0 = off, 1 = on 0
cksum Checksum of Image 0-65535 0
ftime Time in Milsecs/Filter Mtr Step 0-65535 100 NV
TNINIT Initial value of Tension DACS 0-255 7 NV
(used during LOAD MEDIA)
TENINC Increment value of Tension DACS 0-255 5 NV
(used during LOAD MEDIA)
SCLENS Scan Lens Correction Start Val. 0-255 0 NV
PLCVAL Page Length Correct Val 98.00% to 102.00% 10000 NV
For an explanation of the pause constants and functions, see paragraph 5.12. The
PUP Port flag turns on input from the RS232 port on the Engine Control Board.

5-11
AccuSet Service Manual

Mnemonic Name Range Default

(NVRAM)

A SBSTN L For AGFA media. Number of lines 0-4 1

to boost before a stop. Used at
600, 1200, or 1800 dpi.

A SDBST L For AGFA media. Amount of 0.0 - 100.0% 0

boost, in 0.1% increments, to
boost lines before a stop. Used at
600, 1200, and 1800 dpi.
A RBSTN L For AGFA media. Number of lines 0-4 0
to boost after a stop. Used at 600,
1200, and 1800 dpi.

A RDBSTL S For AGFA media. Amount of 0.0 - 100.0% 0

boost, in 0.1% increments, to
boost lines after a stop. Used at
600, 1200, and 1800 dpi.
A RDBSTL L For AGFA media. Amount of 0.0 - 100.0% 0
boost, in 0.1% increments, to
boost lines after a stop of 10 or
more seconds. Used at 600, 1200,
or 1800 dpi.

A PRECAL For AGFA media. Number of cali- 0 - 50 25

brate cycles to run before imag-
ing the first line after a stop.

A SBSTN H For AGFA media. Number of lines 0-4 1

to boost before a stop. Used at
2400 and 3000 dpi.

A SDBST H For AGFA media. Amount of 0.0 - 100.0% 0

boost, in 0.1% increments, to
boost lines before a stop. Used at
2400 and 3000 dpi.
A RBSTN H For AGFA media. Number of lines 0-4 1
to boost after a stop. Used at 2400
and 3000 dpi.

A RDBSTH S For AGFA media. Amount of 0.0 - 100.0% 0

boost, in 0.1% increments, to
boost lines after a stop. Used at
2400 and 3000 dpi.

5-12
PUP

Mnemonic Name Range Default

(NVRAM)

A RDBSTH L For AGFA media. Amount of 0.0 - 100.0% 0

boost, in 0.1% increments, to
boost lines after a stop of 10 or
more seconds in length. Used at
2400 and 3000 dpi.
O SBSTN L For non-AGFA media. Number of 0-4 0
lines to boost before a stop. Used
at 600, 1200, and 1800 dpi.

O SDBST L For non-AGFA media. Amount of 0.0 - 100.0% 0

boost, in 0.1% increments, to
boost lines before a stop. Used at
600, 1200, and 1800 dpi.
O RBSTN L For non-AGFA media. Number of 0-4 0
lines to boost after a stop. Used at
600, 1200, and 1800 dpi.

O RDBST L For non-AGFA media. Amount of 0.0% - 100.0% 0

boost, in 0.1% increments, to
boost lines after a stop. Used at
600, 1200, and 1800 dpi.
0 PRECAL For non-AGFA media. Number of 0 to 50 3
calibrate cycles to run before
imaging the first line after a stop.

O SBSTN H For non-AGFA media. Number of 0-4 0

lines to boost before a stop. Used
at 2400 and 3000 dpi.

O SDBST H For non-AGFA media. Amount of 0.0 - 100.0% 0

boost, in 0.1% increments, to
boost lines before a stop. Used at
2400 and 3000 dpi.
O RBSTN H For non-AGFA media. Number of 0-4 0
lines to boost, in 0.1% increments,
after a stop. Used at 2400 and
3000 dpi.
O RDBST H For non-AGFA media. Amount of 0.0 - 100.0% 0
boost, in 0.1% increments, to
boost lines after a stop. Used at
2400 and 3000 dpi.
AMNTUSED Value stored in tens of feet or in 0 - 99999 0
meters show how much media
had passed through the system.

5-13
AccuSet Service Manual

PROC CUT 0 - 10000 9

CASS FULL 0 - 10000 500

5.7.5 SERIAL NO.

This command changes the serial number that is stored in non-volatile RAM and
that is printed with the CF patterns. Because the serial number is stored in non-
volatile RAM, it does not have to be entered each time the machine is turned on.
The serial number can be entered in decimal, up to 65535, and can be stored by
pressing ENTER while the cursor is in the upper left portion of the display.

5.8 ERRS

The Errs Menu contains commands that are used to display errors and clear the
error log. Abort is also found here. This menu can be entered by pressing ENTER
while the cursor is positioned under Errs in the upper PUP Menu. The SELECT
and ON LINE keys are used to cycle through the command selections.

5.8.1 ABORT IMAGING

This command aborts the printing of a pattern. This command can be executed by
pressing ENTER.

5.8.2 DISPLAY ERRORS

This command displays the last, up to 50, errors that occurred. The errors are kept
in NVRAM. All system errors, not just PUP errors are logged. If an error occurs
twice in a row, the second occurrence is NOT logged. Each error is displayed for
two seconds. This command can be executed by pressing ENTER.

5.8.3 CLEAR ERRORS

This command clears the error log that is kept in NVRAM. See the Display Error
Log command. This command can be executed by pressing ENTER.

5.9 PATTERN DESCRIPTION

The following paragraphs provide a brief description of each test pattern listed
below.

Exposure
HOR & VERT Rulings
Incremental Leading
Halftone Screens
HOR & VERT Lines
Vertical MTF
Horizontal MTF
Fog Test
Checkerboard Squares
Square Dots
One Inch Grid with Targets
One Inch Grid with Patterns

5-14
PUP

5.9.1 EXPOSURE

The exposure test pattern consists of equal sized horizontal bands of video data
each exposed at an incrementally higher laser power level than the preceding
band. The intensity control port is used to vary the exposure level.

The test consists of two different video data patterns; 141 lpi halftone screens at
50%, and 100% pattern densities.

5.9.2 HOR & VERT RULINGS

The rulings consist of scales that extend both horizontally and vertically over the
full specified page dimensions. The resultant grid is at a fixed size of 1/10 inch
with the line thickness being variable.

5.9.3 INCREMENTAL LEADING

The incremental leading test consists of inserting calibrated pauses to the leading
system while writing 1-ON x 2-OFF horizontal lines or a 50% screen at maximum
throughput. This simulates RIP interrupts to the normal writing mode of varying
durations and repetition rates. The key factor is to assure that such starts and
stops produce no visible effects in copy.

5.9.4 HALFTONE SCREENS

This test consists of producing halftone screens of size 6 x 12 pixels (at 1200 dpi)
which are 141 cycles per inch. One hundred shades of grey are supported (for the
sake of percentages). Some percentages are produced by alternating plus or
minus one dot, every other screen line. Each incremental grey level will be repre-
sented by a full width horizontal stripe on copy.

In addition to the stripes of halftone screen samples, large full page samples of
several key grey tones will be produced.

The screens are produced at 1200 and 2400 dpi only.

5.9.5 HOR & VERT LINES

Horizontal and vertical lines represent a whole category of test patterns. The vari-
ables are line width and spacing, both in pixels. Vertical lines highlight pixel tim-
ing errors and cross scan characteristics. Their position on the scan axis provides a
measure of variation of these characteristics over the image plane. Horizontal lines
highlight leading, and cross scan height characteristics. The intent of these pat-
terns is not to isolate any given fault mechanism but rather to measure the com-
bined effect of them all. The line widths will be chosen to test the worst case
combinations of the fault mechanisms.

5-15
AccuSet Service Manual

5.9.6 VERTICAL MODULATION TRANSFER FUNCTION

This test consists of generating sets of ON/OFF horizontal line pairs over a wide
range of spatial frequencies. The vertical axis spatial frequency is varied by chang-
ing the width of the horizontal line and space. The key characteristics of the pat-
tern to observe are the contrast ratio between the ON and OFF lines and the vari-
ation of this with position on the scan axis. This is a measure of the Writing
Engine vertical resolution.

5.9.7 HORIZONTAL MODULATION TRANSFER FUNCTION

This test consists of generating sets of ON/OFF vertical line pairs over a wide
range of spatial frequencies. The key characteristics of the pattern to observe are
the ON/OFF contrast ratio and the variation of this along the scan axis.

5.9.8 FOG TEST

In this test the leading stops every 0.2 inches for a calibrated amount of time
while printing a pattern. The pattern is a full width of 6-ON by 6-OFF vertical
lines. The time at each stop is the maximum time that the media sensor LEDs are
left on. The number of lines printed between stops is equivalent to a band for
an Image Control System having a 1 Megabyte buffer. The object of this test is to
check that any stray emissions dont create a visible effect or fogging during the
maximum stop length and stop frequency.

5.9.9 CHECKERBOARD SQUARES

This pattern consists of equal size black and white squares. Rows of the squares
alternately begin with black then white squares. The squares can be used to pro-
duce the equivalent of various square screen sizes at fifty percent (and with a 45
degree angle).

5.9.10 SQUARE DOTS

This pattern consists of square dots placed at a 45 degree angle. The result is the
same as certain densities of a square screen. For example, a 6 x 12 screen with 4
dots turned on results in squares, 2 pixels on a side. The pattern requires only 3
different scan lines of data, thereby being easy to produce at all resolutions. The
dots can be white in a black field or black in a white field.

5.9.11 ONE INCH GRID WITH TARGETS

The one inch grid with targets, otherwise known as the Flying Geese, is a
repeatability test pattern. The targets consist of 2 pixel squares arranged in a V
formation, thus evoking the geese name. The grid consists of 4 pixel lines at one
inch intervals in both the horizontal and vertical directions. Note that at the inter-
secting points of the grid lines, the lines are dashed so that automatic measuring
equipment can better find these intersections. This pattern runs at 1200 dpi only.

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PUP

5.9.12 ONE INCH GRID WITH PATTERNS

A one inch grid is produced with some sections containing other patterns. The
grid is unbroken over the outer boarders. The other patterns produced within the
grid are: 1 x 2 horizontal lines, 1 x 4 vertical lines, a 6 x 6 checkerboard, and all
black. Note that at the intersecting points of the grid lines, the lines are dashed so
that automatic measuring equipment can better find these intersections. This pat-
tern runs at 1200 dpi only.

5.10 COMMAND FILE LIST

The CF command takes two numbers. The first number is the CF number all of
which are described below. The second number is the resolution. Some CFs look
the same at all resolutions. For example, the 50% tints (checkerboards) are adjust-
ed to produce the equivalent of the 50% 141 line screen at 1200 dpi. The horizon-
tal and vertical line patterns are not adjusted.

Certain files, such as tints, will not run at all resolutions. An error, Bad com-
mand, is generated. This resolution restriction is noted under the file description,
below.

CF 01 Horizontal Exposure using the first 16 exposure values, set by the

Exposure Array command. Two screens, 50% and 100%, are alternated
across the line in one inch blocks. Length = 8 inches.

CF 02 50% 141 line tint for 18 inches.

CF 03 50% 141 line tint for 6 inches.

CF 04 94.4% 141 line tint for 6 inches.

CF 05 Exposure Test using 24 exposure values, set by the Exposure Array

Command, and one screen, a 100% screen for a total of 12 inches.

CF 06 Horizontal Lines, 1 x 2 for 6 inches

CF 07 Vertical Lines, 1 x 2 for 6 inches

CF 08 Grid, 0.1 spacing, .001667" lines for 18 inches. Note that the line thick-
ness has been changed (from previous products) to accommodate all
resolutions. The thickness is equivalent to 1 pixel lines at 600 dpi.

CF 09 Reserved.

NOTE: BAD COMMAND is displayed when outputting reserved com-

mands, or if CF files are run at unsupported resolutions.

CF 10 Vertical line pairs for 7 inches. The On Off pairs are: 1 x 1, 1 x 2, 2 x 2,

3 x 3, 4 x 4, 6 x 6, and 10 x 10, each for 1 inch

CF 11 Horizontal line pairs for 7 inches. The On Off pairs are: 1 x 1, 1 x 2,

2 x 2, 3 x 3, 4 x 4, 6 x 6, and 10 x 10, each for 1 inch.

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AccuSet Service Manual

CF 12 A 50% tint with stops. Seven one inch deep bands are printed. Each
band has a different line and pause value. They are: lines, pauses;
300,1; 300, 2; 300, 4; 501, l; 501, 2; 501, 4; 501, 20. Pauses are in units of
100 milliseconds (1/10 second).

CF 13 1 x 1 horizontal lines with stops. 18 inches are printed with a starting

pause of 1 and a starting line count of 300. Both the pause and line
count increase by 1, every stop. Pauses are in units of 100 milliseconds
(1/10 second).

CF 14 Fog Test: a 6 On, 6 Off vertical line pattern with increasing length paus-
es. The pattern is placed in the middle two inches of the page with
tick marks at the pauses. Pauses are every 600 lines for increasing
pause lengths. The first pause is 1 second and increasing by 1 second.
Total length is 10 inches.

CF 15 A 94.4% tint with stops. 18 inches are printed with a starting pause of 1
and a starting line count of 300. Both the pause and line count increase
by 1, every stop. Pauses are in units of 100 milliseconds (1/10 second).

CF 16 95% tint for 18 inches with 10 second stops every 1/2 inch. This pattern
runs at 1200 dpi. only.

CF 17 Reserved.

CF 18 Reserved.

NOTE: BAD COMMAND is displayed when outputting reserved com-

mands, or if CF files are run at unsupported resolutions.

CF 19 Horizontal Lines, 1 x 1 for 1/2 inch followed by Vertical Lines, 1 x 1 for

1/2 inch followed by Horizontal Lines, 1 x 2 for 1/2 inch followed by
Vertical Lines, 1 x 4 for 1/2 inch followed by Checkerboard squares, 6 x
6 for 1/2 inch followed by Solid Black for 1/2 inch.

CF 20 Left Margin Measurement Scale, a ruler pattern with a longer line at 1/4
inch from beginning of scan, for checking margin alignment.

CF 21 95% tint for 18 inches with 10 second stops every 1/2 inch. This pattern
runs at 2400 dpi. only.

CF 22 One inch grid with fiducials for a length of 18 inches. This CF will run
at 1200 dpi only.

CF 23 One hundred shades of grey, one half inch for each shade. This pattern
runs at 1200 and 2400 dpi only.

CF 24 Shades of grey, the short version. Percentages 1 to 10 and 91 to 100 are

produced. This pattern runs at 1200 and 2400 dpi only. At 2400 dpi 2
even amounts are output across the width of the page with a large
white space in the middle of the page to separate the 2 halves of the
halftone screen.

CF 25 Parameter Dump. Prints out all the parameters found in the Load
Params menu in PUP and associated values.

5-18
PUP

CF 26 1200 dpi only. Represents of the DBOOST values used for 600, 1200
and 1800 dpi. Consists of 3 four inch bands of 85%, 90%, and 95% tints
with stops every inch. These patterns are printed with 8%, 10%, and
12% DAC BOOSTs. The stop length is set from the SET/DISPLAY
PARAM C2 Parameter.

CF 27 2400 dpi only. Represents DBOOST values for 2400 and 3000 dpi.
Consists of 3 four inch bands of 85%, 90% and 95% tints with stops
every inch. These patterns are printed with 8%, 10% and 12% DAC
BOOSTs. The stop length is set from the SET/DISPLAY PARAM C2
Parameter.

CF 28 One inch grid with patterns. Four sections or one inch bands are filled
in with 1 x 2 horizontal lines, 1 x 4 vertical lines, a 50% tint and a 100%
tint. This CF will run at 1200 dpi only.

CF 29 Filter 2 cross over point (F2C0P) for density variations due to tempera-
ture. The file outputs 1/2 bands separated by 1/10 white spaces
between bands and 3/10 white spaces between band pairs. A band
pair consists of the two 100% screens. The first (top) band runs using
Filter 2 with a consistent density, the second band is run using Filter 1
with a varying density due to the varying F2C0P. The number of band
pairs to be run is selectable and is controlled by a function found under
the Params menu. The operator must choose the correct resolution for
the file. This is determined by choosing the resolution where the
System Power Number (SPN) is closest to the current.

Special Test Files:

CF 30 Light Leak Test. Customized to match the dimensions of the AccuSet

media path.

CF 31 Scratch Test.

CF 32 Reserved for a Customer Test File.

CF 33 Reserved for a Customer Test File.

CF 34 100% tint FOREVER. This is a special Leading Electrical Adjustment file.

A No Media Load is executed.

5.11 PAT COMMANDS

The following lists the pattern numbers and parameters associated with the PAT
command:

PAT 01 Grid or Graph, 2 parameters: line thickness in pixels and length in

tenths of inches.

PAT 02 Halftone Screens with a Single Density, 2 parameters: Density in per-

centage (l to 100) and total lines. This pattern will run at 1200 and 2400
dpi only.

PAT 03 Horizontal Lines, 3 parameters: On lines, Off lines, and total lines.

PAT 04 Vertical Lines, 3 parameters: On lines, Off lines, and total lines.

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AccuSet Service Manual

PAT 05 One Inch Grid with Fiducials, One parameter total lines. (Run at 1200
dpi only.)

PAT 06 Square Dots, 3 parameters: white size, black size, and total lines. The
total of the white and black should add up to an even number. The
total of the black and white is equal to the horizontal width of a screen,
for example, 12 for a 6 x 12 screen. If black is greater than white, then
the result is a greater than 50% tint.

PAT 07 Checkerboard Squares (50% Halftones with variable size), 2 parameters:

Square (side) Size in pixels, and Total Lines.

PAT 08 Print CF Header, no parameters. The CF number, density, serial number,

and resolution are printed in that order. If the exposure flag is set, then
the exposure start and increment values are also printed. This pattern is
normally printed by a CF file and may produce unexpected results if
run alone.

PAT 09 Print Machine Settings. The mnemonic or setting name, as it appears in

the alignment menu, is printed along with the associated value in deci-
mal. One parameter specifies the machine setting to print, numbered 0
to 9, in the order it appears in the PUP alignment menu.

PAT 10 Multiple Pattern, a one inch grid pattern with sections of horizontal
lines, vertical lines, 50% tint and all black. One parameter Total Lines.
(Run at 1200 dpi only.)

PAT 11 Prints the number pattern. Used internally by CF files to print parameter
values. Up to 4 parameters, indicating the parameter position in the
parameter list. Zero ends the list.

PAT 12 Reserved.

PAT 13 Exposure pattern, one inch blocks of 50% tint alternating with all black.
One parameter, total lines.

5.12 PUP PAUSE FUNCTIONS

In order to simulate a RIP, the PUP has the ability to insert stops while printing a
pattern.

The length and frequency of the pauses are controlled by several parameters
accessed via the change parameter command.

Mnemonic Name Range Default

pf Pause function 0-2 0

pflag Pause Flag l = ON, O = OFF 0
lfunc Line Function 0-2 0
c1 Pause Constant C1 Starting n for lines 300
c2 Pause Constant C2 Starting n for pauses 10
c3 Pause Constant C3 Constant for lines 0
c4 Pause Constant C4 Constant for pauses 0

5-20
PUP

Both the pause time, in units of 100 milliseconds (1/10 second), and the number
of scan lines between pauses can be specified. The pause or line function controls
how the lengths change. Constants C1 and C2 are used for starting values.
Constants C3 and C4 are used for a constant (see function 1).

The Functions all start with the number N = C1 for lines and C2 for pauses. The
line function or pause function can be set to 0 through 2 where:

Function 0 is Next N = last N (always stays at starting n)

Function 1 is Next N = last N plus constant.
Function 2 is Next N = random (last n).

Finally, the pause flag must be set to 1 to turn on the pauses during the next pat-
tern generation.

For example, setting the pause function to 1, the line function to 0, the starting n
for lines (C1) to 64, the starting n for pauses (C2) to 1, and the pause constant
(C4) to 1, will cause a pause to happen every 64 lines. The pause length will start
at 1 and increase by 1 every pause.

5-21
Procedures

CHAPTER SIX: PROCEDURES

6.1 INTRODUCTION

Chapter 6 describes the procedures to be used when removing, replacing, aligning

or adjusting components in the AccuSet system. The first part of chapter 6 con-
tains the removal/replacement procedures. The alignment/adjustment procedures
are described at the end of the chapter.

6.2 REMOVAL/REPLACEMENT PROCEDURES

The following paragraphs describe the removal/replacement procedures.

6.2.1 FRONT, LEFT AND RIGHT COVER

Tools Required: None

1. Gently pull the lower corners out to disengage the strike from the latch
mechanism.

2. Lift the cover straight up to remove.

Replacement

1. Reverse the order of the removal procedure taking care not to damage
the strike or latch mechanism.

6.2.2 REAR PANEL (ELECTRONIC ENCLOSURE)

Tools Required: 1/4" Nut driver

1. Remove the screw at the top of the panel.

2. Lift the panel straight up and out to remove.

Replacement

1. Insert the bottom of the panel over the lip on the rear of the unit.

2. Slide the panel down while ensuring the top lip on the panel engages
with the mounting panel.

3. Re-install screw removed in step 1.

6-1
AccuSet Service Manual

6.2.3 TOP COVER ASSEMBLY

Tools Required: 5/16", 1/4" Nut drivers, small flat blade screwdriver

1. Remove the left and right side covers and the rear.

2. Unplug the phone jack connector from J8 on the IEC.

3. Remove the upper-right corner screw that grounds the control panel cable
to the IEC and the cabinet.

4. Unwind the control panel cable cutting any tie wraps that hold the con-
trol panel cable to the imagesetter wiring.

5. Remove the two screws securing the cover mounting bracket to the
frame.

6. Lift the top covers to the upright position.

7. Rotate the cover and mounting bracket toward the rear of the unit and lift
the entire assembly out.

6.2.4 TENSIONER ASSEMBLY

Tools Required: 5/16" Nut drivers, small flat blade screwdriver

Removal

1. Remove the light seal strip from around the tensioner by lifting the four
plastic clips which secure the seal.

2. Remove the four nuts that secure the tensioner.

3. Insert a thin blade screwdriver between the tensioner and the media
frame (front) and gently disengage the locking tab on the tension from
the media frame.

4. Lift the tensioner assembly up to expose the potentiometer connectors

located at the front of the unit.

5. Remove the connectors from the potentiometers.

6. Remove the tensioner assembly from the system.

Replacement

1. Place the tensioner into the system, such that the rear of the tensioner is
down and the front is raised slightly to give access to the potentiometer
connectors.

2. Install the connectors on the potentiometers ensuring that the supply side
potentiometer (left) is connected to the wiring marked supply and that
the take-up side potentiometer (right) is connected with the wiring
marked take-up.

6-2
Procedures

3. Seat the tensioner assembly over the mounting screws, push the assembly
toward the rear of the unit and ensure the retaining tab on the tensioner
locks into the media frame.

4. Re-install the hardware that was removed in step 2 of the removal proce-
dure, but do not tighten.

5. Push the tensioner against the stops on the media frame and tighten the
mounting hardware while holding the tensioner in position. The rear of
the tensioner is moved to the left while the front is moved to the right.

6. Re-install the light seal strip removed in step 1 of the removal procedure.

7. Perform the electronic alignment procedure. Refer to 6.3.1.

Rear of
AccuSet

Figure 6-1 Tensioner Assembly

6.2.5 TENSIONER POTENTIOMETERS/PCB

Tools Required: 1/4" Nut drivers, 5/64" Allen wrench

Removal Procedure

1. Remove the tensioner assembly from the system.

2. Remove the screw securing the potentiometer to the tensioner.

3. Loosen the set screw on the tensioner roller pin.

4. Remove the potentiometer/PCB.

6-3
AccuSet Service Manual

Replacement Take-up Side

1. With the component side of the PCB facing toward you, rotate the shaft
on the potentiometer fully counterclockwise on the take-up side (-501) or
fully clockwise for the supply side (-502).

NOTE: A common PCB blank is used for both potentiometers. Read

the dash condition on the component side.

2. Insert the potentiometer shaft into the coupling (a slight adjustment to the
shaft may be necessary to line the flat on the shaft to the flat on the ten-
sioner pin) and mount the PCB to the tensioner using the hardware
removed in step 2 of the removal procedure.

3. Tighten the set screw on the coupling.

4. Re-install the tensioner into the media frame.

5. Perform the Electrical Alignment procedure. Refer to 6.3.1.

Figure 6-2 Media Transport

6-4
Procedures

6.2.6 DRIVEN NIP ROLLER/DOOR AND CUTTER COVER AS SINGLE UNIT

1. Loosen the two thumb screws on the cutter cover.

2. Lift the assemblies out together.

Replacement

1. Reverse the order of steps one and two in the removal procedure.

6.2.7 DRIVEN NIP ROLLER/DOOR ASSEMBLY

Removal

1. Lift the door assembly to the upright position.

2. Remove the five nuts securing the stiffener plate to the door.

3. Lift the door assembly straight up to disengage the hinges from the cutter
cover.

Replacement

1. Slide the door hinges into position on the cutter cover.

2. Re-install the stiffener plate.

6.2.8 DRIVER NIP ROLLER

1. Remove the Driven Nip Roller/Door and Cutter cover as a single unit.

2. Loosen the two set screws on the coupling (roller side) attaching the
roller shaft to the motor.

3. Lift the roller which includes bearings from the mounting blocks.

Replacement

1. Insert the roller/bearings into the coupling and seat the bearing in the
mounting blocks.

2. Position the roller such that the flats on the shaft line up with the set
screws in the coupling, and tighten the set screws. Ensure that there is no
friction between the coupling and bearing. (There is a little side to side
play in mounting blocks.)

3. Re-install the cutter cover and door assembly.

6-5
AccuSet Service Manual

6.2.9 TAKE-UP MOTOR

Removal

1. Remove the cutter cover and driven nip/door assembly.

2. Remove the nut securing the motor cover and remove the cover.

3. Loosen the set screws on the coupling at the motor side.

4. Disconnect the power and ground wires from the motor.

5. Remove the screws (2) from the encoder cable and unplug.

6. Lift the motor out of mounting block and retain the light seal (located
between the motor and coupling).

Replacement

1. Reverse the order of the removal procedure.

NOTE: The motor rests in a V block and is retained by the cover.

Ground connection mounts with the spade lug facing down-
ward.

6.2.10 CUTTER MOTOR

Removal

1. Remove the cutter cover and driven nip roller/door assembly.

2. Remove the nut securing the motor cover and remove cover.

3. Remove the screws securing the mounting clamp and remove clamp.

4. Remove wires from motor.

5. Lift the motor from mounting block.

Replacement

1. Position the cam assembly on the motor so that it is orientated as shown

in figure 6-3.

2. Install the thrush bushing into the end of the cam.

3. Position the motor into the V-block so that the bushing butts up to the
sensor housing.

4. Re-install the clamp and screws removed in step 3 of the removal proce-
dure, maintaining the orientation shown in figure 6-3.

5. Attach wiring to motor (white wire to pin 1, white and black wire to pin 2).

4. Re-install the motor cover, cutter cover, and driven nip roller/door.

6-6
Procedures

Figure 6-3 Cutter Motor Assembly (Showing Proper Orientation)

6.2.11 PLATEN ASSEMBLY

Removal

1. Remove the cutter cover and driven nip roller/cover assembly.

2. Remove the screws securing the assembly to the media frame (2 screws,
one on each end).

3. Lift the platen assembly straight up.

Replacement

1. Reverse the removal procedure.

6-7
AccuSet Service Manual

6.2.12 CUTTER ASSEMBLY

1. Remove the cutter cover and driven nip roller/cover assembly.

2. Remove the Platen Assembly.

3. Remove the screw securing the spring to the cutter shaft.

4. Remove the four screws securing the cutter to the media frame.

5. Lift the cutter out of the unit.

Replacement

1. Reverse the order of the removal procedure.

NOTE: Prior to tightening the hardware, position the cutter assembly,

so that there is a .045" gap between the follower and the
cam.

6.2.13 CUTTER SENSOR

Removal

1. Remove the cutter cover and driven nip roller/cover assembly.

2. Remove the nut securing motor cover and remove cover.

3. Remove the screw securing the sensor mount and lift out.

4. Remove connector from the sensor.

5. Remove the sensor from the mount by squeezing mounting tabs on sen-
sor.

Replacement

1. Reverse the order of the removal procedure.

6.2.14 CASSETTE SENSOR

Removal

1. Remove the screw securing the mounting bracket.

2. Lift bracket from take-up compartment.

3. Remove the connector from the sensor.

4. Remove the sensor from the mount by squeezing mounting tabs on sen-
sor.

Replacement

1. Reverse the order of the removal procedure.

6-8
Procedures

6.2.15 SUPPLY MOTOR

Removal

1. Remove the left side cover.

2. Locate the access cut out on the left side, upper left.

3. Remove the power, ground and encoder connections from the motor.

4. Squeeze the torsion spring together.

5. While holding the spring compressed, lift the motor and mounting brack-
et up from the supply compartment.

6. Remove the two screws securing the motor to the mount (access to the
screws is through the holes in the drive wheel) and remove motor.

7. Loosen the two set screws securing the drive wheel to the motor and
remove.

8. Remove the ground tab from the motor and retain.

Replacement

1. Reverse the order of the removal procedure.

6.2.16 IMAGER FAN

Tools Required: Flat blade screwdriver

Removal

1. Remove the front cover.

2. Disconnect the fan connector.

3. Remove the screw from the fan mounting bracket.

4. Slide the bracket to the right.

5. Remove the four nuts securing the fan to the isolation mount.

Replacement

1. Reverse the order of the removal procedure.

6-9
AccuSet Service Manual

6.2.17 IMAGER

Tools Required: 1/4" Nut driver, 1/2" socket and wrench

Removal

1. Remove the front, left and rear covers.

2. Remove spin mtr, filter and encoder connectors from the IEC and fan con-
nector located in the imager compartment.

3. Remove grounding P-clamps and pass cables through access holes.

4. Loosen the single screw securing the shield over the Laser Driver and
remove shield.

5. Disconnect the video and ribbon cable from the LDM.

5A If this is an Accuset 1500, you must turn the quick-disconnect connector

to remove the vacuum hose from the rear bulkhead of the vacuum assem-
bly.

6. Insert inflatable lift (shipped with new imager) under the imager and
inflate, using a can of compressed air. See instructions shipped with
imager.

7. Loosen the three bolts securing the imager to the frame.

8. Deflate the lift while steadying the imager (see instructions.)

9. Carefully remove the imager from the unit.

Replacement

1. Lay the imager on the deflated lift.

2. Steady the imager while inflating the lift.

3. When the imager is in position, ensure the mounting/alignment pins are

tight against the mating surfaces on the frame.

4. Install and tighten mounting bolts while holding the imager against mat-
ing surfaces. Check for 0 clearance between mounting pins and mating
surfaces.

5. Reverse the remaining steps of the removal procedure.

6. Enter NVRAM values from the label located on the imager.

6-10
Procedures

6.2.18 CAPSTAN MOTORS AND ENCODERS

The two piece capstan motor and encoder unit manufactured by Heidenhain has
been superceded by a unit manufactured by Computer Optical Products (COPS).
The units are not interchangeable. The COPS unit consists of an sealed flywheel
encoder assembly to which the pancake motor is attached.

Inspect the AccuSet to determine which type of capstan motor and encoder is
installed.

If a Heidenhain encoder and motor is installed, go to

Paragraphs 6.19.1 or 6.19.2.
If a COPS unit is installed, go to Paragraph 6.19.3.

6.2.18.1 HEIDENHAIN CAPSTAN ENCODER

Tools Required: Flat blade screwdriver, 5/64" allen wrench

1. Remove the rear panel and top cover/rear support assembly as shown in
paragraphs 6.2.2, and 6.2.3.

2. Remove the ground clamp from encoder cable.

3. Disconnect connector J703 from the IEC pcb.

4. Loosen the set screws on the coupling at the encoder side.

5. Loosen the fastener that secures the encoder to the mounting bracket and
remove the encoder.

Replacement

1. Reverse the removal procedure. Ensure that the cable exiting the encoder
is orientated to the 9 oclock position.

6.2.18.2 HEIDENHAIN PANCAKE (CAPSTAN) MOTOR

Tools Required: Flat blade screwdriver, 5/64" allen wrench

1. Remove the rear panel and the top cover/rear support assembly as shown
in paragraphs 6.2.2, and 6.2.3.

2. Loosen the coupling at the capstan side and remove the encoder assem-
bly from the mounting bracket.

3. Scribe the location of the encoder mounting bracket on the mating plate.

4. Remove the four screws securing the mounting bracket and remove.

5. Disconnect the motor connector.

6. Remove the four screws securing the motor.

7. Slide a sharp blade screwdriver or equivalent under the motor, twist the
screwdriver to break the magnetic bond, and remove the motor.

8. Loosen the set screws on the armature and remove the capstan motor.

6-11
AccuSet Service Manual

Replacement

1. Reverse the order of the removal procedure ensuring a gap of .025"

between the armature and the mounting plate.

6.2.18.3 COPS PANCAKE (CAPSTAN) MOTOR

Removal

1. Remove the rear panel as shown in paragraphs 6.2.2, and the top
cover/rear support assembly and 6.2.3.

2. Remove the tensioner assembly, as shown in Paragraph 6.2.4.

3. Unclip and remove the plastic light shield at the encoder motor end of
the capstan.

4. Use a 1/4 nut driver to remove the nut that holds the encoder cable
ground clamp to the floor of the upper cabinet.

5. Disconnect connector J703 from the IEC PCB.

6. Unplug the 4-pin connector that connects the capstan pancake motor to
the wiring harness.

7. Remove the hex head bolt that holds the ground braid to the stator of the
pancake motor.

8. Remove the remaining three hex head bolts that hold the pancake motor
stator to the flywheel assembly.

9. Gently pry off and remove the pancake motor stator. The attraction of the
field magnet holds the stator to the flywheel body.

10. Loosen the two hex setscrews that hold the pancake armature to the cap-
stan shaft.

11. Remove the pancake armature from the shaft.

12. Remove the black foam light baffle that surrounds the encoder motor.

13. Use a long shank 3/32 hex-ball bolt driver to back off both setscrews
from the capstan shaft. The shank length must be grater than 5 1/2 inch-
es.

14. Make sure the capstan roller is fully disconnected from the motor.

15. Use a 5/16 nut driver to remove the three nuts that hold the COPS
motor/encoder to the frame of the AccuSet.

16. Remove the capstan encoder/flywheel unit from the AccuSet. Because
this step might pull the capstan free of the front bearing, make sure the
spacer, shims, and bearing do not get loose and tumble into the engine.

6-12
Procedures

Replacement

1. Reverse the order of the removal procedure.

2. After you install the pancake armature on the capstan shaft, manually turn
the capstan to make sure the armature is clear of the encoder body.

3. After you install the pancake motor stator, repeat the above step. Making
sure the armature is free and not scraping on the stator.

4. Perform the capstan servo alignment procedure, as shown in

paragraph 6.3.3.

6.2.19 CAPSTAN ROLLER

Tools Required: Flat blade screwdriver, 5/64" allen,

1. Remove the top cover/rear support assembly.

2. Remove the capstan encoder and motor, as shown in paragraph 6.2.18.

3. If the capstan encoder and motor removed above is a COPS unit, go to

step 4:

a. Remove the four screws securing the mounting plate and remove the
plate.

b. Loosen the two set screws securing the flywheel to the roller shaft
and remove.

c. Loosen and remove the three allen screws securing the housing to the
media frame.

4. Remove the aperture assembly from under the capstan.

5. Slide the capstan roller out toward the back of the unit using caution not
to drop the spacer and Bellville washers.

Replacement

1. Reverse the order of the removal procedure. Ensure that the housing and
mounting plate are centered around the roller shaft. Make sure the
encoder mounting bracket lines up to the scribe marks on the mounting
plate.

NOTE: Use the spacer that was installed on the original roller and
check for side to side movement. There should be none,
other than that allowed by the Bellville washer.

2. Perform the capstan servo alignment procedure, as shown in

Paragraph 6.3.3.

6-13
AccuSet Service Manual

6.2.20 IMBEDDED ENGINE CONTROLLER (IEC)

The revised IEC board (shown in Figure 6-4) replaces the older version (shown in
Figure 6-5) and is necessary for an Accuset 1500. The removal and replacement
procedures for both boards are the same, except that the revised board has one
additional connector (J20). The part numbers for the two boards are listed in
Chapter 8.

Removal

1. Log the following NVRAM values if possible: Values within the cassette
fields, Load Params and Set Params values found under Align Mode
using PUP.

These values with the exception of the cassette field values will be
shipped with the system.

2. Turn the power off and remove the line cord from the system.

3. Remove the rear cover.

4. Remove connectors J703, J704, J709, J5, J8, J20 (AccuSet 1500 only) ,
J55, J3, J9, J481, J2, J523 and J522.

5. Remove the 11 screws securing the PCB to the enclosure and remove the
PCB.

NOTE: The two inside screws on the left edge of the PCB have
nylon washers between the screw and the board. Retain
these washers for use when installing the new PCB.

Replacement

1. Reverse the order of the removal procedure.

2. Enter the NVRAM values logged.

6-14
Procedures

Capstan/Supply Supply/Take-up
Capstan & Take-up Tensioner/Encoder
Encoder Motor Drive Cassette Sensor APIS to RIP

J703
J704 J709 J5

1 Amp To
APIS F3 J8 Control
Comms Panel
J712 J713 U 732
1 Amp F3
Control
U 718 Panel Remote
J7 Diagnostics
1 - Sup_Cntl
2 - Enc_Pulses 1 Amp
Edge Connector

3 - Ground On-line J6
Processor F1 On-line
4 - Sync_Pulse DPI Volts Proc.
5 - Ground 3000 1
6 - T/U_Cntl 2400 1.25 Power
7 - Capstn_Tac 1800 1.75 J55 Cutter
8 - Phase B 1200 2.5 & Sensor
Remote Diag. I/F
9 - Phase AB 600 5
10 - Phase AA Z8530
Serial Comms Cont Aux
J710 11 - n/u U30
12 - n/u J4 Power
Out
Test Z8530
Points Serial Comms Cont
U27
DC
J3 Power

Video to
BNC Laser
Video J9
Diode

32K System
Laser
J481

RAM - U33 J713 Drive to

Imager
Boot ROM
U9
Filter/
J2 Aperture
NVRAM Drive/
U7 CR11 Sensor
N/U
Punch
Spin
J523

Apps/PUP 80188
ROM - U8 J10 I/F Motor
16 MHz CPU
Y1 U3 Encoder

Spin
Motor Spin
J522

Drivers Motor
Drive

Figure 6-4 IEC

6-15
AccuSet Service Manual

Capstan/Supply
& Take-up
Motor Drive
Supply/Take-up
Capstan Tensioner/Encoder
Encoder Cassette Sensor APIS to RIP Frame
Ground

J704 J709 J5

J703
C19
F1 To
U7 J8 Control
F2
Panel

F1 J5 P-36 1A J7 Remote
J710 Test Diagnostics
F2 J8 P-1 1A
Points F4
F4 J20 P-3 3A Vacuum pump,
1 - Sup_Cntl Switch, and
J6 J20 Solenoid
2 - Enc_Pulses
3 - Ground (AccuSet 1500 only)
Edge Connector

DPI Volts
4 - Sync_Pulse
5 - Ground 3000 1 Power
6 - T/U_Cntl 2400 1.25 J55 Cutter
1800 1.75 & Sensor
7 - Capstn_Tac 1200 2.5
8 - Phase B 600 5
9 - Phase AB Aux
U46 U47 J4 Power
10 - Phase AA
11 - n/u
Out
12 - n/u
Z8530
Remote
Diagnostic I/F

J3 DC
Power

Video to
32K System J9 Laser
RAM - U98 Diode
BNC
Laser
J481

Boot ROM
U106 Drive to
U109 Imager
NVRAM
U118
Filter/
Apps/PUP CR34 80188 J2 Aperture
ROM - U125 CPU Drive/
U124 Sensor
Spin
16 MHz Motor
Y1 Drivers Spin
J523

Motor
Encoder

Spin
J522

Motor
Drive

Figure 6-5 Layout of the New IEC

6-16
Procedures

6.2.21 CONTROL PANEL

Removal

1. Turn off power to the system.

2. Open the top cover.

3. Remove the two screws securing the shield over the interface cable.

4. Remove the screw and lock washer from the cable ground.

5. Disconnect the phone jack connection.

6. Remove the six screws securing the control panel to the top cover and
remove the control panel.

Replacement

1. Reverse the removal procedure.

6.2.22 LINE LENGTH CORRECTION

1. Using the PUP, run a CF28.

2. Develop and measure the copy. The grid should measure 13.0" +/ .008.

3. If the line length measurement is too long or short, change the PXCLK
value. To change PXCLK enter the PUP, select the Load Params menu,
and select the Align mode.
If too long, add the number of thousandths the line length is off to
the value .
If too short, decrease the value of PXCLK.

6.2.23 JOB DEPTH CORRECTION

If you replaced the capstan roller, check or change the value of PLCVAL. To
change PLCVAL, enter the PUP, select the PARMS menu, and select the Set/Disp
Params mode

1. Each roller has a diameter marked on it. Look this value up in Table 6-1.
There is a correction value for each diameter listed.

2. Enter the value taken from the table in PAGE LENGTH under Params
within the SET DISP mode.

6-17
AccuSet Service Manual

Table 6-1

Roller diameter PLCVAL

1.5863 9999
1.5864 9999
1.5865 10000
1.5866 10001
1.5867 10001
1.5868 10002
1.5869 10003
1.5870 10003
1.5871 10004
1.5872 10004
1.5873 10005
1.5874 10006
1.5875 10006
1.5876 10007
1.5877 10008
1.5878 10008
1.5879 10009
1.5880 10009
1.5881 10010
1.5882 10011
1.5883 10011

6.2.24 ACCUSET 1200 HARD DRIVE

Removal

1. Remove the left side panel. Remove the rear cover by using a 1/4" hex
drive on the securing screw at the top of the cover.

2. Remove the ribbon (interface), power, and ground cables from the drive.

3. Gaining access through the imager enclosure (left side), remove the four
screws, using a 1/4" hex drive, securing the hard drive to the standoff
mounts located in the electronics enclosure.

4. Remove the standoffs from the hard drive with the 1/4" hex drive.

NOTE: Access to the mounting screws is through the four holes

located behind the standoffs. Hold the drive while removing
the mounting hardware.

Replacement

1. Add the standoffs to the new hard drive, P/N 2551-501, and follow
reverse order of the removal procedure.

2. Boot up the AccuSet and verify that the hard drive is operational and soft-
ware is loaded.

6-18
Procedures

6.2.25 RIP PCB

Removal

1. Remove the rear cover from the system.

2. Remove the APIS, power, and drive interface cables from the PCB.

3. Remove the communications cables from the interface bracket.

4. Remove the five screws securing the interface bracket to the system.

5. Remove the three screws securing the PCB to the stand-offs inside the
enclosure, and remove the board from the system.

6. Remove the four screws mounting the adapter bracket to the interface
bracket, and retain screws and adapter.

Replacement

1. Install the adapter bracket, removed in step 6 of the removal procedure,

onto the new RIP PCB interface bracket.

2. Reverse the order of the removal procedure.

Centronics Serial Appletalk
APIS Ethernet Reset Parallel (RS232) (RS 422)
37 pin 15 pin 18 pin 25 pin 15 pin
JP 1 J6
JP 7
F JP 8 Boot

Power
Monitor-PostScript
CR 14 1/2 amp CR 4
CR 1
20 MHz
F Crystal CR 2
1 amp J5
CR 3
SCSI

off on
CR 10
JP 6
CR 11
CR 12
CR 13 Adobe Soft Roms
52.3
CR 9
16 MByte DRAM
CR 8 off on CR 15
CR 7
Socket H Mips
for T RWB
HTA A JP 4
JP 2 JP 3

JP 5
FPU CPU
R 3010 R 3000
off on

Figure 6-6 RIP PCB

6-19
AccuSet Service Manual

6.2.26 VACUUM PUMP/AND MOTOR SYSTEM (ACCUSET 1500 ONLY)

Vacuum Pump Assembly

Figure 6-7 shows the AccuSet 1500 vacuum pump and associated hardware. It is
installed on the floor of the AccuSet cabinet, at the front left-hand side. Not shown
are the quick disconnect vacuum hose that connects the vacuum pump to the
imager assembly.

The entire assembly shown in Figure 6-7 cannot be ordered as a replacement part.
The assembly consists of the following components:

1. Vacuum pump/motor assembly.

2. Solenoid valve.

3. Vacuum sensor switch.

1 2
3

Figure 6-7 The Vacuum Pump Assembly

6.2.26.1 Removal of the Vacuum Pump/Motor Assembly

1. The AccuSet must be powered down and unplugged from the AC power
line.

2. Pull the vacuum line off of the suction (rear) connector of the pump.

3. Disconnect the two motor lead-in wires from the cable harness.

4. Remove the four screws that hold the motor flange to the base plate.

6-20
Procedures

Replacement of the Vacuum pump/Motor

1. To replace the vacuum pump/motor assembly, reverse the removal

procedure.

2. When attaching the vacuum hose to the pump assembly, be careful how
you run the vacuum hose. If the hose is configured incorrectly, it might
transfer vibrations from the pump/motor to the frame of the AccuSet
1500. These frame vibrations can shake the spin motor and distort the
printed image.

6.2.26.2 Removal of the Vacuum Switch

1. The AccuSet must be powered down and unplugged from the AC power
line.

2. Remove the plastic cap that covers the switch connectors.

3. Unplug the two connectors from the switch.

4. Pry the vacuum hose off of the switch.

5. Undo the single nut that holds the switch assembly to the right-side bulk-
head of the vacuum assembly. When replacing this nut, do not over tight-
en.

Replacement

1. To replace the vacuum switch, reverse the above procedure.

2. The black wire connects to the COM (right) connector and the yellow
connects to the NC (middle) connector. The NO (left) Connector is
unused.

3. When attaching the vacuum hose to the pump assembly, be careful how
you run the vacuum hose. If the hose is configured incorrectly, it might
transfer vibrations from the pump/motor to the frame of the AccuSet
1500. These frame vibrations can shake the spin motor and distort the
printed image.

6.2.26.3 Removing the Vacuum Solenoid

1. The AccuSet must be powered down and unplugged from the AC power
line.

2. Pull the two vacuum hoses off the connectors.

3. Unplug the two connectors that connect the motor to the wire harness.

4. Unplug the two connectors that connect the switch to the wire harness.

5. Pinch together the clips holding the 4-pin plug into the bulkhead mount-
ing hole. Remove the connector from the rear bulkhead.

6. Remove the two screws and nuts holding the solenoid to the rear bulk-
head of the vacuum assembly.

6-21
AccuSet Service Manual

6.3 ELECTRONIC ALIGNMENT PROCEDURES

The following paragraphs describe the alignment/adjustment procedures.

6.3.1 TENSIONER ADJUSTMENTS (MECHANICAL POSITIONING)

Do the following before starting adjustment procedures:

Unload the media from the capstan supply and take up rollers.
On newer AccuSet models it might be necessary to partially remove the
tensioner assembly to gain access to the potentiometer coupling. Perform
steps 1 through 4 of Paragraph 6.2.4, but do not remove the tensioner
assembly or the connectors.
This adjustment requires accessing an IC on the IEC board.
If an original IEC PCB is installed, that IC is U732 which is shown on
Figure 6-4.
If a new IEC PCB is installed, that IC is U7 which is shown on
Figure 6-5.

Supply Tensioner Arm

1. Attach the probe of a scope or an accurate multimeter to pin-1 of

U732 or U7.

2. Move the tensioner arm down and up to verify that the scope is connect-
ed properly. The voltage should change with the tensioner position.

3. Allow the arm to relax in the up position, with the tensioner closed, and
read the measurement.

4. The voltage reading must be 48030 mv. If the test fails, perform the
adjustment procedure in steps 5, 6, and 7.

5. Remove the tensioner assembly from the system.

6. Loosen the phillips screw that holds the tensioner arm to the potentiome-
ter coupling.

7. Adjust the coupling until a reading of 480 30 mv is obtained.

8. Tighten the Phillips screw while holding the coupling in position. Refer to
Figure 6-8.

9. Re-install the tensioner and check the voltage. Repeat as required until
the correct voltage is achieved.

Take-up Tensioner Arm Adjustment

1. Attach the probe of a scope or an accurate multimeter to pin-14 of U732

or U7.

2. Perform steps 2 through 7 from the supply tensioner procedure.

6-22
Procedures

Rear of
AccuSet

Figure 6-8 Tensioner Assembly

6.3.2 TENSIONER ALIGNMENT (ELECTRICAL)

Supply Side

1. Enter PUP and the Alignment mode, select LOAD PARAMS.

2. Attach scope probe to connector J710, pin 1 (SUP_CNTL).

3. Using the arrow keys, move to the sub-menu.

4. Using the Select key, move to SUPMIN.

5. Using the arrow key, move to the value field.

6. Make sequential entries until a voltage level of just negative of reference

ground is achieved.

Take-Up Side

1. Enter PUP and the Alignment mode, select LOAD PARAMS.

2. Attach scope probe to connector J710, pin 6 (T/U_CNTL).
3. Using the arrow keys, move to the sub-menu.
4. Using the Select key, move to TKPMIN.
5. Using the arrow key, move to the value field.
6. Make sequential entries until a voltage level of just negative of reference
ground is achieved.

6-23
AccuSet Service Manual

6.3.3 CAPSTAN SERVO ALIGNMENT

Capstan servo alignment is a critical step in servicing the AccuSet and should be
checked whenever any of the following symptoms are present:

Gaps in copy
White or Black lines
Banding
Media, Media Motor, *Out of Media Errors*
Registration & Repeatability issues
* Out of Media errors can also be as a result of poor tensioner assembly align-
ments. Always check that the latest software is installed and the tensioner align-
ments are correctly set as outlined in the Electronic Alignment Procedures 6.3.1
and 6.3.2.

This procedure must also be performed when any of the following components
have been replaced:

Capstan encoder
Capstan motor
Tensioner assembly
IEC PCB
Capstan roller
NOTE: All adjustments should be considered through at least one
revolution of the capstan.

CAPSTN_TAC Adjustment

1. Remove the media from system if installed. Ensure tensioner is closed

before proceeding.

2. Enter PUP and the ALIGN mode. Display the menu LOAD PARAMS.
Change the sub-menus ALEADS to 1 and AA_LAG to 28.

3. Display the menu LEADING MTR and select sub-menu FWD 1800
LOCKED. The capstan should begin turning in the forward direction.

4. Attach scope channel 1 to J710, pin 8 (PHASE_B). Trigger on rising edge

and display at least four (4) complete cycles. Select chop channel display
mode.

5. Attach scope channel 2 to J710, pin 7 (CAPSTN_TAC). Set channel

VOLTS/DIV for best resolution..

6. Display the menu LOAD PARAMS and sub-menu GAIN_A. Vary the
value of GAIN_A until minimum ripple is observed on scope channel 2
(CAPSTN_TAC). See figure 6-9.

6-24
Procedures

GAIN "A" POOR GAIN "A" GOOD

Minimize ripple using the Gain A Adjustment

channel 1, J710, pin 8 (PHASE_B)

channel 2, J710, pin 7 (CAPSTN_TAC)

Figure 6-9
7. When ripple minimized has been achieved vary the values equally of both
GAIN_A and GAIN_B until the specified voltage is observed on scope
channel 2 (CAPSTN_TAC). See figure 6-10.
AccuSet 1500 = 2.55vdc AccuSet 800-1400 = 1.68vdc

AccuSet 800,1000, 1200,1400 AccuSet 1500

Adjust Amplitude to 1.68v Adjust Amplitude to 2.55v

2.55 vdc
1.68 vdc

Ref. 0 vdc Ref. 0 vdc

Vary the values equally of both "GAIN_A" and "GAIN_B"

until the specified voltage is observed on the scope.

channel 2, J710, pin 7, (CAPSTN_TAC)

Figure 6-10

6-25
AccuSet Service Manual

Phase AA, Phase AB Adjustment

1. Attach scope channel 1 to J710, pin 4 (SYNC_PULSES). Trigger on rising

edge. Adjust scope to display two (2) complete cycles.
2. Adjust scopes horizontal position to align the trailing edge of second
cycle with nearest vertical grid line. Make a note of its position and do
not alter until cycle adjustment is complete. See figure 6-11.

Trigger on rising edge.

Adjust scope to display
two (2) complete cycles.

Align the trailing edge of

the second cycle with nearest
vertical grid line. Make note of
its position and do not alter.

channel 1, J710, pin4

(SYNC_PULSES)

Note position of
Second Cycle Trailing
Edge.

Figure 6-11
3. Attach scope channel 2 to J710, pin 9 (PHASE_AB) and display waveform.
Change scope trigger to channel 2.

4. Adjust sub-menu OFFSET_B to align falling edge of PHASE_AB with

selected vertical grid line. See figure 6-12.

5. Move scope channel 2 to J710, pin 10 (PHASE_AA).

6. Adjust sub-menu OFFSET_A to align falling edge of PHASE_AA with
selected vertical grid line. See figure 6-12.

Ref. Sync and noted

position of Trailing
Edge of Second
Cycle.

Channel 2 J710, Pin 9 Phase_AB Adj. with OFFS_B

&
Channel 2 J710, Pin 10 Phase_AA Adj. with OFFS_A

Figure 6-12

6-26
Procedures

90 Degree Phase Adjustment

1. Change trigger back to scope channel 1 to J710, pin 4 (SYNC_PULSES).
Adjust the scope to display one (1) complete cycle on channel one. See
figure 6-13.

2 Adjust the scope horizontal position to align the trailing edge of cycle
with the nearest vertical grid line. Make a note of its position and do not
alter until the phase adjustment is complete. See figure 6-13.

Channel 1 J710, Pin 4

(SYNC_PULSES)
One full cycle.
Note position of Trailing
Edge

Figure 6-13
3. Move the scope channel 1 to J710, pin 9 (PHASE_AB).

4. If the scope channel 2 (PHASE_AA) rising* edge is aligned with the verti-
cal grid line proceed to PHASE_B Symmetry Adjustment. See figure 6-14.

5. If the scope channel 2 (PHASE_AA) rising* edge is to the left of the verti-
cal grid line, then skip to step 7. See figure 6-14.

Channel 1 J710, Pin 9

PHASE_AB

Channel 2 J710, Pin 10

PHASE_AA
Rising* edge aligned with
noted position.
Adjust with AA_LAG if left
of noted position. If not,
change ALEADS to "0" and
proceed.

* May be rising or falling

edge dependent on
ALEADS position.

Figure 6-14
6. If the scope channel 2 (PHASE_AA) rising edge is to the right of the verti-
cal grid line, then change ALEADS to 0 and proceed.

7. Adjust sub-menu AA_LAG to align displayed edge of PHASE_AA (scope

channel 2) with selected vertical grid line.

NOTE: The displayed edge may be a rising or falling edge which

depends on whether the ALEADS is set to 0 or 1.

6-27
AccuSet Service Manual

Phase_B Symmetry Adjustment

1. Attach the scope channel 1 to J710, pin 8 (PHASE_B). Adjust the scope to
display one (1) complete cycle.

2. Adjust sub-menu ATN_A to attain the best symmetrical waveform. See

figure 6-15.

BAD GOOD
Symmetry Symmetry
"Not Equal" "Equal"

Channel 1, J710, Pin 8, PHASE_B

Adjust with ATN_A to achieve a symmetrical wave form.

Figure 6-15

6-28
Procedures

Capstan Synchronization Measurement

1. Attach the scope channel 1 to J710, pin 4 (SYNC_PULSES). Trigger on

falling edge. Adjust the scope to display one (1) cycle.

2. Adjust the scope horizontal position to center waveforms rising edge on

the nearest vertical grid line. Do not alter until the measurement is com-
plete.

3. Attach the scope channel 2 to J710, pin 2 (ENC_PULSES).

4. Monitor the rising edge of ENC_PULSES relative to the selected vertical

grid line through one (1) revolution of capstan. Drift window should be
no more than 10 % of one (1) complete cycle. Example: If the display
grid has 10 divisions and one cycle covers 8 divisions the drift should not
exceed .8 of one division. See figure 6-16.

5. In the menu LEADING MTR, select all other locked resolutions and
repeat steps 1 through 4 in this procedure. Confirm that the measure-
ments meet specifications.

Reference
Sync.
Channel 1, J710, Pin 4

Reference
Encoder
Channel 2, J710, Pin 2

Check for no more than

10% drift of one full cycle.

10%
NOTE: 600 DPI not valid for the AccuSet 1500 and 3000 DPI not valid for
the AccuSet 800

Be sure to use only FWD xxxx Locked or you will not get both signals
triggered together.

Figure 6-16

6-29
AccuSet Service Manual

6.4 FIRMWARE DOWNLOAD PROCEDURE FOR SYSTEMS WITH EXTERNAL

AGFA SINGLE BOARD RIPS

1. Power cycle the AccuSet and press the 3 key when CODE appears at
the display.

2. Power cycle the external Single Board RIP (SBR). The Engine Control
Panel will display:
PROGRAM DOWNLOAD
POWER UP

After 30 seconds the control panel will display:

PROGRAM DOWNLOAD
ERROR: APIS cmd

Ignore this error message. After 60 seconds the Control panel will display:
PROGRAM DOWNLOAD
POWER UP

3. If you are downloading from a MAC, wait for chooser to display Run
EEPROM downloader

4. Run SEND PS tool.

5. Download the Downloader ver. X.X file on the Downloader disk.

6. AccuSet engine will display (for approximately 4 to 5 minutes):

PROGRAM ERASE

7. AccuSet engine will display (for approximately 20 to 25 minutes):

PROGRAM DATA

8. AccuSet engine will display (for approximately 30 seconds):

PROGRAM VERIFY

9. AccuSet engine will briefly display briefly:

PROGRAM STARTING

10. Wait for AccuSet to display:

ON LINE

11. Power Cycle the RIP to re-initialize.

6-30
Procedures

6.5 FIRMWARE DOWNLOAD PROCEDURE FOR SYSTEMS WITH INTERNAL

AGFA SINGLE BOARD RIPS

l. Power cycle AccuSet and press the 3 key when CODE appears at the
display. The Engine Control Panel will display:
PROGRAM DOWNLOAD
POWER UP

Wait approximately 5 minutes (9 minutes with TCPIP) for a display of:

PROGRAM DOWNLOAD

2. Run SEND PS tool.

3. Download the Downloader ver. X.X file on the Downloader disk.

4. The AccuSet will display (for approximately 4 to 5 minutes):

PROGRAM ERASE

5. The AccuSet will display (for approximately 20 to 25 minutes):

PROGRAM DATA

6. The AccuSet will display (for approximately 30 seconds):

PROGRAM VERIFY

7. The AccuSet will briefly display:

PROGRAM STARTING

8. Wait for AccuSet engine to display:

ON LINE

NOTE 1: The SEND PS Tool does not complete the download of this
file gracefully and will post a message of Had trouble send-
ing Downloader ver. x.x. As long as the AccuSet Control
Panel displays ON LINE within 5 to 10 minutes, ignore this
message.

NOTE 2: If you are doing the download from a PC the same directions
apply, with the exception of the PostScript Download tool
and the bogus message returned by SEND PS.

6-31
Preventive Maintenance

CHAPTER SEVEN: PREVENTIVE MAINTENANCE

7.1 INTRODUCTION

The objective of the preventive maintenance (PM) is to prolong the reliability and
performance of the AccuSet.

To meet this objective, the mechanical and operational procedures outlined below
must be performed once per year.

7.2 PRE-INSPECTION PROCEDURES

Begin the PM by discussing the systems performance with the key operator(s).
Determine if there has been any malfunctions since the last service call and verify
that all scheduled upgrades have been performed. All upgrades should be per-
formed according to the instruction found in the Field Service Bulletins (FSB).

7.3 INSPECTION PROCEDURES

The following describes the procedures to be used during the PM.

7.3.1 MECHANICAL INSPECTION

1. Power down and unplug the line cord.

2. Inspect the system for the following:

a. Damage to exterior (covers, panels)

b. Damaged, missing or loose hardware and connectors.

c. Loose or damaged harness or line cord.

d. Damaged components.

3. Check the supply and take-up cassettes for proper operation.

4. Clean the capstan roller with a clean lint free cloth and isopropyl alcohol.

5. Clean the leading transport area by removing debris using a vacuum or

damp cloth.

6. Remove the cutter motor cover. Inspect the cutter cam and follower for
wear. Lubricate with white lithium grease as required.

7. Remove and clean the air intake filters located in the back of the system.

7-1
AccuSet Service Manual

7.3.2 MOTOR MAINTENANCE FOR CLEANING DC BRUSHLESS TENSION

MOTORS

Perform an unload operation as outlined in the AccuSet User Guide.

NOTE: If the unload operation is not performed before Motorcleaning ,

then a Mediapresent error will display.

Selectable via the OPTIONS menu. The tension motors are spun for approx. 20
seconds and then automatically turned off. Media must be out of the system
before it is activated and the Control Panel Keyboard is ignored during the clean-
ing.

7.3.3 Operational Inspection

1. Plug in the line cord and power up the system.

2. Observe the basic confident checks and diagnostics and ensure they are
working properly. Refer to chapter 4.

3. Load the media into the leading transport and ensure proper operation.

4. Check the cutter assembly for proper operation.

5. Enter the service routine and run CF files 16, 19, and 21. Examine the out-
put and resolve any outstanding issues.

6. Discuss the results of the inspection with the customer and complete all
paperwork.

7-2
Parts List

CHAPTER EIGHT: PARTS LIST

8.1 FIELD REPLACEABLE UNITS (FRU)

Line
Item Description Part Number

1. Vacuum Pump (and motor) Assembly 2775-501

2. Switch (vacuum sensor) 67314-001
3. Solenoid Vacuum Valve (and wire harness) 2775-502
4. IEC AccuSet 800 2589-502
4. IEC AccuSet 1000/1200 2589-501
4. IEC AccuSet 1500 2589-503
5. Control Panel 208929-551
6. Control Panel Assembly 2473-562
7. Internal RIP 208467-551
8. 200 MB Hard Disk Drive 2551-501
9. Power Supply 65940-002
10. Imager Assembly 800/1000/1200 2473-553
10. Imager Assembly AccuSet 1500 2710-553
11. Imager Fan 66658-006
12. Tensioner Assembly 2473-560
13. Tensioner Potentiometer (supply) 208931-502
14. Tensioner Potentiometer (take-up) 208931-501
15. Capstan Roller 206807-001
16. Bearing 66438-001
17. Spring Washer 64757-007
18. Shims (Capstan dimensions determine shim used) 206822-001
through
206822--007
19. Capstan Motor (Heidenhain) 66135-001
20. Capstan Encoder (Heidenhain) 208821-0001
20. Capstan (motor and encoder) Assembly (COPS) 066648-001
21. Driver Roller 206794-001
22. Driver Nip Roller Assembly 2473-571
23. Supply Motor/Encoder 66596-001
24. Take-up Motor/Encoder 66389-001
25. Auto Cutter Assembly 66492-001
26. Auto Cutter Motor 66582-001

8-1
AccuSet Service Manual

Line
Item Description Part Number

27. Cassette/Cutter Sensor 66394-001

28. Platen Assembly (complete) 2473-570
29. Flex Platen 206762-001
30. Upper Platen 206763-001
31. Lower Platen 206764-001
32. Coupling, Servo 66447-001
33. Coupling, Nip 58050-002
34. Fan Assembly 65162-001
35. Fan Filter 54467-001
36. Supply Cassette 2473-506
37. End Cap (left) 212775-501
38. End Cap (right) 212775-502
39. Take-up Cassette 2473-507
40. Panel Front 207285-001
41. Cover Right 207286-001
42. Panel Left 207287-001
43. Panel Rear 207288-001
44. Leading Cover 206811-001
45. Cover Media Path 206804-001
46. Panel Cover Support 206817-001
47. Light Seal Leading 207260-001
48. Light Seal Cutter 207260-002
49. Strike 60445-001
50. Latch 60446-001
51. Supply Motor Door 206766-001
52. Nip Motor Cover 207359-001

8.1.1 CABLES

53. AC Filter to Switch 208806-501

54. AC Switch to Power Supply 208807-501
55. AC Selector Switch 208808-501
56. Imager Fan 208809-501
57. DC Power 208810-501
58. Enclosure Fan 208811-501
59. Control Panel 66610-131
60. Encoder and Sensor 208812-501
61. Video Cable 66613-001
62. Media Drive 208814-501
63. Supply Motor Ground. Braid 66611-1009
64. Capstan Motor Ground. Braid 66611-204

8-2
Parts List

Line
Item Description Part Number
65. Cutter Platen Ground. Braid 66611-002
66. Take-up Motor Ground. Braid 66611-009
66. Power Cutter 208819-501
67. Density 66157-026
68. IEC to RIP 66477-1613
69. SCSI 66157-718
70. Apis to External Port 66667-1316
71. Current Limit 200591-502
72. Hard Drive DC Ground. 201446-503

8.2 OPTIONS (PIECE PARTS)

Line
Item Description Part Number
1. Halftone Accelerator 208911-501

8.3 HARDWARE DIAGNOSTIC TOOL KIT

Special tools needed, excluding new-hire issue.

Line
Item Description Part Number
1. CGEN Loopback Tester 2362-502
2. Dolch Portable PC w/modem and software 78470-501
3. 20 x Eye Loop 85235-001

8-3
The AccuSet 1500

APPENDIX A
THE ACCUSET 1500

This appendix gives an overview of the following:

New AccuSet Service manual information

AccuSet 1500 imagesetter
New imbedded engine controller (IEC) board
Summary

Additional information about details of the AccuSet 1500 can be found throughout
the following chapters of this service manual:

Chapter 3: The values of many numbers in the Functional Analysis section

shift when the IEC is configured as an AccuSet 1500 controller.
Chapter 4: In addition to the value shifts mentioned above, the following
core and sub-system diagnostics tests are different:
4.3.11 Power up testing
4.4.5 Spin motor encoder and index testing
4.6 Revised 3x Error Messages
Chapter 6: The removal and replacement procedures for the IEC board,
vacuum system components, capstan motors, and imager assembly are
new or revised.

A.1 Product Overview

The AccuSet 1500 maintains high image quality at increased media speeds.
(about 50% faster than the Accuset 1000). The increased media speed is pro-
duced by increasing the spin motor speed from 18,000 to 27,000 RPM. The
faster spin motor speed increases the clocking frequency that regulates the
speed of the supply and capstan motors.
NOTE: 600 dots-per-inch (DPI) resolution is unavailable in the
AccuSet 1500.
Except for the following new parts, the AccuSet 1500 is the same as the
Accuset 1000:
The vacuum system is necessary for high speed image quality.
The IEC PCB is modified with new connectors, firmware, and is backwards-
compatible.
The spin motor is enclosed in a vacuum sealed shroud.
A surface reflecting spin mirror is used in place of the prism.
The new spin motor runs at 27,000 RPM.

A-1
AccuSet Service Manual

A.2 Vacuum System

The vacuum system consists of a sealed spin motor, a shock mounted vacu-
um pump and motor, and the interconnecting vacuum lines. It removes the
air, which would cause defects in the printed image, from the sealed shroud
that encloses the spin motor.

If the air remained in the shroud, the heat and rotation of the 27, 000 RPM
spin mirror would create air currents that would distort the laser scanning
beam. This distortion would appear on the printed image. The vacuum sys-
tem works to prevent this distortion.
Figure 1 shows the AccuSet 1500 vacuum pump and associated hardware. It
is installed on the floor of the AccuSet cabinet, at the front left-hand side.
Not shown are the quick disconnect vacuum hose that connects the vacuum
pump to the imager assembly.

The entire assembly shown in Figure 1 cannot be ordered as a replacement

part. The assembly consists of the following components:
1 Vacuum pump and motor assembly
2 Solenoid valve
3 Vacuum sensor switch
4 Base plate and shock mounts
1 2
3

4
Figure 1: The Vacuum Pump Assembly
NOTE: The field replaceable components are the vacuum pump and
motor, the switch, and the solenoid. See the removal and
replacement procedures in Paragraph 6.2.28. Part numbers
are in Chapter 8. The base plate and mounting bracket are
not field replaceable.

A-2
The AccuSet 1500

Pump and Motor Assembly

The vacuum pump and drive motor are mounted on the base plate and are
replaced as a unit.

The motor is a 24-volt direct current motor The armature drives a crankshaft
and connecting rod that moves the piston in the pump cylinder. In the
pump, the reed or flapper type valves open and close to direct air through
the two threaded ports that emerge from the cylinder head. The ports are fit-
ted with push-on type connectors and labeled as Pressure and Suction.

Solenoid Valve
The solenoid and valve body are bulkhead mounted and replaced as a unit.
The 4-pin plug that connects the vacuum assembly to the IEC is also part of
the solenoid valve.

The vacuum solenoid valve works to protect the air bearings in the spin
motor. The solenoid is wired in parallel with the pump motor. When the
pump is turned off, the solenoid valve quickly opens to allow atmospheric
pressure into the imager cavity. This provides sufficient air for the spin
motor air bearings as the motor slows to a stop.

The valve body has three connectors. The top connector labeled IN is con-
nected to the suction connector of the vacuum pump. The connector labeled
OUT connects through a T-connector to the vacuum switch and to the quick
bulkhead mounted quick disconnect connector. The connector labeled EXH
has a filter installed.

Vacuum Switch
The vacuum switch is a single component bulkhead mounted device that
connects, through the T-connector, to the OUT connector of the vacuum
valve and to the quick-disconnect connector.

The vacuum switch monitors the strength of the vacuum. The switch opens
when the vacuum raises above six (6) inches of mercury and stays open
until the vacuum falls below that value. When there is no vacuum present,
the switch CLOSES.

The switch connectors are labeled COM (common), NO (normally open),

and NC (Normally closed). The COM and NC contacts are used. The NO
contact is unused.

Base Plate and Shock Mounts

The base plate, shock mounts, and sheet-metal mounting bracket are not
field replaceable components.

Vibrations that are created by the pump and motor are absorbed by the base
plate and four shock mounts.

Be aware that misconfigured vacuum lines can transfer some of the motor
and pump vibration through the frame, imager, and spin motor to the print-
ed image. Vibrational distortion appears as variations in line spacing.

A-3
AccuSet Service Manual

A.3 The New IEC PCB

This paragraph describes the redesigned IEC printed circuit board (IEC board).
The new IEC operates the AccuSet 1500 and has been updated with new firmware
revisions and components.

Physical Description
Figure A-2 shows an outline of the new IEC board. The board is installed at
the rear of the AccuSet cabinet. The physical dimensions, mounting hard-
ware and most of the connections are the same. The J20 connector has been
added to connect the vacuum system. There are several new integrated cir-
cuits. Notice the Z85C30 communication ICs.

Functional Description
The redesigned IEC can be configured to operate the AccuSet 800, AccuSet
1000, or the AccuSet 1500. Configuration consists of changing several socket
mounted integrated circuits.

The AccuSet 1500 must have a new IEC installed the older IEC will not
work.

Diagnostics
When powered up, all the diagnostic tests listed in Chapter 4 of this service
manual, run and test the IEC electronics and the attached AccuSet compo-
nents.

The new IEC software performs configuration testing to determine which

type of AccuSet is installed and to assure that the correct components are
installed on it.

The IEC reads the Model ID register (Address 07h), which is inside of the
U83 IC, to determine the model AccuSet. Table A-1 shows the coding found
in bits 0-3 of that register:
Table A-1 Model ID Register Test Results

Bits 0-7 Test Results

0 Standard Accuset 1000
1 AccuSet 800
2 AccuSet 1500

The IEC then reads bit-3 of the Diagnostic Feedback Port #2. This bit is con-
trolled by pin-8 of J523 which connects the spin motor to the IEC. If bit-3 is
Low: a 27,000 RPM AccuSet 1500 spin motor is connected.
High: a 18,000 spin motor or no spin motor is connected.
The results of the model ID and the bit-3 test verifies that the attached spin
motor is the correct type. The message 30 Wrong Spin motor is displayed if
the incorrect spin motor is attached.

A-4
The AccuSet 1500

If the previous tests indicate an AccuSet 1500 and a high speed spin motor is
is attached, vacuum testing is performed. This is done by reading bit-4 of the
Diagnostic Feedback Port #2. This bit is read during the power up diagnos-
tics and periodically during normal operation.

This bit is controlled by pin-1 of J20 which connects the vacuum sensing
switch to the IEC. Bit-4 is pulled low by the vacuum switch when no vacu-
um is present. This bit goes high when the vacuum switch opens or is dis-
connected.
At power up and during normal operations, this test assures that no vacu-
um is present before the spin motor is turned on.
If the IEC detects that bit-3 has gone low while the spin is running, it dis-
plays an error message but continues to operate the AccuSet.

J704 J709 J5

J703
C19
F1
U7 J8
F2

F1 J5 P-36 1A
J7
J710 Test F2 J8 P-1 1A
Points F4 J20 P-3 3A F4
1 - Sup_Cntl J6 J20
2 - Enc_Pulses
3 - Ground
Edge Connector

DPI Volts
4 - Sync_Pulse
5 - Ground 3000 1
6 - T/U_Cntl 2400 1.25 J55
1800 1.75
7 - Capstn_Tac 1200 2.5
8 - Phase B 600 5
9 - Phase AB
U46 U47 J4
10 - Phase AA
11 - n/u
12 - n/u
Z8530
Remote
Diagnostic I/F

J3

32K System J9
RAM - U98
BNC
J481

Boot ROM
U106
U109

NVRAM
U118

Apps/PUP CR34 80188 J2

ROM - U125 CPU
U124 Spin
16 MHz Motor
Y1 Drivers
J523
J522

Figure A-2 The New IEC

A-5
Index

INDEX

A C

Abort Imaging, 5-14 Cover Remove/Replace

Aborting Job, 4-16 Top Assembly, 6-2
Advancing Media, 4-16 Side, 6-1
AccuSet 1500 Cut Key, 5-3
Error Messages, 4-14 Cutter Assembly
Spin Motor, 3-1, 3-12, 4-5, Remove/Replace, 6-8
Align Menu, 5-6 Cover Unit, 6-5
Alignment Routines, 5-2 Jam, 4-17
APIS Loopback, 4-2 Motor, 6-6
Arrow Keys, 5-4 Sensor, 6-8
Cutting Media, 4-17
B
D
B-List, 5-9
Backup Operation, 3-9 Date, 5-10
Bad Command, 4-16 DC Brushless Tension Motors, 7-2
BOL Signal, 3-12 Debug Mode, 4-1
Boot Version, 4-2 Debugger, 4-2
Bridge Overrun, 4-17
Delivery and Inspection, 1-3
Burn-in Once, 5-9
Busy, 4-17 Diagnostics
About, 4-1, 4-20
C Tool Kit, 8-3
Display Errors, 5-14
Cables, 8-2
Capstan Download Procedures, 6-30
Command Signal, 3-1, 3-12 Driven (Driver) Nip Roller/Door, 6-5
Encoder and motor, 6-11 E
Motor Test, 4-8
Roller, 6-11 EEPROM,
Servo Alignment, 6-24 Diagnostic, 4-6
Servo, 3-6 Load, 4-2
Cass, Key 5-3
Electrical Specifications, 1-2, 1-3
Cassette
Full, 4-17 Electronic
Sensor, 6-8 Alignment Procedures, 6-22
CF File, 5-8 Enclosure, 6-1
CGEN Loopback Test, 4-17 Encoder
Checkerboard Squares, 5-16 Diagnostic, 4-8
Clear Errors, 5-14 Signals, Optical, 3-4
Clear Key, 5-3 Spin encoder pulses, 3-1
Color Separation, 1-3 Phasing with the Capstan, 3-7
Command File List, 5-17 Phasing with the pixel clocks, 3-12
Commands, PUP, 5-2 End Of Take, 4-17
Computer Optical Products (COPS), 6-11
Enter Key, 5-3
Constraints, 5-1
Control Panel Environmental
Remove/Replace, 6-17 Specifications, 1-3
Loopback, 4-5 Limitations, 1-2
Core Testing, 4-3

i-1
AccuSet Service Manual

Errors I
Display and Clear, 5-14
Messages, 4-14 Imaging, 4-17
Reporting, 4-13 Incremental Leading, 5-15
Exit Command, 5-8, 5-9 Index Frequency, 4-7
Exp. Start, Inc, 5-10 Initial Testing, 1-3
Exposure, 5-15 Inspection
Installation, 1-4
F Preventive Maintenance , 7-1
Installation, 1-11-6
Feed Key, 5-3
Interconnect Diagram, 4-21
Feedback Control Loop, 3-16
Interface Requirements, 5-2
Field Replaceable Units (FRU), 8-1
Internal Timer
Filter Motor, 4-10, 5-7
0, 1, and 2, 4-4
Firmware Download, 6-30 Register, 4-4
Interrupt Controller Register, 4-4
Flash EEPROM, 4-6
Invalid Op-Code, 4-4
Fog Test, 5-16
Invoking the PUP, 5-4
Forced Load, 4-1
Functional J
Analysis, 3-13-18
Requirements, 5-2 J20, 6-14, A-6,
Job Depth Correction, 6-17
G
K
Grid with
Patterns, 5-17 Keypad, 5-3
Targets, 5-16 L
H
Laser Diode
Halftone Screens, 5-15 Driver, 3-14
Hard Drive, AccuSet 1200, 6-18 Diode, 3-14, 3-18, 5-8
Hardware Driver Module, 4-10
Error, 4-17 Filter Err, 4-17
Diagnostic Tool Kit, 8-3 Safety, 1-1
Heidenhein Motor and Encoder, 6-11 Leading Motor,
Home Sense Test, 4-10 Diagnostic, 4-8
Hor & Vert Rulings, 5-15 PUP Command, 5-8
Horizontal Modulation Transfer, 5-16 System, 3-3
Limitations, 5-1
I Line Length Correction, 6-17
Load
IEC, 6-14, A-5
Key, 5-3
Illegal Mode, 4-17
Params, 5-7
Image
Program, 4-18
Buffer Memory, 4-6
Loading Media, 4-18
Density Feedback Loop, 3-16
Quality Test Patterns, 5-2
Imager,
Remove/Replace, 6-10
Fan, 6-9
Vacuum 6-10, A2

i-2
Index

M P

Maintenance, 7-1, 7-2 Pancake Motors, 6-11

Mechanical Inspection, 7-1 Power Cutter
Media PUP Key, 4-3
Jam, 4-18 Test, 4-12
Low, 4-18 Power Up
Motor Err, 4-18 Display, 4-19
Present, 4-18 Test, 4-5
Transport System, 3-3 Pre-inspection Procedures, 7-1
Cutting, 4-17 Pre-installation, 1-3-1-4
Memory, Preventive Maintenance, 7-1, 7-2
Diagnostic, 4-3 Print Test Page, 4-20
Image Buffer, 4-6 Procedures, 6-1
Missed Brkpoint, 4-18 Processing, 4-19
Modes of Operation, 4-1 Processor
Module Overview, PUP, 5-1 Error, 4-19
Motor Maintenance, 7-2 not RDY, 4-20
PUP
N
About, 5-1, 5-21
Nip Roller/Door, 6-5 Main Menu, 5-5
No Commands Pause Functions, 5-20
Cassette, 4-18 Q
Media Load, 5-9
Power Cutter, 4-19 Quick Disconnect Connector,
Non-Volatile RAM, 4-6 6-20, 6-10, A-3
Normal load, 4-1
R
NVRAM Error Log, 4-13
O RAM
Diagnostics, 4-4
On Line Key, 5-3 Non-Volatile, 4-6
Operational Inspection, 7-2 Rear Panel (Electronic Enclosure), 6-1
Operations, 2-1, 2-2 Recalibration Test, 4-10
Operator Control Panel Loopback, 4-5 Removal/Replace Procedures, 6-1, 6-19
Optical Encoder Signals, 3-4 Remove Cassette, 4-20
Options (Piece Parts), 8-3 Reset System, 4-20
Out Of Media, 4-19 Resolution
Over Current, 4-19 Command, 5-9
Overview, 1-1 AccuSet 1500, A-1
Restart Operation, 3-9
P
RIP
Page Length Correction, 3-8 Boot Error, 4-20
Pancake Motor, 6-11 PCB, 6-17
Params, 5-10 ROM CRC, 4-3
Parts List, 8-1, 8-3
PAT Commands, 5-19
Pat, 5-9
Pattern Description, 5-14
Patterns, 5-8
Pause Pending, 4-19
Phase-Lock Loop, 3-9
Pixel-Clock Phase-Lock Loop, 3-9
Platen Assembly, 6-7

i-3
AccuSet Service Manual

S T

Safety, Laser, 1-1 Take-Up Motor

SBR to Engine, 4-7 Diagnostic, 4-9
Scan Rate, Remove/Replace, 6-6
Low and High Speed 3-1, 3-2 Servo, 3-5
Select Key, 5-3 Tension Motor,
Selectable Tests, 4-2, 4-11 Diagnostic, 4-8
Serial Communication Controllers, 4-4 Maintenance, 7-2
Serial No, 5-14 Adjustments, 6-20
Set/Disp. Params, 5-10 Alignment, 6-22
Shared Code, 5-2 Assembly, 6-2
Specifications, 1-2 Potentiometers/PCB, 6-3
Spin Motor Training, Customer, 1-6
Drive, 3-1
U
Power Up Test, 4-5
Spinner Mtr, 5-8 Unload, Key, 5-3
Square Dots, 5-16 Unloading Media, 4-21
Status Messages, 4-16 Unpack and Inventory, 1-3
Stop/Backup/Restart Operation, 3-9 User Guide, 2-1
Storing Values, 4-20 User Interface Requirements, 5-2
Sub-system Tests, 4-6
Supply Motor V
Test, 4-9
Vacuum System
Remove/Replace, 6-9
Errors, 4-14
Servo, 3-5
Purging, 3-3
System
V-Lines, 5-6
Interconnect Diagram, 4-21
Vertical Modulation Transfer, 5-16
Memory, 4-3
Video Feedback Test, 4-11
Ram, 4-4
W

Work Space Allocation, 1-3

Wr Density, 5-6

i-4