platinum support manual
Contents
1. IN ADDITION SINCE THE BEAM MIGHT BE INADVERTENTLY DEFLECTED DURING ADJUSTMENT OF THE TEST EQUIPMENT THE OPERATOR MUST TAKE APPROPRIATE PRE CAUTIONS TO SAFEGUARD OTHERS IN THE VICINITY 7 Youneed to set the filter wheel to the open position currently position 7 e Inthe current version of the Engineer s startup disk you need to use the TTL prompt in order to move the filter wheel to the Open position MS DOS 6 22 Startup Menu Carriage Vacuum oletest Timescan Expose Filter Shutter Laser TTL vonoa0V01PkwN HH Enter choice 9 e Then type the following commnands at the TTL prompt LC_Shutter 1 SC_CalibrationDetector 0xc300 LaserOn 1 lt lt 0 MC_Command LaserOn 8 The full power beam from the main laser is now under the control of the Invert switch on the test box Since the scanner is unplugged and therefore stationary the beam is deflected to a single point in the centre of the scan Page C 53 Platinum Support Manual Beam Power Test Copyright HighWater Designs Limited 1998 10 11 12 13 Position the laser power meter sensor in the beam on the platen The portable pen power meter currently used by HighWater service engineers is shown below Refer to the operating instructions that came with the meter for full details of usage Ss Nal Te Fer 7 e YOU MUST USE THE FILTER WHEN YOU MEASURE THE BEAM AT FULL POWER e You must set the wavele2. 1 Power up the Platinum with the engineer s floppy disc Page C 43 Platinum Support Manual Changing the Mole and the Graticule Copyright HighWater Designs Limited 1998 3 Select Moletest from the first menu MS DOS 6 22 Startup Menu Carriage Vacuum Moletest Timescan Expose Filter Shutter Laser TTL eou An AUNE Enter choice 3 You will be presented with a set of options for the Mole test Eye test e or run test r or e x it Eye Test 4 From the Mole test command line select the Eye Test The Platinum monitor now shows a value scrolling up the left hand side of the screen This is the light measurement from the mole s eyes and is in the range 0 to 255 for dark to full brightness In normal room lighting conditions the value should be zero or about zero If it is not zero hold an opaque surface over the mole head at a distance of about 10mm your hand will do and check that the reading is zero Next take the eye probe and carefully illuminate one of the three eyes Maintain a spacing of a few millimetres to avoid any risk of damaging the eye Also ensure that no light spreads from the probe to either of the other eyes The monitor will now show a reading which is the eye s sensitivity to the light level from the probe The value should be in the range 100 to 200 Note the value in the space provided in the checklist Repeat the test for the other eyes The absolute value is
3. Test copy the contents of the SP5 directory from the CD Rom to the K partition back onto the D drive This will test the SCSI bus termination Load the HighWater Disk profiler and ensure the performance of the Stripe set is around 8 MBytes second HighWater Application Software Refer to the Platinum Installation Guide for information about the Calibration Tool and RIP page set ups l Log in as Administrator and use the User administration tools to create a user called Platinum with no password and administrator capabilities only Next create a user called Engineer with the password highwater and administrator capabilities Log in as Platinum and load the Platinum GUI on the D partition following the instructions on the floppy disks Log off Then log in as Engineer and load the engineering software Log off Page C 72 DEC Alpha Configuration Platinum Support Manual Copyright HighWater Designs Limited 1998 Log back in as Platinum and change the user privileges to Power User only Edit plotter cfg so that the drive letter for the PLOTDATA directory is the same as the drive letter that you used to install the Platinum GUI the Stripe set partition normally kK Load the Torrent RIP software Follow the instructions in the Torrent Manual Don t forget to set the Torrent directory to TORRENT Its default is HIGHWA and set Zero Large System Cache Registry Key and Auto Start Rip on Reset opt
4. reverse traversing of the mole When the times are below 45 seconds the test can be terminated by hitting the lt Return gt key on the keyboard Note on the checklist the number of cycles run and the final timings Shut down the software and switch off Remove the preparation rig from the machine The graticule can now be fitted Lubricating the Mole leadscrew While the mole is running in continuous mode you could add two or three drops of 3 in 1 oil to the mole leadscrew This will be spread along the leadscrew by the mole as it runs forwards and backwards Page C 45 Platinum Support Manual Changing the Mole and the Graticule Copyright HighWater Designs Limited 1998 C10 7 Replacing the graticule The graticule is fragile and must be handled carefully 1 Ensure that the graticule is free from dust and grease WARNING DO NOT USE ACETONE ON THE GRATICULE 2 Ifyou use a cleaning substance do not use acetone Use only IPA WARNING YOU MUST ENSURE THAT THE GRATICULE IS INSERTED WITH THE CORRECT ORIENTATION 3 Check that the graticule is oriented correctly e It has two sides make sure that the mirror surface is upward and the glass surface downward e The mirrored surface has a thin line scored from front to back and a series of bars scored horizontally Make sure that the line along the graticule is on the right of the horizontal bars 4 Slot the graticule o
5. use this for the beam power test and with the SpotViewer in the Optical Diagnostics Invert Use this to switch between the on and the off beams Measuring the Voltage Use a Differential VoltMeter across the two points marked Mod Monitor The voltage with the beam on should be 1V and with the beam off should be OV Page C 51 Platinum Support Manual Beam Power Test Copyright HighWater Designs Limited 1998 C13 BEAM POWER TEST C13 1 Introduction This procedure tests the power of the laser beam WARNING THE MACHINE WILL HAVE MAINS POWER APPLIED AND THE LASERS WILL BE OPERAT ING THE APPROPRIATE SAFETY PROCEDURES MUST BE OBSERVED C13 2 Equipment e Optical Test Set Box e Engineer s floppy disc e Differential VoltMeter e Laser dongle e Laser power meter e Lid bipass switch C13 3 Procedure 1 Install the Optical Test Set Box and laser dongle as described in procedure 12 2 Insert lid bipass switch 3 Disconnect the scanner by removing cable TR2335 from the Power Rack 4 Connect cable TR2334 to the Optical Test Set Box 5 Power up the Platinum with the engineer s floppy disc 6 Wait for the laser output power to stabilize Page C 52 Beam Power Test Platinum Support Manual Copyright HighWater Designs Limited 1998 WARNING THE FOLLOWING OPERATIONS INVOLVE THE FULL UNSCANNED BEAM FROM THE 50mW LASER THIS BEAM IS DANGEROUS AND SUITABLE SAFETY GOGGLES MUST BE WORN
6. been cleaned successfully WARNING THESE CLEANING FLUIDS SHOULD ONLY BE USED ON GLASS SURFACES THEY REMOVE PAINT Page C 18 Cleaning the Optics Platinum Support Manual Copyright HighWater Designs Limited 1998 C5 3 Identifying the lenses and mirrors The diagrams below show the Optics Carriage from two positions and identify the six lenses or mirror surfaces which can be cleaned The Optics Carriage Scanner Section shown enlarged below Beam expander 2 Flat mirror this may be cleaned 1 Mirror surface partially obscured This may be cleaned 3 Lens at exit of beam expander this may be cleaned Page C 19 Platinum Support Manual Cleaning the Optics Copyright HighWater Designs Limited 1998 Optics Carriage from underneath In this image the Optics carriage is at the right hand end of the Platinum The camera is looking upwards from the front of the machine to the underside of the Optics Carriage Underneath of upper guide rail Back of the Platinum Flat mirrors Main lens C5 4 Procedure l Ensure that the Platinum is disconnected at the mains Remove the Platinum lid and the optics covers as described in chapter 1 Make sure that the Platinum bed is covered for example with old discarded plates You should either wear clean disposable gloves or you should make sure that your hands are free from grease using detergent based soap and water Use a d
7. being powered up 2 Login as Engineer The calibration software should automatically launch during the login procedure If it does not you will need to locate the current version of caltool exe Platinum 9 0 0 0 Calibration Tool Output Settings SCSI Target amp Platinum Calibration Set None Selected m Edit Calibration Plate I Laser Power Variables yX Lead Screw Scale Engine Settings About m Calibration Tool Log File View Empty P m Platinum Engine Log Files Done View Get Linear Calibration 3 Click on the Linear Calibration button 4 Click the radio button labelled Approximate and then click on Run 5 Once this has completed click the radio button labelled Refine and then click on Run Page C 39 Platinum Support Manual Replacing the Processor Unit boards Copyright HighWater Designs Limited 1998 Linear Calibration x The linearity calibration will take around 40 minutes to complete Refine af C Approximate Run 6 The process can take about 40 minutes and does not need operator intervention Versions of the software later than 8 3 3 require that the Refine procedure is run a minimum of 4 times It is vital that the full calibration stages of Approximate and Refine are run to ensure accurate linearity These require two full runs of the mole from front to rear and back in addition to rope findin
8. black and white dots When the laser is in focus the edges should be sharp and the corners of the squares should be touching Check that the adjoining black and white lines have the same width When the laser is out of focus the widths will be unequal Check the radial spokes When the laser is in focus the spokes should be clear and distinct towards the centre However the spokes rapidly fill in when the laser is out of focus Bear in mind that the ideal focus at the front and back of the plate may be slightly different to the ideal focus at the centre This takes two forms There may be a slant across the focus columns Or there may be a slight curve across the focus columns Page C 64 Fine Focus Set up Platinum Support Manual Copyright HighWater Designs Limited 1998 If the ideal focus varies across no more than three columns this is acceptable You should then select the middle column of those three If the ideal focus varies across more than three columns you should check with HighWater Designs as to whether further changes are needed When you have found the correct focus look at the number you wrote as the label for the strip This corresponds to the number of 1 32 4s to turn the focus ring back to the focus for that strip C15 5 Completion 1 Shut down the software and switch off the machine 2 Remove the preparation rig from the machine and reinstate the covers Page C 65 Platinum Support Manual Fine Foc
9. default page set ups if they need to create additional ones for the customer This is not part of the Production and Test procedure Setting up the Platinum Calibration Tool k 2 Login as Engineer The CalTool should start automatically Click on the Plate button and enter the following values On Laser Power Test Image Set Width 25 40 Set Gap 1 00 Page C 73 Platinum Support Manual Copyright HighWater Designs Limited 1998 On Scaling Test Image On Plate Size On Exposure Set Width 558 80 Set Width 550 00 Check the Positive Plate checkbox Click on the OK button 3 Click on the Variables button 4 Click on the Tplot Executable button and select D Platinum LevelnPn TPLOTW exe where n relates to the release version Click on the OK button 5 Click on the Archived Cal Sets button and select DEC Alpha Configuration Set Depth 25 40 Set Depth 558 80 D Platinum LevelnPn engine_calibrations where n relates to the release version Click on the OK button 6 Click on the Platinum Log Files button and select D Platinum LevelnPn engine_logs where n relates to the release version Click on the OK button 7 Click on the OK button and click Done on the Main Dialog C17 4 Check List Checked Installation Step Refer to E Check the Dec Alpha system against the current spec and that it boots up Section 3 Section 4 1 step 1 4 Add the H
10. machine Slightly move the graticule out from the slot grab the projected front end of the graticule and lift out USING EXTREME CARE C10 4 Removing the old mole assembly l If the graticule is not already removed remove it as described in the previous section Remove the screw at the front of the mole assembly tunnel Gently remove the mole assembly from the tunnel pulling forward out of the tunnel Page C 42 Changing the Mole and the Graticule Platinum Support Manual Copyright HighWater Designs Limited 1998 4 Disconnect the electrical cable of the mole assembly C10 5 Replacing the new mole assembly 1 Connect the electrical cable to the socket on the new mole assembly There is only one socket and there is only one way to attach the cable 2 Ensure that the cable runs flat along the mole assembly and slot the mole assembly gently into the mole assembly tunnel until it is fully home The mole assembly will have been tested beforehand so that the mole should fit in the tunnel with some clearance Channel for graticule Tunnel for mole assembly Cross section of mole tunnel 3 Replace the screw at the front of the mole assembly tunnel C10 6 Verification The purpose of the Verification procedure is to ensure that it is correctly installed and that the mole is bedded in Equipment Take an eye probe TR791 and plug it into the spare power socket on the interlock control board Preparation
11. need to set up a optical test set box to drive the modulator via the modulator drive cable TR2334 To do this you will connect the box using cables that are currently attached to the back of the processor unit Therefore place the test box on the shelf close to the PC Glitch oO oO Reset Power Ke Mod Monitor Scan1 Scan2 Mo Dim Pos Pos Dot Cont Invert 25 866 o c 1 Remove scanner cable TR2335 2 Detach the cable TR2334 mod drive from the back of the PC and connect it to the socket on the test box marked Mod 3 Detach the cable TR2345 P o s from the back of the PC and connect it to the socket on the test box marked Pos 4 Detach the cable TR2343 Scan 1 from the back of the PC and connect it to the socket on the test box marked Scan 1 5 Detach the cable TR2343 Scan 2 from the back of the PC and connect it to the socket on the test box marked Scan 2 Page C 50 The Optical Test Set Platinum Support Manual Copyright HighWater Designs Limited 1998 6 Attach a power supply cable to the socket at the back of the machine and connect to a power supply WARNING You must ensure that the scanner cable TR2335 is disconnected from the power rack so that the galvo will be stopped C12 4 Controlling the laser beam For the procedures in this manual the beam can be controlled using three of the buttons Cont Provides a continuous beam Pos Dot The beam appears as a bright dot
12. only Remove the leadnut by unscrewing it off the leadscrew and fit the new leadnut to the leadscrew by screwing it on If you are changing the leadscrew only Check whether the new leadscrew has a leadnut with it If not remove the leadnut from the old leadscrew and attach to the new leadscrew Attach the coupling If you are changing both the leadscrew and leadnut Make sure that the new leadscrew has the new leadnut attached to it Attach the coupling C7 4 Mounting amp aligning the Leadscrew Overview There are three stages to this procedure 1 Clamping the leadscrew into the right hand end of the machine 2 Roughly aligning the left hand end 3 Completing the left hand end alignment The Procedure 1 Move the Optics Carriage to the right hand end of the machine 2 Remove the end plate from the new leadscrew Page C 28 Changing the Leadscrew on Machines with Coupling Platinum Support Manual Copyright HighWater Designs Limited 1998 3 Insert the leadscrew through the large hole at the right of the machine and then slot the end of the leadscrew through the 22mm clearance hole at the left Insert into the mount at the right hand end Replace the four screws of the right hand bearing flange which you removed in step 5 of the previous section 4 Screw in the coupling clamp and use a torque screwdriver to torque down to 1 7Nm Coupling clamp 5 Replace the screws at the base of the coupling unit onto the c
13. the Platinum Expected power lt bed with the beam OFF 30UW What equipment did you use Insert a pen power meter at position C What is the power there Expected power gt 45mW Insert a pen power meter at position D What is the power there Expected power gt 45mW Insert a pen power meter at position E What is the power there Expected power gt 50mW Voltage on the Optical Test Set procedure 12 What is the voltage measured across the Mod Monitor points on the Optical Test Set Expected voltage 1V Beam pattern section 14 4 What are the on beam and off beam patterns Sketch them here Name of service engineer Today s date Page C 61 Platinum Support Manual Fine Focus Set up Copyright HighWater Designs Limited 1998 C15 FINE FOCUS SET UP C15 1 Introduction For a Platinum engine in the field only fine focussing adjustments should be necessary You should be aware that the best focus varies according to the thickness of the medium Film is approximately 0 1mm thick whereas metal plates tend to be either 0 15mm or 0 3mm thick You should therefore focus using the plate that will be used most often WARNING THE MACHINE WILL HAVE MAINS POWER APPLIED AND THE LASERS WILL BE OPERAT ING THE APPROPRIATE SAFETY PROCEDURES MUST BE OBSERVED C15 2 Equipment e You will be exposing one or more plates in the course of this p
14. HighWater Designs Limited 1 6 St George s Business Park Alstone Lane Cheltenham GL51 2HF OJ 2230 Platinum Support Manual General Release Volume Volume C version 1 0 Applicable to Build A7 Prod41 onwards May 19 1998 HighWater Designs Limited is not responsible for errors or omissions in this document It is subject to change without notice Platinum Support Manual Copyright HighWater Designs Limited 1998 Other documentation Before starting you need to be aware of the information contained in the published HighWater manuals Platinum Installation Manual This provides information on the installation of Platinum at a customer site It leads you through the installation and calibration of the Platinum engine the configuration of the workstation and the creation and calibration of Page Setups on the Torrent RIP Platinum User Guide This provides information for the user once Platinum has been installed and calibrated It describes operation of the Platinum engine and of the layout software together with how to use the Torrent RIP Torrent Installation Guide This provides a thorough description of the installation of the Torrent RIP from scratch This guide is regularly updated to keep track of changes to the RIP and to the Windows operating system Torrent User Guide This is the OEM User Manual provided by Harlequin for all of their ScriptWorks based products and should be consulted f
15. NUM LID AND THE OPTICS COVERS C1 1 Introduction Many of the procedures require that you remove the lid from the Platinum Other procedures also require that you remove the covers from the Optics Carriage This section describes how you would achieve both C1 2 Equipment e Allen key to remove lid bolts C1 3 Removing the Platinum Lid This procedure requires two people to lift the lid off 1 The two gas struts one on either side of the Platinum lid need to be disconnected Unscrew them either at the top or the bottom the bottom is easier to access One of the two gas struts which control how far the lid opens You must disconnect the gas struts by unscrewing at either the top or the bottom before you can lift the lid off 2 There are 7 bolts on each side of the Platinum lid Remove these bolts from the outside and store them somewhere safe Page C 10 Removing the Platinum lid and the Optics covers Platinum Support Manual Copyright HighWater Designs Limited 1998 3 With one person on either side of the Platinum lift the lid clear and place somewhere away from the machine C1 4 Removing the Optics covers The Optics carriage has three covers on the right and left sides together with a metal plate at the rear These are attached with a set of screws Unscrew these and store safely Remove the covers and store safely C1 5 Protecting the Platinum Bed The Platinum bed is made of a soft metal and can easily
16. W448 card and the SCSI extension and test Section 4 1 steps 2 to 5 Add the Fast Wide Disks and test Check that the SCSI drivers are installed for the two fast SCSI drives currently Adaptec 294x AIC 78xx PCI and or NCR Section 4 1 steps 6 to 8 Use SP5 to ensure that the operating system mods are current and to test the SCSI bus termination Use the HighWater Disk profiler to check the performance of the Stripe set Section 4 1 steps 9 to 10 Section 4 1 step 11 Create a Platinum and Engineer login as Administrator Load the Platinum software and the engineering software Set the Platinum login to a Pwer User only Edit plotter cfg so that PLOTDATA points to the Stripe set partition Section 4 2 steps 1 to 4 Page C 74 DEC Alpha Configuration Platinum Support Manual Copyright HighWater Designs Limited 1998 Lj Load the Torrent RIP install the dongle and check Section 4 2 steps the RIP pagebuffers and workspace directories and 5 to 7 the RIP memory set up LJ Set up the Platinum Calibration Tool Section 4 3 Lj Attach all labels and the serial number Make sure that all the relevant manuals and cables are packed with the machine Page C 75
17. adscrew and leadnut If necessary refer to the chapter on replacing the leadscrew C8 5 Implications If there is grease or dirt trapped under the rail the focus will be affected causing areas of density change in a flat tint which remain from plate to plate You should therefore output a plate with a flat 50 tint on it to check this Page C 35 Platinum Support Manual Copyright HighWater Designs Limited 1998 C9 REPLACING THE PROCESSOR UNIT BOARDS C9 1 Introduction This procedure describes the replacement of the processor boards together with the calibration and verification process for the pixel clock board C9 2 Equipment e Screwdrivers for opening the PC unit and replacing the board e ESD grounding wrist strap e 2 open ended spanners e 1 meter steel rule C9 3 Anti static precautions WARNING Before you begin the installation process you must discharge any static electricity from yourself and the PC Once you have opened the case tap your finger on the metal frame of the PC chassis We also recommend that you leave the PC unit plugged in but switched off at the mains This ensures that the it is grounded without being connected to a power source Wear an ESD grounding wrist strap The ESD wrist strap is supplied with its own instructions for wear and use Do not remove the antistatic wrappers from the board until you are grounded and about to start installation Always return
18. arriage 6 Align the leadscrew by eye and then attach the end plate at the left end which you removed in step 3 Screw in the end plate but not too tight you will tighten it up later after you have made other adjustments 7 Move the optics carriage to the left hand end of the machine 8 Tighten up the screws in the left hand end plate C7 5 Verification Carriage drive test To verify that the leadscrew has been aligned correctly you need to get the carriage to traverse at full speed from end to end If there is a misalignment there will be a loud Page C 29 Platinum Support Manual Changing the Leadscrew on Machines with Coupling Copyright HighWater Designs Limited 1998 howling sound where the misalignment has occurred If this occurs re do the necessary part of the alignment procedure K Power up the Platinum with the engineer s floppy disk inserted in the disk drive Close the Platinum lid Select Carriage from the first menu MS DOS 6 22 Startup Menu Carriage Vacuum oletest Timescan Expose Filter Shutter Laser TTL OMNIA AO KBWDN a aa Enter choice 1 The Platinum will go through a standard checking procedure When the checking procedure has finished you will be offered three choices Type 1 for Bednut Slow Type 2 for Bednut Fast Type 9 for Exit Do not choose the Bednut Fast option unless the optics carriage is at the right hand end Therefore choose Bednut Slow
19. be damaged You need to protect the bed from falling screws oil drips scrapes etc Whenever you are servicing the Platinum you should cover the Platinum bed with old metal plates to protect its surface Page C 11 Platinum Support Manual Using the Engineer s Floppy Disk Copyright HighWater Designs Limited 1998 C2 USING THE ENGINEER S FLOPPY DISK C2 1 Introduction Many of the procedures described in this support manual require that you re boot Platinum using the Engineer s floppy disk This chapter describes this process C2 2 Equipment e The Engineer s floppy disk TTL disk e Keyboard and monitor to attach to the Processor unit The connections are the standard ones for a PC and the monitor can be just a basic one capable of displaying lists of DOS commands C2 3 Procedure 1 Ensure that Platinum has been powered down 2 Insert the engineer s floppy disk into the disk drive on the Processor unit 3 Press the Power button on the Processor unit 4 Once the boot sequence has been completed you will be presented with an inital menu MS DOS 6 22 Startup Menu Carriage Vacuum oletest Timescan Expose Filter Shutter Laser oo oO 1 Oo FSF W N FP TTL Enter choice 5 Enter the number of the menu item that you want to choose and follow the instructions provided in the service procedure you are following see the table on the next page Page C 12 Using the Engineer s Flopp
20. ctions C3 2 Equipment e Adrycloth C3 3 Dirt pile ups Use the dry cloth to remove the dirt pile ups Use the cloth to clean the leadscrew and the guide rails C3 4 Fans 1 Ensure that the Platinum is disconnected at the mains 2 Remove the back panel of the Platinum to reveal the three units on the Processor rack 3 The picture on the next page shows the location of the fans Remove the panels of each unit and clean the fans and the filters There are three fans located within the processor rack Page C 14 General Cleaning Platinum Support Manual Copyright HighWater Designs Limited 1998 Page C 15 Platinum Support Manual Lubrication Copyright HighWater Designs Limited 1998 C4 LUBRICATION C4 1 Introduction Both the leadscrew and the guide rails need lubrication C4 2 Equipment You need a light machine oil SAE 10 15 for example a multi purpose electrolube oil 3 in 1 oil is too runny although it may be used if you have absolutely no other option WARNING e NEVER USE AEROSOL OR SPRAY OILS THESE WILL CONTAMINATE THE OPTICS e VERY LITTLE OIL IS NEEDED TOO MUCH OIL WILL DAMAGE THE PLATINUM C4 3 Procedure The basic problem with applying the oil is that you must avoid any drips going onto the Platinum bed WARNING YOU MUST PROTECT THE PLATINUM BED FROM OIL DRIPS COVER THE BED WITH OLD METAL PLATES TO CATCH THE DRIPS Applying oil to t
21. e Laser dongle e Laser power meter e Lid bipass switch e Spot Viewer Page C 56 Optical diagnostics Platinum Support Manual Copyright HighWater Designs Limited 1998 C14 3 The Optics Path The optical path is shown below with the five test points marked A to E The table on the next page summarises the measurements expected at these points Platinum Expose Beam Optical Path simplified Laser Focus Lens Modulator Collimator Lens First t1 beam Fold Prism x gt gt a SS E Ben a gt AD Laser wavelength is 532nm beam waist inside modulator is 50um dia Safety Shutter t0 beam absorbed internally Piezo Mirror Fold Mirror cee IK B T HH a c Second Fold Prism Beam Expander ND Filter Y y e Mirror Y Laser Scanning Lens Ze Exposing Plate These five test points are readily accessible on the Platinum once the covers of the Optics Carriage have been removed Page C 57 Platinum Support Manual Optical diagnostics Copyright HighWater Designs Limited 1998 OPTICS CARRIAGE WITH THE COVERS REMOVED Place a sheet of paper over the end B of the beam expander to observe the beam pattern You may need to remove the metal plate at E before you can measure the power there PLATINUM WITH SECTION CUT AWAY TO SHOW LOCATION OF OPTICS CARRIAGE Insert the pen meter in the beam just before the fold prism You will need to remove the filte
22. e the mass damper off the motor shaft If you are changing the mass damper and nothing else jump to step 9 Page C 22 Changing the Mass Damper and Stepper Motor Platinum Support Manual 9 Copyright HighWater Designs Limited 1998 Stepper Motor Mass Damper One of the four bolts which attaches the stepper motor to the Platinum PC cable connection Loosen the screw of the clamping ring so that the Stepper Motor can be removed in the next step This screw is only accessible from the rear of the machine Screw of the clamping ring The Stepper Motor is connected with four Allen bolts and a PC connector Detach the PC connection first Then remove the four bolts and store safely If you are changing the clamping ring e Unscrew the clamping ring and remove it e Place the new clamping ring over the four split bush e Tighten the new clamping ring with a torque screwdriver to 1 7Nm Attach the new Stepper Motor Connect the Stepper Motor PC connection 10 If you are changing the mass damper acquire the new mass damper Page C 23 Platinum Support Manual Changing the Mass Damper and Stepper Motor Copyright HighWater Designs Limited 1998 Place the mass damper onto the motor shaft Make sure that the motor shaft does not cross the gap layer to check this either use a depth gauge through the right hand end of the mass damper or improvise with something like an Allen key 11 Using a torque screwdriver t
23. face Remove the cover of the Processor Rack by removing the six screws at the back Remove the jumper cables and co ax cables from the board Remove the retaining screw which attaches the board to the rack Slide out the board from the machine C9 6 Inserting the new board 1 If you are changing the Pixel Clock Board check the link and the switch setting positons using the table below SWI SW2 Pins 1 16 ON Pins 1 16 OFF Pins 2 15 OFF Pins 2 15 OFF Pins 3 14 ON Pins 3 14 OFF Pins 4 13 ON Pins 4 13 OFF Pins 5 12 OFF Pins 5 12 OFF Pins 6 11 ON Pins 6 11 ON Pins 7 10 ON Pins 7 10 OFF Pins 8 9 OFF Pins 8 9 OFF 2 Slot the board into place and screw in the retaining screw 3 Attach the jumper cables and co ax cables 4 Replace the cover of the Processor Rack and return the Processor Rack to the shelf on the Platinum 5 Re connect all the cables at the back of the Processor Rack taking care that the cable designation matches the socket designation Page C 38 Replacing the Processor Unit boards Platinum Support Manual Copyright HighWater Designs Limited 1998 C9 7 Pixel Clock Calibration If you have installed a new pixel clock board you must perform the pixel clock calibration 1 Power up the Platinum with the normal software and the front end system connected and operating This procedure requires a stable laser it takes about 8 10 minutes for the laser to become stable after
24. g cycles Verification For confidence that the linearity has been achieved we recommend that at a later stage in the testing you e Take a film with a suitable front to back scale e Overlay the front half on the rear half e Inspect the coincidence of the tick marks under a microscope Alternatively e Output a density calibration film e g laser50_150_2540 TIF and use the ruler to measure C9 8 Completion Shut down the software and switch off the machine if it is not needed in this configuration for subsequent tests Page C 40 Replacing the Processor Unit boards Platinum Support Manual Copyright HighWater Designs Limited 1998 Page C 41 Platinum Support Manual Changing the Mole and the Graticule Copyright HighWater Designs Limited 1998 C10 CHANGING THE MOLE AND THE GRATICULE C10 1 Introduction This procedure describes how to replace both the mole assembly and the graticule C10 2 Equipment Allen keys Screwdrivers Torch Eye probe Monitor and keyboard Engineer s floppy disk Oil 3 in 1 for the mole leadscrew optional IPA cleaning fluid optional C10 3 Removing the old graticule The graticule is fragile and must be handled carefully l Remove the black guard which protects the graticule from plate damage This can be done by removing the 3 Allen screws Unscrew the clamps fully at the front and the back of the graticule and store safely Use the torch to see at the back of the
25. he guide rails You may use one of the following methods to apply the oil e Puta little oil onto the felt pads of the PTFE feet and set the optics carriage to traverse left to right OR e Puta little oil onto a rag and wipe the guide rail with it Page C 16 Lubrication Platinum Support Manual Copyright HighWater Designs Limited 1998 Applying oil to the leadscrew This is only applicable if the old gimbal alignment system is in use see procedure 6 Place a little oil onto the felt wiper of the leadscrew and set the optics carriage in motion Gimbal Unit from underneath removed from Platinum for clarity Mounting bracket leadnut with felt wiper leadscrew retaining ring Leadscrew Page C 17 Platinum Support Manual Cleaning the Optics Copyright HighWater Designs Limited 1998 C5 CLEANING THE OPTICS C5 1 Introduction The Optics surfaces which are easily visible need to be cleaned regularly Do not attempt to clean any optics surface which is not easily visible C5 2 Equipment e For the Optics cleaning fluid you should ideally use Acetone If this is not available use pure IPA isopropyl alcohol at least 99 7 pure e You will find it convenient to use a pump dispenser so that you can use VERY small amounts of fluid at any one time e Use either a lint free cloth or lint free cotton buds to apply the cleaning fluid e You should use a torch with which you can check whether the surfaces have
26. ighten down the screws of the mass damper to 1 7Nm C6 4 Implications You need to test for slippage between the mass damper and the leadscrew motor coupling 1 Grip the leadscrew with a dry cloth WARNING NEVER GRIP THE LEADSCREW WITH PLIERS 2 Turn the mass damper 3 Ifthe mass damper turns independently of the leadscrew then you need to locate the cause of the slippage The symptoms of slippage are light dark lines on the output in the fast scan axis and distortion of the image Page C 24 Changing the Mass Damper and Stepper Motor Platinum Support Manual Copyright HighWater Designs Limited 1998 Page C 25 Platinum Support Manual Changing the Leadscrew on Machines with Coupling Copyright HighWater Designs Limited 1998 C7 CHANGING THE LEADSCREW ON MACHINES WITH COUPLING C7 1 Introduction New Platinum machines later than January 1998 have been fitted with a coupling system for connecting the optics carriage to the leadscrew Previous to this the machine will have the old gimbal system Check the type of connection before proceeding This procedure explains how to remove the leadscrew from the Platinum engine and to replace it with a new one If you wish to change the leadscrew nut the procedure is very similar since it also requires the leadscrew to be removed first and then re attached afterwards C7 2 Equipment In addition to the new leadscrew and or the new leadscrew nut you
27. ions on the first dialog Remember to install the Dongle and the Appletalk drivers Macintosh Services on NT Server Fit the dongle to the parallel port and check operation by booting up the RIP Remember to set low priority on the RIP by adding pidle to the Shortcuts of the Properties of the Torrent program in the Startup and Platinum Executables program groups To do this select the right mouse button on the Start Icon on the Start Menu bar and select Open Click on Programs then Startup Select the right mouse button on the Torrent program and select the Properties menu Select shortcut and then enter pidle at the end of the target directory Repeat for the Torrent program in the Torrent program group Make sure that the RIP PageBuffer and Workspace directories and the RIP memory are set up correctly Login as Platinum The Torrent RIP should start automatically If the Inputs have already been started click on Start Inputs to deselect it stop inputs Click on Configure Rip Set up both the PageBuffer and the Workspace directories to point to the striped drive normally the K drive Then click on Options and make sure the following settings apply Minimum Memory Set to 30000 Memory for RIP Make sure that the box is checked set the value to 80000 Note Installation engineers must also make sure that the page set ups are configured correctly for Platinum 32 bit aligned and single strip We recommend that engineers copy the
28. ised as follows TNT BIN This directory contains the binaries that are required for the tnt dos extender BC5 BIN This directory contains the binaries that are required for Borland 5 support LOGS This directory contains the daily engine log files Note Part of each log is stored in the engine software directory PLATINUM VxBy until the engine software has processed the arg file and located the LOGS directory CALIB This directory contains all the calibration files version 6 and higher Page C 68 Platinum Engine Software Platinum Support Manual Copyright HighWater Designs Limited 1998 PLATINUM VxBy This directory contains the engine software vxBy identifies the version number For example Version 6 1 0 0 is in C PLATI NUM VxBy C16 3 Useful Batch Files You need to be aware of several batch files c autoexec bat This boots the engine and intialises the DOS and memory manager c platinum bat This is called by autoexec bat It sets up the path so the correct versions of the various software components are found This will allow us to release newversions that might use either or all of newer versions of TNT Borland or Platinum software c PLATINUM VxBy go bat This is called by autoexec bat after calling plati num bat and ensures that the current version of engine software is executed C16 4 Upgrade Strategy e Install any new software into a unique directory e Do not delete the previous versi
29. le Connections for filter wheel 3 Disconnect the cables Page C 48 Changing the Filter Wheel Platinum Support Manual Copyright HighWater Designs Limited 1998 4 Unscrew the Allen screws on the underside of the Optics carriage and save the screws 5 Remove the old filter wheel 6 Insert the new filter wheel fitting tight and square into the angle of the carriage 7 Screw in the new filter wheel and re connect the cables C11 4 Verification You should verify that the filter wheel operates correctly by running the filter wheel test using the Engineer s Startup Disk see procedure 2 1 Choose Filter from the first menu MS DOS 6 22 Startup Menu Carriage Vacuum oletest Timescan Expose Filter Shutter Laser TTL OmMAIANAUO BR WNE Enter choice 6 2 The Platinum will now cycle through the filter wheel positions displaying the cycle number and the number of retries 3 After a sufficient number of cycles hit all three buttons on the Platinum to quit C11 5 Implications The machine may need to be re calibrated Page C 49 Platinum Support Manual The Optical Test Set Copyright HighWater Designs Limited 1998 C12 THE OPTICAL TEST SET C12 1 Introduction The Optical Test Set box is required for use with the Beam Power test and for the Optical diagnostics C12 2 Equipment e Optical Test Set Box e Differential Voltmeter C12 3 Installing the Optical Test Set Box You
30. m Support Manual Copyright HighWater Designs Limited 1998 C17 2 Initial System Checks The first task is to assemble the machine as delivered and check that it conforms to the specification on the Purchase Order and Delivery Note Required Components Dec Alpha System see previous section HW 448 card Platinum cable NT software amp manuals Torrent software amp manuals Platinum software and manuals Optional software and manuals including Spooler and InkDuct software C17 3 Configuration Procedure Hardware and System Software l Test that when the system is assembled the NT system will boot satisfactorily this will ensure the integrity of the file system Log in as administrator and examine the file system and disk partitions to check all is well Power down the system and observe ESD Static precautions Insert the HW448 card in a spare PCI slot It may be necessary or desirable to move the existing SYMBIOS disk controller because of physical cable connector constraints Power on the system and check that NT boots correctly If not then it may be due to the ordering of the SYMBIOS and HW448 cards within the PCI bus Either switch the positions of the cards or use the BIOS menu to edit the NT boot hardware configuration Use Supplementary menu Boot Management menu Hardware Configuration menu Change the values from SCSI 0 to SCSI 1 Note the changes made Reboot the system and check NT operation P
31. ngth to 532nm If necessary you can move the carriage manually to a convenient position by turn ing the mass damper disc located on the right hand side of the Platinum towards the back Using the Optical test set ensure that the modulator is not inverted and measure the beam power The on beam should be gt 20mW If you need to measure the extinction contrast ratio e On the test set box switch the invert switch on This will give the off beam power e Measure the power of the off beam It should be lt 301 W e The extinction contrast ratio is the ratio of the on beam power to the off beam power It should be above 500 1 Record these results in the engine log If the on beam and off beam measurements are satisfactory go to section 13 5 Completion C13 4 Adjusting the Beam Power If the maximum beam power is too low you should check the setting of the Modulator Driver The Modulator Driver is located at the left hand end of the electrical rack Adjust the modulator driver trim pot to find the maximum power reading The manufacturer s name should be marked on the modulator driver e On Isomet modulators use a terminal screw driver or trim tool through the hole marked PWR ADJ e On Isle Optics modulators use a terminal screw driver or trim tool through Page C 54 Beam Power Test Platinum Support Manual Copyright HighWater Designs Limited 1998 the hole marked LEVEL e On A amp A Systems modulat
32. ning the Leadscrew C 28 C7 5 Verification C 29 Page C 3 Platinum Support Manual Contents Copyright HighWater Designs Limited 1998 C8 Changing the Guide Rail Strips C 32 C8 1 Introduction C 32 C8 2 Equipment C 32 C8 3 Supporting the Optics Carriage C 32 C8 4 Procedure C 34 C8 5 Implications C 35 C9 Replacing the Processor Unit boards C 36 C9 1 Introduction C 36 C9 2 Equipment C 36 C9 3 Anti static precautions C 36 C9 4 Identifying the boards C 37 C9 5 Removing the old board C 38 C9 6 Inserting the new board C 38 C9 7 Pixel Clock Calibration C 39 C9 8 Completion C 40 C10 Changing the Mole and the Graticule C 42 C10 1 Introduction C 42 C10 2 Equipment C 42 C10 3 Removing the old graticule C 42 C10 4 Removing the old mole assembly C 42 C10 5 Replacing the new mole assembly C 43 C10 6 Verification C 43 C10 7 Replacing the graticule C 46 C11 Changing the Filter Wheel C 48 C11 1 Introduction C 48 C11 2 Equipment C 48 C11 3 Procedure C 48 C11 4 Verification C 49 C11 5 Implications C 49 C12 The Optical Test Set C 50 C12 1 Introduction C 50 C12 2 Equipment C 50 C12 3 Installing the Optical Test Set Box C 50 C12 4 Controlling the laser beam C 51 C13 Beam Power Test C 52 C13 1 Introduction C 52 C13 2 Equipment C 52 C13 3 Procedure C 52 C13 4 Adjusting the Beam Power C 54 C13 5 Completion C 55 Page C 4 Contents Platinum Support Manual Copyright HighWater Designs Limited 1998 C13 6 Implications C 55 C14 Optical diagno
33. not critical since the test environment and procedure are crude However a fairly good balance within 20 should be obtained across all three eyes if the system is working correctly 10 Terminate the test by typing lt Return gt on the keyboard Page C 44 Changing the Mole and the Graticule Platinum Support Manual Copyright HighWater Designs Limited 1998 Run Test 11 12 13 14 15 16 12 18 Select the Run Test from the Mole test command line The Run Test menu provides options to drive the mole to the front to the rear and continuously backwards and forwards Move mole to f ront or b ack or c ontinuous or e x it Any operation can be terminated by hitting the lt Return gt key Using the first two command options and a stop watch measure the time taken for the mole to travel from the front stop to the rear stop and from the rear stop to the front stop Note the times in the checklist If the time is less than 45 seconds then this test can be terminated immediately If the time is greater than 45 seconds then it is necessary to bed in the mole drive system To do this select the Continuous Running test This drives the mole forwards for 60 seconds and backwards for 60 seconds then repeats indefinitely The monitor records the number of forward and backward cycles The machine can be left with this test running Periodically return to the machine to monitor progress and time the forward and
34. nto the channel above the mole assembly Rope T Rungs of ladder Graticule Page C 46 Changing the Mole and the Graticule Platinum Support Manual Copyright HighWater Designs Limited 1998 5 When the graticule is nearly inserted fully into the tunnel use a flat surface to push the assembly so that it is flush with the end of the tunnel 6 The graticule must be placed hard up against the left edge To ensure this insert a folded piece of shim between the right edge of the graticule and the right edge of the tunnel so that the graticule is pushed over to the left 7 Move the clamp at the back over the graticule and screw into place 8 Attach the front clamp over the front end of the graticule 9 Replace the guard Page C 47 Platinum Support Manual Changing the Filter Wheel Copyright HighWater Designs Limited 1998 C11 CHANGING THE FILTER WHEEL C11 1 Introduction The filter wheel can be changed via a straightforward procedure If an individual filter is defective it will be best to change the whole filter wheel C11 2 Equipment In addition to the new filter wheel you will need e Allen key e Flat head screwdriver e The Engineer s floppy disk TTL disk for the verification C11 3 Procedure 1 Remove the lid and the optics covers see procedure 1 2 The filter wheel is attached with two screws on the underside of the optics carriage and is connected with two small cables ee DA Expander Cab
35. on Curve Entry No 5 a ame 24 zi repeat value glitch tolerance 2 Centre Value clear all 00 gt gt 100 Filter Automatic C Manual Run x backlash tif reload filter Restore Last Apply gt Done Test File In the Test File box choose the appropriate test file e g Laser50 150 2540 tif and click on Run 9 Choose a Start Power of 100 and Step Size of 0 Page C 63 Platinum Support Manual Fine Focus Set up Copyright HighWater Designs Limited 1998 10 KL 12 13 14 Laser Power Settings r Laser Start Power f 00 Step Size fo OK Cancel When the Platinum has finished outputting the first test strip it will bleep for about ten seconds While it is bleeping turn the focus ring clockwise by 1 32 of a turn After the Platinum has finished bleeping the second test strip will be output Repeat this procedure until all the test strips have been output Process the plate film Carefully label the strips as follows the last strip which represents the current focus position should be labelled 0 the others should be labelled 1 2 3 C15 4 Assessing the focus Determining the best focus is a subjective process The following comments provide a guide Refer to the image on the next page to idenitify the key features of the test image When the 50 tint is viewed at high magnification it will appear as a chequer board of square
36. on of the software You may wish to delete versions prior to that e The platinum bat is copied to platinum old and a new platinum bat is installed that points at the new version of code Is this manual or automatic This strategy will allow you to revert quickly to the original software by copying platinum old which sets the software path to platinum bat Page C 69 Platinum Support Manual DEC Alpha Configuration Copyright HighWater Designs Limited 1998 C17 DEC ALPHA CONFIGURATION C17 1 Specification The specification of the base system is subject to constant review and change The intention is to have the most powerful platform solution available Hardware The Dec Alpha workstations are purchased with a minimum of 128Mb RAM fitted The current system specification is e Minimum 128MByte RAM e Fast Wide SCSI controller e PCI graphics controller amp 17 Monitor e Network card definable by customer e SCSI system drive e CD Rom drive e Floppy drive e Configurable fast wide SCSI drives A HW448 card is added at HighWater to connect to the Platinum Software The system disk should have two partitions one small partition set up as C for the operating system Windows NT 4 0 or later and the remainder set up as D for software paging files etc The Platinum software and the Torrent RIP software is installed at HighWater and shipped with the Torrent dongle Page C 70 DEC Alpha Configuration Platinu
37. or a detailed understanding of the operation of the Torrent RIP HighWater Output Spooler User Guide This contains instructions on the installation and operation of the Spooler together with appendices that describe its operation with associated software including Platinum Version information 1 0 May 1998 First General Release Version Includes new coupling for leadscrew Page C 2 Contents Platinum Support Manual Copyright HighWater Designs Limited 1998 Contents C1 Removing the Platinum lid and the Optics covers C 10 C1 1 Introduction C 10 C1 2 Equipment C 10 C1 3 Removing the Platinum Lid C 10 C1 4 Removing the Optics covers C 11 C1 5 Protecting the Platinum Bed C 11 C2 Using the Engineer s Floppy Disk C 12 C2 1 Introduction C 12 C2 2 Equipment C 12 C2 3 Procedure C 12 C2 4 Completion C 13 C3 General Cleaning C 14 C3 1 Introduction C 14 C3 2 Equipment C 14 C3 3 Dirt pile ups C 14 C3 4 Fans C 14 C4 Lubrication C 16 C4 1 Introduction C 16 C4 2 Equipment C 16 C4 3 Procedure C 16 C5 Cleaning the Optics C 18 C5 1 Introduction C 18 C5 2 Equipment C 18 C5 3 Identifying the lenses and mirrors C 19 C5 4 Procedure C 20 C6 Changing the Mass Damper and Stepper Motor C 22 C6 1 Introduction C 22 C6 2 Equipment C 22 C6 3 Procedure C 22 C6 4 Implications C 24 C7 Changing the Leadscrew on Machines with Coupling C 26 C7 1 Introduction C 26 C7 2 Equipment C 26 C7 3 Removing the Leadscrew C 26 C7 4 Mounting amp alig
38. ors use a terminal screw driver or trim tool through the hole marked POWER ADJ 2 Ifthe modulator is an Isle Optics back off the trimmer until the power is at 95 of maximum You do not need to do this for modulators manufactured by either Isomet or A amp A Systems 3 Once you have made this setting record in the checklist the power with the modu lator on and off C13 5 Completion 1 Shut down the software and switch off the machine 2 Remove the engineer s disk 3 Remove the Optical Test Set Box from the back of the machine and re connect the cables 4 Re attach the Scanner Cable TR2335 to the Power Rack C13 6 Implications If you made an adjustment to the setting of the modulator driver you need to re calibrate the Platinum output using the method described in the Platinum Installation and Maintenance Manual Page C 55 Platinum Support Manual Optical diagnostics Copyright HighWater Designs Limited 1998 C14 OPTICAL DIAGNOSTICS C14 1 Introduction If there are problems with Platinum s optics it is essential to invest time in diagnosing the problem so as to minimise machine down time later The aim of this chapter is to fill in the diagnostics form at the end which should then be faxed to HighWater This will enable Platinum service engineers to provide further guidance on the problem C14 2 Equipment e Optical Test Set Box e Engineer s floppy disc e Keyboard and monitor e Differential VoltMeter
39. ould rest on the Platinumbed To observe the on beam 1 Set up the Optical Test Set as described in procedure 12 2 Reboot the Platinum using the Engineer s Floppy Disk described in procedure 2 Page C 59 Platinum Support Manual Optical diagnostics Copyright HighWater Designs Limited 1998 3 From the menu choose the Laser Option which is option 8 MS DOS 6 22 Startup Menu Carriage Vacuum oletest Timescan 1 2 3 4 5 Expose 6 Filter 7 Shutter 8 Laser 9 TTL Enter choice 8 4 The laser should be left for 10 minutes or so to ensure that it is stable 5 Slide the filter into place to reduce the intensity of the beam that will be observed 6 Place the SpotViewer onto the Platen and observe the beam pattern To observe the off beam 7 On the Optical Test Set hit the Invert button 8 Move the filter on the SpotViewer out of the beam path 9 Observe the beam pattern Page C 60 Optical diagnostics To HighWater Designs Ltd ATTN Platinum Service Engineer Your contact phone number Your fax number Platinum Support Manual Copyright HighWater Designs Limited 1998 Fax 44 1242 251600 E mail address Information about the machine Customer s name and address Engine s serial number Beam Power procedure 13 What is the power measured on the Platinum Expected power gt bed with the beam ON 20mW What is the power measured on
40. ower down the system and observe ESD Static precautions Connect the SCSI cable extension IDC to Honda connector to the end of the narrow SCSI bus Page C 71 Platinum Support Manual DEC Alpha Configuration Copyright HighWater Designs Limited 1998 10 11 12 13 14 Note Check the SCSI bus termination and if necessary remove the termination from the CD Rom drive Remove the Termination jumper on the configuration pins adja cent to the SCSI connector Label the narrow SCSI the wide SCSI and also the Platinum connectors for easy identification Use the NT Administrative Tools to determine the available SCSI ids on the bus Use Windows NT diagnostics Tools Registry Editor H Key LOCAL MACHINE Hardware Devicemap SCSI to check ids If not already used set the Fast Wide disks to ids 5 amp 6 and connect to the wide 68 pin connector Ensure the external box is correctly terminated Power on the system and check the SCSI visibility using the BIOS menus If the disks are not visible check the cable connections Boot NT and use the Disk Administration tool to create an 8 Gigabyte Stripe set partition across the two Wide disks Use Quick Format to save time Ensure the Stripe set is configured as drive K Obtain the Microsoft developer CD and copy the Service Pack 5 ALPHA directory onto partition D Run setup exe in the SP5 ALPHA directory on the D drive to ensure to operating system mods are current
41. r wheel which is normally located here before you can measure the power Measuring the power at A is the first step in diagnosing a problem in the optics path The Optical Path Test Points The expected results from the five test points are summarised below For the power measurements refer to procedure 13 for details Beam diameter Power Comments A 25um 20mW 4 power loss at each of the mirror surfaces Use the Spot Viewer to examine the beam here B 20mm Good position for paper test ofthe broad beam If the beam is defective beam here the problem is earlier If the beam is OK here but the output is defective the problem is later C 2 beams approx 0 6mm 45mW Minimal power loss through fold prisms Remove filter wheel to measure power D 2 beams at 0 33mm 45mW Approx 5mW lost through modulator and lenses E 0 33mm 50mW Nominal power The beam power is not measurable at position B it is too broad for the power meter Page C 58 Optical diagnostics Platinum Support Manual Copyright HighWater Designs Limited 1998 C14 4 Using the Spot Viewer The Spot Viewer has been designed to observe the beam pattern at the platen marked position A on the diagrams in the previous section Beam hole Place this hole in the path of beam Filter to reduce intensity of the on beam Do not use when observing the off beam Base of SpotViewer which sh
42. rocedure e A magnifier approximately x100 to examine the exposed plates e Partial temporary right hand cover C15 3 Procedure You should only perform this procedure when you have established the optimum power In order to ascertain the best focus you will output the standard test image a number of times with each output being performed with a different focus setting The fine focussing adjustment is done with the focus ring on the end of the beam expander The ring is marked in increments of 1 16 You should test the focus in increments of 1 324 Page C 62 Fine Focus Set up Platinum Support Manual Copyright HighWater Designs Limited 1998 Remove the top cover and the right hand carriage cover from the machine Fit the partial temporary right hand cover which provides access to the focus adjustment whilst masking off most of the laser reflections towards the platen Power up the Platinum Override the cover safety interlock to ensure a successful load On the focus ring of the beam expander you should mark the position of the current focus Decide how many test strips can be fitted onto the plate film and move the focus ring anticlockwise so that the original focus position will be the middle test strip on the plate Login to the workstation as engineer The Platinum calibration software will launch automatically Click the Laser Power button Laser Power Agfa 0 2 plate 2540x2540 Changes Correcti
43. ry lint free cloth to remove any dust from the lens surface Dip the lint free cloth or the cotton bud into the acetone or IPA and wipe gently over the lens surface The acetone or IPA will evaporate quickly Use a dry part of the cloth to wipe away any excess material Shine the torch onto the lens surface to check that it is free of dust and smears If not repeat the procedure from step 4 onwards Page C 20 Cleaning the Optics Platinum Support Manual Copyright HighWater Designs Limited 1998 Page C 21 Platinum Support Manual Changing the Mass Damper and Stepper Motor Copyright HighWater Designs Limited 1998 C6 CHANGING THE MASS DAMPER AND STEPPER MOTOR C6 1 Introduction Of the three components of this procedure the stepper motor is the one most likely to fail This procedure will therefore primarily describe changing the stepper motor with options for changing the mass damper and clamping ring C6 2 Equipment e Flathead screwdrivers e A torque screwdriver e Allen keys C6 3 Procedure Motor drive assembly from mass damper to leadscrew View from back of Platinum looking down Mass Stepper Edge of Clamping Leadscrew Damper Motor Platinum ring 1 Ensure that the Platinum is disconnected at the mains 2 Remove the lid 3 In order to remove the stepper motor you first need to remove the mass damper The mass damper is attached with two Allen screws Remove the screws and store safely 4 Slid
44. section of the machine checklist Output check Expose a plate with a tint of approximately 50 and check that there is no banding If there is banding you will need to re do the alignment procedure Page C 31 Platinum Support Manual Changing the Guide Rail Strips Copyright HighWater Designs Limited 1998 C8 CHANGING THE GUIDE RAIL STRIPS C8 1 Introduction In normal usage the guide rail strips are unlikely to wear out However if they are damaged they need to be changed The guide rail strips provide a smooth surface for the optics carriage to move left and right There are three of them the upper strip is located at the front of the Platinum and supports the top part of the optics carriage the lower strip and the back strip are located at the back of the Platinum and support the base of the optics carriage Two people are needed to carry out this procedure C8 2 Equipment In addition to the new guide rail strips you will need the following equipment e Screwdrivers e Support for the optics carriage you will be taking it off the rails e SprayMount or similar adhesive C8 3 Supporting the Optics Carriage When you change the guide rail strips you must ensure that the optics carriage is supported adequately Do not attempt to change the upper guide rail strip at the same time as either the lower or back ones If you are changing the upper guide rail strip Optics Carriage PTFE feet Upper Guide rail
45. stics C 56 C14 1 Introduction C 56 C14 2 Equipment C 56 C14 3 The Optics Path C 57 C14 4 Using the Spot Viewer C 59 C15 Fine Focus Set up C 62 C15 1 Introduction C 62 C15 2 Equipment C 62 C15 3 Procedure C 62 C15 4 Assessing the focus C 64 C15 5 Completion C 65 C16 Platinum Engine Software C 68 C16 1 Introduction C 68 C16 2 Engine Software C 68 C16 3 Useful Batch Files C 69 C16 4 Upgrade Strategy C 69 C17 DEC Alpha Configuration C 70 C17 1 Specification C 70 C17 2 Initial System Checks C 71 C17 3 Configuration Procedure C 71 C17 4 Check List C 74 Page C 5 Platinum Support Manual Contents Copyright HighWater Designs Limited 1998 Page C 6 Tools and Spares Tools and Spares Platinum Support Manual Copyright HighWater Designs Limited 1998 This section lists the tools that are required to perform the procedures in this manual together with the spares that should be readily available HW indicates that the equipment is only available from HighWater Equipment Required Allen keys ball end Procedures Used In Most Table 1 Tools List Set size 1 5 to 10mm Flat head screw drivers Most Open ended spanners 6 6 7 8 mm 2 13mm Engineers Floppy Disk Most HW Keyboard and monitor Most For use with Engineer s floppy Dry Cloth 3 Torque screwdriver 4 5 6 Light Machine Oil 4 5 6 7 11 SAE 10 15 e g multi purpose electrolube oil Leadscre
46. strip View at front of Platinum of Optics Carriage on the Upper Guide Rail Page C 32 Changing the Guide Rail Strips Platinum Support Manual Copyright HighWater Designs Limited 1998 You need to lift the optics carriage off the upper guide rail Remove the leadscrew and store safely as described in section 7 Changing the Leadscrew The optics carriage must be rested off the guide rail strip A block of wood located between the optics carriage and the guide rail is adequate Optics carriage Block of wood to support the optics carriage PTFE foot Center sunk screws Guide rail If you are changing the lower and or back guide rail strips You need to lift the optics carriage off the lower guide rail and support it l Remove the leadscrew refering to section 7 Changing the Leadscrew You will need to improvise a method for supporting the optics carriage A 20 30 litre waste bottle together with additional blocks of wood for added height is adequate for the task WARNING THE GUIDE RAIL STRIPS ARE VERY SHARP THEY MUST BE HANDLED WITH EXTREME CARE Page C 33 Platinum Support Manual Changing the Guide Rail Strips Copyright HighWater Designs Limited 1998 C8 4 Procedure 1 Remove the screws at both ends of the strip Upper guide rail strip Guide rail strip end screw Front right corner of Platinum upper guide rail 2 Pull off the strip making sure yo
47. the board to its antistatic bag if you have to remove it from the PC By following these procedures you will protect both yourself and the board from static electricity Page C 36 Replacing the Processor Unit boards Replacing the Processor Unit boards Platinum Support Manual Copyright HighWater Designs Limited 1998 C9 4 Identifying the boards OD 000 O0 000 O0 0 VIEW AT C Power On Button IEC Mains Input IEC Mains Output SMA Coax to Modulator Driver TR2334 HW448 Differential SCSI SMC Coax to POS Power Rack TR2345 SMA Coax to Optics Carriage TR2343 To Interlock Board P4 TR2330 To Interlock Board P2 TR2356 Video Port To Power Rack Drive Amp TR2333 To Vacuum Rack TR2355 To Power Rack Scanner Amp TR2349 Standard PC Ports TR2346 Cable TR2348 Cable TR2344 Cable Motor Drive Board TR2001 Scan Correction Board TR2501 21 Pixel Clock Board TR2401 16 VIEW AT B 22 HW448 Differential SCSI Board 23 HW443 Data Path Board Page C 37 Platinum Support Manual Replacing the Processor Unit boards Copyright HighWater Designs Limited 1998 C9 5 Removing the old board l 73 8 Switch off the power Remove the back panel of the Platinum Disconnect all the cables from the back of the Prcocessor Rack Remove the Processor Rack from the shelf on the Platinum and place onto a convenient working sur
48. to move the carriage to the right hand end When the carriage has reached the limit hit the limit switch the black and yellow striped bar Choose Bednut Fast This test runs the carriage through one cycle from right to left and back slightly faster than the normal fast retrace carriage motion If the carriage runs without stalling and without abnormal sounds e g shrieks then all is well and the test is completed Otherwise you will need to re do the leadscrew alignment If the carriage shows signs of stalling then the drive system needs to be bedded in To do this select Bednut Slow This runs the carriage at a much reduced speed Page C 30 Changing the Leadscrew on Machines with Coupling Platinum Support Manual Copyright HighWater Designs Limited 1998 where it will not stall even if the mechanism is tight The test runs continuously so the machine can be left unattended The monitor records the number of cycles run 10 After a suitable interval terminate the Bednut Slow test by hitting the limit switch towards which the carriage is moving 11 Re run Bednut Fast If the carriage runs without stalling then all is well and the test is completed If not then repeat the Bednut Slow treatment 12 Keep track of the number of cycles run under Bednut Slow so that the final total can be recorded on the machine checklist Completion 1 Shut down the software and switch off 2 Remove floppy disk 3 Complete the appropriate
49. u do not damage either yourself or anyone else nearby with the strip 3 Clean off the adhesive remaining on Platinum using a light duty solvent The surface of Platinum needs to be very clean and free of marks 4 Ensure that the new strip is also clean free of grease and other marks 5 Use an adhesive on the underside of the new strip using an adhesive like SprayMount WARNING KEEP THE SPRAYMOUNT WELL AWAY FROM THE PLATINUM OPTICS DO NOT SPRAY THE STRIP IN THE SAME ROOM AS THE PLATINUM OR ANY OTHER SENSITIVE OPTICS 6 Screw the right hand end of the strip hard into the right hand end of the Platinum The second person needs to keep the remainder of the strip well away from the guide rail 7 Proceed slowly along the rail pushing the strip hard into the rail and keeping it flush with the edges If the strip is slightly wider than the guide rail it should only protrude over the inner edge and not the outer edge for safety reasons DO NOT PULL THE GUIDE RAIL STRIP VIOLENTLY OTHERWISE IT WILL GET A KINK AND WILL NEED TO BE SCRAPPED Page C 34 Changing the Guide Rail Strips Platinum Support Manual Copyright HighWater Designs Limited 1998 8 At the end put the last screw back in 9 Adda small piece of black insulator tape over each end of the strip 10 Remove the mechanism supporting the optics carriage so that the optics carriage can now rest back on the guide rail 11 Replace the le
50. us Set up Copyright HighWater Designs Limited 1998 Features of the standard test image 50 tint When viewed at high magnification this is a compact chequerboard Check that the dots are square with sharp edges 46 Black and white lines When in focus the black and white lines should have the same widths Radial spokes Fine lines The central region smears out rapidly when the laser is not well focussed Thin concentric rings Tests roundness of spot shape Pattern should be consistent along strip Page C 66 Fine Focus Set up Platinum Support Manual Copyright HighWater Designs Limited 1998 Page C 67 Platinum Support Manual Platinum Engine Software Copyright HighWater Designs Limited 1998 C16 PLATINUM ENGINE SOFTWARE C16 1 Introduction This document describes the Platinum engine software that is the software that is installed on the Platinum Processor Rack The software for the front end system is described separately This document describes e The directory structure on the Platinum hard drive e Important batch files e Upgrade strategy For information about configuring individual boards in the Processor PC and the BIOS settings refer to TRO49 doc Processor Rack Configuration C16 2 Engine Software The platinum hard drive is organ
51. w Alignment Tool HW Used with old gimbal alignment system only ESD grounding wrist strap Anti static prevention Steel rule 1 meter Acetone Optics cleaning fluid IPA Isopropyl Alcohol 99 7 pure Optics cleaning fluid Lint free cloth or lint free cotton buds Pump dispenser For the optics cleaning fluid Torch Eye probe Optical Test Set Differential Voltmeter Laser Dongle Laser Power Meter Magnifier 100x Spot Viewer HW Optical diagnostics equipment Densitometer e g Gretag Used for density calibrations Page C 7 Platinum Support Manual Copyright HighWater Designs Limited 1998 Page C 8 Tools and Spares Table 2 Spares List Equipment Notes Leadscrew leadnut coupling unit It is recommended that these are kept as a complete set Chapters 5 and 6 Mass Damper Chapter 4 Stepper Motor Chapter 4 Pixel clock board Chapter 8 Scan corrector board Chapter 8 Motor drive board Chapter 8 Data path board Chapter 8 SCSI interface board Chapter 8 Filter Wheel Chapter 10 Mole Chapter 11 Graticule Chapter 11 Tools and Spares Platinum Support Manual Copyright HighWater Designs Limited 1998 Page C 9 Platinum Support Manual Removing the Platinum lid and the Optics covers Copyright HighWater Designs Limited 1998 C1 REMOVING THE PLATI
52. will need to use the following e Torque screwdriver to obtain a precise torque of 1 7Nm e Allen keys e Light machine oil as described in procedure 6 Lubrication e Engineer s floppy disk for the verification stage see procedure 2 C7 3 Removing the Leadscrew WARNING NEVER GRIP THE LEADSCREW WITH PLIERS 1 Remove the Platinum lid and the optics cover Page C 26 Changing the Leadscrew on Machines with Coupling Platinum Support Manual Copyright HighWater Designs Limited 1998 2 Remove the 2 screws at the base of the coupling unit Leadscrew Coupling Unit 3 Remove the 2 screws from the end plate on the left hand side of the machine which attaches the leadscrew and remove the end plate Put the screws some where safely for example put them back in to their sockets Screws at left end of leadscrew 4 Undo the coupling clamp at the right hand end of the leadscrew This is only acces sible from the rear of the machine The screw of the coupling clamp Page C 27 Platinum Support Manual Changing the Leadscrew on Machines with Coupling Copyright HighWater Designs Limited 1998 5 Remove the four screws of the right hand bearing flange and store safely Undo these four screws 6 Slot the leadscrew through the 22mm clearance hole at the left for 6 to 12 inches then remove through the large hole on the right of the machine 7 Ifyou are changing the leadnut
53. y Disk Platinum Support Manual Copyright HighWater Designs Limited 1998 Startup disk Brief Description option 1 Carriage Procedure 3 Carriage Drive Test 2 Vacuum This tests the vacuum switching on and off 3 Moletest Procedure 11 Changing the Mole and the Graticule 4 Timescan This gives an indication of the timings of the Platinum such as the frequency of the galvo timing of the scanner etc Ss This produces a 10x10 chequerboard on the Platinum bed 6 Filter Procedure 10 Changing the Filter Wheel 7 Shutter This tests the opening and closing of the shutter 8 Laser This turns the laser on and opens the shutter Used if the laser beam is required on the Platinum bed 9 TTE If all else fails you may want to use this option Check the TTL document TR036 together with any necessary additional infor mation C2 4 Completion l Shut down the software and switch off 2 Remove floppy disk 3 Complete the appropriate section of the machine checklist Page C 13 Platinum Support Manual General Cleaning Copyright HighWater Designs Limited 1998 C3 GENERAL CLEANING C3 1 Introduction Build ups of dirt tend to occur in the following locations e at both ends of the leadscrew e at both ends of the guide rails You also need to make sure that the fans located within each of the modules on the processor rack are free from dust and other obstru
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