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DIAGNOSTICS
for the
Kodak DirectView CR 950 SYSTEM
Service Code: 4826
Important
Qualified service personnel must repair this equipment.
H196_0500GC
DIAGNOSTICS
26AUG04
DG4826-1 PLEASE NOTE The information contained herein is based on the experience and knowledge relating to the
Page subject matter gained by Eastman Kodak Company prior to publication.
2 of 206
No patent license is granted by this information.
Eastman Kodak Company reserves the right to change this information without notice, and
makes no warranty, express or implied, with respect to this information. Kodak shall not be
liable for any loss or damage, including consequential or special damages, resulting from any
use of this information, even if loss or damage is caused by Kodak’s negligence or other fault.
This equipment includes parts and assemblies sensitive to damage from electrostatic
discharge. Use caution to prevent damage during all service procedures.
Table of Contents
Description Page
Important
For systems with Software Version ≤ 4.1, you must have a “Session ID” for access to the
“Service Functions” and “Diagnostics”. See SERVICE BULLETIN 843.
.
Checks the operation of the MASTER CENTRAL
PROCESSING UNIT BOARD A2 by running the following
tests:
Completes the following diagnostic tests:
• “GALVO BOARD COMMUNICATION” - checks the
connection of the CABLE between:
– GALVO BOARD A4
– MASTER CENTRAL PROCESSING UNIT BOARD A2
• “GALVO REFERENCE” - reads the GALVO AGC
CHANNEL connected to the reference voltage of the
GALVO
• “GALVO MOTOR” - reads the voltage of the GALVO AGC
to check for problems with the GALVO
• “GALVO SWEEP” - checks the functions of reading and
writing of the REGISTERS on the GALVO BOARD A4
• “LASER OFFSET”
• “PMT BOARD TEST” - checks the connection of the
CABLE between:
– MASTER CENTRAL PROCESSING UNIT BOARD A2
– PMT/DAS BOARD A5
• “MASTER CENTRAL PROCESSING UNIT BOARD
MEMORY TEST” - checks for errors in the reading and
writing of data to each of the image buffers
DIAGNOSTICS Using the Diagnostics
26AUG04
DG4826-1 Diagnostic Tests
Page
28 of 206 Light Test
1 On the “System Service Diagnostic” screen, touch [Light Test].
2 Touch [TEST].
3 Wait for the test to complete.
4 Check that “PASS” displays in “AUTO-ZERO”.
5 Touch [START GRAPH].
DIAGNOSTICS Using the Diagnostics
26AUG04
DG4826-1
Page
29 of 206
Laser Power
Laser Warning
Prevent direct exposure to the laser beam.
Galvo Test
1 On the “System Service Diagnostic” screen, touch [Galvo Test].
DIAGNOSTICS Using the Diagnostics
26AUG04
DG4826-1 2 Touch:
Page
34 of 206 • [START GALVO]
• [LASER ON]
DIAGNOSTICS Using the Diagnostics
26AUG04
DG4826-1
Page
35 of 206
Laser Warning
Prevent direct exposure to the laser beam.
CR 950 SYSTEM
TOP COVER
COLLECTOR
paper
H196_1801HCA
laser beam FOLD MIRROR H196_1801HC
PMT Test
1 On the “System Service Diagnostic” screen, touch [PMT Test].
GALVO PLOT
Important
The “Galvo Plot” screen has more “Cassette Size” options with Software Version ≤ 4.1.
GALVO PLOT with low HOOK GALVO PLOT with excessive HOOK
2 Touch either:
• [Sort By Date],
• [Sort By Error Code], or
• [Sort By Cassette ID]
DIAGNOSTICS Using the Diagnostics
26AUG04
DG4826-1 Checking the Error Frequency Log
Page
43 of 206 1 On the “System Service Diagnostic” screen, touch [Error Frequency Log].
2 Touch either:
• [Sort By Date],
• [Sort By Error Code], or
• [Sort Error Frequency]
DIAGNOSTICS Using the Diagnostics
26AUG04
DG4826-1 Checking the Actuation Logs
Page
44 of 206 1 On the “System Service Diagnostic” screen, touch [Actuation Log].
DIAGNOSTICS Using the Diagnostics
26AUG04
DG4826-1 Storing the Error Logs on a Disk
Page
45 of 206 1 On the “System Service Diagnostic” screen, touch [Export Log Files].
Important
If the value is –7000, the home position is not adjusted automatically. Set the value manually.
Caution
Downloading the “SSC BOOT” can cause damage to the SLOW SCAN CONTROLLER
BOARD A6. Only download the “SSC BOOT” if necessary.
DIAGNOSTICS Using the Diagnostics
26AUG04
DG4826-1 2 Touch either:
Page
51 of 206 • [DOWNLOAD MCPU APPLICATION],
• [DOWNLOAD MSC APPLICATION],
• [DOWNLOAD SSC BOOT and APPLICATIONS],
• [DOWNLOAD SSC APPLICATIONS], or
• [DOWNLOAD SSC PARAMETERS]
DIAGNOSTICS Error Codes
26AUG04
DG4826-1
Page
Section 2: Error Codes
52 of 206
Overview
The first 2 digits of the error code identifies the subsystem or component with the error.
Example: 10003
The “1” and the “0” indicate that the error occurred in the subsystem BAR CODE.
1 Use Table 8 to help identify the component with the error.
2 Advance to the error code to diagnose the error.
11006 - CAM OUTER SENSOR did not detect position of DUPLEX CAM
Cause: The DUPLEX CAM malfunctioned.
Action: Do the checkout for the CASSETTE HANDLING AY.
11007 - CAM INNER SENSOR did not detect Home Position for DUPLEX
CAM
Cause: The DUPLEX CAM malfunctioned.
Action: Do the checkout for the CASSETTE HANDLING AY.
DIAGNOSTICS Error Codes
26AUG04
DG4826-1 11009 - DUPLEX CAM: Movement failure
Page
55 of 206 Cause: The DUPLEX CAM malfunctioned.
Action: Do the checkout for the CASSETTE HANDLING AY.
11015 - Move command failure because SLOW SCAN not at home position
Cause 1: The DUPLEX CAM malfunctioned.
Action: Do the checkout for the CASSETTE HANDLING AY.
Cause 2: The SLOW SCAN CONTROLLER BOARD A6 malfunctioned.
Action: Do the checkout for the SLOW SCAN CONTROLLER BOARD A6 and COIL
BOARD A7.
Error
Description
Code
12202 Error occurred during downloading to the SLOW SCAN CONTROLLER BOARD A6.
12203 Memory error on the SLOW SCAN CONTROLLER BOARD A6.
12204 Memory error on the SLOW SCAN CONTROLLER BOARD A6.
12216 Communication error between the SLOW SCAN CONTROLLER BOARD A6 and the
MOTION SYSTEM CONTROL BOARD A1.
12217 Communication error between the SLOW SCAN CONTROLLER BOARD A6 and the
MOTION SYSTEM CONTROL BOARD A1. Error “EM17 - Receive Buffer Overflow.”
12218 Error during downloading of code or parameters for the SLOW SCAN
CONTROLLER BOARD A6.
12219 Error during downloading of code or parameters for the SLOW SCAN
CONTROLLER BOARD A6.
12220 Error “EM20 - New Bootstrap Program, Download all Boot and Program Modules.”
12221 Malfunction of the SLOW SCAN CONTROLLER BOARD A6.
12222 Checksum error occurred during downloading of code to the SLOW SCAN
CONTROLLER BOARD A6.
12223 Checksum error occurred during downloading of code to the SLOW SCAN
CONTROLLER BOARD A6.
12228 Error occurred during downloading of the code to the SLOW SCAN CONTROLLER
BOARD A6.
DIAGNOSTICS Error Codes
26AUG04
DG4826-1 Error
Page Description
Code
69 of 206
12230 Error “EM30 - Host Flash Download Copy Boot Memory Error.”
12240 Error occurs during downloading to the SLOW SCAN CONTROLLER BOARD A6.
Error “EM40 - Illegal Record Type.”
12241 Error occurs during downloading to the SLOW SCAN CONTROLLER BOARD A6.
Error “EM41 - Invalid Extended Address.”
12242 Error occurs during downloading to the SLOW SCAN CONTROLLER BOARD A6.
Error “EM42 - Invalid Erase Block ID.”
12243 Error occurs during downloading to the SLOW SCAN CONTROLLER BOARD A6.
Error “EM43 - Receive Record Checksum Error.”
12244 Error when initializing. Error “EM44 - File Sum of Record Checksum Error, Download
Program.”
12245 Program error. Error “EM45 - Boot Checksum Write Error.”
12246 Error occurs during downloading to the SLOW SCAN CONTROLLER BOARD A6.
Error “EM46 - FIX_APP Code Block Checksum Write Error.”
12247 Error occurs during downloading to the SLOW SCAN CONTROLLER BOARD A6.
Error “EM47 - Code Page Checksum Write Error.”
12248 Error “EM48 - Parameters Save Flash Error.”
12250 Error occurs during downloading to the SLOW SCAN CONTROLLER BOARD A6.
Error “EM50 - Flash Write Address Out Of Range.”
12251 Error occurs during downloading to the SLOW SCAN CONTROLLER BOARD A6.
Error “EM51 - Flash Program Error: Erase.”
12252 Error occurs during downloading to the SLOW SCAN CONTROLLER BOARD A6.
Error “EM52 - Flash Program Error: Low Voltage.”
12253 Error occurs during downloading to the SLOW SCAN CONTROLLER BOARD A6.
Error “EM53 - Flash Program Error: Program.”
12254 Error occurs during downloading to the SLOW SCAN CONTROLLER BOARD A6.
Error “EM54 - Flash Program Error: Sequence.“
DIAGNOSTICS Error Codes
26AUG04
DG4826-1 Error
Page Description
Code
70 of 206
12255 Error occurs during downloading to the SLOW SCAN CONTROLLER BOARD A6.
Error “EM55”
12260 Error recording the parameters to the SLOW SCAN CONTROLLER BOARD A6.
Error “EM60 - Parameters Save Flash Error.”
ERASE LAMPS
13001 - 13008 - ERASE LAMP PAIRS
Code Log Message
13001 ERASE LAMP PAIR No. 1 malfunctioned
13002 ERASE LAMP PAIR No. 2 malfunctioned
13003 ERASE LAMP PAIR No. 3 malfunctioned
13004 ERASE LAMP PAIR No. 4 malfunctioned
13005 ERASE LAMP PAIR No. 5 malfunctioned
13006 2 ERASE LAMP PAIRS malfunctioned
13007 3 ERASE LAMP PAIRS malfunctioned
13008 4 ERASE LAMP PAIRS malfunctioned
Cause: One or more ERASE LAMP PAIRS malfunctioned.
Action: Install a new ERASE LAMP PAIR.
DIAGNOSTICS Error Codes
26AUG04
DG4826-1 13009 - All ERASE LAMPS malfunctioned
Page
75 of 206 Cause 1: The power to the ERASE LAMPS malfunctioned.
Action: 1. De-energize the ERASE LAMPS.
2. Check for 120 V AC across the AC side of RELAY K1.
3. If 120 V AC is not indicated at RELAY K1, check:
• ERASE LAMP AY is fully closed
• FUSE F1
• TERMINAL BLOCK TB1
• condition of the CONNECTOR P1/J1 on the ERASE LAMP AY
• condition of the INTERLOCK SWITCH S8
• wires to the POWER SUPPLY PS1
4. If 120 V AC is indicated on RELAY K1, connect the MULTIMETER to the AC
side of the RELAY.
5. Energize and de-energize the ERASE LAMPS. With the LAMPS energized, you
should measure < 2 V AC.
6. If the 120 V AC does not change to a Lo signal, check the DC side of RELAY
K1:
• connect the MULTIMETER TL-4114 negative to the violet wire
• connect the MULTIMETER TL-4114 positive to the blue wire
• check for 4.5 - 5.0 V DC on K1 with the ERASE LAMPS energized
7. Check the CONNECTOR J10 on the MOTION SYSTEM CONTROL BOARD
A1.
Cause 2: The MOTION SYSTEM CONTROL BOARD A1 malfunctioned.
Action: Do the checkout for the MOTION SYSTEM CONTROL BOARD A1.
DIAGNOSTICS Error Codes
26AUG04
DG4826-1 13010 - ERASE LAMP PAIRS: Timeout Error
Page
76 of 206 Cause: The MOTION SYSTEM CONTROL BOARD A1 malfunctioned.
Action: Do the checkout for the MOTION SYSTEM CONTROL BOARD A1.
POWER SUPPLY
14001 - SLOW SCAN: Malfunction of 24 V Power
Description: The 24 V DC CIRCUIT BREAKER of the SLOW SCAN is open.
Cause: Malfunction of the 24 V DC power distribution.
Action: Do the checkout for the MOTION SYSTEM CONTROL BOARD A1.
DIAGNOSTICS Error Codes
26AUG04
DG4826-1 14002 - STEPPER: Malfunction of 24 V Power
Page
77 of 206 Description: The 24 V DC CIRCUIT BREAKER of the STEPPER is open.
Cause: The STEPPER DRIVER BOARD has a 24 V DC power malfunction.
Action: Do the checkouts:
• STEPPER MOTOR INTERLOCK BOARD A15
• STEPPER MOTOR DRIVER BOARD A12
• STEPPER MOTOR DRIVER BOARD A13
• STEPPER MOTOR DRIVER BOARD A14
• STEPPER MOTOR DRIVER BOARD A16
DATA PATH
15001 - MCPU BOARD A2: Fatal Error in Software
Description: A PSOS system error occurred that is not possible to repair. The “Event
Log” includes the PSOS system error number, module, and line number.
Cause: The MASTER CENTRAL PROCESSING UNIT BOARD A2 malfunctioned.
Action: Do the checkout for the MASTER CENTRAL PROCESSING UNIT BOARD A2.
Important
If the laser power is > 25.0 mW and < 28.5 mW, an error is recorded to the error
log for each cycle.
Important
A malfunction of the PCMCIA CARD is the last possible cause. Check all other
malfunctions before installing a new PCMCIA CARD.
Cause 1: The PCMCIA CARD operates correctly, but another malfunction occurred.
Action: Check the error logs for the malfunction. Use Checking the Error Logs.
Cause 2: The PCMCIA CARD malfunctioned.
Action: Install a new PCMCIA CARD.
16005 - Calibration Error: Routine did not receive image in the time
allowed
Cause 1: The MASTER CENTRAL PROCESSING UNIT BOARD A2 malfunctioned.
Action: Do the checkout for the MASTER CENTRAL PROCESSING UNIT BOARD A2.
Cause 2: The DIGITIZER BOARD A3 malfunctioned.
Action: Do the checkout for the DIGITIZER BOARD A3.
Cause 3: The GALVO BOARD A4 malfunctioned.
Action: Do the checkout for the GALVO BOARD A4.
DIAGNOSTICS Error Codes
26AUG04
DG4826-1 16006 - Calibration Error: Did not obtain image
Page
89 of 206 Cause 1: The MASTER CENTRAL PROCESSING UNIT BOARD A2 malfunctioned.
Action: Do the checkout for the MASTER CENTRAL PROCESSING UNIT BOARD A2.
Cause 2: The DIGITIZER BOARD A3 malfunctioned.
Action: Do the checkout for the DIGITIZER BOARD A3.
Cause 3: The GALVO BOARD A4 malfunctioned.
Action: Do the checkout for the GALVO BOARD A4.
18039 - ELEVATOR: Down timeout because the CAM is not in the home
position
Cause: The CAM malfunctioned.
Action: 1. Open and close the FRONT DOOR.
2. Check the CAM SENSOR BOARD A8.
3. Check the CONNECTOR P13/J13.
4. Adjust the CAM.
5. Do the checkout for the MOTION SYSTEM CONTROL BOARD A1.
18056 - The LOAD/UNLOAD BAR move did not actuate the necessary
SENSOR(S)
Cause: The LOAD/UNLOAD BAR is not aligned correctly.
Action: Check the error logs for more information. Use Checking the Error Logs.
18058 - LOAD BAR did not move to the LOAD BAR HOME SENSOR S16
Cause: The LOAD BAR is not aligned correctly.
Action: Check the alignment of the LOAD BARS.
18059 - LOAD BAR did not complete its move to the LOAD BAR ENGAGED
SENSOR S14
Cause: The LOAD BAR is not aligned correctly.
Action: Check the alignment of the LOAD BARS.
18060 - UNLOAD BAR did not complete its move to the UNLOAD BAR
HOME SENSOR S15
Cause: The UNLOAD BAR is not aligned correctly.
Action: Check the alignment of the UNLOAD BARS.
18061 - UNLOAD BAR did not complete its move to the UNLOAD BAR
ENGAGED SENSOR S13
Cause: The UNLOAD BAR is not aligned correctly.
Action: Check the alignment of the UNLOAD BARS.
DIAGNOSTICS Error Codes
26AUG04
DG4826-1 18063 - CASSETTE was not detected correctly
Page
107 of 206 Description: The CR 950 SYSTEM has CASSETTES in SLOTS that are not correct.
Cause: The UPPER CONTROL AY malfunctioned.
Action: Do the instructions on the TOUCH SCREEN.
18065 - The SIZE CHANGER did not move to the SIZE CHANGER HOME
SENSOR
Cause 1: The SIZE CHANGER is not aligned correctly.
Action: Check the alignment of the SIZE CHANGER HOME POSITION SWITCH.
Cause 2: The SIZE CHANGER HOME SENSOR S25 malfunctioned.
Action: Check the SIZE CHANGER HOME SENSOR S25.
Cause 3: The STEPPER MOTOR DRIVER BOARD A16 malfunctioned.
Action: Do the checkout for the STEPPER MOTOR DRIVER BOARD A16.
Cause 4: The SIZE CHANGER STEPPER MOTOR malfunctioned.
Action: Check the SIZE CHANGER STEPPER MOTOR.
DIAGNOSTICS Error Codes
26AUG04
DG4826-1 18068 - The SIZE CHANGER did not move to the SIZE CHANGER HOME
Page
108 of 206
SENSOR
Cause 1: The SIZE CHANGER is not aligned correctly.
Action: Check the alignment of theSIZE CHANGER HOME POSITION SWITCH.
Cause 2: The SIZE CHANGER HOME SENSOR S25 malfunctioned.
Action: Check the SIZE CHANGER HOME SENSOR S25.
Cause 3: The STEPPER MOTOR DRIVER BOARD A16 malfunctioned.
Action: Do the checkout for the STEPPER MOTOR DRIVER BOARD A16.
Cause 4: The SIZE CHANGER STEPPER MOTOR malfunctioned.
Action: Check the SIZE CHANGER STEPPER MOTOR.
22001 - MSC BOARD A1: Memory did not erase during Download
Description: At the start of downloading to the MOTION SYSTEM CONTROL BOARD
A1, the flash memory was erased.
Cause: The software did not download.
Action: 1. Download the software again.
2. Do the checkout for the MOTION SYSTEM CONTROL BOARD A1.
3. If the error continues, install a new MOTION SYSTEM CONTROL BOARD A1.
22004 - MSC BOARD A1: The test of the RAM had a failure
Description: A failure occurred during the test of the RAM on the MOTION SYSTEM
CONTROL BOARD A1.
Cause: The software did not download.
Action: 1. Download the software again.
2. Do the checkout for the MOTION SYSTEM CONTROL BOARD A1.
3. If the error continues, install a new MOTION SYSTEM CONTROL BOARD A1.
30040 - The DEAD STOP was pressed while the CASSETTE was advancing
Cause 1: The SLOT SENSORS 1 - 8 malfunctioned.
Action: 1. Check the SLOT SENSORS 1 - 8.
2. Check the test points for the TOP SENSOR BOARD A11.
Cause 2: The DEAD STOP INTERLOCK S24 malfunctioned.
Action: Check the DEAD STOP INTERLOCK S24.
Cause 3: The INTERLOCK CONNECTOR P/J6 malfunctioned.
Action: Check that the INTERLOCK CONNECTOR P/J6 is correctly seated.
Cause 4: The TOP SENSOR BOARD A11 malfunctioned.
Action: 1. Check the test points for the TOP SENSOR BOARD A11.
2. Install a new TOP SENSOR BOARD A11.
DIAGNOSTICS Error Codes
26AUG04
DG4826-1 32001 - Communications malfunctioned between MCPU and SSC BOARDS
Page
119 of 206 Description: A message from the MASTER CENTRAL PROCESSING UNIT BOARD
A2 did not complete before another message was received.
Cause 1: The MASTER CENTRAL PROCESSING UNIT BOARD A2 malfunctioned.
Action: Do the checkout for the MASTER CENTRAL PROCESSING UNIT BOARD A2.
Cause 2: The MOTION SYSTEM CONTROL BOARD A1 malfunctioned.
Action: Do the checkout for the MOTION SYSTEM CONTROL BOARD A1.
Cause 3: The SLOW SCAN CONTROLLER BOARD A6 malfunctioned.
Action: Do the checkout for the SLOW SCAN CONTROLLER BOARD A6 and COIL
BOARD A7.
47550 - The BATTERY in UPS1 is too low. A System shutdown will occur in
1 minute
Cause 1: Malfunction of the utility power.
Action: 1. Check the POWER PLUG.
2. Wait for the power to start.
Cause 2: The charge of the BATTERY is 25% or less of the maximum charge.
Action: Do the checkout for the UNINTERRUPTED POWER SUPPLY UPS1.
DIAGNOSTICS Error Codes
26AUG04
DG4826-1 47551 - Unable to establish communications with UPS1
Page
123 of 206 Cause 1: Malfunction of the utility power.
Action: 1. Check the POWER PLUG.
2. Wait for the power to start.
Cause 2: The charge of the BATTERY is 25% or less of the maximum charge.
Action: Do the checkout for the UNINTERRUPTED POWER SUPPLY UPS1.
DICOM
50016 - DICOM - Negotiation Association Failed -%s, missing
implementation UID
Cause: The DICOM file does not have an IMAGE INSTANCE UID. The file is not stored.
Action: None.
DIAGNOSTICS Error Codes
26AUG04
DG4826-1 Installation
Page
126 of 206 55100 - Error on the Options Diskette or this is not a valid Options
Diskette
Cause: A DISKETTE that is not an OPTIONS DISKETTE is installed.
Action: Install a new OPTIONS DISKETTE.
55101 - Could not open files on the Options Diskette. Try another Options
Diskette
Cause: The file on the OPTIONS DISKETTE malfunctioned.
Action: Install a new OPTIONS DISKETTE.
55102 - Pentium III identification not enabled on this Pentium III class
machine
Note
This error does not display on a Pentium 4 PROCESSOR.
Cause: The serial number of the Pentium III PROCESSOR is not enabled.
Action: Enable the serial number of the Pentium III PROCESSOR.
DIAGNOSTICS Error Codes
26AUG04
DG4826-1 55103 - Could not open files on the Options Diskette
Page
127 of 206 Cause: The file on the OPTIONS DISKETTE malfunctioned.
Action: Install a new OPTIONS DISKETTE.
55106 - The Options on this diskette are already enabled on this system
Cause: The options are available for use.
Action: None.
Cause: The correct configuration for this CR 950 SYSTEM was not provided.
Action: 1. Do a shutdown of the CR 950 SYSTEM.
2. De-energize the CR 950 SYSTEM.
3. Energize the CR 950 SYSTEM.
4. Install the OPTIONS DISKETTE again.
DIAGNOSTICS Error Codes
26AUG04
DG4826-1 55113 - Error obtaining MAC address for card name specified in
Page
129 of 206 AdapterName in General Equipment on Pentium 4 class machine
Note
This error does not display on a Pentium III PROCESSOR.
Cause: The correct configuration for this CR 950 SYSTEM was not provided.
Action: 1. Do a shutdown of the CR 950 SYSTEM.
2. De-energize the CR 950 SYSTEM.
3. Energize the CR 950 SYSTEM.
4. Install the OPTIONS DISKETTE again.
DIAGNOSTICS Troubleshooting
26AUG04
DG4826-1
Page
Section 3: Troubleshooting
130 of 206
Initialization Errors
“Power-On-Self Test” (POST) Errors
Important
• An error occurs if the CR 950 SYSTEM energizes, but does not display the main menu.
• In normal operation, the computer in the CR 950 SYSTEM emits one beep after
energizing and initializing.
• The computer emits more than one beep when a malfunction occurs.
• If the TOUCHSCREEN displays a POST error or a beep occurs, see the “Troubleshooting
Section” of the Owner’s Manual for the IBM COMPUTER.
Image Quality
For image quality problems, see the CD for the “Kodak DirectView CR SYSTEMS Artifact
Database”.
DIAGNOSTICS Checkout Procedures
26AUG04
DG4826-1
Page
Section 4: Checkout Procedures
133 of 206
CASSETTE HANDLING AY
DUPLEX CAM
1 On the “System Service Diagnostic” screen, touch [CAM Position Actuation].
DIAGNOSTICS Checkout Procedures
26AUG04
DG4826-1 2 If the DUPLEX CAM does not move, check the CAM MOTOR M1.
Page
134 of 206 3 Rotate the DUPLEX CAM by touching each of the following:
a. [HOME CAM]
b. [UNPINCH POSITION]
c. [HOOKS UP POSITION]
d. [PINCH POSITION]
e. [LATCH POSITION]
f. [UNLATCH POSITION]
4 Check that the position of the DUPLEX CAM matches the table for each BUTTON:
H177_3023GCB
H177_3023GC
DIAGNOSTICS Checkout Procedures
26AUG04
DG4826-1 CAM MOTOR M1
Page
136 of 206
2 SCREWS
SLED
DUPLEX CAM
CAM MOTOR M1
CONNECTOR H196_1802BCA
H196_1802BC
1 Remove:
• 2 SCREWS
• SLED CAM FOLLOWER
2 Manually move the SLED and check for binds.
3 Check the DUPLEX CAM for binds.
4 Check for 24 V DC at the CONNECTOR of the CAM MOTOR M1:
DUPLEX CAM Voltage
Not moving 0 V DC
Moving 24 V DC
5 Check for broken wires to the CAM MOTOR M1.
6 Do the checkout for the MOTION SYSTEM CONTROL BOARD A1.
DIAGNOSTICS Checkout Procedures
26AUG04
DG4826-1 EXTRACTION BAR SENSOR S9
Page
137 of 206
FRONT
DOOR
Warning
Dangerous Voltage
INTERLOCK
H196_0128ACA
SWITCH S8 H196_0128AC
DIAGNOSTICS Checkout Procedures
26AUG04
DG4826-1 3 Check:
Page
138 of 206 EXTRACTION BAR • SLOW SCAN AY moves:
SENSOR S9
– down for 3 seconds
– up to the home position
EXTRACTION BAR
• EXTRACTION BAR HOME
POSITION
SENSOR
S9 FLAG • condition of:
– EXTRACTION BAR SENSOR S9
– SENSOR S9 FLAG
SLOW SCAN AY
H177_3023GCC
H177_3023GC
LEVER
H177_3025GCB
H177_3025GC
DIAGNOSTICS Checkout Procedures
26AUG04
DG4826-1 CAM SENSORS S10 and S11
Page
140 of 206 DUPLEX CAM ENCODER
BOARD A8
SENSOR S11
SENSOR S10
DUPLEX CAM
H194_1033ACA
H194_1033AC
Important
• The MOTION SYSTEM CONTROL BOARD A1 controls most of the electrical and
mechanical functions of the CR 950 SYSTEM.
• The MOTION SYSTEM CONTROL BOARD A1 changes the +24 V DC to +5 V DC and
+12 V DC.
• SWITCH S1:
– S1-A: “Off”
– S1-B: “Off”
– S1-C: “Off”
– S1-D: “On” - Actuates the LEDs on the BOARD, “Off” - Normal operation
MASTER
CENTRAL
PROCESSING
UNIT
BOARD A2
TP8 TP21
TP5
CONNECTOR
TP4
P5
TP1
TP14
H196_1804BCA
H196_1804BC
DIAGNOSTICS Checkout Procedures
26AUG04
DG4826-1 1 Check for the correct voltages on the CONNECTOR P5:
Page
145 of 206 MULTIMETER
Voltage
Ground Positive
+24 V DC P5-3 or P5-4 P5-1 or P5-2
2 If the voltage is not correct, do the checkout for the POWER SUPPLY PS1.
3 Measure the following voltages at the indicated test points.
MULTIMETER
Voltage
Ground Positive
TP5 TP4 +3.3 ± 0.1 V DC, Linear
TP5 TP21 +3.3 ± 0.1 V DC, Analog
TP5 TP1 +5 ± 0.1 V DC
TP5 TP14 +12 ± 0.2 V DC
TP5 TP8 +24 ± 0.5 V DC
4 Do all of the voltages match the table?
Yes No
Continue with Step 5. a. Install a new MASTER CENTRAL
PROCESSING UNIT BOARD A2.
b. Continue with Step 5.
5 Determine if the software version of the MASTER CENTRAL PROCESSING UNIT
BOARD A2 is correct. Use Displaying the Software Versions.
6 If the TOUCH SCREEN displays “Not Responding”, check for problems with the
communications between:
• MASTER CENTRAL PROCESSING UNIT BOARD A2
• INTERNAL COMMUNICATIONS NETWORK CARD
7 Download the software to the MASTER CENTRAL PROCESSING UNIT BOARD A2.
8 If you cannot successfully download the software, install a new MASTER CENTRAL
PROCESSING UNIT BOARD A2.
DIAGNOSTICS Checkout Procedures
26AUG04
DG4826-1 9 Download the software to the MASTER CENTRAL PROCESSING UNIT BOARD A2. See
Page Downloading Software to the BOARDS.
146 of 206
10 Set the SWITCHES on the MASTER CENTRAL PROCESSING UNIT BOARD A2.
DIGITIZER BOARD A3
Important
The DIGITIZER BOARD A3:
• receives the image data from the PMT/DAS BOARD A5
• changes the input 24 V DC to 5 V DC
• sends the timing signal to the GALVO BOARD A4
CONNECTOR
P2
TP1
TP2
TP3
DIGITIZER
BOARD A3
H196_1805BCA
H196_1805BC
GALVO BOARD A4
TP1
TP15
TP13
TP6
TP5
H196_1806BCA
H196_1806BC CONNECTOR P2
TP23
TP17 TP22 TP20
TP21
TP14
TP19 TP18 TP16 TP15 TP13
TP12 TP11
TP10 TP9
TP24
TP8 TP26 TP25
TP7
P3
H196_1807HCA
PMT/DAS BOARD A5 H196_1807HC
Important
The PMT/DAS BOARD A5:
• increases the outputs of the PMTs
• routes 5 V DC from the DIGITIZER BOARD A3
DIAGNOSTICS Checkout Procedures
26AUG04
DG4826-1 1 Measure the following voltages at the test points:
Page
151 of 206 MULTIMETER
Voltage
Ground Positive
5 ± 0.2 V DC, Digital TP7 TP8
5 ± 0.1 V DC, Isolated TP11 TP9
5 ± 0.2 V DC, Analog TP10 TP19
12 ± 0.5 V DC TP10 TP18
−12 ± 0.25 V DC TP10 TP17
13.5 ± 0.1 V DC TP10 TP6
−13.5 − 1.5 V DC TP10 TP5
24 ± 2.5 V DC TP1 TP2
5 ± 0.2 V DC, Startup TP1 TP3
2 If any of the voltages do not match, install a new PMT/DAS BOARD.
TP1
TP2
TP15
TP16
TP14
TP18
COIL
BOARD A7 H196_1808HCA
CONNECTOR J1 CONNECTOR J4 H196_1808HC
Important
To do Step 3, you must:
• install the INTERLOCK KEY, or
• close the FRONT DOOR
DIAGNOSTICS Checkout Procedures
26AUG04
DG4826-1 3 Check the voltage on the SLOW SCAN CONTROLLER BOARD A6:
Page
153 of 206 MULTIMETER
Voltage
Negative Positive
TP1 TP18 +24 V DC
4 If the voltage is not correct, check the INTERLOCK SWITCH S8.
5 Check the voltage on the SLOW SCAN CONTROLLER BOARD A6:
MULTIMETER
Voltage
Negative Positive
TP1 TP2 +5 V DC
6 On the “System Service Diagnostics” screen, touch [Display Software Versions].
7 Check for the correct software versions for the MOTION SYSTEM CONTROL BOARD A1
and the SLOW SCAN CONTROLLER BOARD A6.
8 If the screen displays “Not Responding”, check that the RS-232 communications on the
CABLE A6J5 operate correctly.
9 Download the software to the SLOW SCAN CONTROLLER BOARD A6.
10 If you cannot successfully download the software, install a new SLOW SCAN
CONTROLLER BOARD A6.
11 After you install a new SLOW SCAN CONTROLLER BOARD A6, adjust the Height of the
EXTRACTION BAR. See EXTRACTION BAR HOME POSITION.
12 Install the software to the SLOW SCAN CONTROLLER BOARD A6. See Downloading
Software to the BOARDS.
13 Set the SWITCHES on the SLOW SCAN CONTROLLER BOARD A6.
14 During the time the equipment is energized, disconnect the CONNECTOR J1 from the
SLOW SCAN CONTROLLER BOARD A6.
Note
Disconnecting the CONNECTOR J1 allows you to manually rotate the LEAD SCREW on the
SLOW SCAN AY.
DIAGNOSTICS Checkout Procedures
26AUG04
DG4826-1 15 Manually rotate the SLOW SCAN AY and check for the correct voltage measurements at
Page the following test points:
154 of 206
MULTIMETER HALL EFFECT Voltage
Negative Positive SENSOR High Low
TP17 TP14 HALL A 4 - 5 V DC < 1 V DC
TP17 TP16 HALL B 4 - 5 V DC < 1 V DC
TP17 TP15 HALL C 4 - 5 V DC < 1 V DC
16 If a measurement does not match the specification, install a new COIL BOARD A7.
17 Connect the CONNECTOR J1.
18 Check the COILS and FUSES on the COIL BOARD A7.
Important
Do not rotate the SLOW SCAN AY when you measure the following resistances.
+5V GND
J2
+24V GND
J5
1 3
2 4
H196_1810BCA
STEPPER MOTOR DRIVER BOARD A12 H196_1810BC
+5V GND
J2
+24V GND
J5
1 3
2 4
H196_1811BCA
STEPPER MOTOR DRIVER BOARD A13 H196_1811BC
+5V GND
J2
+24V GND
J5
1 3
2 4
H196_1812BCA
STEPPER MOTOR DRIVER BOARD A14 H196_1812BC
Important
• The STEPPER MOTOR INTERLOCK BOARD A15 disconnects the +24 V DC from the 4
STEPPER MOTOR DRIVER BOARDS A12, A13, A14, and A16 when:
– a CASSETTE moves beyond SLOT -8 and actuates the INTERLOCK
– the DEAD STOP INTERLOCK S24 is actuated
• This BOARD has no adjustment points.
DIAGNOSTICS Checkout Procedures
26AUG04
DG4826-1
Page P1
161 of 206
CONNECTOR P1
DS2 K1
K2
DS3
STEPPER MOTOR
INTERLOCK
BOARD A15
1 24V OK
P2
2 DS1
CONNECTOR P3
P3 H196_1814BCA
H196_1814BC
+5V GND
J2
+24V GND
J5
1 3
2 4
H196_1813BCA
STEPPER MOTOR DRIVER BOARD A16 H196_1813BC
2 Touch [THRESHOLD].
3 Check that “Laser Power” is 0 - 5 mW.
4 Touch:
• [LASER ON]
• [READ]
5 Check that the “Laser Power” is 28 - 32 mW.
DIAGNOSTICS Checkout Procedures
26AUG04
DG4826-1 6 Is the value correct?
Page
166 of 206 Yes No
Continue with the next test. 1. Touch [SWEEP].
2. Check that the laser beam scans.
3. Check the connections to the LASER
DRIVER BOARD A17.
4. Install a new OPTICAL MODULE.
DIAGNOSTICS Checkout Procedures
26AUG04
DG4826-1 Power
Page
167 of 206 POWER SUPPLY PS1
Important
• The POWER SUPPLY PS1 provides the 3 voltages to components of the CR 950
SYSTEM, including the BOARDS and the TOUCH SCREEN.
– 24 V DC: V1
– 12 V DC: V2
– −24 V DC: V3: black wire fastens to the positive TERMINAL to provide negative
voltage
• Do not disconnect the wires of POWER SUPPLY PS1. PS1 must have all the wires
correctly connected to the CR 950 SYSTEM.
• The DC OK LED remains illuminated when the V3− circuit has a short circuit.
DIAGNOSTICS Checkout Procedures
26AUG04
DG4826-1
Page DC TERMINAL V3- V3+
168 of 206
V1-
POWER
SUPPLY PS1
V1+ V2-
V2+
NEUTRAL GROUND
AC TERMINAL AC
H194_0039HCA
H194_0039HC DC OK LED AC OK LED
TRANSFORMER T1
CIRCUIT BREAKER
TRANSFORMER T1 Important
UTILITY-STATUS LED
If the CR 950 SYSTEM does not energize,
the cause of the malfunction might be
either:
• TRANSFORMER T1
• UNINTERRUPTED POWER SUPPLY
UPS1
FAULT-ALARM LED
H177_1822ACB
POWER CORD
H177_1822AC
DIAGNOSTICS Checkout Procedures
26AUG04
DG4826-1 1 Observe the status of the 2 LEDs:
Page
170 of 206 LED Condition Normal
UTILITY-STATUS Normal operation of the Illuminated
TRANSFORMER T1
FAULT-ALARM Malfunction of the TRANSFORMER T1 Not illuminated
2 If both LEDs are not illuminated, check the site power to the TRANSFORMER T1.
3 Is the FAULT-ALARM LED illuminated?
Yes No
Continue with Step 4. Advance to Step 6.
4 Check and reset the CIRCUIT BREAKER on the TRANSFORMER T1.
5 Remove and then install the POWER CORD on the TRANSFORMER T1.
Note
This should reset the TRANSFORMER T1.
/TEST Bypass
Line On Line
On Battery
GND
TP1
VCC P1 P3
TP2 P18 P2 F1
P4
DS8
J1 P17
F2
TP3
P5
J2 F4
J3
U33
TP4 TP5
P8
TP6
S1 TP7
TP9 TP8
TP10
U55 P6
P7
P10
S2 P9
P19 TP11
P11
P16
TP12 TP13
P12 P13 P14 P15
H177_1814HA
DIAGNOSTICS Test Points and LEDs
26AUG04
DG4826-1 Table 12 Test Points on the MOTION SYSTEM CONTROL BOARD A1
Page
177 of 206 Test Point Description Expected Signal
1 Ground 0 V DC
2 Output of the +5 V DC 4.9 - 5.1 V DC
REGULATOR
3 +24 V DC after FILTER for 22.5 - 25.5 V DC
accessory +5 V DC REGULATOR
4 Output of accessory +5 V DC 4.8 - 5.1 V DC
REGULATOR
5 Accessory +5 V DC after FILTER 4.8 - 5.1 V DC
6 A/D CONVERTER Chan 7 A/D CONVERTER Chan 7
7 Incoming +24 V DC power 22.5 - 25.5 V DC
8 +12 V DC supply for DAC and 12 ± 0.5 V DC
Vref
9 +24 V DC after FERRITE FILTER, 22.5 - 25.5 V DC
but before FILTER P1 for +5 V DC
REGULATOR
10 +24 V DC after FILTER for 22.5 - 25.5 V DC
+5 V DC REGULATOR
12 Ground (GND) 0 V DC
13 +24 V DC power input voltage • 1.43 V DC when input power is
monitor +24 V DC
• 1.25 V DC if the input power drops to
+21 V DC. A power interrupt signal is
sent to the CPU
DIAGNOSTICS Test Points and LEDs
26AUG04
DG4826-1 Table 13 LEDs on the MOTION SYSTEM CONTROL BOARD A1
Page
178 of 206 LED Description
DS1 LARGE CLAMP SOLENOID
DS2 SMALL CLAMP SOLENOID
DS3 COMMON CLAMP SOLENOID
DS4 not used
DS5 not used
DS6 SIZE CHANGER SOLENOID
DS7 not used
DS8 DC MOTOR 24 V SUPPLY RELAY
DS9 not used
DS10 REFERENCE BLOCK SOLENOID
DS11 COLLECTOR NOSEPIECE SOLENOID
DS12 LASER SHUTTER SOLENOID
DS13 not used
DS14 STEPPER MOTOR 24 V SUPPLY RELAY
DS15 SLOW SCAN 24 V SUPPLY RELAY
DS16 ERASE LAMP RELAY
DS17 HEARTBEAT LED
DS18 STATUS LED - not used
DS19 not used
DS20 ELEVATOR DOWN SENSOR
DS21 not used
DS22 ELEVATOR MIDDLE SENSOR
DS25 INTERLOCK INDICATOR
DS26 CAM POSITION SENSOR U2
DS27 CAM HOME SENSOR U1
DS28 EXTRACT BAR SOT_IN SENSOR
DIAGNOSTICS Test Points and LEDs
26AUG04
DG4826-1 LED Description
Page
179 of 206 DS29 PLATE PRESENT
DS30 ELEVATOR UP SENSOR
DS31 UNLOAD BAR is engaged
DS32 LOAD BAR is engaged
DS33 LOAD BAR is in the home position
DS34 UNLOAD BAR is in the home position
DS35 Pressure high
DS36 Pressure low
S1
P6
J2
DS6
J1
J5
S2
DS2 DS3 DS4 DS5
DS1
TP18 TP20
TP10
TP12
TP7
TP13
TP16
P2
P1
J4
P4
TP3
U8
TP2
P3
TP11
TP15
TP17
TP19
TP6
TP21
S4
TP9
U10
U1
U4
S3
TP8
J3
P5
TP14
TP5
TP4
TP1
H194_0016HC
Important
• The SWITCHES on the MASTER CENTRAL PROCESSING UNIT BOARD have no
service functions.
• You must use the table to set the correct positions of the SWITCHES.
DIAGNOSTICS Test Points and LEDs
26AUG04
DG4826-1 Table 17 SWITCHES on the MASTER CENTRAL PROCESSING UNIT BOARD A2
Page
182 of 206 SWITCH S3 SWITCH S4
Position Setting Position Setting
1 “ON” 1 “ON”
2 “ON” 2 “ON”
3 “ON” 3 “ON”
4 “ON” 4 “ON”
5 “ON” 5 “OFF”
6 “ON” 6 “ON”
7 “ON” 7 “ON”
8 “ON” 8 “OFF”
DIAGNOSTICS Test Points and LEDs
26AUG04
DG4826-1 DIGITIZER BOARD A3
Page
183 of 206
P3 P2
J1
TP15
TP5 TP7 TP6
FL1
P8 P7 P4
TP14
TP2
U3 TP3
P5
U1
TP13
U4 U2
TP9
TP8
TP12
P6
H194_0018HC
TP7
TP10
TP4
R112
TP11
TP1
R2
R1
E1
1
TP13
3
C55 TP14
TP17 TP9
TP15
TP6
TP12
TP5
1
TP3
6
TP16
TP2
H194_0017HC
DIAGNOSTICS Test Points and LEDs
26AUG04
DG4826-1 Table 19 Test Points on the GALVO BOARD A4
Page
186 of 206 TP Description Expected Signal
1 Ground 0 V DC
2 Ground 0 V DC
3 Ground 0 V DC
4 Ground 0 V DC
5 +15 V DC power supply 14.4 - 15.6 V DC
6 –15 V DC power supply –14.7 - –5.3 V DC
7 COIL RETURN SIGNAL of the –1.25 - +1.25 V DC
GALVO
9 Speed of the GALVO Signal is used to set the speed at the end of
the motion of the GALVO
10 ACTUAL POSITION -----
11 DESIRED POSITION -----
12 “Line Done” signal indicates to High pulse approximately every 13 mS
the DIGITIZER BOARD A3 to during scanning
start the next line
13 AGC voltage for GALVO • 9.9 to 10.1 V DC
SENSORS • < 20 mV AC
14 POSITION SUMMING AMP -----
15 +5 V DC power supply 4.8 - 5.2 V DC
16 –24 V LASER –23.5 - –24.5 V DC
17 BACK_FACET_VOLTAGE 1.0 - 1.1 V DC with the laser at full power
TP23
TP17 TP22 TP20
TP21
TP14
TP19 TP18 TP16 TP15 TP13
TP12 TP11
TP10 TP9
TP24
TP8 TP26 TP25
TP7
P3
Bottom
H194_0015BC
P2
J7 J6
GND
TP1
J5
TP2
TP3
TP4
GND
TP11 TP10
P3 TP5
TP12
TP6
TP7
TP15 TP13
TP16 TP14
GND
TP17
TP8
TP18 TP9
P4 J3
P1
H177_1824DC
DIAGNOSTICS Test Points and LEDs
26AUG04
DG4826-1 Table 22 Test Points on the SLOW SCAN CONTROLLER BOARD A6
Page
190 of 206 TP Description Expected Signal
1 Ground 0 V DC
2 5 V DC 5.0 V DC
14 HALL EFFECT SENSOR 5.0 V DC and 0.0 V DC when the
ROTOR is rotating
15 HALL EFFECT SENSOR 5.0 V DC and 0.0 V DC when the
ROTOR is rotating
16 HALL EFFECT SENSOR 5.0 V DC and 0.0 V DC when the
ROTOR is rotating
17 Ground 0 V DC
18 12 V DC 12.0 V DC
Note
The SLOW SCAN CONTROLLER BOARD A6 has no field adjustment points. All adjustments
are preset.
DIAGNOSTICS Test Points and LEDs
26AUG04
DG4826-1 TOP SENSOR BOARD A11
Page
191 of 206
TP13
TP18
TP17
TP16 TP21
TP14 TP15
TP20
TP19 SLOT 1 SLOT 2 SLOT 3 SLOT 4 SLOT 5 SLOT 6 SLOT 7 SLOT 8
CASSETTE
PRESENT SLOT 0 INTERLOCK MAIN BELT
4 3 2 1 P4 4 3 2 1 P5 3 21 P6 3 21 P7
H187_1820BC
BLK RED
J3 VERT
TP2 TP1
J1 ADJ.
1 2
3 4
5 6 J10 J9 J8 J7 J6
7 8
9 10
11 12
13 14
15 16
+5V GND
1 3
J2
2 4
+24V GND
1 3
J4
2 4
H187_1821HC
BLK RED
J3
TP2 TP1
J1 VERT
ADJ.
1 2
3 4
5 6 J10 J9 J8 J7 J6
7 8
9 10
11 12
13 14
15 16
+5V GND
J2
+24V GND
J5
1 3
2 4
H187_1822HC
BLK RED
J3 VERT
TP2 TP1
J1 ADJ.
1 2
3 4
5 6 J10 J9 J8 J7 J6
7 8
9 10
11 12
13 14
15 16
+5V GND
1 3
J2
2 4
+24V GND
J5
1 3
2 4
H187_1823HC
K1 K2 24V OK
DS1
P1 P3
14 +24 +24 1
13 GND 2
12 GND GND 3
11 4
10 5
9 6
8 7
7 +24 +24 8
6 GND GND 9
5 GND
DS2 DS3 10
4 11
3 12
2 13
1 14
P2
1 2
824HC
BLK RED
J3 VERT
TP2 TP1
J1 ADJ.
1 2
3 4
5 6 J10 J9 J8 J7 J6
7 8
9 10
11 12
13 14
15 16
+5V GND
1 3
J2
2 4
+24V GND
J5
1 3
2 4
H187_1823HC
R2
U2
Q1 P1
6
U1 FL2
VR1 CR1
FL1
U3
L1 Buf_Bf
Q2
N2P5 FL3 1
C1 U4
LEN
AGND
l_op VR2
VN5
H194_0027HC
DIAGNOSTICS Test Points and LEDs
26AUG04
DG4826-1 Table 35 Test Points on the LASER DRIVER BOARD
Page
204 of 206 Name Description Expected Signal
AGND Circuit ground 0.0 V DC
VN5 ------ –5.00 to –5.50 V DC
LPN Power to the LASER • LASER de-energized - 0.0 V DC
• Threshold - 0.0 V DC
• LASER energized - –5.0 V DC
LEN ----- • LASER de-energized - 0.0 V DC
• Threshold - –5.0 V DC
• LASER energized - –5.0 V DC
Iop ---- • LASER de-energized - –5.0 V DC
• Threshold - –4.25 to –4.75 V DC
• LASER energized - –3.35 to –4.35 V DC
Vpd ----- • LASER de-energized - –2.3 to –2.5 V DC
• Threshold - –2.6 V DC
• LASER energized - –2.9 V DC
Buf_BF ----- • LASER de-energized - 0.0 V DC
• Threshold - –0.06 to –0.08 V DC
• LASER energized - –1.0 to –1.2 V DC
DIAGNOSTICS Test Points and LEDs
26AUG04
DG4826-1 LASER DRIVER PRE-REGULATOR BOARD A18
Page
205 of 206 TP1 TP2 TP3