SapphireService (46181 B)

PlateJet Sapphire
Service Manual
Document #45563
Revision B: December 2000
Gretag Imaging Group

Professional Imaging Division
13231 Delf Place, #501
Richmond, British Columbia, Canada V6V 2C3
Phone: (604)273-7730
Fax: (604)273-2775
Web:
www.cymbolic.com
FTP Site: ftp.cymbolic.com
COPYRIGHT 2000 Gretag Imaging Group

ALL RIGHTS RESERVED
RESTRICTION ON DISCLOSURE, USE, OR DUPLICATION OF PROPRIETARY INFORMATION

This document contains information proprietary to Gretag Imaging Group, to its subsidiaries, or to third parties to which Gretag
Imaging Group may have a legal obligation to protect such information from unauthorized disclosure, use or duplication. Any
disclosure, use, or duplication of this document or of any of the information contained herein for other than the specific
purpose for which it was disclosed is expressly prohibited, except as Gretag Imaging Group may otherwise agree to in writing.
WARNING
This equipment generates, uses and radiates radio frequency energy and if not installed and used as designed or
intended, may cause interference to radio communications. This equipment has been tested and found to comply
with the limits for a Class A computing device. This equipment has been designed to provide reasonable protection
against such interference when operated in residential, light industrial and commercial environments. Operation of
this equipment in a residential area may cause interference, in which case the user, at his own expense, is required
to take whatever measures are required to correct the interference.
United States Of America - FCC
This device complies with Part 15 of the FCC
Rules. Operation is subject to the following two
conditions: (1) This device may not cause harmful
interference, and (2) This device must accept any
interference received, including interference that
may cause undesired operation.
Canada - ICES-003
This Class A/B digital apparatus meets all requirements
of the Canadian Interference-Causing Equipment
Regulations.
Cet appareil numerique de la classe A/B respecte toutes
les exigences du Reglement sur le materiel brouilleur du
Canada.
European Community - EMC

This device complies with Class A/B emission limits in accordance with EN55022.
SPECIFICATION
Electromagnetic compatibility - Emissions
Electromagnetic compatibility - Immunity
Low voltage
EC DIRECTIVE
89/336/EEC
89/336/EEC
73/23/EEC
Table of Contents
Section One: Introduction..........................................................................................1-1
PlateJet Sapphire Product Applicability ............................................................................ 1-1
Laser Safety and Warnings for Visible PlateJet Service Personnel .................................. 1-1
Laser Specification ....................................................................................................... 1-1
Safety Labels Visible PlateJet....................................................................................... 1-2
Laser Safety and Warnings for Thermal PlateJet Service Personnel................................ 1-4
Laser Specification ....................................................................................................... 1-4
Laser Safety Labels ...................................................................................................... 1-5
Common Safety and Miscellaneous Labels ...................................................................... 1-8
Error Code label ........................................................................................................... 1-9
Section Two: Product Description ............................................................................2-1

Introduction to the PlateJet Sapphire................................................................................ 2-1
PlateJet Sapphire Functional Component Groups ........................................................ 2-1
PlateJet Sapphire Specifications................................................................................... 2-3
Section Three: Theory of Operation .........................................................................3-1

Linear Motor Micropositioner ............................................................................................ 3-1
Mechanical Drive System ............................................................................................. 3-1
Air Bearing Supply ........................................................................................................ 3-1
Linear Motor Drive ........................................................................................................ 3-1
Motor Controller Box..................................................................................................... 3-1
Linear Scale.................................................................................................................. 3-2
Westwind Spinner Motor............................................................................................... 3-2
Focus Lens ................................................................................................................... 3-2
Linear Motor Micropositioner ........................................................................................ 3-2
Care and Handling........................................................................................................ 3-3
Main Processor Board Assembly...................................................................................... 3-3
SCSI Interface on the Controller Board......................................................................... 3-4
PS I/O Board Assembly.................................................................................................... 3-4
Switching DC Power Supply............................................................................................. 3-5
Instrument Control & Power Panel Assembly ................................................................... 3-5
Air Supply......................................................................................................................... 3-6
Media Handling ................................................................................................................ 3-6
Vacuum Control............................................................................................................ 3-7
Vacuum Pump .............................................................................................................. 3-7
Media Guide Control..................................................................................................... 3-7
The Visible Optics System................................................................................................ 3-8
The Diode Pumped Frequency Doubled YAG Laser..................................................... 3-9
Laser Output Power Control ....................................................................................... 3-10
The Neutral Density (ND) Filter Wheel........................................................................ 3-10
The TILT Plate............................................................................................................ 3-10
The Beam Splitter ....................................................................................................... 3-10
The Photodetector Board............................................................................................ 3-11
See disclosure, use or duplication restrictions on the back of the front page
45563-B
PlateJet Sapphire Service Manual
AOM Focusing Lens and Shutter Assembly................................................................ 3-11

Acousto-Optical (A-O) Modulator ................................................................................ 3-11
Beam Expander Lens ................................................................................................. 3-12
Collimating Lens ......................................................................................................... 3-12
Prism Spinner ............................................................................................................. 3-12
Safety Interlock System .............................................................................................. 3-12
The Thermal Optics System ........................................................................................... 3-13
Optical System ........................................................................................................... 3-14
First-Order vs. Zero-Order Imaging Setup.............................................................. 3-15
Monolithic Diode Array Laser...................................................................................... 3-16
Collimating Lens ......................................................................................................... 3-17
Beam Splitter .............................................................................................................. 3-17
Photodetector Assembly ............................................................................................. 3-17
A-O Modulator ............................................................................................................ 3-17
Prism Spinner ............................................................................................................. 3-17
Shutter Assembly........................................................................................................ 3-18
Safety Interlock System .............................................................................................. 3-18
Section Four: Installing PlateJet ...............................................................................4-1

The PlateJet Sapphire Shipment ...................................................................................... 4-1
Inspecting the PlateJet Shipment.................................................................................. 4-2
Unpacking the PlateJet Crate ....................................................................................... 4-2
Verifying the Contents .................................................................................................. 4-3
Installing the PlateJet Sapphire ........................................................................................ 4-3
Section Five: PlateJet Packaging Removal..............................................................5-1

Introduction ...................................................................................................................... 5-1
Removing The Slide door (Thermal units only)................................................................. 5-1
Removing the Chamfer Panel .......................................................................................... 5-2
Removing the Chamfer Panel - Visible ......................................................................... 5-2
Removing the Chamfer Panel - Thermal....................................................................... 5-2
Removing the Column Doors ........................................................................................... 5-2
Section Six: The Visible Optics Plate .......................................................................6-1

Accessing and Restoring the Optics Plate........................................................................ 6-1
Replacing Optical Components ........................................................................................ 6-2
Replacing the Green YAG Laser................................................................................... 6-2
Replacing the 3.5D Filter Wheel Assembly ................................................................... 6-3
Replacing the Photodetector Board Assembly .............................................................. 6-4
Replacing the A-O Modulator........................................................................................ 6-6
Replacing the Shutter Assembly ................................................................................... 6-6
Replacing the Green YAG Laser Controller .................................................................. 6-7
Replacing the A-O Modulator Driver ............................................................................. 6-8
Cleaning the Visible PlateJet Optics ............................................................................. 6-9
Aligning the Optics System............................................................................................. 6-10
Aligning the Optics after a YAG Laser Replacement................................................... 6-12
Preparing the PlateJet for Aligning the Optics............................................................. 6-15
Restoring the PlateJet After Aligning the Optics.......................................................... 6-15
Adjusting the TILT Plate.............................................................................................. 6-16
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Table of Contents
Adjusting the A-O Modulator for Optimum Diffraction Efficiency.................................. 6-17

Measuring the A-O Modulator Diffraction Efficiency .................................................... 6-20
Measuring the A-O Modulator Transmission Efficiency ............................................... 6-20
Beam Pointing Alignment............................................................................................ 6-21
Lens Centration Alignment.......................................................................................... 6-25
Setting the Exposure (Power)......................................................................................... 6-27
Auto-Positive Silver-Halide ......................................................................................... 6-27
Auto-Negative Photopolymer Plates ........................................................................... 6-27
Section Seven: The Thermal Optics Plate................................................................7-1

Accessing and Restoring the Thermal Optics Plate .......................................................... 7-1
Cleaning the Thermal PlateJet Optics .............................................................................. 7-1
Replacing Plug & Play Optical Components..................................................................... 7-2
Replacing the Laser...................................................................................................... 7-3
Laser Controller Unit..................................................................................................... 7-6
Photodetector Board (backscan sensor) ....................................................................... 7-6
AOM (Acousto-Optical Modulator) ................................................................................ 7-6
Optics Plate Spinner (Dove Prism Spinner) .................................................................. 7-8
Shutter Assembly.......................................................................................................... 7-9
Cross-Scan Spinner.................................................................................................... 7-10
Alignment Procedures .................................................................................................... 7-12
Alignment for Zero-Order Imaging (default setup) ....................................................... 7-12
Alignment for First-Order Imaging (optional setup)...................................................... 7-13
Focus Adjustment .......................................................................................................... 7-14
Setting Phase and Focus Together ................................................................................ 7-17
Adjusting Image Quality ................................................................................................. 7-19
PlateJet ToolKit Sweeps ............................................................................................. 7-20
Using the Sweep Function .......................................................................................... 7-20
Exposure Sweep......................................................................................................... 7-21
Spinner Phase Offset Sweep ...................................................................................... 7-22
Spinner Speed Scaling Sweep.................................................................................... 7-23
Evaluating Image Quality................................................................................................ 7-23
Setting Exposure ........................................................................................................ 7-23
Determining Proper Spinner Phase Offset .................................................................. 7-25
Determining Proper Spinner Speed Scaling Factor..................................................... 7-26
Image Quality Testing Sequence.................................................................................... 7-26
Section Eight: Linear Drive System Maintenance ...................................................8-1

Replacing the Westwind Spinner...................................................................................... 8-1
Replacing the Linear Motor Micropositioner Coil Assembly .............................................. 8-2
Replacing the Magnetic Track Assembly.......................................................................... 8-4
Replacing the 0.25 Diameter Magnet .............................................................................. 8-5
Replacing the Linear Scale Head Assembly ..................................................................... 8-6
Aligning the Linear Scale Head..................................................................................... 8-8
Replacing the Linear Scale RG2 Encoder Tape ............................................................... 8-9
Replacing the 14-Conductor Flex Cable ......................................................................... 8-10
Replacing the 25-Conductor Flex Cable ......................................................................... 8-11
Replacing the Bonded Air Pressure Tube....................................................................... 8-12
Replacing the Flex Cable Board Assembly..................................................................... 8-13
Replacing the Home and Away Limit Switches............................................................... 8-15
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iii
Replacing the Start of Image RGM22S Reference Mark .............................................. 8-16

Replacing the Westwind Prism Spinner Driver Board (Thermal PlateJet Only)............... 8-17
Replacing the Linear Motor Micropositioner Controller Assembly ................................... 8-17
Testing the Air Pressure Switch...................................................................................... 8-17
Adjusting the Linear Motor Micropositioner Air Bearing Pressure ................................... 8-18
Setting the Start of Line and Start of Image.................................................................... 8-18
Section Nine: Media Transport Maintenance ...........................................................9-1

PlateJet Sapphire Media Transport .................................................................................. 9-1
Replacing the Media Guide Motor................................................................................. 9-1
Replacing the Media Guide Limit Switches ................................................................... 9-2
Replacing the Vacuum Pump ........................................................................................... 9-5
Replacing the Vacuum Solenoid Assembly ...................................................................... 9-6
Replacing the Vacuum Switch.......................................................................................... 9-7
Testing the Vacuum Switch .............................................................................................. 9-8
Replacing the Vacuum Gauge.......................................................................................... 9-8
Adjusting Media Skew ...................................................................................................... 9-9
Adjusting Image Skew ................................................................................................ 9-10
Section Ten: Electronic System Maintenance .......................................................10-1

Foreword........................................................................................................................ 10-1
Replacing the Internal SCSI Cable ................................................................................. 10-2
Replacing the SCSI-U2 Splice Connector ...................................................................... 10-3
Replacing the Air Pressure Switch ................................................................................. 10-4
Replacing the Air Pressure Regulator ............................................................................ 10-4
Replacing the Micropositioner Gauge............................................................................. 10-5
Replacing the System Gauge......................................................................................... 10-6
Replacing the Toggle Switches ...................................................................................... 10-7
Replacing the Power Circuit Breaker Switch................................................................... 10-8
Replacing the 230VAC Vacuum Pump Solid State Relay ............................................... 10-9
Replacing the EMI Filter ................................................................................................. 10-9
Replacing the Transient Suppressor ............................................................................ 10-10
Replacing the Switching DC Power Supply .................................................................. 10-11
Replacing the PS I/O Board Assembly ......................................................................... 10-13
Replacing the Main Processor Board Assembly ........................................................... 10-15
Replacing the Operator Control Panel .......................................................................... 10-16
Replacing the Operator Control Panel Controller PCB ................................................. 10-17
Replacing the Two Main Exhaust Fans ........................................................................ 10-17
Replacing the System Air Filter Assembly .................................................................... 10-18
Replacing the Drum Circulation Fan............................................................................. 10-19
Appendix A: Table of Figures................................................................................... A-1

Appendix B: Installation Checklist........................................................................... B-1
Appendix C: Special Tools List ................................................................................ C-1
PlateJet Sapphire Recommended Tools List................................................................... C-1
Appendix D: Spare Parts .......................................................................................... D-1

Spares Common to the 4Up Model ................................................................................. D-1
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45563-B
Table of Contents
Appendix E: Wiring Diagrams .................................................................................. E-1

Cables Common to Thermal and Visible (46184) .............................................................E-1
Cables for the Visible System (46182) .............................................................................E-3
Cables For the Thermal System (46183)..........................................................................E-5
End of Section
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THIS PAGE LEFT BLANK INTENTIONALLY
vi
45563-B
Section One: Introduction

PlateJet Sapphire Product Applicability
This manual is applicable to the PlateJet Sapphire Manual products. The manual indicates where
models differ by referencing the product feature that is the source of the difference as follows:
Thermal - PlateJet Sapphire equipped with the Thermal Laser.
Visible - PlateJet Sapphire equipped with the Visible Yag laser.
PlateJet - All the above.
Laser Safety and Warnings for Visible PlateJet Service Personnel
Laser Specification
The following special note provides the laser specifications in the Visible PlateJet.
SPECIAL NOTE:
LASER DEVICES PRESENT WITHIN THIS EQUIPMENT ARE HAZARDOUS. THE
INTERNAL LASER HAS THE FOLLOWING OUTPUT CHARACTERISITCS UNDER
MAXIMUM CONDITIONS:
Laser Type
Wavelength
(mn)
DIODE PUMPED FREQUENCY DOUBLED YAG
532
Output Power
(mW)
Beam Divergence
(mRad)
50/100
2.2
(YTTRIUM ALUMINUM GARNET)
The following warnings are provided for the protection of Visible PlateJet service personnel.
CAUTION: USE OF CONTROL OR ADJUSTMENTS OR PERFORMANCE OF PROCEDURES
OTHER THAN THOSE SPECIFIED HEREIN MAY RESULT IN HAZARDOUS LASER RADIATION
EXPOSURE.
ATTENTION:
LE CONTROLE ET LAJUSTEMENT AINSI QUE LA MODIFICATION DES
PERFORMANCES AUTRES QUE CEUX STIPULS DANS CE MANUEL PEUVENT CRER DES
EFFETS IMPRVUS DE LA RADIATION LASER.
VORSICHT:
ANDERE,
ALS
HIER
VORGESCHRIEBENE,
BENUTZUNG
VON
KONTROLLSCHALTERN, JUSTIERUNGEN UND DURCHFUEHRUNG VON VORSCHRIFTEN, KANN
ZU GEFAEHRLICHER BESTRAHLUNG FUEHREN.
45563-B
1-1
DANGER LASER RADIATION: THIS EQUIPMENT WILL EMIT LASER RADIATION WHEN OPEN
AND INTERLOCK SWITCHES DEFEATED. AVOID EYE EXPOSURE TO DIRECT AND SCATTERED
LASER RADIATION.
DANGER- RADIATIONS LASER: CET QUIPEMENT PEUT METTRE DES RADIATIONS LASER
LORSQUIL EST OUVERT ET EN CAS DE DFAILLANCE DES INTERRUPTEURS DE SECURIT.
EVITER TOUT CONTACT DES YEUX AUX RAYONS DIRECTS ET INDIRECTS DES LASERS.
GEFAHR -- LASERSTRAHLUNG:
IM OFFENEM ZUSTAND UND MIT BERBRCKTEN
SICHERUNGSSCHALTERN WIRD VON DIESEM GER\T LASERSTRAHLUNG EMITTIERT.
VERMEIDEN SIE DIE BESTRAHLUNG DER AUGEN DURCH DIREKTE ODER GETREUTE
LASERSTRAHLUNG.
DANGER -- LASER RADIATION: THE YAG LASER USED IN THIS EQUIPMENT EMITS UP TO 100
MILLIWATTS OF LASER RADIATION WHICH CAN CAUSE PERMANENT DAMAGE TO THE
UNPROTECTED EYE. WEAR SAFETY GLASSES (# 37180 / #37179) AT ALL TIMES AND AVOID
LOOKING DIRECTLY INTO THE BEAM.
DANGER RAYONNEMENT LASER: LE LASER YAG UTILIS DANS CET QUIPEMENT PEUT
METTRE UN RAYONNEMENT DE 100 MILLIWATTS. SANS PROTECTION, VOUS POUVEZ SUBIR
DES DOMMAGES PERMANENTS AUX YEUX. PORTER DES LUNETTES DE PROTECTION (#
37180 / #37179) EN TOUT TEMPS ET VITER DE REGARDER DIRECTEMENT LE FAISCEAU
LASER.
GEFAHR LASERSTRAHLUNG: DER YAG LASER, DER IN DIESEM GERT VERWENDUNG
FINDET, EMITTIERT BIS ZU 100 MILLIWATT LASER AUSGANGSLEISTUNG, WODURCH EIN
UNGESCHTZTES AUGE DAUERHAFT GESCHDIGT WERDEN KANN. BITTE TRAGEN SIE
STETS EINE SCHUTZBRILLE (NR. 37180 / NR. 37179) UND VERMEIDEN SIE, DIREKT IN DEN
LASERSTRAHL ZU BLICKEN.
DANGER: LASER RADIATION WHEN OPEN. AVOID DIRECT EXPOSURE TO BEAM.
DANGER: EVITER TOUTE EXPOSITION DIRECTE AUX RAYONS EN CAS DOUVERTURE.
GEFAHR: LASERSTRAHLUNG IM GEOEFFNETEN ZUSTAND UND NICHT FUNKTIONIERENDER
ODER UEBERBRUECKTER SICHERUNG. DIREKTE BESTRAHLUNG DURCH DEN STRAHL MUB
VERMIEDEN WERDEN.
Safety Labels Visible PlateJet

The Visible PlateJet is equipped with warning labels as shown in Figure 1-1 and Figure 1-2. Each label
is identified by its Part Number. Please familiarize yourself with these safety issues.
1-2
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Introduction
Figure 1-1 Visible Laser Safety Label Locations - Front
Figure 1-2 Visible Laser Safety Label Locations - Left
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1-3
Label 41772 shown in Figure 1-1 is iterated below with French and German translations.
CAUTION: LASER LIGHT WHEN OPEN AND INTERLOCKS DEFEATED.
EXPOSURE TO BEAM.
AVOID DIRECT
ATTENTION:
RADIATIONS LASER A LOUVERTURE ET EN CAS DE DFAUT
LINTERRUPTEUR DE SCURIT. VITER TOUTE EXPOSITION DIRECTE AU RAYON.
DE
VORSICHT: LASERSTRAHLUNG IM GE|FFNETEN ZUSTAND UND NICHT FUNKTIONIERENDER

ODER BERBRCKTER SICHERUNG. DIREKTE BESTRAHLUNG MUA VERMIEDEN WERDEN.
DANGER: LASER LIGHT WHEN OPEN. AVOID DIRECT EXPOSURE TO BEAM.
DANGER: RADIATIONS LASER EN CAS DOUVERTURE. VITER TOUTE EXPOSITION DIRECTE
AU RAYON.
GEFAHR: LASERSTRAHLUNG IM GE|FFNETEN ZUSTAND.
VERMIEDEN WERDEN.
DIREKTE BESTRAHLUNG MUA
Label 41842 shown in Figure 1-1 and Figure 1-2 indicates there is related information in the Product
Manual(s).
Label 25446 shown in Figure 1-2 is a laser classification label.
Laser Safety and Warnings for Thermal PlateJet Service Personnel

Laser Specification
The following special note provides the laser specifications in the Thermal PlateJet.
SPECIAL NOTE:
THE LASER DEVICE PRESENT IN THIS EQUIPMENT IS HAZARDOUS. THE INTERNAL LASER
HAS THE FOLLOWING OUTPUT CHARACTERISITCS UNDER MAXIMUM CONDITIONS:
PlateJet Laser Type
ALGAAS LASER DIODE ARRAY
Wavelength
(nm)
780-850
Output Power
(Watts)
50
Beam Divergence
(mRad)
30
(ALUMINUM GALLIUM ARSENIDE SEMICONDUCTOR)
The following warnings are provided for the protection of Thermal PlateJet maintenance personnel.
1-4
45563-B
Introduction

EXPOSURE.
ATTENTION: LE CONTROLE ET LAJUSTEMENT AINSI QUE LA MODIFICATION DES
VORSICHT: ANDERE, ALS HIER VORGESCHRIEBENE, BENUTZUNG VON
KONTROLLSCHALTERN, JUSTIERUNGEN UND DURCHFUEHRUNG VON VORSCHRIFTEN,
KANN ZU GEFAEHRLICHER BESTRAHLUNG FUEHREN.
CAUTION INVISIBLE LASER RADIATION: THIS EQUIPMENT WILL EMIT INVISIBLE LASER
RADIATION WHEN OPEN AND INTERLOCK SWITCHES DEFEATED. AVOID EYE OR SKIN
EXPOSURE TO DIRECT OR SCATTERED LASER RADIATION.
ATTENTION RAYONNEMENT INVISIBLE LASER: CET QUIPEMENT PEUT METTRE DES
RAYONNMENT INVISIBLE LASER DANGEREUX EN CAS DOUVERTURE ET LORSQUE LA
SCURIT EST NEUTRALISE. EXPOSITION DANGEREUSE DE LOEIL OU DE LA PEAU AU
RAYONNEMENT DIRECT OU DIFFUS.
VORSICHT UNSICHTBARE LASERSTRAHLUNG: IM OFFENEM ZUSTAND UND MIT
BERBRCKTEN SICHERUNGSSCHALTERN WIRD VON DIESEM GERT UNSICHTBARE
LASERSTRAHLUNG EMITTIERT. VERMEIDEN SIE DIE BESTRAHLUNG DER AUGEN ODER
HAUT DURCH DIREKTE ODER GESTREUTE LASERSTRAHLUNG.
CAUTION INVISIBLE LASER RADIATION: THE LASER USED IN THIS EQUIPMENT EMITS UP
TO 50 WATTS OF INVISIBLE LASER RADIATION WHICH CAN CAUSE PERMANENT DAMAGE
TO THE UNPROTECTED EYE. WEAR SAFETY GLASSES (# 39952 / #39953) AT ALL TIMES AND
AVOID LOOKING DIRECTLY INTO THE BEAM.
ATTENTION RAYONNEMENT INVISIBLE LASER: LE LASER UTILIS DANS CET
QUIPEMENT PEUT METTRE UN RAYONNEMENT INVISIBLE DE 50 WATTS. SANS
PROTECTION, VOUS POUVEZ SUBIR DES DOMMAGES PERMANENTS AUX YEUX. PORTER
DES LUNETTES DE PROTECTION (# 39952/ #39953) EN TOUT TEMPS ET VITER DE
REGARDER DIRECTEMENT LE FAISCEAU LASER.
VORSICHT UNSICHTBARE LASERSTRAHLUNG: DER LASER IN DIESEM GERT EMITTIERT
BIS ZU 50 WATT UNSICHTBARE LASERSTRAHLUNG, WODURCH EIN UNGESCHTZTES
AUGE DAUERHAFT GESCHDIGT WERDEN KANN. BITTE TRAGEN SIE STETS EINE
SCHUTZBRILLE (NR. 39952 / NR. 39953) UND VERMEIDEN SIE DIREKT IN DEN LASERSTRAHL
ZU BLICKEN.
Laser Safety Labels

The Thermal PlateJet is equipped with warning labels as shown in Figure 1-3 and Figure 1-4. Each
label is identified by its Part Number. Please familiarize yourself with these safety issues.
45563-B
1-5
Figure 1-3 Thermal Laser Safety Label Locations - Front
Figure 1-4 Thermal Laser Safety Label Locations - Left
1-6
45563-B
Introduction
Label 45737, shown in Figure 1-3 and Figure 1-4, is iterated below with French and German
translations.
CAUTION: INVISIBLE LASER RADIATION WHEN OPEN AND INTERLOCK SWITCHES
DEFEATED AVOID EYE OR SKIN EXPOSURE TO DIRECT OR SCATTERED LASER RADIATION.
ATTENTION: RAYONNEMENT INVISIBLE LASER DANGEREUX EN CAS DOUVERTURE ET
LORSQUE LA SCURIT EST NEUTRALISE EXPOSITION DANGEREUSE DE L OEIL OU DE
LA PEAU AU RAYONNEMENT DIRECT OU DIFFUS.
VORSICHT: UNSICHTBARE LASERSTRAHLUNG IM OFFENEM ZUSTAND UND MIT
BERBRCKTEN SICHERUNGSSCHALTERN. VERMEIDEN SIE DIE BESTRAHLUNG DER
AUGEN ODER HAUT DURCH DIREKTE ODER GESTREUTE LASERSTRAHLUNG.
Label 41842, shown in Figure 1-3 and Figure 1-4, indicates there is related information in the Product
Manual(s).
CAUTION: INVISIBLE LASER RADIATION WHEN OPEN. AVOID EYE OR SKIN EXPOSURE TO
DIRECT OR SCATTERED LASER RADIATION.
ATTENTION: RAYONNEMENT INVISIBLE LASER EN CAS DOUVERTURE EXPOSITION
DANGEREUSE DE L OEIL OU DE LA PEAU AU RAYONNEMENT DIRECT OU DIFFUS.
VORSICHT: UNSICHTBARE LASERSTRAHLUNG IM OFFENEM ZUSTAND. VERMEIDEN SIE
DIE BESTRAHLUNG DER AUGEN ODER HAUT DURCH DIREKTE ODER GESTREUTE
LASERSTRAHLUNG.
The laser mounted on the optics plate, is also equipped with warnings, and is identified as a class 4
laser. This device is located behind the optics plate cover.
Label 42289 shown in Figure 1-4 indicates this is a laser device.
Label 42290 shown in Figure 1-4 indicates that the laser beam is emitted from the aperture.
INVISIBLE LASER RADIATION: AVOID EYE OR SKIN EXPOSURE TO DIRECT OR SCATTERED
LASER RADIATION. CLASS 4 LASER PRODUCT 50W MAXIMUM AT 780 TO 850 NM.
RAYONNEMENT INVISIBLE LASER: RAYONNEMENT INVISIBLE LASER EN CAS
DOUVERTURE EXPOSITION DANGEREUSE DE L OEIL OU DE LA PEAU AU RAYONNEMENT
DIRECT OU DIFFUS. LASER DE CLASSE 4, PUISSANCE DE 50W MAX ENTRE 780 ET 850 NM.
UNSICHTBARE LASERSTRAHLUNG: VERMEIDEN SIE DIE BESTRAHLUNG DER AUGEN
ODER HAUT DURCH DIREKTE ODER GESTREUTE LASERSTRAHLUNG. KLASSE 4 LASER
PRODURT 50W MAXIMAL WISEHEN 780 UND 850 NM.
For additional information regarding laser safety, European service personnel may refer to the IEC825-1 Standard for Safety of Laser Products Users Guide Section 3. United States service personnel
may refer to ANSI Z136.1 Standard for the safe use of lasers.
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1-7
Common Safety and Miscellaneous Labels

As shown in Figure 1-5 and Figure 1-6, the PlateJet is equipped with a product label (#41314), a laser
classification label (#41763) and a CE compliance label (#41761).
Figure 1-5 Common Safety Label Locations - Back

CAUTION: CONTAINS HAZARDOUS VOLTAGES, NO USER SERVICEABLE PARTS INSIDE.
ATTENTION: TENSION DANGEREUSE. AUCUNE PICE RPARABLE PAR LUTILISATEUR
VORSICHT: STROMSCHLAGGEFAHR, ENTHLT KEINERLEI REPARATURANFLLIGE
GERTETEILE.
WARNING: LINE VOLTAGE ALWAYS PRESENT.
AVERTISSEMENT: PRSENCE CONSTANTE DE TENSION DE LIGNE.
WARNUNG: STANDIG UNTER NETZSPANNUNG.
DANGER: HIGH VOLTAGE
DANGER: HAUTE TENSION
GEFAHR: HOCHSPANNUNG
1-8
45563-B
Introduction
Label 31104 shown in Figure 1-5 is a mains flash symbol.

Label # 40796 indicating that the voltage is 230 and Label # 30643, which provides the fuse rating
further emphasizes these warning labels.
Error Code label
The Error Code Label, Part Number 39959, lists all error codes displayed by the Operator Control
Panel and is located as shown in Figure 1-6.
Figure 1-6 Error Code Label Locations - Right Door Open
End of Section
45563-B
1-9
1-10
45563-B
Section Two: Product Description

Introduction to the PlateJet Sapphire
The PlateJet is a Computer-to-Plate (CTP) imaging device (platesetter) capable of producing high
resolution printing plates from PostScript ripped files. The PlateJet Sapphire product line meets the
needs of a broad range of Commercial Printers. The following features are common to all PlateJet
Sapphire platesetters:
Internal Drum, Spinning Mirror
Adjustable Exposure
Selectable Resolutions (factory configured)
Static Media
Manual Load/Unload of Media
Standard Ultra 2 SCSI interfaces to a variety of RIPs and networks provides open workflow.
Handles a wide range of media sizes.
Supports both positive and negative media by exposing either the image or non-image areas.
PlateJet Sapphire Functional Component Groups
The PlateJet Sapphire is composed of the following functional component groups:
Media Handling - Comprised of a PinBar, media guide, and vacuum assemblies. The PinBar
accurately positions the media (plate or film) relative to the scanning beam, the media guide
constrains the media in the internal drum until vacuum is applied. Vacuum is applied from a
vacuum pump directly to a default area of the internal drum. The remaining area is selected
sequentially (the size is defined by the host computer software) via ten vacuum solenoids.
Linear Motor Micropositioner - A Westwind self-generating air bearing spinner motor assembly
is supported on carriage driven by a linear motor. The spinner motor scans the laser light in the
along scan direction while the linear motor moves the carriage in the cross scan direction. The
speeds of these two motors are accurately controlled in order to maintain accurate &
synchronized pixel and line spacing.
Visible Optics Plate1 - A frequency-doubled YAG laser head as the light source, an ND filter
wheel & Photodetector board for exposure control, a shutter to prevent stray light from entering
the imaging area while not imaging and an accousto-optical modulator (AOM) to turn the beam
on & off as a function of input data. The final focus lens and spinner mirror cube located on the
spinner carriage completes the optical path to the media.
Notes:
1
Applicable to the Visible PlateJet.

45563-B
2-1
Thermal Optics Plate1 - Consists of a monolithic diode array laser head as the light source. A
Photodetector board is used for exposure control. A Westwind self-generating air bearing spinner
motor rotates the laser energy and a shutter prevents stray light from entering the imaging area
while not imaging. An accousto-optical modulator (AOM) turns the beam on and off as a
function of input data. The final focus lens and spinner mirror cube, located on the spinner
carriage, completes the optical path to the media.
AC and DC power distribution - Comprised of the Instrument Control & Power Panel and DC
Distribution Panel located behind the Instrument Control & Power Panel. AC power (230VAC)
is connected to the power outlet on the Instrument Control & Power Panel, turned on by the
circuit breaker switch CB1 and directed to the DC Power Supply and vacuum pump. DC power
is used to power the Controller Board assembly, media guide motor, vacuum solenoids, the
gripper air supply solenoid, laser, modulator driver and cooling fans.
The electronics - Comprised of the Controller Board assembly, Linear Motor Micropositioner
Controller assembly, portions of the DC distribution assembly, modulator driver, laser controller1
or laser controller box2 and Photodetector board.
The locations of the various components in the PlateJet are shown in Figure 2-7 and Figure 2-8.
Figure 2-7 PlateJet Component Layout (Front View)2
Notes:
1
Applicable to the Thermal PlateJet .
Items displaying a superscripted T" are applicable to the thermal laser (Thermal PlateJet). Items displaying a superscripted
V" are applicable to the visible laser (Visible PlateJet).
2-2
45563-B
Product Description
PlateJet Sapphire Specifications

The PlateJet Sapphire specifications are:

Visible Laser:
Thermal Laser:
Minimum Media sizes:
Maximum Media sizes:
Minimum Media Thickness:
Maximum Media Thickness:
Imaging Resolutions:
Geometric Accuracy:
Geometric Repeatability:
Geometric Skew
Doubled-YAG Green Laser (532 nm wavelength)

Laser Diode Array (810 nm wavelength)
18 (cs) 15 (as)
44 (cs) 36 (as)
0.006
0.012
any resolution between 1000 - 2000dpi with the low-resolution
optic plate, or 1800 - 3600dpi with the Hi resolution optic plate.
Screen rulings up to 300 lpi on either plate.
3 mils
A 2 mil line exposed 10 times will not grow larger than 5 mils1
0mils
Figure 2-8 PlateJet Component Layout (Rear View)2
End of Section
Notes:
1
The cross scan is not synchronized with along scan. This means that a repeated scan line can be place accurately within one
scan line.
2
Items displaying a superscripted T are applicable to the thermal laser (Thermal PlateJet). Items displaying a superscripted
V are applicable to the visible laser (Visible PlateJet)
45563-B
2-3
2-4
45563-B
Section Three: Theory of Operation

Linear Motor Micropositioner
The Linear Motor Micropositioner system is a reliable, almost service free, assembly capable of
creating high quality images. The Linear Motor Micropositioner is based on an air bearing system to
support the spinner carriage. Both the air bearing and the linear motor technologies lend themselves
to our precise imaging system.
Mechanical Drive System
The air bearing structure is based on an accurately machined and anodized aluminum beam having a
4X6 cross section. The spinner carriage rides on a uniform cushion of air supplied at a regulated 60
psi through porous sintered ports embedded in the carriage. Magnets in the spinner carriage pull
down on two steel strips embedded in the aluminum beam, which opposes the air pressure, thereby
creating a very stiff pre-load effect. This stiff pre-load causes the system to resist angular motion of
the stage which maybe caused by external effects. The air bearing/magnet sets are located at the top
and side of the beam, to counteract any pitch or yaw motion of the carriage.
Air Bearing Supply
The Linear Motor Micropositioner air bearings requires a regulated 60psi of air pressure. The
regulator is located on the inside of the Instrument Control & Power Panel, just behind the Linear
Motor Micropositioner air pressure gauge (see Figure 10-2).
Linear Motor Drive
The linear motor is the system that drives the spinner carriage down the length of the beam. It can be
thought of as an unwound DC motor, with the coils moving in a linear fashion instead of a rotational
one. Since the linear motor coils located on the spinner carriage have no iron, there is no attraction to
the magnets1 located under the beam, until energy is applied. Energy is applied as part of a servo
control loop that employs a sub-micron linear encoder imbedded on the underside of the beam.
Motor Controller Box
The Linear Motor Controller box controls the Linear Motor Micropositioner. The Motor Controller
box contains the servo controller, amplifier, backplane board and provision for some analog filters.
The Motor Controller box communicates with the PlateJet Main Processor Board via an RS232 link.
The drive signals are generated as ASCII control characters, which are used by the Motor Controller
box to define direction and speed.
Notes:
1
These magnets should not be confused with the magnets used to hold the carriage onto the beam. These are the magnets
that form part of the linear motor.
45563-B
3-1
Linear Scale
The linear scale is a non-contacting type comprised of a reading head mounted on the spinner carriage
and a scale located under the beam. The reading head contains an infrared light source and two
sensors. The two sensors detect reflected radiation from the scale1 that have evenly spaced lines. The
sensors are arranged so that the two tracks generate signals that are 90 out of phase. By having one
signal occur before the other, direction of travel2 can be determined as well as speed. INDEX for
Start of Image is determined by a magnetic sensor at the HOME3 end. Imaging always occurs from
HOME to AWAY4. Both the reading head and reflected tape can be replaced in the field.
Westwind Spinner Motor
The PlateJet uses a Westwind self-generating air bearing motor. The Westwind spinner is a 3-phase
motor running at 300 - 400 Hz that requires no external air supply or protection circuitry. The drive
signals are provided by the Main Processor Board. The carriage is designed so that the motor is hard
referenced against the back of the spinner mount eliminating the need for a spacer block (gauge) to
position the spinner.
Focus Lens
The focus adjustment must be done with a micrometer tool, which is part of the Service Tool Kit for
this product. After adjustment is made, focus position is locked down and the tool removed. Lens
centration is adjustable by a 1.5mm hex key with no need for a lock down plate. The Focus Lens
assembly can be removed, cleaned and replaced with no change to focus or centration.
The replaceable items on the Linear Motor Micropositioner include:
Flexible cables and tubing
Motor coil
Linear scale read head
Linear scale tape
Magnetic limit switches
Magnet track
Preventative maintenance5 includes replacement of the coalescing filter element every 6 months.
Notes:
1
2
3
4
The fixed scale is in the form of a tape with an adhesive backing.

The normal imaging direction is from HOME to AWAY.
Other magnetic switches at HOME and AWAY are also used as limits of travel for the spinner carriage.
At the termination of each image the spinner carriage is returned to the HOME end in preparation for the next image.
There are no adjustments that can be made to a functioning system to improve performance. Under no circumstance should
the carriage or mount be removed from the main beam, they are aligned at the factory. It is expected that the motor controller box
may need replacement as a unit and sent back to the factory for repair.
3-2
45563-B
Theory of Operation
Care and Handling

Care must be taken to avoid damage to the top and front surface of the air-bearing beam. In the event
that a critical surface is damaged, the service engineer should slowly run the air bearing over the area
and see if the material damage can be detected. If it is not detected, run an image and note any
artifacts in the area of damage. If damage can be felt by hand, the system should not be run until the
damage is repaired. Care must be taken avoid damage to the flexible cabling which supplies power
and signals to the carriage.
Main Processor Board Assembly

Electronic control originates from a single board called the Main Processor Board. The Main
Processor Board is enclosed in a metal chassis and mounted behind and above the Instrument Control
& Power Panel as shown in Figure 2-8. The Main Processor Board is powered by the DC power
supply via the PS I/O Board. Currently the only function not directly controlled by the Main
Processor Board is the Linear Motor Micropositioner. The layout of the Main Processor Board is
shown in Figure 10-6.
The Main Processor board does all of the data processing and controls all of the internal operations in
the PlateJet imaging machine, including the following:
Controls Image data processing (decompression, etc.), buffering, and transmission
Controls Host computer SCSI communications
Controls Linear Motor Driver Electronics
Controls Spinner Drive Signals
Controls the Optics plate, and drives the laser light attenuator and the optical modulator
Controls the vacuum pump, gripper and media vacuum solenoid actuator
Drives the user control panel and auxiliary serial ports.
Controls step-down of the DC power supplies for IC power and high-sensitivity sections
A single CPU oversees the operation of all of the above areas, while much of the bulk processing and
specialized work is done by a dedicated SCSI controller and state machines inside two large FPGAs.
The Main Processor Board also has extensive self-test capabilities.
The Main Processor Board is connected to the PS I/O Board, which sources several voltages to the
Main Processor Board and drives the power relays and air solenoids. Multiple cables connect the
Main Processor Board to all of the sensors, motors, and actuators that are not otherwise connected to
the PS I/O Board.
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3-3
SCSI Interface on the Controller Board

The Main Processor Board provides the SCSI interface to the host computer. This interface can be
either a SCSI-U2 Wide Differential or a SCSI Wide single-ended. The Main Processor Board autosenses and configures the interface, allowing a service representative to connect their laptops using a
single ended cable with a Wide SCSI connector at one end and a regular SCSI connector at the other.
This then allows service functions to be performed through PlateJet Toolkit. See the PlateJet
Sapphire Maintenance Manual for a full description of PlateJet Toolkit.
PS I/O Board Assembly

The name, PS & I/O stands for Power Supply and Input/Output. The PS & I/O Board is enclosed in a
metal chassis and mounted behind and above the Instrument Control & Power Panel as shown in
Figure 2-8. All system power is supplied by a power supply mounted on a wall inside the service
bay. The I/O portion of the PCB contains drivers and receivers that connect to the following electromechanical devices:
Squeegee motor / Media Guide motor
Squeegee limit switches / Media Guide limit switches
Vacuum solenoids 1 through 10
Vacuum pump on/off control
Air and vacuum pressure sensors
Multi-pass and spinner shutdown switches1
Media tray in and out limit switches
Media sensors
Shutter continuity check
Small EEPROM for future use
Many of the system cables plug directly into the PS & I/O board including all power distribution to
the following external subsystems:
Linear motor controller power
Modulator driver power
Laser power
Imaging fan and rear cooling fan power
Controller board power
The layout of the PS & I/O Board is shown in Figure 10-5.
Notes:
1
The spinner shutdown switch is not applicable to the Thermal PlateJet .

3-4
45563-B
Theory of Operation
Switching DC Power Supply

The PlateJet Sapphire employs the use of low voltage DC loads. The DC power supply (located as
shown in Figure 2-8) is a switching 800 Watt power supply with the following outputs: +28 VDC,
+24VDC, +15VDC and +12VDC. All other voltages required by the Main Processor Board are
derived locally using DC to DC converters.
There are two sources available for the DC power supply, Switching Systems International (SSI) and
Astec. The two types are slightly different, however, from a service perspective they are replaced the
same way. Both types have auto ranging for an AC input of between 90 to 265VAC and operate
between 47 to 63Hz.
Instrument Control & Power Panel Assembly

The Instrument Control & Power Panel Assembly provides for a single phase AC input power of
230V by way of a 15A plug-in connector. Refer to two Figure 10-1 and Figure 10-2.
The single Power Circuit Breaker functions as the ON & OFF switch for the PlateJet. The Power
Circuit Breaker is a double-pole 15A circuit breaker situated electrically between the primary power
inlet connector and the rest of the PlateJet. Turning off the Power Circuit Breaker effectively
removes all power to the PlateJet.
Power from the Power Circuit Breaker first passes through a transient suppressor then through an
EMI filter before providing power to the rest of the system. A 6-position terminal block that is split
evenly between L1 and L2 locally distributes AC power1. From this terminal block, AC power is
provided to the vacuum pump via solid state relay (SSR), to the Switching DC Power Supply via a
5A SLO-BLO fuse and to an auxiliary connector via a second fuse holder.
Two toggle switches provide active low signals to enable the MultiPass Test mode or to stop the
spinner motor2. The switches are identified as shown in Figure 10-1.
The three gauges on the Instrument Control & Power Panel are as follows:
The uppermost gauge displays the regulated Linear Motor Micropositioner air pressure.
regulator is mounted on the backside of this gauge to maintain a constant 60psi.
The bottom right gauge displays the system (external house) air pressure and is set to 80psi.
The bottom left gauge registers the vacuum that is applied to the internal drum to hold the media.
The gauge must read = 7 in-hg to successfully load the media in the internal drum.
Notes:
1
In North America both L1 and L2 are hot relative to ground (or neutral) and are as such two phases of a two or three phase
electrical system. However, since neutral is not used in the PlateJet Sapphire, this arrangement is considered to be a single
230VAC system. For international 230VAC electrical power, L1 is hot and L2 is at zero potential (neutral) relative to ground.
2
The Spinner On/Off switch is absent in the Thermal PlateJet.
45563-B
3-5
The actual value observed varies with media size and altitude. The PlateJet is equipped with a
vacuum sensor switch mounted on the back of the vacuum gauge. This sensor is set to operate at the
appropriate vacuum setting for the product type. Any vacuum less than this will prevent the image
from proceeding.
A bulkhead hose fitting marked AIR IN is present between the two bottom gauges. This fitting is
used to bring the system air (via a air line) to the Linear Motor Micropositioner air bearings.
A wide Ultra 2 SCSI connector is provided for communication between the Main Processor Board
and the host computer. Cut outs for two 9-pin connectors are provided under the Ultra 2 SCSI
connector. The right one is designated as a serial Diagnostic Port to the Main Processor board and the
left one is for the Automatic Loader.
Air Supply
The air supply is used to support the spinner carriage on the Linear Motor Micropositioner. The
external air is connected to the 3/8 port on the Instrument Control & Power Panel, fed through a 6.0
micron coalescing filter to the SYSTEM air pressure gauge, and Linear Motor Micropositioner air
pressure regulator. The air pressure to the Micropositioner is regulated to 60psig as measured by the
MICROPOSITIONER gauge. A pressure switch connected to the back of the MICROPOSITIONER
gauge is used to stop the Micropositioner drive in the event the regulated air pressure drops below
57psi. This is a safety precaution to prevent damage to the Micropositioner due to loss of air.
Media Handling
The PlateJet uses a PinBar to move and position media into the internal drum. These systems can be
upgraded in the field to the AutoLoading Systems. The PinBar system center-justifies the media in
the drum. The PinBar aligns the media with the drum during imaging, maintaining media registration
and repeatability1.
This process requires the operator to place pre-punched media onto the PinBar. Once the media is on
the PinBar, the operator simply pushes the media into the drum. A media guide prevents the media
from falling away from the drum. When the plate is fully inserted into the PlateJet three limit
switches are depressed (two for safety which controls the operation of the shutter, and one that reports
media loaded allowing vacuum system to start). The media guide will stay in position until an image
is requested, then vacuum is applied to the vacuum grooves in the drum. If sufficient vacuum is
sensed2, the media guide will move out of the imaging path.
Notes:
1
See section two System Specification for values.
A vacuum switch is used to determine if there is sufficient vacuum. The amount of vacuum varies depending on the media size
but it must achieve the minimum of 7 in-hg.
3-6
45563-B
Theory of Operation
When an image is requested the host computer sends the plate size to the PlateJet. The cross scan (cs)
will fast slew to the start of image location {22 [plate size 2] + offset} from the index pulse on
the linear scale. When the plate size is sent from the host the image will start at the edge of plate plus
any offset specified by the operator.
If the host software does not specify the plate size, the image size will be used to determine start of
image location. The cross scan (cs) will fast slew to the start of image location {22 [image size
2] + offset} from the index pulse on the linear scale. When image size is substituted for plate size the
image will be centered on the plate plus any offset specified by the operator.
At the end of imaging (or anytime the media is requested to be removed) the vacuum system is deactivated allowing the operator to pull the media out of the PlateJet Sapphire.
Vacuum Control
The vacuum to hold the media is applied via groups of short and long grooves1 machined in the
internal drum which are spaced about 2.5cm (1) apart. A default area (equal to minimum media
size) is evacuated whenever the vacuum pump comes on. The remaining grooves are selected (in
pairs of one short and one long groove) based on the requested cross scan media size2 by 24VDC
solenoids. There are a total of ten vacuum solenoids selecting twenty vacuum grooves (in pairs of
short and long ones). The Main Processor Board via the PS I/O Board controls the vacuum solenoids.
Vacuum Pump
PlateJet Sapphire has a rotary vane vacuum pump that requires no oil and has one intake filter. This
pump requires very little maintenance. The pump is located on the bottom left side (as viewed from
the back) of the PlateJet, mounted on a large and heavy steel anti-vibration plate and controlled by a
large (25amp) solid state relay at 230VAC3.
Media Guide Control
The media guide is used to prevent media from falling away from the internal drum during loading
and unloading. It is also used to position the media close enough for the vacuum to pull it against the
drum. A 24VDC motor with gearbox4, rotating at 39RPM, drives the media guide. At this speed, the
media guide will rotate in or out of position in about 8 seconds.
The media guide in the PlateJet Sapphire is a freely rotating roller mounted on a rotating cage. This
assembly has been referred to as the squeegee. This term is a misnomer in the sense that no actual
squeegee action on the media takes place.
Notes:
1
Short and long grooves are required to handle the range of media supported by the PlateJet Sapphire product.
The host computer downloads the plate (or image) size to the PlateJet prior to every image. This information is used to select
the appropriate solenoid(s) to hold the media in place.
3
4
The vacuum pump and its relay is the only device in the PlateJet Sapphire that operates at 230VAC.
The motor and gear box are replaced as one unit.
45563-B
3-7
The motor moves the cage through two rotating friction-drive pulleys attached to a driveshaft. A flex
coupling is used to connect the motor shaft to this driveshaft. Also attached to the cage is a
perforated plate used to catch any media falling away from the drum. This plate moves with but
ahead of the freely rotating roller. When the media is pushed into the drum, the roller is moved to the
bottom of the drum. When the vacuum comes on and activates the vacuum switch, the roller starts to
move up forcing the media close to the drum surface. During imaging the roller is parked at the top
of the internal drum.
The Visible Optics System

Before performing any procedures involving the Optics System, please review the laser safety issues
in Laser Safety and Warnings for Visible PlateJet Service Personnel on page 1-1.
Most of the optical components, used in the Sapphire, are located on the visible optics plate mounted
at the left side of the internal drum. The layout of the Visible Optics Plate is shown in Figure 3-9.
Figure 3-9 The Visible Optics Plate
3-8
45563-B
Theory of Operation
The Diode Pumped Frequency Doubled YAG Laser

The Sapphire optics uses a Diode Pumped Frequency Doubled YAG Laser system. The light output
has a wavelength of 532nm at a maximum of 100mw. The laser system is made up of two
components, the analog controller and laser head. The system is powered from +24VDC1 supplied
from the main DC power supply. The DC power goes to the analog controller and is fused for 10A at
the DC input power connector. The analog controller is mounted remotely from the laser head. Since
no high voltage is involved, connection between the laser controller and laser head is done via a flat
ribbon cable.2
The optical schematic of the laser head is as shown in Figure 3-10. A diode laser provides the
reference light source for the laser. This diode emission is focused onto the laser rod passing through
the YAG crystal.3 Two diochroic mirrors, the YAG crystal and frequency doubling crystal make up
the resonator to generate a visible green light at 532nm. After emerging from the resonator, the beam
is collimated and then exits through the case window. The beam exiting the laser head has a diameter
of 0.32
0.02nm.
Since the diode laser exhibits a variation of wavelength with temperature (approximately 0.3nm/C),
fine control of its wavelength is achieved by controlling the operating temperature. A Thermoelectric
Cooler is mounted in the laser head to provide heating and cooling. Excess heat is transferred to the
optics plate, which acts as a heat sink, via the base-plate of the laser head.4
Figure 3-10 The YAG Laser Optical Schematic
Notes:
1
The laser controller can operate from +12VDC to +26VDC.
The manufacture of the laser requires that we replace both the laser controller and laser head when either of them fails.
Matching serial numbers are tracked and warranty replacement has been refused when not returned as a set.
3
YAG stands for Yttrium Aluminum Garnet and is a crystal used in the resonator to produce radiation at 1064nm. The final light
output from the laser is at 532nm due to the additional frequency doubling crystal in the laser head.
4
Thermal compound is applied between the laser head and optics plate (heat sink) to facilitate the heat transfer.
45563-B
3-9
Laser Output Power Control

A device called an Autostart adapter1 is used with the analog controller to start the laser without
need of user furnished analog control devices. The laser power can be adjusted with the Laser
Power Setpoint Adjust potentiometer2 by using a small screwdriver. Turning the potentiometer
clockwise increases the Setpoint. The new Setpoint is either stored in the analog controller after the
Setpoint Enter Button is pressed during operation or after the next turn-on of the power supply
(automatic enter). The Laser Ready LED turns on if the actual power is within 10% of the Setpoint
power.
The Neutral Density (ND) Filter Wheel
The purpose of the ND filter wheel is to set the exposure for different media resolutions. The Main
Processor Board controls the ND wheel but the exposure value originates from the RIP. Prior to
every image, the RIP downloads the exposure value for that image.3 The ND Filter Wheel is located
as shown in Figure 6-2.
The ND filter wheel has a nominal density range of 3.5D/-0.2+0.3. This tolerance provides a
minimum exposure range of 2000:1.4 The position of the wheel is servo controlled with a stepper
motor and Photodetector. The density of the ND filter wheel is not linear and there is much finer
control in the dark end than in the clear where the wheel saturates at about the 320 point.
The TILT Plate
The beam exiting the YAG laser can exhibit both angular and offset displacement relative to an ideal
position. This displacement can vary from laser to laser and therefore must be re-aligned when
replacing a laser. Two optical components are used to re-position the beam (if required) after a laser
replacement. The first is a folding mirror (mirror #1) used for angular displacement and the second is
the TILT Plate used for offset displacement.. The locations of these two optical components are
The Beam Splitter
The beam splitter is used to deflect a portion (
5%) of the laser light to the Photodetector. The beam
splitter is located in the beam path after the Photodetector board. This component is the second
largest contributor of the optical system light loss after the A-O modulator. The Beam Splitter is
located as shown in Figure 3-9.
Notes:
1
Do not remove the Autostart adapter during operation.
The adjustment on the Autostart potentiometer is 3/4 turn. The potentiometer on the Autostart is very delicate so DO NOT
force the adjustment past its setpoint limits.
3
The RIP also downloads the resolution and the image size (or plate size)
The efficiency of the optical system is approximately 50%. This means for a 100mw laser, the optics can deliver 50mw to the
media plane (surface).
3-10
45563-B
Theory of Operation
The Photodetector Board

The Photodetectors function is to detect the amount of light from the ND filter wheel to be used in a
servo system with the ND filter wheel stepper motor to set and maintain a constant light output to the
media. The Photodetector is located as shown in.
AOM Focusing Lens and Shutter Assembly
The AOM Focusing Lens and Shutter assemblies are combined into one component by clamping the
shutter assembly to the focusing lens assembly. By positioning the shutter in front of the A-O
modulator, the laser beam is prevent from passing through the modulator crystal except when
imaging. By minimizing the modulator crystal's exposure to laser light, discoloration of the crystal is
also minimized, providing a longer crystal life.
The A-O modulator focusing lens is used to focus the lasers collimated beam to the optimum spot
size. Since the spot size at the A-O modulator is duplicated at the media plane, incorrect focus to the
A-O modulator will have an adverse affect on the media focus and exposure. This is a factory setting
that should never need changing.
The shutter is a simple device used to prevent the laser light from reaching the imaging area. The
shutter opens at the start of image and closes at the end of it. It does not open or close between lines.
It is primarily a laser safety device but also prevents light leakage from fogging the media (if left in
the internal drum for extended lengths of time without imaging).
Acousto-Optical (A-O) Modulator
The A-O Modulators sole function is to turn the beam on and off. This is accomplished by
deflecting a large portion (
70%) of the light from the zero(0) order beam to one of the two first(1st)
order beams. The components are positioned on the optics plate so that only the chosen 1st order
beam will correctly pass through the lenses downstream of the A-O modulator.1 The A-O Modulator
is located as shown in Figure 3-9.
The RF drive signal to the A-O modulator is 200MHz. The A-O modulator chosen for this application
is tuned to the 532nm (green) wavelength of light and the RF drive frequency is tuned to the A-O
modulator. To optimize the performance of the A-O modulator, several other things must be done.
1. The beam must be properly focused to the modulator.
2. The beam must be properly centered to the modulator crystal. It is not sufficient to simply pass
the beam through the crystal.
Notes:
1
In general, A-O Modulators can also control exposure. This is done by varying the amplitude of the RF drive signal as a
function of some pre-defined input voltage. In this application the input drive signal to the modulator driver is a TTL (+5VDC)
compatible on or off signal level. Consequently since only one bit is required to define a pixel, the A-O modulator is either full on or
completely off (ignoring light leakage).
45563-B
3-11
3. The angle of the incident beam (0 order) must be set correctly relative to the crystal. This angle is
called the Bragg angle.
The instructions to perform these adjustments in the field are defined in Section Seven. Under normal
conditions, adjusting the focus should not need to be changed from the factory setting.
Beam Expander Lens
The beam expander lens is a plano-concave (negative) lens used to shorten the optical distance
between the A-O modulator and collimating lens while still achieving the correct beam diameter at
the collimating lens. Since the Sapphire have different beam size requirements based on resolution
range, the position of this lens varies. The beam diameter for a resolution range of 1200dpi to
2540dpi has a smaller collimated beam than a resolution range of 1800dpi to 3600dpi. The Beam
Expander Lens is located as shown in Figure 3-9.
Collimating Lens
As the name implies, the collimating lens converts the expanding (diverging) beam from the A-O
modulator into a column of light that does not change in size for long distances. This collimated beam
allows the focusing lens and spinner mirror (cube) mounted on the spinner motor carriage to maintain
constant focus across the entire media area. The Collimating Lens is located as shown in Figure 3-9.
Prism Spinner
The prism spinner is used to rotate the generated beam throughout the remaining optical path. It
operates at between 300 rps (Hz) and 400 rps (Hz); the speed is varied for different imaging
resolutions. A control board mounted in the lower frame drives the spinner.
Safety Interlock System
The safety interlocking system is necessary to prevent exposure to laser radiation. The interlock
switches when open will close the shutter in the optics plate. When the shutter is close laser radiation
is prevented from exiting the optics plate.
Under no circumstances will these interlock switches be defeated, without having written
documentation detailing the procedures to be completed, and only by factory trained engineers. The
location of these interlock switches are shown in .
3-12
45563-B
Theory of Operation
Figure 3-11 Visible Laser Interlock Switch Locations
The Thermal Optics System

Before performing any procedures involving the Thermal Optics System, please review the laser
safety issues in Laser Safety and Warnings for Thermal PlateJet Service Personnel on page 1-4.
Most of the optical components, used in the Thermal PlateJet, are located on the optics plate mounted
at the left side of the internal drum. The layout of the Thermal Optics Plate is shown in Figure 3-9.
The components of the optics plate are as follows:
45563-B
3-13
Figure 3-12 The Thermal Optics Plate

The T-Wave system utilizes a unique imaging technique that takes advantage of the properties of the
internal drum imaging architecture, and overcomes some of the obstacles associated with the
properties of most thermal media. These media properties were considered hindrances in the past,
and most CTP manufacturers were forced to utilize external drum architectures to overcome problems
such as the requirement for long exposure/dwell times.
The following sections provide an operational overview of the major components used on the thermal
optics plate , and some of the natural advantages of our imaging techniques.
Optical System
There are three main components in the T-Wave imaging system. These are the laser, the AcoustoOptical Modulator (AOM), and the Optics Plate Spinner. Other than these components, the basic
architecture of the T-Wave system is very similar to our traditional visible YAG laser systems.
As mentioned above, pixels are imaged on the plate in a serial fashion. To do this, a pixel pattern is
scrolled through the laser stripe in one direction, as the laser stripe moves in the opposite direction
across the media (at exactly the same speed. The stripe moves in the direction of the long axis of the
stripe). This results in a pattern of pixels that is stationary on the media surface although the stripe is
moving at a constant speed.
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Theory of Operation
Scrolling the pixels through the stripe is accomplished by the AOM. Sound waves are introduced
into the crystal at one end of the stripe, and they travel across the width of the stripe until they reach
the end of the stripe. Each wave represents a single pixel, and many waves fit within the width of the
stripe (approximately 250 pixels). This way, a single data path can image many pixels
simultaneously, reducing the electronic and optical complexity of a multi-pixel system.
On a typical internal drum system, due to the rotation of the mirror on the cross-scan spinner, the
laser spot rotates 180 degrees as it moves up the platen. This is ok on a point-source laser system
because the spot is symmetrical in shape. However, this would cause problems with a stripe-shaped
laser. To compensate for this, we use a special spinner on the optics plate that negates the rotation of
the spot on the platen by rotating the beam in the opposite direction at the exact same speed1.
First-Order vs. Zero-Order Imaging Setup
The T-Wave system can be configured for either First Order or Zero Order imaging. The
differences between these two setups, and the advantages of each are explained below.
Zero-Order Imaging (default setup)
The standard setup for a T-Wave PlateJet is to use the Zero-Order laser beam to image on the plate.
This means that when no signal is sent to the Acousto-Optical Modulator (AOM), the laser light
reaches the media surface. Turning the signal ON in the AOM causes the laser light to be diffracted
so that it does not expose the media. This is the opposite of most of Gretags other imaging
equipment.
The advantage of using Zero-Order imaging is higher efficiency. By using the non-diffracted light
path for imaging, almost 100% of the laser light hits the media surface. The drawback is that when
we apply a signal to the AOM, the light level is only reduced by about 70%. This means that when
the system is properly aligned, there is approximately 30% leakage light (which exposes the entire
media surface, including background). For most thermal media, this is not a problem, as the media
has a very high-contrast response.
First-Order Imaging (optional, not currently implemented)
By re-aligning two mirrors and the AOM crystal, the T-Wave system can quickly be re-arranged into
using the First-Order laser beam to image the media. This means that when there is no signal to the
AOM, no laser light reaches the media. By applying a signal to the AOM, the laser light is diffracted
into a path that allows it to reach the media and expose it.
Notes:
1
The optics plate spinner actually rotates at exactly the speed of the cross-scan spinner. This is due to the optical characteristics
of the optics plate spinner, where the laser stripe rotates 720 degrees for every 360-degree rotation of the spinner itself.
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3-15
The advantage of using First-Order imaging is extremely high contrast: approximately 10000:1 or
higher (as opposed to 7:3 of a Zero Order system). The drawback is efficiency: the highest
achievable light level is only about 65-70% of the full laser power. For low-contrast, highly sensitive
media, this is the best choice of imaging setup.
The details on how to align the T-Wave system for each setup are described in the Alignment
Procedures section of this manual.
NOTE: All procedures for replacing the optical components assume that you are using the
default Zero-Order imaging setup. If the PlateJet you are servicing is set up for FirstOrder imaging, refer to Section 5, Alignment Procedures for differences between the two
setups.
Monolithic Diode Array Laser
The Thermal PlateJet Sapphire uses a monolithic diode array laser system consisting of two major
components; the Laser Head mounted on the optics plate and the Diode Laser and TEC Control Unit
is mounted in the lower frame section. The Diode Laser and TEC Control Unit houses the laser
power supply and thermo-electric controller. The light output of the laser head has a wavelength of
780-850nm at a maximum of 50 Watts and is powered, regulated and electrically cooled by
components inside the Diode Laser and TEC Control Unit. The laser power supply operates from the
machine input voltage and internally converts to a maximum of 360VDC. The Laser Head draws
approximately 35 amps at 2 VDC when operating at 30 watts. A thermo-electric cooler, mounted
behind the laser head, provides regulated cooling. The controller for the thermo-electric cooler is
mounted inside the Diode Laser and TEC Control Unit. The laser power supply also receives a DC
signal from the photodetector to provide closed loop exposure control.
The diode laser is powered by two power supplies as follows:
A power factor corrected front end with input capability between 90-265 VAC and an output of
360 VDC.
A high current source requiring 360 VDC input and providing up to 40 ADC @ 5VDC output.
During laser operation the output voltage is approximately 2.2 V.
Most 830nm lasers are not point-source lasers, meaning that they do not produce a circular spot of
energy. The multi-diode array technology used for these lasers usually produces a stripe or bar of
light instead. This makes it very difficult to utilize the laser light to image a single pixel at a time, as
the laser spot shape is not the same aspect ratio as the pixels.
This means that to effectively use the light from these laser sources, multiple pixels are imaged at the
same time across the width of the stripe of laser light.
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Theory of Operation
In most of our competitors equipment, the stripe is used to image a swath of pixels in parallel
fashion on the media. The swath is the same width as the number of pixels that are being imaged,
which is also the width of the long axis of the laser stripe. After one swath is imaged, the laser head
moves over to image the next swath. Each pixel within the swath is exposed by a different part of the
laser stripe. For uniform results, the intensity of the stripe must be exactly the same across the entire
width of the swath. If one diode in the stripe becomes brighter or dimmer, or even fails, the entire
imaging head needs immediate replacement, and the platesetter is down.
T-Wave technology is not nearly as susceptible to these types of failures. This is because the laser
stripe is used to image pixels in a serial fashion rather than a parallel fashion. Using the stripe this
way means that slight variations in brightness along the stripe, including the possibility of failed
diodes, do not affect the image whatsoever. This built-in safety margin means more reliability, less
downtime and lower costs of ownership.
Collimating Lens
The collimating lens converts the expanding (diverging) beam from the laser head into a column of
light that does not change in size over a certain distance. This collimated beam allows the beam
splitter and focus lens to receive an optically consistent and stable beam. The Collimating Lens is
located as shown in Figure 3-9.
Beam Splitter
The beam splitter allows most of the beam to pass directly through while a small percentage is
reflected back on to the photo detector for use in the closed loop circuit.
Photodetector Assembly
The photo detector is an optical-electric device that receives the reflected beam and converts this
thermal energy into a DC voltage. This voltage, ranging from 0 to 12VDC, is used by the Laser
Power Supply for the purpose of laser output power regulation.
A-O Modulator
The A-O Modulators sole function is to turn the imaging beam on and off at start and stop of
plot respectively. The A-O Modulator operates at 80Mhz.
Prism Spinner
The prism spinner is used to rotate the generated beam throughout the remaining optical path. It
operates at approximately 240rps, and is driven by a control board mounted in the lower frame.
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3-17
Shutter Assembly
The shutter assembly is designed to open at start of plot, then remains open until the plot has been
completed. The shutter is interlocked to prevent the laser beam from entering the imaging drum
whenever any of the outside panels are removed, or if the machine is not plotting. Before performing
any procedures involving the Optics System, please review the laser safety issues in Laser Safety
and Warnings for Thermal PlateJet Service Personnel on page 1-4.
Safety Interlock System
The safety interlocking system is necessary to prevent exposure to laser radiation. Some interlock
switches remove power to the laser and others close the shutter. In all these cases preventing laser
radiation from exiting the optics plate. Under no circumstances will these interlock switches be
defeated, unless done so by a factory-trained engineer. The PlateJet must also be secured to prevent
entry of none trained personnel. The location of the these interlock switches can be found in Figure
3-13.
Figure 3-13 Thermal Laser Interlock Switch Locations
End of Section
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Section Four: Installing PlateJet

The PlateJet Sapphire Shipment
As shown in Figure 4-1 the PlateJet is packed in a wooden crate that has sufficient strength, support,
and shock isolation to ensure safe transportation via an air-cushioned truck. The dimensions of the
crate are as shown. To receive and unpack the PlateJet, the customer must provide a forklift as
instructed in the PlateJet Sapphire Site Preparation Manual.
Figure 4-1 The PlateJet Crate

It is the service engineers responsibility to ensure that the customer provides easy access for the
PlateJet through the premises to the installation location. The best path from the receiving area to the
systems room is short distances, minimizing turns and corners while avoiding rough or carpeted floor
surfaces, and ramps or stairways.1 Pre-installation activities include inspecting the customer site for
compatibility with the system. Special attention should be taken to ensure that the site meets power
and installation requirements.
Notes:
1
Due to uneven weight distribution, only move the crate with a forklift from the side marked Forklift Side. The PlateJet must
not be tipped but remain upright during its travels. Avoid personal injury; use safe lifting practices when removing the PlateJet
Sapphire from the crate and while moving it to the systems room.
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4-1
Inspecting the PlateJet Shipment

As shown in Figure 4-1, the crate is fitted with SHOCK WATCHES that turn from white to red when
their specified limits have been exceeded. Tamper proof seals are also added to ensure the crate has
not been opened and the contents interfered with.
Inspect the crate for any physical damage and note if any of the shock watches have been tripped.1
After inspecting the crate, report any problems to the shipping company and then proceed to unpack
the equipment.
After un-crating the equipment, visually inspect the components for any damage that may have
occurred during shipment.
Check for dents, scratches, damaged hinges and panels, and evidence of water damage.
Check internal components for loose, broken, or missing hardware.
Check wiring for frayed, broken, or loose connections.
Unpacking the PlateJet Crate
The shipping documents are located in a clear plastic pouch attached to the side marked OPEN ME
FIRST. Remove these documents before proceeding with the unpacking3.
The crate is designed to be lifted and moved by pallet-jack or forklift. Once un-crated, the PlateJet
can be moved along a level floor on built-in castors4.
The crate is assembled using mostly 127mm X 6mm (5 X 0.25) bolts that require an 13 mm (1/2)
hex wrench or socket to remove them. However, two of the internal braces use 100mm (4) long lag
screws that require 11mm (7/16) hex wrench or socket2.
Unpacking the Crate
1. Remove the crate front panel marked OPEN ME FIRST. A 13mm (1/2) hex wrench or socket
is required.
2. Pull out the polyethylene foam inserts at the top of the PlateJet.
3. Remove the front top PlateJet panel1 and set it aside.
Notes:
1
Shock watches can be tripped without causing any physical damage to the crate. However if tripped, internal damage to the
equipment may have occurred which may prevent the system from performing properly.
3
Where practical and economical, Cymbolic Sciences may request that the crate be shipped back to the factory for re-cycling. If
this is the case, instructions will be included in the shipping documents. Your responsibility will then be to re-assemble the crate and
inform the Shipping Supervisor in Vancouver that it is ready for pick-up. If instructions are not included, it is assumed that the crate
is to be disposed of by the customer. Unpacking of the PlateJet Sapphire should only be done by qualified Customer Support
Engineers factory trained by Cymbolic Sciences.
4
Because of its weight (Approx. 1,000 Kgs), up to four people may be required to move and guide the PlateJet Sapphire to its
final location.
5
The use of a power or high speed mechanical socket drive tool will significantly reduce the un-crating time.
4-2
45563-B
Installing the PlateJet
4. Remove the two cross braces which are held in place by the 100mm (4) lag screws. A 11mm
(7/16) hex wrench or socket is required.
5. Remove the box(es) and set them aside.
6. Remove the side panels and set them aside.
7. Remove the crate back panel marked FORKLIFT SIDE ONLY. A 13mm (1/2) hex wrench or
socket is required.2
8. Insert the forks of the forklift into the two bottom channels of the PlateJet.3
9. Using the forklift, lift the PlateJet just enough to take the weight off the bottom.
10. Pull the PlateJet out of the crate with the forklift and set it on the floor supported by its four
lockable castors.4
11. Remove the plastic covering from the PlateJet.5
Verifying the Contents
A packing slip, included with the shipping documents, details the contents of the crate. Use this slip
to verify that the order is complete and report any omissions to the Shipping Supervisor at Gretag
Imaging.
Installing the PlateJet Sapphire

To install the PlateJet Sapphire perform the following steps:
1. Move the PlateJet into the installation room.
2. Locate the PlateJet in room as shown in Figure 4-2.
The shoulder bolt stored on the top right corner of the front panel is used to lock the panel onto the PlateJet. This bolt is
required to meet regulatory agency laser safety.
2
3
4
5
The crate is designed to maintain its integrity with both the OPEN ME FIRST and FORKLIFT SIDE ONLY panels removed.
The channels are spaced 53cm (20.75) center to center. Each channel is 23cm (9) wide.
The two bottom support plates should come out with the PlateJet. Move them out of the way.
Lifting the PlateJet off the wheels with the forklift may be required to remove the bottom part of the plastic covering.
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4-3
Figure 4-2 PlateJet Room

3. Open the front access door and side column doors.
4. Remove two back panels.
5. Do a visual inspection of the following components1:
Media Tray
Media Guide
Optics Plate
Laser Controller2 or Laser Controller Box3
Modulator Driver
Notes:
1
2
3
Rough handling in transit can cause hidden damage to the PlateJet even without apparent external damage.
The laser controller is applicable to the Visible PlateJet.
The laser controller box is applicable to the Thermal PlateJet.
4-4
45563-B
Switching DC Power Supply

Main Processor Board
PS I/O Board
Vacuum Solenoid
Vacuum Pump
Air Filter
6. Remove the red anodized retaining bracket fastening the spinner carriage to Micropositioner cross
beam.
7. Rotate the red bracket 180 and re-attach to the crossbeam for storage in case the machine ever
needs to be moved.
9. Remove the four M10 retaining bolts and red anodized spacers supporting the internal drum
(platen) end plates. The bolts are accessed from inside the lower frame.
10. Remove the media guide assembly retaining bolts. The head of the bolts is painted white for easy
identification.
11. Remove the two pieces of rigid foam wedged between the vacuum pump mounting plates.
12. Remove the red shipping brackets on the vacuum pump anti-vibration plate.
13. Unscrew the thumscrews located on each side of the slide door, as shown in .
Figure 4-3 Thumbscrew Location

14. Locate the four shock absorbent pads under the four leveling bolts near each of the four casters at
the corner of the PlateJet.
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4-5
Figure 4-4 Leveling the PlateJet

15. Using a 19mm open ended wrench, initially adjust the four corner bolts until the PlateJet is just
lifted off the four casters.
16. As shown in Figure 4-4, set a level on top of the spinner carriage assembly (positions 1-3) while
adjusting the four corner feet bolts until the PlateJet is level in both width and depth directions.
17. Using a polypropylene air line, connect the input air supply to the AIR IN port located on the
Instrument Control & Power Panel at the back of the PlateJet.
18. Turn the air on and set the pressure to about 80psi.1
19. Using a voltmeter, check the dedicated wall power outlet for correct wiring, voltage and ground
isolation. The voltage should be 230 VAC 10% at a line frequency of between 47 and 63 Hz.
Correct any problems before proceeding.
Notes:
1
It is the customers responsibility to provide compressed air meets the requirements set out in the PlateJet Sapphire Site
Preparation Manual.
4-6
45563-B
20. Install all the panels onto the PlateJet.

21. Connect the AC power cord to the back of the PlateJet.
22. Connect the PlateJet power cord to the wall outlet.
23. Turn on the Power Circuit Breaker switch on the Instrument Control & Power Panel at the back
of the PlateJet.
24. Allow the PlateJet to power up, if no major fault conditions are detected, power off the PlateJet.
25. Connect the SCSI cable to the connector at the back of the Instrument Control & Power Panel.
26. Run the SCSI cable to the RIP location and connect it to the host computer, ensuring any throughwall openings are properly sealed against light leakage.1
27. Turn on the AC power to the PlateJet.
28. Test Media Handling by loading test media for all the sizes, intended to be used by the customer.
29. Set the exposure for each of the media types to be used on the PlateJet. See Setting the
Exposure (Power) on page 6-27.
30. Sign off the "Installation Completion" form and fax it as indicated at the bottom of the form.2
31. Use the Installation CheckList to verify all procedures have been completed. See Installation
Checklist in Appendix B.
End of Section
Notes:
1
It is the customers responsibility to supply the RIP computer using the specifications as defined in the PlateJet Sapphire Site
Preparation Manual.
2
The current form is shipped with the PlateJet.
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4-7
4-8
45563-B
Section Five: PlateJet Packaging Removal

Introduction
The PlateJet Sapphires Packaging has been designed to provide clear access to the serviceable
components of the PlateJet. If it is desirable, to provide better access, the following parts can be
removed:
Thermal Slide Door
Chamfer Panel
Column Doors
Removing The Slide door (Thermal units only)
To remove the sliding door, perform the following procedure. Tools required are 3mm, 5mm, 8mm
hex keys, 8mm wrench and Key-Latch( P/N 45230).
1. Open the left and right side column doors.
2. Remove the laser safety baffles with the 3mm hex key, both sides.
3. Slide the door up until it hits the upper bumper.
4. Remove the lower two M4 screws that hold the gray slide door to the steel bracket, both sides.
DO NOT REMOVE THE UPPER M4 SCREW YET.
5. Slide the door down until it hits the lower bumper.
6. LOCK THE DOOR IN PLACE by screwing the thumbscrew into the bracket behind, both sides.
7. Check that the door is locked in place and does not move when pulled upwards.
8. Remove the top M4 screw, each side. The door should be loose and resting on the top of the
media tray.
9. With one hand firmly on the slide bracket, loosen the thumb screw on the bumper bracket. Let
the bracket slide up gently to the upper stop position. USE CARE, THIS IS A SPRING
LOADED ASSEMBLY. IT WILL NOT FLY APPART, BUT WILL SLAM UPWARDS TO
THE UPPER BUMPER STOP UNLESS CONTROLLED.
10. Remove one of the slide door brackets from the endplate by removing the three M6 screws.
11. Slide the door out from between the end panels.
Install the slide door by reversing the above steps.
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5-1
Removing the Chamfer Panel

The Chamfer panel is the gray angled-panel located directly above the media tray. The chamfer
panels are made up of three pieces; a center panel, a left mount and a right mount. The Chamfer
panel can be removed in whole, or in pieces. Required Tool: a 3mm Hex Key.
Removing the Chamfer Panel - Visible
The Chamfer panel is mounted to the blue end panels. To remove the it perform the following steps:
1. Open the left and right column doors.
2. Unscrew the four M4 screws (two per side) which hold the pieces together.
Removing the Chamfer Panel - Thermal
The panel is mounted to the cast endplates. To remove it perform the following steps:
1. Open the front upper door.
2. Slide the slide door all the way down.
3. Unscrew the four M4 screws from above the panel.
Removing the Column Doors
This task requires no tools. To remove the column doors perform the following steps:
1. Open the side door using the 8mm hex tool or Key-latch (P/N #45230) as usual.
2. Swing the door open to about perpendicular to the machine.
3. Firmly grab the handle on the door (about waist height).
4. Lift the door directly upwards and remove the door from the packaging frame.
To replace the door perform the following steps:
1. Make sure the female hinge parts are above the male pins in the end panel frame.
2. Butt the bracket up against the right panel sill and pull the door outwards (keeping it vertical).
3. Lower the door into place. It should self align and drop into the hinge pins.
THERE ARE NO SERVICABLE PARTS INSIDE OF THE DOOR. DO NOT DISMANTLE.
End of Section
5-2
45563-B
Section Six: The Visible Optics Plate

Accessing and Restoring the Optics Plate
in Laser Safety and Warnings for Visible PlateJet Service Personnel on page 1-1.
The Optics Plate is located at the upper left side of the PlateJet. The following tools will be needed:
Latch Key (P/N #45230), 3mm Allen key.
To access the Optics Plate, do as follows:
1. Turn the power off to the PlateJet.
2. Using the Latch Key, open the left column door.
3. Using a M3 hex tool, remove the five M4 screws attaching the top plate1 of the black cover over
the Optics Plate2.
4. If required, remove the outside frame of the Optics Plate cover. The frame is attached with six
M4 screws3.
5. If required, pull off the beam tube located between the beam expander (negative) lens and
collimating lens.
When the procedure you did is completed, perform the following steps to restore the Optics Plate:
1. If required, install the beam tube between the beam expander (negative) lens and collimating lens.
2. If required, connect any cables that may have been disconnected.
3. Install the outside frame of the cover. Six screws are required.
4. Install the top plate of the cover. Five screws are required.
5. Close and lock the left column door.
6. Turn the power on to the PlateJet.
Notes:
1
The plate rests in a slot at the bottom, therefore it will not fall after the screws are removed.
Many of the components are accessible after the top plate is removed, therefore the outside frame of the cover may not need
to be removed.
3
One screw is hidden inside on the bottom right next to the large folding mirror (mirror #3). Four of the screws are in slotted
holes indicating the cover can be slipped off. Unfortunately, mirror #3 interferes, preventing that from happening.
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6-1
Replacing Optical Components

Replacing the Green YAG Laser
The Green YAG Laser is located as shown in Figure 6-1. The Laser Controller located in the lower
frame at the back must be replaced with the Green YAG Laser. This is a requirement from the
manufacturer, which will otherwise void the warranty.
Figure 6-1 Replacing the Green YAG Laser

The following tools will be needed to perform this procedure: Latch Key (P/N #45230), 2.5mm and
3mm hex keys, medium screwdriver, thermal compound.
1. Access the Optics Plate. See Accessing and Restoring the Optics Plate on page 6-1.
2. Remove the green YAG laser connector at the top of the laser by simply pulling it off.
3. Remove the four securing bolts using a 2.5mm hex key.
4. Use a screwdriver to pry the laser from the optics plate and pull it off the two end dowel pins.
5. Apply thermal compound to the back of the laser.
6. Install the laser onto the two dowel pins with the output window facing the first folding mirror.
6-2
45563-B
The Visible Optics Plate
7. Secure the laser with the 4 M3X8 screws using a 2.5mm hex key.
8. Install the green YAG laser connector to the top of the laser by carefully pushing on it.1
9. If attached, remove the white plastic cover over the output window of the laser and transfer it to
the old laser before returning it for repair.
10. Replace the laser controller in the lower frame. See Laser Controller Unit on page 7-6.
11. Align the Green YAG Laser Optics. See Aligning the Optics after a YAG Laser Replacement
on page 6-12.
12. Restore the Optics Plate. See Accessing and Restoring the Optics Plate on page 6-1.
Replacing the 3.5D Filter Wheel Assembly
The 3.5D Filter Wheel Assembly is a variable optical attenuator used to set and control the exposure
to the media. It is located as shown in Figure 6-2.
Figure 6-2 Replacing the 3.5D Filter Wheel Assembly
Notes:
1
Make sure none of the pins get bent while inserting the connector onto the laser.
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6-3
To remove the 3.5D Filter Wheel Assembly the following tools will be needed: Latch Key (P/N
#45230), 3mm hex key, wire cutter, cable ties.
2. Cut any cable ties to free the filter motor cable.
3. Disconnect the filter wheel motor cable.
3. Remove the two screws attaching the 3.5D Filter Wheel Assembly.
4. Remove the old 3.5D Filter Wheel Assembly.
5. Install the new 3.5D Filter Wheel Assembly onto the Optics Plate. Locate it and then replace the
two screws attaching it.
6. Connect the filter wheel motor cable.
7. Apply cable ties to the filter motor cable.
8. Clean any contamination with lens cleaning paper and alcohol1. Avoid putting any fingerprints
on the filter wheel.
9. Restore the PlateJet. See Restoring the PlateJet After Aligning the Optics on page 6-15.
Replacing the Photodetector Board Assembly
The Photodetector board is located as shown in Figure 6-3.2 To remove the Photodetector Board
Assembly the following tools will be needed: Latch Key (P/N #45230), 2.5mm and 3mm hex keys.
Notes:
1
2
If alcohol does not remove the contamination, use a laboratory grade acetone.
A 1.0D filter is bonded to the front of the Photodetector to cover the entire exposure range and also prevent it from saturating.
6-4
45563-B
Figure 6-3 Replacing the Photodetector Board

2. Disconnect the Photodetector board control cable located at the top corner of the board.
3. Remove the Photodetector Board Assembly from the Optics Plate by removing the two M3
screws using a 2.5mm hex tool.
4. Install the new Photodetector Board Assembly to the Optics Plate by replacing the two M3
screws using a 2.5mm hex tool.
5. Connect the Photodetector board control cable.
6. Put on laser safety glasses.
8. Position the Photodetector Board Assembly so that to the light beam passes through the center of
the 1.0D ND filter which is bonded to the front of the Photodetector.
10. Restore the Optics Plate. See Accessing and Restoring the Optics Plate on page 6-1
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6-5
Replacing the A-O Modulator

The A-O Modulator is located as shown in Figure 6-4. To remove the A-O Modulator the following
tools will be needed: Latch Key (P/N #45230), 2.5mm and 3mm hex keys.
Figure 6-4 The A-O Modulator on the Optics Plate

1. Access the Optics Plate. See Accessing and Restoring the Optics Plate on page 6-1
2. Disconnect the RF control cable located at the base of the A-O Modulator.
3. Remove the A-O Modulator from the mount, by removing the two screws.
4. Install the A-O Modulator onto the modulator split mount, using the two screws and washers1
removed in step 3.
5. Connect the RF control cable to the base of the A-O Modulator.
6. Adjust the A-O Modulator Bragg angle for optimum diffraction efficiency. See Adjusting the
A-O Modulator for Optimum Diffraction Efficiency on page 6-17.
Replacing the Shutter Assembly
The Shutter Assembly is located as shown in Figure 6-5. To remove the Photodetector Board
Assembly the following tools will be needed: Latch Key (P/N #45230), 2.5mm and 3mm hex keys.
Notes:
1
It is very important that washers are used with the screws to prevent indenting the slotted holes of the A-O Modulator. Once
the slotted holes are indented, the screw heads fall into them making fine adjustments difficult, if not impossible.
6-6
45563-B
Figure 6-5 Replacing the Shutter Assembly

2. Disconnect the shutter control cable located at the top of the assembly.
3. Remove the shutter assembly from the Optics Plate. The shutter clamps onto the mount of the
focusing lens for the A-O Modulator.
4. Install the Shutter Assembly onto the Optics Plate.
5. Connect the shutter control cable.
8. Position the shutter assembly so that the beam passes unobstructed through its aperture.
9. Restore the Optics Plate. See Accessing and Restoring the Optics Plate on page 6-1.
Replacing the Green YAG Laser Controller
See Figure 6-6 for the location of the Green YAG Laser Controller.1 The manufacturer requires that
both the Green YAG Laser and Controller be replaced at the same time. The following tools will be
needed: 2.5mm and 8mm hex keys, wire cutter, cable ties.
Turn off the power to the PlateJet.
Notes:
1
The laser controller is applicable to the Visible PlateJet only.
45563-B
6-7
1. Unplug the PlateJet AC power cord from the wall outlet.

2. Remove the rear bottom right panel (as viewed from the back).
4. Disconnect the ribbon cable and DC power cable connectors from the laser controller.
5. Using a 2.5mm hex tool, remove the two top screws and washers attaching the laser controller to
the right sidewall.
6. Using a 2.5mm hex tool, loosen the two bottom screws and lift off the laser controller.
7. Remove the Autostart adapter and return it with the Green YAG Laser and Controller.
Replacing the ribbon cable is not required unless faulty or damaged.
8. Install the laser controller by reversing the above steps. Do not forget to attach the Autostart
adapter to the laser controller. The Green YAG laser cannot operate without so it.
Replacing the A-O Modulator Driver
See Figure 6-6 for the location of the A-O Modulator Driver. The following tools will be needed:
3mm and 8mm hex keys, wire cutter, cable ties.
1. Turn off the power to the PlateJet.
3. Remove the rear bottom right panel (as viewed from the back).
4. Cut any cable ties.
5. Disconnect the DC power, the TTL input coaxial and the RF output coaxial cables.
6. Using a 3.0mm hex tool, remove the two screws attaching the A-O Modulator Driver to the right
sidewall.
7. Install the A-O Modulator Driver by reversing the above steps.
6-8
45563-B
Figure 6-6 Location of A-O Modulator Driver
Cleaning the Visible PlateJet Optics

Cleaning the optics is an essential part of maintaining the optimum imaging capability of the product.
Contamination on the optics will degrade the spot quality and significantly attenuate the beam power.
Fine dust accumulation on optical components that pass or reflect large diameter beams are the cause
of most of the beam power attenuation. These components are the beam expander (negative) lens,
collimating lens, optics plate exit window, final focus lens and spinner cube. The optics plate is fairly
well sealed from dust (and thermal currents), therefore, airborne dust is more likely to accumulate on
components outside of the optics such the spinner cube, final focus lens and optics plate exit.
Optical components that pass or reflect small diameter beams typically are not affected by fine dust
because the beam usually burns it off. However, a high concentration of large diameter dust particles
can cause beam flaring and distortion. The best way to determine if an optical component is
attenuating a small concentrated beam is to measure the intensity, using a light meter, before and after
the optical component. The efficiency of most optical components is 96% or better. For example, if
the beam power before a lens is 80mw, the power after the lens should be about 77mw or better.
Large diameter beams cannot be measured by normal light meters so it is best to observe these beams
using a target like a white business card. Distortions to the spot and artifacts due to contamination are
readily visible using this technique.
45563-B
6-9
The optics can be cleaned using high-grade1 alcohol or acetone and sterilized lint free cotton swabs or
lens cleaning tissues. As a precaution, always clean your hands thoroughly with soap and water
before handling the optics or cleaning material. When cleaning a lens or mirror using a cotton swab,
soak the tip with the chemical, carefully shake off any excess fluid from the swab and begin cleaning
from the center of the optical component to the outer edges in a spiral motion. Rotate the swab and
repeat the procedure several times, using a different part of the swab, until the component appears
clean. The use of a flashlight or equivalent external light source can be used to better inspect each
optical component for cleanliness. DO NOT RE-USE THE SAME SWAB OR PART OF THE
SWAB MORE THAN ONCE otherwise, you risk transferring contamination back to the optical
surface.
When using a lens cleaning tissue, again apply the high-grade alcohol or acetone to the tissue, shake
excess fluid away and clean the surface of the optical component with a spiral motion. Use a new
clean tissue with every application.
Aligning the Optics System

This procedure assumes the optics are being aligned due to a YAG laser head replacement and to a
lesser extent because the A-O modulator was replaced. The Optics Plate is located on the upper left
side of the machine (as viewed from the front). The layout of the Optics Plate is as shown in Figure
6-7.
Figure 6-7 The Optics plate

Notes:
1
It is important to acquire high-grade alcohol or acetone from a pharmaceutical or laboratory supply outlet. Low grade
chemicals for machine shop use contain too many impurities and are therefore, not acceptable.
6-10
45563-B
In most cases, aligning the optics requires observing the spot quality and beam positions after the A-O
modulator and collimating lens using a white target such as a business card. These procedures
assume all the optical components were previously aligned and all that is required is to compensation
for small differences in the components being replaced, namely the YAG laser and A-O modulator.
Do not replace the laser and A-O modulator at the same time as it will make the combined alignments
difficult and potentially confusing.
If the alignment is due to a YAG laser replacement, go to Aligning the Optics after a YAG Laser
Replacement on page 6-12. If it is due to an A-O modulator replacement, go to Adjusting the A-O
Modulator for Optimum Diffraction Efficiency on page 6-17.
Other alignment procedures such as Beam Pointing Alignment on page 6-21 and Lens Centration
Alignment on page 6-25 are normally not required for simply replacing the laser or A-O modulator.
These procedures are included in the event:
the final large mirror #3 on the optics plate has been moved
the entire optics plate has been moved or replaced
the final focus lens on the spinner carriage is replaced
the spinner motor is replaced
The latter of the above group resulting in a significant skew of the scan line that cannot be corrected
with the registration pins in the gripper.
Performing Beam Pointing and Lens Centration alignments requires a set of special jigs as shown in
Figure 6-8. Beam Pointing refers to pointing the beam at the center of the spinner cube. This
procedure is done with the final focusing lens removed and requires the Target-1 hole and Assy-Jig 1
hole jigs.
Lens Centration refers to positioning the final focus lens so that the beam remains centered onto the
spinner cube. Since the relative position of the final focus is done at the factory, it normally doesnt
need to be done when the laser is replaced. Situations where the Lens Centration may need to be
done would be when high geometric accuracy is required or the final focusing lens is replaced. This
procedure is done with the final focusing lens removed and requires the Target-1 hole and Assy
Spinner Lens Centering hole jigs.
Figure 6-8 Optical Alignment Jigs
45563-B
6-11
Aligning the Optics after a YAG Laser Replacement

To align the optics after replacing a YAG laser, the following tools will be needed: Latch Key (P/N
#45230), 4mm hex key, 2.5mm and 3mm hex keys.
1. Prepare the PlateJet to align the optics. See Preparing the PlateJet for Aligning the Optics on
page 6-15.
2. Place the business card (target) after the collimating lens as shown in Figure 6-9 and check if the
beam is passing through the center of the collimating lens.
3. If required, adjust the TILT plate to position the beam through the center of the lens. See
Adjusting the TILT Plate on page 6-16 for details. Only use the TILT plate to center the
beam through the collimating lens, not mirror #1.
Figure 6-9 Viewing the Beam After the Collimating Lens
6-12
45563-B
4. As shown in Figure 6-10, place the business card after the A-O modulator (over mirror #2) and
observe the beam pattern. The ideal pattern is with the maximum amount of energy in the first
order beam above (or to the left) of the zero order and a sharp black line1 through the center of the
zero order beam as shown in Figure 6-162.
Figure 6-10 Viewing the A-O Modulator Beam Pattern Using a Business Card
5. If required, adjust the pan adjust screws of mirror #1 to sharpen the dark line3. See Figure 6-11
for details the mirror #1 adjustments. Only use mirror #1 to optimize the beam pattern
through the A-O modulator, not the TILT plate.
6. If required, adjust the tilt adjust screws of mirror #1 to center the dark line through the zero
order beam. See Figure 6-16 for the desired beam pattern and Figure 6-11 for details of the
adjustment screws. Only use mirror #1 to optimize the beam pattern through the A-O
modulator, not the TILT plate.
Notes:
1
This sharp dark line phenomenon is often referred to as the cats eye.
Due to the difficulty in providing a true representation of the cats eye phenomenon, the zero order beam in Figure 6-16 is
shown a two small beams touching.
3
When the tilt position (not to be confused with the TILT plate) of the beam through the A-O modulator is not centered, the dark
line can appear anywhere in the beam pattern. This is normal until the tilt adjustment is made, so proceed with the pan adjustment.
45563-B
6-13
Figure 6-11 Adjusting Mirror #1 on the Optics Plate

7. Again place the business card after the collimating lens and check if the beam is still passing
through the center of the collimating lens.
8. If it is still centered go to next step, otherwise iterate between steps 8 and 13 until the beam is
centered through the collimating lens and the desired beam pattern is achieved after the A-O
modulator.
9. Remove the business card from the optics plate.
10. Ensure the laser beam is still passing through the clear part of the ND filter wheel.
11. With the spinner carriage at the AWAY end, slowly rotate the spinner mirror (cube) until the
beam is pointing on an accessible part of the internal drum.
12. Check the spot quality, by placing a business card in front of the beam and moving it from the
internal drum towards the spinner mirror.
13. If the beam is symmetrical and Guassian1 (from previous step), measure the light power at the
internal drum using a light meter (Coherent). The efficiency of a well-aligned optical system is
between 47% to 53% of the laser output power. For example, if the YAG laser outputs 100mw,
the power at the internal drum should be between 47mw to 53mw. If the beam power is within
acceptable limits, the alignment is complete.
Notes:
1
Guassian refers to a bell shaped beam that is brightness at the center and fading out towards the outer edges.
6-14
45563-B
14. Depending on the requirement go to Beam Pointing Alignment on page 6-21 or Lens
Centration Alignment on page 6-251, otherwise go to next step.
Preparing the PlateJet for Aligning the Optics
To align the optics after replacing a YAG laser, the following tools will be needed: Latch Key (P/N
#45230), 2.5mm, 3mm, 4mm hex key, and 8mm hex keys.
To prepare to align the Optics perform the following steps:
1. If required, access the Optics Plate. See Accessing and Restoring the Optics Plate on page 6-1.
2. Open the left side door using an 8mm hex key.
3. Turn the Spinner On/Spinner Off toggle switch to OFF on the Instrument Control & Power
Panel.
4. Apply tape to the Spinner On/Spinner Off toggle switch to prevent turning it on accidentally.
5. If required, turn on the system air supply and set it to 80 psi.
7. Turn the main power CB1 circuit breaker switch to ON and wait until the laser output has
stabilized (about 5 minutes).
8. Move the spinner carriage to the AWAY end.
9. Open the shutter.
10. Turn on the A-O modulator.
11. Set the ND filter wheel to the clear area.
Restoring the PlateJet After Aligning the Optics
1. Turn off the A-O modulator.
2. Close the shutter.
3. Move the spinner carriage to the HOME end.
4. Turn the main power CB1 circuit breaker switch to OFF.
5. Remove the laser safety glasses.
6. Remove the tape from the Spinner On/Spinner Off toggle switch.
7. Turn the Spinner On/Spinner Off toggle switch to ON.
8. Connect the air mixing fan cable.
Notes:
1
When a laser is being replaced, the Beam Pointing alignment must always be done before the Lens Centration.
45563-B
6-15
9. Close the right column door.

10. If required, restore the Optics Plate. See Accessing and Restoring the Optics Plate on page 6-1.
Adjusting the TILT Plate
The TILT plate is located as shown in Figure 6-12. The TILT plate has two levels of adjustment. It
can be tilted to offset the beam on one axis as shown in Figure 6-13 and then the beam can be rotated
around that axis as shown in Figure 6-14.
Figure 6-12 Adjusting the TILT Plate on the Optics Plate
Figure 6-13 Offsetting the beam Using the TILT Plate
6-16
45563-B
Figure 6-14 Rotating the Beam Using the TILT Plate Barrel
The displacement of the beam is achieved by passing the light through a flat piece of optical grade
glass plate set at an adjustable angle.
As shown in Figure 6-15 the angle of the plate can be changed by turning the 4X6 (M3) SSTL
shoulder screw using a 2 mm hex tool, and the barrel rotated 360.
Figure 6-15 TILT Plate Rotation
Adjusting the A-O Modulator for Optimum Diffraction Efficiency

Adjusting the A-O1 Modulator for Optimum Diffraction Efficiency entails repositioning the crystal
onto the optical axis and setting the Bragg angle. These adjustments are performed entirely at the AO modulator split mount. Do not adjust any other components such as the TILT plate or mirror #1
when replacing the A-O modulator.
Notes:
1
A-O stands for Accousto-Optical (Modulator).
45563-B
6-17
Two adjustments are required to set the correct beam pattern through the A-O Modulator, which
results in achieving the optimum diffraction efficiency for imaging. One adjustment centers the
incident beam through the A-O Modulator crystal using the depth adjustment on the A-O Modulator
split mount1. The other sets the correct angle (called the Bragg angle) for maximum intensity of the
light on the optical axis by rotating the A-O Modulator on it slotted mounting holes. The rotation is
centered on a dowel pin that is in turn referenced to the center of the modulator crystal.
To Adjust the A-O Modulator for Optimum Diffraction Efficiency, the following tools will be
needed: Latch Key (P/N #45230), 2.5mm and 3mm hex keys. To adjust the A-O Modulator for the
correct beam pattern and achieve optimum diffraction efficiency, do the following:
1. Prepare the PlateJet for aligning the optics. See Preparing the PlateJet for Aligning the Optics
on page 6-15.
2. Tighten the A-O Modulator mounting screws to ensure it is flush against the split mount.
3. Before proceeding, measure the A-O Modulator Transmission Efficiency. See Measuring the AO Modulator Transmission Efficiency on page 6-20.
4. Place a business card after the A-O modulator (over mirror #2) and observe the beam pattern. The
ideal pattern is with the maximum amount of energy in the first order beam above (or to the left)
of the zero order and a sharp black line2 through the center of the zero order beam as shown in
Figure 6-163.
5. If required, adjust the depth of the A-O Modulator split mount until multiple beams begin to
appear4 similar to the patterns as shown in Figure 6-16. When beams appear, continue the
adjustment until they disappear again, to get a feel for the optimum position. Choose the position
where there are the most beams while at the same time looking for dark lines (or bands) anywhere
in the pattern of beams. Stop when the lines appear the sharpest.
6. If required, loosen the A-O Modulator mounting screws and adjust the "Bragg" angle by rotating
the modulator until a sharp dark band appears in the zero order beam5 and the brightest spot is to
the left6 (or above) the zero order beam.
Notes:
1
The AOM split mount uses two screws (on the left of the mount) as a push-pull system to open or close the space (gap) in the
mount.
2
This sharp dark line phenomenon is often referred to as the cats eye.
Due to the difficulty in providing a true representation of the cats eye phenomenon, the zero order beam Figure 6-16 is shown
as two small beams touching.
4
Since there is no logical way to determine which way to go, in or out, choose out. If after a few turns of the screws, no beams
appear, stop before damaging the mount and try the opposite direction.
5
To distinguish the zero order beam from all the others, tape the business card to mirror #2 so that all the beams hit the card.
Turn off the A-O Modulator and mark the position of the remaining beam (zero order) with a pen or pencil.
6
This is the desired first order beam.

6-18
45563-B
Symetric Beam Pattern
First
Order
Zero
Order
First
Order
Rotate Modulator
Clockwise
Move Beam in
Towards Optics Plate
(Pan Adjustment)
Figure 6-16 The Balanced Modulated Beam Pattern

7. Observe the beam pattern. If the final pattern is as shown in Figure 6-171, no addition
adjustments are required. Go to next step, otherwise, iterate between steps 4 and 5.
8. Tighten the two securing screws on the modulator, making sure the A-O Modulator does not
move in the process.
9. Remove the business card from the optics plate.
10. Ensure the laser beam is still passing through the clear part of the ND filter wheel.
11. With the spinner carriage at the AWAY end, slowly rotate the spinner mirror (cube) until the
beam is pointing on an accessible part of the internal drum.
12. Check the spot quality, by placing a business card in front of the beam and moving it from the
internal drum towards the spinner mirror.
Figure 6-17 Setting the Bragg Angle on the Modulator

Notes:
1
A weak dark band, passing through the center of the zero-order beam, should be apparent when the Bragg angle is properly
aligned.
45563-B
6-19
13. If the beam is symmetrical and Guassian1 (from previous step), measure the light power at the
internal drum using a light meter (Coherent). A well-aligned optical system will have an
efficiency of between 47% to 53% of the laser output power. For example, if the YAG laser
outputs 100mw, the power at the internal drum should be between 47mw to 53mw. If the beam
power is within these acceptable limits, the alignment is complete, go to step 15 otherwise, go
next step.
14. Repeat steps 4 to 13 and if it is still not at the correct media plane power, check the A-O
Modulator Diffraction Efficiency. See Measuring the A-O Modulator Diffraction Efficiency on
page 6-20 for details.
Measuring the A-O Modulator Diffraction Efficiency
Measure the diffraction efficiency of the A-O Modulator as follows.
2. Turn on the A-O Modulator.
3. Using a photometer, measure the first-order beam power while making sure that the detector head
is positioned so that light from the other diffraction orders is not incident upon it. Record the
reading as Imod.
4. Turn off the A-O Modulator.
5. Measure the zero-order beam power. Record the reading as Io.
6. Calculate the Diffraction Efficiency using the following formula2:
DiffractionEfficiency
I mod
Io
Measuring the A-O Modulator Transmission Efficiency

Measure the Transmission Efficiency of the A-O Modulator as follows.
2. Turn off the A-O Modulator.
3. Using a photometer, measure and record the beam entering (E1) and exiting (E2) the A-O
Modulator.
4. Calculate the Transmission Efficiency using the following formula:
Notes:
1
2
Guassian refers to a bell shaped beam that is brightest at the center and fades out towards the outer edges.
The Diffraction Efficiency should be between 70% and 80%. Adjust the Bragg angle if this range is not achieved.
6-20
45563-B
TransmissionEfficiency
E 2 100
5. If the Transmission Efficiency is not between 95% and 100%, try adjusting the A-O Modulator
and/or mount to change the crystal's position. If still unsuccessful, replace the A-O Modulator.
See Replacing the A-O Modulator on page 6-5 for details.
Beam Pointing Alignment
on page 6-15.
2. Mount the Target-1 Hole onto the Optics Plate as shown in Figure 6-18
3. Remove the final focusing lens assembly from the spinner carriage.
4. Mount the Assy-Jig 1 Hole onto the mirror cube of the Westwind spinner motor as shown in
Figure 6-19.1
5. With the spinner carriage at the AWAY end, adjust the angle of the Assy-Jig 1 Hole so that the
return spot hits the white surface of the Target-1 Hole. Make the distance between the light
source (pinhole in the Target-1 Hole) and the return spot as far as possible. The reason being
that they will get closer as the spinner carriage is moved towards the HOME end.
Notes:
1
Do not spin the Westwind spinner with the Assy-Jig 1 hole attached to the spinner cube. Spinning the motor with the Jig
attached will permanent damage the spinner motor air bearings.
45563-B
6-21
Figure 6-18 Mounting the Target-1 hole

6. With the spinner carriage at the AWAY end, observe the brightness of the return beam hitting the
Target-1 Hole1.
7. Move the spinner carriage to the HOME end. While in motion, observe the brightness of the
return spot on the Target-1 Hole. If the brightness does not remain the same (or may in fact
disappear) then the beam is not on the optical axis, go to next step. If the brightness remains the
same, go to step 16.
Notes:
1
The brightness is a function of how well the beam was centered through the collimating lens and the efficiency of the A-O
Modulator.
6-22
45563-B
Figure 6-19 Mounting the Assy-Jig 1 hole

8. With the spinner carriage at the HOME end, observe the position of the pinhole light beam onto
the Assy-Jig 1 Hole. If the pinhole light beam is centered onto the hole of the Assy-Jig 1
Hole go to step 13, otherwise go to next step.
9. To correct for vertical offset displacement, move the base plate of mirror #3. See Figure 6-20 for
details of mirror #3. This is accomplished by loosening the two screws attaching the base plate to
the mount of mirror #3. The holes in the base plate are slotted for side to side adjustment. Since
only one positioning screw (located on the left side) is available to push the base plate, start the
adjustment from the left and move the base plate until the pinhole light beam is in line vertically
with the hole in the center of the Assy-Jig 1 Hole.
10. Tighten the two screws attaching the base plate to the mount of mirror #3.
11. To correct for horizontal offset displacement, the entire Optics Plate must be moved up or down.
This is accomplished by loosening the three nuts of the bolts attaching the Optics Plate to the
internal drum end plate. The holes in the Optics Plate are slotted for up and down adjustment.
As shown in Figure 6-21, an adjustment bracket located under the Optics Plate is used to raise or
lower the Optics Plate using a slotted screwdriver. Move the Optics Plate up or down until the
pinhole light beam is in line horizontally with the hole in the center of the Assy-Jig 1 Hole.
12. Tighten the three nuts attaching the Optics Plate to the internal drum end plate.
45563-B
6-23
Figure 6-20 Aligning Mirror #3
Figure 6-21 Adjusting the Horizontal Position of the Optics Plate
6-24
45563-B
13. Drive the spinner carriage to the AWAY end and note the position of the pinhole light beam onto
the Assy-Jig 1 Hole. If the pinhole light beam remains in the center the Assy-Jig 1 Hole, go
to step 16, otherwise go to next step.
14. Adjust mirror #3 to correct for any angular displacement. See Figure 6-20 for details of mirror
#3. The rear of the mount of mirror #3 has three pairs of push-pull screws1 used the angle of
mirror. Use these adjustments to position the pinhole light beam onto the center of the Assy-Jig
1 Hole.
15. Iterate between steps 8 to 14 until the beam is centered onto the Assy-Jig 1 Hole at both the
AWAY and HOME ends.
16. Tighten all mounting screws.
17. Remove the Target-1 Hole from the Optics Plate.
18. Remove the Assy-Jig 1 Hole from the spinner mirror (cube).
19. Check the Lens Centration. Go to Lens Centration Alignment on page 6-25.
Lens Centration Alignment
on page 6-15.
2. If required, mount the Target-1 Hole onto the Optics Plate as shown in Figure 6-18.
3. If required, move the spinner carriage to the AWAY end.
4. Mount the Assy-Spinner Lens Centering Jig2 onto the spinner mirror (cube) as shown in Figure
6-22.
Notes:
1
Each pair is comprised of a regular pan head screw for pulling on the mirror mount and a smaller setscrew for pushing.
The surface on the Assy-Spinner Lens Centering Jig is extremely delicate. Avoid touching or cleaning it. It is better to leave
a fingerprint on the surface than to try and clean it.
45563-B
6-25
Figure 6-22 Mounting the Assy-Spinner Lens Centering Jig

5. Adjust the angle (tilt) of the Assy-Spinner Lens Centering Jig so that the return spot hits the
surface of the Target-1 Hole.
6. With the return spot on target, slowly rotate1 the spinner cube (by hand only) and observe that it
remains centered relative to the rotating return spot2.
7. If the light source is not centered to the rotating return spot, adjust the position of the final
focusing lens using the horizontal and vertical set-screws located as shown in Figure 6-23.
8. Remove the Assy-Spinner Lens Centering Jig from the spinner mirror (cube).
9. Remove the Target-1 Hole from the Optics Plate.
Notes:
1
Do not spin the Westwind motor otherwise damage can occur. Slowly position the return spot to the two vertical and horizontal
positions and note the distances from the source.
2
If the lens is properly centered, the return spot will remain the same distance from the light source (pinhole in the 1-Hole Target)
regardless of the spinner cube position.
6-26
45563-B
Figure 6-23 Adjusting for Lens Centration
Setting the Exposure (Power)

Exposure values are determined for each Media/Resolution combination. The method used to set
exposure levels depends on the media. This section discusses the general procedures for auto-positive
Silver-Halide and auto-negative Photopolymer plates.
Auto-Positive Silver-Halide
For setting exposure levels for Auto-Positive Silver-Halide plates use the Sweep procedure. See
PlateJet ToolKit Sweeps on page 7-20.
Auto-Negative Photopolymer Plates
There are two methods for determining the exposure level for Auto-Negative Photopolymer Plates.
The first uses a conventional wedge and the second uses the Exposure Sweep in PlateJet Toolkit (See
PlateJet ToolKit Sweeps on page 7-20).
Setting Exposure Levels with a Wedge
To set the exposure level on Auto-Negative Photopolymer Plates, using a conventional wedge,
perform the following steps:
1. Tape either a 41 step .05D or a 14 step .15D wedge to the plate.
2. Load the plate into the PlateJet
3. Image a solid square through the wedge onto the plate.
4. Carefully peal the tape off, remove the wedge and process the plate.
5. Locate the scum point. This is the step that appears slightly fogged rather than completely or
almost completely dark.
45563-B
6-27
6. Compare the achieved scum point with the target scum point of 30 for the 41 step .05D wedge or
10 for the 14 step .15D wedge. If you are below the target increase the exposure, if you are above
the target decrease the exposure.
7. Repeat until the achieved scum point is the same as the target.
End of Section
6-28
45563-B
Section Seven: The Thermal Optics Plate

Accessing and Restoring the Thermal Optics Plate
Before performing any procedures involving the Optics System, please review the laser safety issues in
Laser Safety and Warnings for Thermal PlateJet Service Personnel on page 1-4.
EXPOSURE.
ATTENTION: LE CONTROLE ET LAJUSTEMENT AINSI QUE LA MODIFICATION DES
VORSICHT: ANDERE, ALS HIER VORGESCHRIEBENE, BENUTZUNG VON
KONTROLLSCHALTERN, JUSTIERUNGEN UND DURCHFUEHRUNG VON VORSCHRIFTEN, KANN
ZU GEFAEHRLICHER BESTRAHLUNG FUEHREN.
DANGER LASER RADIATION: THIS EQUIPMENT WILL EMIT LASER RADIATION WHEN OPEN
AND INTERLOCK SWITCHES DEFEATED. AVOID EYE OR SKIN EXPOSURE TO DIRECT OR
SCATTERED LASER RADIATION.
DANGER- RADIATIONS LASER: CET QUIPEMENT PEUT METTRE DES RADIATIONS LASER
LORSQUIL EST OUVERT ET EN CAS DE DFAILLANCE DES INTERRUPTEURS DE SECURIT.
EXPOSITION DANGEREUSE DE LOEIL OU DE LA PEAU AU RAYONNEMENT DIRECT OU
DIFFUS.
GEFAHR -- LASERSTRAHLUNG: IM OFFENEM ZUSTAND UND MIT BERBRCKTEN
SICHERUNGSSCHALTERN WIRD VON DIESEM GER\T LASERSTRAHLUNG EMITTIERT.
VERMEIDEN SIE DIE BESTRAHLUNG DER AUGEN ODER HAUT DURCH DIREKTE ODER
GESTREUTE LASERSTRAHLUNG.
DANGER -- LASER RADIATION: THE LASER USED IN THIS EQUIPMENT EMITS UP TO 50
WATTS OF LASER RADIATION WHICH CAN CAUSE PERMANENT DAMAGE TO THE
UNPROTECTED EYE. WEAR SAFETY GLASSES (# 37180 / #37179) AT ALL TIMES AND AVOID
LOOKING DIRECTLY INTO THE BEAM.
DANGER RAYONNEMENT LASER: LE LASER UTILIS DANS CET QUIPEMENT PEUT
METTRE UN RAYONNEMENT DE 50 WATTS. SANS PROTECTION, VOUS POUVEZ SUBIR DES
DOMMAGES PERMANENTS AUX YEUX. PORTER DES LUNETTES DE PROTECTION (# 37180 /
#37179) EN TOUT TEMPS ET VITER DE REGARDER DIRECTEMENT LE FAISCEAU LASER.
GEFAHR LASERSTRAHLUNG: DER YAG LASER, DER IN DIESEM GERT VERWENDUNG
FINDET, EMITTIERT BIS ZU 50 WATT LASER AUSGANGSLEISTUNG, WODURCH EIN
UNGESCHTZTES AUGE DAUERHAFT GESCHDIGT WERDEN KANN. BITTE TRAGEN SIE
STETS EINE SCHUTZBRILLE (NR. 37180 / NR. 37179) UND VERMEIDEN SIE, DIREKT IN DEN
LASERSTRAHL ZU BLICKEN.
Cleaning the Thermal PlateJet Optics

in Laser Safety and Warnings for Thermal PlateJet Service Personnel on page 1-4.
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Due to the dangers of invisible exposure to direct and scattered laser radiation, all optics inspection
and (if necessary) cleaning, should be performed with the Thermal PlateJet turned OFF. Use
flashlight or equivalent external light source can be used to evaluate the cleanliness of the optical
components.
Cleaning the optics is an essential part of maintaining the optimum imaging capability of the product.
Contamination on the optics will degrade the spot quality and significantly attenuate the beam power.
Fine dust accumulation on optical components that pass or reflect large diameter beams are the cause
of most of the beam power attenuation. These components are the beam expander (negative) lens,
collimating lens, final focus lens and spinner cube. The optics plate is fairly well sealed from both
dust (and thermal currents), therefore, airborne dust is more likely to accumulate on components
outside of the optics plate such as the spinner cube and final focus lens.
Optical components that pass or reflect small diameter beams typically are not affected by fine dust
because the beam usually burns it off. However, a high concentration of large diameter dust particles
can cause beam flaring and distortion.
The optics can be cleaned using high-grade1 alcohol or acetone and sterilized lint free cotton swabs or
lens cleaning tissues. As a precaution, always clean your hands thoroughly with soap and water
before handling the optics or cleaning material. When cleaning a lens or mirror using a cotton swab,
soak the tip with the chemical, carefully shake any excess fluid off of the swab and begin cleaning
from the center of the optical component to the outer edges in a spiral motion. Rotate the swab and
repeat the procedure several times, using a different part of the swab, until the component appears
clean when inspecting it with a flashlight or equivalent external light source.. DO NOT RE-USE
THE SAME SWAB OR PART OF THE SWAB MORE THAN ONCE otherwise, you risk
transferring contamination back to the optical surface.
When using a lens cleaning tissue, again apply the high-grade alcohol or acetone to the tissue, shake
excess fluid away and clean the surface of the optical component with a spiral motion. Use a new
clean tissue with every application.
Replacing Plug & Play Optical Components
Replacing components of the T-Wave optical system is relatively easy and straight forward. Because
each module is pre-aligned to a standard reference at the factory before shipment, alignment is
achieved by simply ensuring that the module is properly seated against the relevant reference points.
The following section describes the replacement of each component in the optical system.
For ALL service procedures described below, begin by powering OFF the PlateJet. All service
on the optical system is performed while the power is off.
Notes:
1
It is important to acquire high-grade alcohol or acetone from a pharmaceutical or laboratory supply outlet. Low grade
chemicals for machine shop use contain too many impurities and are therefore, not acceptable.
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The Thermal Optics Plate
Replacing the Laser

To replace the laser perform the following steps:
1. Turn the PlateJet OFF.
2. Remove the home-end panel from the PlateJet.
3. Remove the Optics Plate cover.
4. Attach a grounding strap to your wrist, and to the body of the laser. The laser head is extremely
static sensitive.
5. Detach connector P89 that connects the laser thermosensor. Do not detach the main laser power
connectors at this time.
6. Remove one 4mm hex mounting bolt from the laser.
7. Install the bolt that you removed in the heat-sink retaining hole above the laser on the optics plate.
This will ensure that the heat sink does not fall into the cooling duct when the laser is removed.
8. Note that there are three white ceramic spacing washers installed between the laser head
and the mounting holes on the optics plate. These isolate the laser electrically. Be sure that
you do not lose these spacers when removing the old laser, and that they are properly reinstalled with the new laser. On some optics plates, they may be attached to the optics plate
itself. This practice has been discontinued because it may cause slight variance in the flatness of
the mounting surface, and misalign the laser head. The washers are installed on the two rightmost mounting holes, and the left-most mounting hole, which are the attachment points from the
laser to the optics plate itself (as opposed to the attachment from the laser to the heat sink).
9. Remove the remaining six 4mm mounting bolts from the laser, while holding the laser so that it
does not fall
10. Carefully remove the laser from the optics plate. Note: the laser power leads are still attached
to the laser at this point.
11. Once the laser is off of the optics plate, detach the two power leads from the laser. Immediately
install a grounding strap between the positive and negative terminals of the laser. This will help
prevent static discharge from further damaging the laser.
To install the new laser head perform the following steps:
1. When handling the laser head, be careful not to touch the output window. Dirt on the output
window will be burned, and may leave significant residue on the glass, causing decreased laser
performance.
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2. If there is no thermosensor installed in the new laser head, remove the sensor from the old head
and install it in the new one. Ensure that adequate thermal paste is applied to the thermosensor
before installation. Use silicone or RTV to secure the thermosensor in the mounting block.
Note: Normally, a thermosensor is installed in each laser at the factory before shipment.
3. Clean any excessive thermal paste from the front surface of the heat sink on the optics plate.
4. Apply a very thin, even coat of thermal paste to the entire rear surface of the new laser. It is
only necessary to apply enough paste to fill in any irregularities in the machining of the laser
base. Too much paste will degrade the performance of the laser system.
5. Remove the grounding strap that is attached between the power terminals on the new laser head.
6. Attach the positive (red) lead to the BASE of the new laser head. This is the upper attachment
screw. Note: The laser is a positive ground system, which helps isolate it from electrical noise.
Because of this, the laser is electrically isolated from the optics plate itself.
7. Attach the negative (black or blue) lead to the round post on the laser body.
8. As shown in Figure 7-1, ensure that the three bolt holes on the optics plate itself (not the four on
the heat sink) have ceramic washers between the laser and the optics plate. These washers isolate
the laser electrically from the optics plate, and may be permanently attached to the surface of the
plate. These are the two right-most holes, and the single left-most hole.
Figure 7-1 Ceramic Washer Locations
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9. Place the laser on the optics plate. Loosely attach the laser through the two right-most holes, and
the left-most hole, using the three 4mm hex bolts with plastic isolating sleeves. It is important
that the laser remain electrically isolated from the optics plate. Do not yet tighten the mounting
bolts.
10. Loosely install three 4mm hex bolts in three of the four remaining attachment holes (two on top,
two on the bottom). These attach the laser to the heat sink.
Figure 7-2 Heat Sinks Laser Head Mounting Holes

11. Remove the bolt that you installed in the heat-sink retaining hole when you removed the old laser
head and install it in the remaining hole in the laser mount.
12. Align the laser head against the three nylon reference pins by pushing the laser UP and RIGHT.
While holding the laser in this position, tighten evenly the two right-most bolts, and the single
left-most bolt.
13. Evenly tighten the four heat-sink mounting bolts (top and bottom of the laser mounting block).
14. Attach connector P89 to the thermosensor in the laser mounting block.
15. Close all optics plate covers, and reinstall PlateJet end panel.
16. Check and adjust lens focus if necessary (see Focus Adjustment on page 7-14).
17. Check and adjust Spinner Phase if necessary (see Setting Phase and Focus Together on page 717).
18. Check and adjust exposure settings for all resolutions (See Adjusting Image Quality on page 719).
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7-5
Laser Controller Unit

To remove the old Laser Controller Unit perform the following steps:
2. Open the lower left panel of the PlateJet below the media tray (PlateJet Emerald or manual
PlateJet Sapphire), or open the left end panel and remove the Laser Controller Access Panel
(PlateJet Sapphire with autoloader).
3. Disconnect all connectors from the front of the laser controller unit.
4. Disconnect connector J47 from the LEFT end of the laser controller unit.
5. Remove the four 3mm hex bolts that secure the laser controller unit to the PlateJet frame.
6. Remove the laser controller unit from the PlateJet.
To Install the new Laser Controller Unit perform the following steps:
1. Reverse the above instructions to install the new laser controller unit. No adjustments are
necessary after replacing the laser controller unit.
Photodetector Board (backscan sensor)
To remove the existing photodetector board perform the following steps:
4. Detach connector P88 from the photodetector board.
5. Remove the two 2.5mm hex bolts that attach the photodetector bracket to the optics plate, and
remove the photodetector bracket from the optics plate.
To install the new photodetector board perform the following steps:
1. Reverse the above instructions to install the new photodetector board.
AOM (Acousto-Optical Modulator)
To Remove the existing AOM perform the following steps:
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4. Remove the signal cable from the right side of the AOM crystal.
5. Remove the two 3mm mounting bolts on the AOM mounting block.
6. Remove the AOM and mounting block from the optics plate
To Install the new AOM perform the following steps:
1. Place the new AOM in position on the optics plate. Ensure that the dowel pin on the bottom of
the AOM mounting block inserts completely into the slot on the optics plate.
2. Loosely install the two 2.5mm mounting bolts for the AOM mounting block.
3. Remove the AOM alignment shim from the optics plate so that you can use it to align the AOM.
As shown in Figure 7-3, a silver shim is attached to the optics plate directly above the AOM by a
single 3mm hex bolt.
Figure 7-3 AOM Alignment Shim Location

4. Push the AOM to the LEFT so that the dowel pin underneath the AOM is at the far left side of the
slot in the optics plate.
5. Insert the AOM alignment shim between the AOM mounting block and the LOWER white
alignment washer on the lower right hand side of the AOM.
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6. Ensure that the AOM is referenced LEFT and DOWN with the shim in place, and tighten the two
3mm hex bolts to secure the AOM to the optics plate.1
7. Remove the AOM alignment shim and reattach it to the optics plate.2
8. Re-attach the signal cable to the right hand side of the AOM.
To make necessary adjustments and checks after replacing the AOM perform the following steps:
Optics Plate Spinner (Dove Prism Spinner)
To Remove the existing Optics Plate Spinner perform the following steps:
4. Note the rotation of the current optics plate spinner. This will help ensure that the new spinner is
installed as close as possible to the proper phase setting, and will greatly reduce the testing
required after replacing the spinner. Use the six screws on the LEFT end of the spinner as a
reference, as well as the approximate angle of the two cables leading to the spinner.
Notes:
1
This alignment instruction assumes that the PlateJet uses the default Zero-Order imaging setup. If you are servicing a machine
that uses First-Order imaging, see Alignment for First-Order Imaging (optional setup) on page 7-13. To Remove the existing
AOM perform the following steps:
2
The AOM alignment shim must always be left with the machine! Slight differences in shim thickness from one optics plate to
another require that the proper shim be used with each optics plate.
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Figure 7-4 Prism Spinner Rotation Referencing

5. Detach connector P3 from the spinner board.
6. Remove the two mounting brackets that hold the spinner by loosening / removing the four 3mm
hex bolts on the spinner mount.
7. Remove the spinner from the optics plate.
To install the new spinner perform the following steps:
1. Place the new spinner in the spinner mount. Place the two mounting brackets over the spinner
and loosely install the four 3mm hex bolts.
2. Slide the spinner to the LEFT until the flange on the spinner is resting against the right side of the
spinner mount.
3. Rotate the spinner so that it is in the same orientation as the original spinner was. Normally, the
connector wires for the spinner will be pointing approximately 45 degrees up from horizontal.
4. Evenly tighten the four mounting bolts to secure the spinner in place.
5. Re-attach connectors P2 and J4 to the optics plate.
To make the necessary adjustments and checks after replacing the Optics Plate Spinner:
1. Check and adjust Spinner Phase if necessary (See Adjusting Image Quality on page 7-19).
Shutter Assembly
To remove the existing shutter assembly perform the following steps:
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4. Disconnect connector P88 from the shutter assembly.
5. Remove the two 3mm mounting bolts that secure the shutter assembly to the optics plate.
6. Remove the shutter assembly from the optics plate.
To install the new shutter assembly perform the following steps:
1. Reverse the above instructions to install the new shutter assembly.
To make the necessary adjustments and checks after replacing the Shutter Assembly perform the
following steps:
1. No adjustments are necessary after replacing the shutter assembly.
Cross-Scan Spinner
To Remove the existing Cross-Scan Spinner perform the following steps:
2. Remove the RIGHT end panel from the PlateJet (away end).
3. With the air pressure to the PlateJet turned ON, manually move the Cross-Scan unit to the away
end of the PlateJet.
4. Turn the air pressure to the PlateJet OFF, so that the Cross-Scan unit will remain locked at the
away end while service is performed.
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Figure 7-5 The Cross Scan Spinner

5. Note the rotation of the old spinner in the spinner mount. This is important so that the new
spinner is installed close to the proper phase setting, which will minimize the setup work required
after replacing the spinner.
6. Note the distance between the flange on the spinner and the spinner mount. Normally, this gap is
set to 8mm, however measuring the gap with a micrometer before replacing the spinner will
ensure that the focus setting is as close as possible to correct when the spinner is replaced. This
will minimize the setup work required after replacing the spinner.
7. Detach connectors P2 and J4 between the spinner and the Cross-Scan stage.
8. Remove the four 3mm hex bolts that attach the spinner mounting bracket. These bolts are spring
loaded, be careful not to lose the springs when removing them.
9. Remove the mounting bracket and the spinner from the PlateJet.
To install the new Cross-Scan Spinner perform the following steps:
1. Place the new spinner in the spinner mount.
2. Install the spinner mount bracket and loosely attach it with the four spring-loaded 3mm hex bolts.
3. Adjust the position of the new spinner so that the gap between the spinner flange and the spinner
mount is the same as the previous spinner (approximately 8mm).
4. Rotate the new spinner so that it is in approximately the same orientation as the previous spinner.
5. Evenly tighten the four 3mm hex bolts to secure the spinner in position.
6. Re-attach connectors P2 and J4 to the Cross-Scan stage. Ensure to attach all of the mounting
screws properly.
7. Re-connect the air supply to the PlateJet.
8. Re-install the end panel on the PlateJet.
To make the necessary adjustments and checks after replacing the Cross-Scan Spinner perform the
following steps:
1. Check and adjust lens focus if necessary (see section Five, Alignment Procedures for details on
how to perform a focus check).
2. Check and adjust Spinner Phase if necessary (See Adjusting Image Quality on page 7-19).
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3. When replacing the Cross-Scan Spinner, it is possible (and likely) that both the Spinner Phase and
Focus settings will be affected. If either of these settings are significantly changed, it may not be
possible to produce an image on plate whatsoever. In order to be able to adjust both phase and
focus, we have developed a special Alignment Procedure. Please see Setting Phase and Focus
Together on page 7-17.
Alignment Procedures
At the time this manual was released, First Order Imaging had not been implemented. Realigning an optics plate to First Order will result in insufficient laser power to properly expose
most plates. Do NOT attempt to convert a Zero Order optics system to First Order without
being directed to by the Global Product Support Group.
T-Wave offers two different imaging setups, as described in First-Order vs. Zero-Order Imaging
Setup on page 3-15. To switch the PlateJet between these two setups, follow the instructions listed
below.
Figure 7-6 Beam Order Adjustment Components
Alignment for Zero-Order Imaging (default setup)

To convert an optics plate to Zero Order Imaging, follow these steps. Please note that this is the
default setup, and you should not normally have to convert a plate to this setup.
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1. Loosen the two 2.5mm hex bolts attaching mirror #1 to the optics plate (see Figure 7-6).
2. Rotate mirror #1 so that the mount is against the reference flat washer on the BOTTOM side of
the mirror.
3. Tighten the two 2.5mm hex bolts attaching mirror #1 to the optics plate.
5. Rotate mirror #2 so that the mount is against the reference flat washer on the TOP side of the
mirror.
7. Loosen the two 3mm hex bolts attaching the AOM mount to the optics plate (see Figure 7-6).
8. Slide the AOM to the LEFT as far as it will go. The dowel pin underneath the AOM is in a slot,
and the AOM will move approximately 1mm.
9. Remove the AOM reference shim from its storage location above the AOM on the optics plate.
It is secured with a 2.5mm hex bolt.
10. Place the shim between the AOM mount and the reference flat washer BELOW the AOM.
11. While putting slight pressure on the AOM to the LEFT and DOWN, tighten the AOM mount in
place with the two 3mm hex bolts that mount it to the optics plate.
12. Remove the AOM reference shim and re-store it on the optics plate using its 2.5mm hex bolt.
Alignment for First-Order Imaging (optional setup)
To convert an optics plate to use First Order Imaging, perform the following steps. Please note that
this procedure should NOT be done unless you are directed to do so by the Global Product Support
Group. The efficiency of the optics path is greatly reduced when First Order Imaging is used in order
to gain contrast. First order imaging achieves 60%-70% of the laser power provided by Zero order
imaging.
2. Rotate mirror #1 so that the mount is against the reference flat washer on the TOP side of the
mirror.
5. Rotate mirror #2 so that the mount is against the reference flat washer on the BOTTOM side of
the mirror.
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7-13
7. Loosen the two 3mm hex bolts attaching the AOM mount to the optics plate.
8. Slide the AOM to the RIGHT as far as it will go. The dowel pin underneath the AOM is in a slot,
and the AOM will move approximately 1mm.
9. For First Order Imaging, the AOM mount is referenced directly against the reference flat washer
below the mount. Do NOT use the alignment shim for this setup.
10. While putting slight pressure on the AOM to the RIGHT and DOWN, tighten the AOM mount in
place with the two 3mm hex bolts that mount it to the optics plate.
Focus Adjustment
Setting focus on a T-Wave system is surprisingly simple compared to a visible laser system. When a
T-Wave PlateJet is out of focus, the symptom is exposure/density non-uniformity rather than image
quality artifacts. The only complicating factors for T-Wave focusing are the safety issues if running
the PlateJet open. Due to this, close the PlateJet before each focus test. To adjust the focus perform
the following steps:
1. Leave the PlateJet powered ON
2. Remove the lower rear panel of the PlateJet to access the electronics section.
3. Remove connector J5, Optics Plate I/O, from the main PCB. This will disconnect the signal
going to the AOM, and effectively expose the media evenly over the entire plate.
4. Open the LEFT side panel of the PlateJet (home end). The interlock system will immediately
turn off the laser when the panel is opened.
5. Ensure that the green laser indicator LED on the top left corner of the optics plate cover is
OFF. This will confirm that the interlock system has disabled the laser system. This is very
important, as you cannot see the laser light with your naked eye.
6. As shown in Figure 7-7, attach the focusing tool (the same tool as used for visible Emerald /
Sapphire PlateJets) to the focusing lens.
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Figure 7-7 Mounted Focusing Tool

7. Loosen the focusing lens lock screw located on the top left of the lens assembly, near the front.
J5, Optics Plate I/O, (show diagram of focusing lens and tool)
8. Determine how large of a range you wish to test for focus, and how fine or coarse your steps will
be. With most thermal media, if the PlateJet is exposing an image on the plate whatsoever, you
are probably within 1mm of the proper focus (+/- 2 turns of the focusing tool). If you are not
getting visible images on the processed plate at all, and think that you may be significantly out,
start with a series of full turn focusing tests.
9. Back the lens out by half the number of turns that you wish to test in your series. (i.e. if you are
going to test over a range of 3 full turns, back the lens out 1.5 turns before starting your tests, so
that you will bracket your tests on either side of the current focus setting).
10. Replace the end panel on the home end of the PlateJet, and ensure that it is locked in place. The
laser system will not work unless you do so, and it is very dangerous to run the PlateJet open with
the interlocks defeated. Do not attempt to perform this test with the PlateJet open!
11. Start PlateJet Toolkit on the host computer, and print a Pattern (any one) that is the full height
of the plate, and about 10 inches wide. This will be sufficient to determine focus, and will allow
you to rotate the media 180 degrees for a second test. Set focus using the normal resolution
that the customer prints at, and the middle thickness of plate. (i.e. if the customer uses 6
gauge, 8 gauge, and 12 gauge plates, focus on the 8 gauge plates. Otherwise, use their most
common plate type). Use the following guidelines to determine what exposure to use for your
testing:
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If you are fine-tuning the focus setting from a reasonable starting position, you should
intentionally underexpose the plate. Pick an exposure that will produce a semi-exposure
only. This will allow you to easily determine how uniform the exposure is from top to
bottom on the plate. If you use a full exposure, it may be impossible to see subtle differences
in density.
If you are setting up a system that is significantly out of focus, choose a normal exposure
level, or even a higher-than-normal exposure level. Once a rough setting is determined for
focus, reduce the exposure to less than normal to complete your setup.
12. After printing the first test pattern, open the PlateJet again and adjust the focus tool by the
increment that you determined you would use. Coarse adjustments should be in full turns or half
turns, while fine adjustments should be in quarter turns or eighth turns.
13. Rotate the media 180 degrees and re-load it into the PlateJet.
14. Print a second test on the same plate. Process your media and determine if your current setting is
correct. Use the following guideline to determine the correct setting:
Examine the uniformity of exposure from top to bottom. If you underexposed the plate as
recommended above, it should be relatively easy to see changes in density in the along-scan
direction.
If the density changes noticeably in the along-scan direction, your focus is not set properly.
The farther out your focus is, the larger the change in density.
As your focus gets closer to perfect, the density changes will get less and less, until you have
a uniform exposure.
15. Once you have performed your first sweep as described above, set the lens to the position that
achieved the most uniform exposure.
16. Continue to fine-tune the focus as follows:
Make a test plate at the current setting (underexposed).
Turn the lens of the increment you chose above counterclockwise and make a test plate.
Turn the lens of the increment you chose above Clockwise and make a test plate.
Process the tests and evaluate the results. You may need to keep lowering the exposure as
you get closer to proper focus so that you can easily see changes in density uniformity.
Set the lens to the position that produced the best density uniformity.
Repeat the above steps, but use an increment that is the size used above.
Continue these steps until the density is almost perfectly uniform from top to bottom.
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17. Once you are satisfied with the focus, lock the focusing lens in place by tightening the set screw.
18. Re-connect connector J5, Optics Plate I/O, to the main processor board.
19. Remove the focusing tool, and replace all covers on the PlateJet.
Setting Phase and Focus Together
In certain circumstances, it is possible that both the Spinner Phase Offset, and the Focus settings are
out of adjustment at the same time. This causes considerable difficulty when attempting to re-adjust
these settings.
If focus is out by more than 1mm, it may not be possible to achieve an image on plate. Similarly, if
the Phase Offset is off by more than 10 units, you will also not be able to produce an image on plate.
Because we rely on the images produced on plate to determine what adjustments to make, it might be
necessary to make many tests at different combinations of phase and focus before ANY image is
produced on plate!
To help get around this possible problem, follow the procedure outlined below. This will eliminate
the phase setting variable while focus is set so that you can quickly restore the PlateJet to imaging
condition.
In order to eliminate the phase variables, we disconnect the optics plate spinner. Although this will
cause the laser stripe to rotate on the plate as it travels up the drum, it also ensures that at ONE point
on the media the stripe will be perfectly in phase. Although only a small portion of our image is
usable (usually a section about 1.5-2 high), it is enough to set focus (see Figure 7-8).
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7-17
Figure 7-8 Image with Dove Prism Stopped

To eliminate the phase variable and set focus perform the following steps:
2. Open the LEFT end panel of the PlateJet over the optics end of the machine.
3. Remove the optics plate cover.
4. Detach connectors P2 and J4 that connect the Optics Plate Spinner to the plugs on the optics
plate. Although the firmware will realize that this spinner is not functioning properly, it will not
cause the plot to fail.
5. Replace the optics plate cover and the PlateJet end panel.
6. Remove the lower rear panel of the PlateJet to access the electronics section.
7. Disconnect connector J5, Optics Plate I/O, from the main processor board. This is the cable
leading to the AOM amplifier. By doing this, we effectively disconnect the AOM which will
allow the laser light to pass through the optics system at all times.
8. Re-install the lower rear panel of the PlateJet
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9. Using PlateJet Toolkit, perform a focus sweep as described earlier in the Focus Adjustment
section. However, use the following guidelines to judge when proper focus is achieved.
Use an exposure level that is slightly lower than the proper exposure for the media type and
resolution you are printing at. This will allow you to see changes in effective density easier.
Set the focus to the point where maximum exposure on plate is achieved, rather than looking
for exposure uniformity. Because you are only seeing a small area of exposed image (due to
the changing phase), you cannot properly judge uniformity.
If it is hard to determine where the maximum exposure point is, lower the exposure number
and produce an additional focus sweep image. Lower exposures make it easier to judge
changes in effective power.
If the small exposed region is at the extreme top or bottom of the plate, you can rotate the
optics plate spinner 1/8th turn by hand and re-print your test. This will move the exposed
region to the middle of the plate.
Once the point of maximum exposure is established, your focus should be very close to
optimal. In any case, you should have enough imaging power so that you can perform a
proper phase sweep, and then fine-tune the focus.
10. After setting focus using this method, turn the PlateJet off and re-connect the Optics Plate Spinner
by reversing the directions for disconnecting it above.
11. Perform a Phase Offset Sweep as described in Section Six, Adjusting Image Quality. You may
need to start with a very coarse Phase Offset sweep (increments of 5 to 10 units) to find the
proper range, and perform a second, finer sweep afterwards.
12. Fine-tune the focus setting using the normal focusing method described in Section Five,
Alignment Procedures.
Adjusting Image Quality
Because the T-Wave optical system is designed to be Plug and Play, there are no physical
adjustments that need to be carried out by the operator. For the service engineer, there is only one
physical adjustment procedure, and that is for setting the final focus lens.
There are three types of adjustments that can be made through software to ensure optimum image
quality.
These adjustments can be performed by printing test patterns using PlateJet Toolkit, and evaluating
the results using a 50x or 100x scope. The following section describes how to perform the three tests,
and what they are used for.
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PlateJet ToolKit Sweeps

PlateJet Toolkit (abbreviated as PJTk) has the ability to print the same image multiple times side-by
side, using different settings for each exposure. This allows us to print a Sweep of small images
using various settings in order to determine the optimum setting to use.
There are three basic types of sweeps that PJTk can print. These are Exposure Sweeps, Phase
Angle Sweeps, and Spinner Speed Sweeps. Each type of sweep has a different variable from
image to image, and each is detailed in the sections below.
Although PJTk can use any image file for a Sweep, we normally use a standard test file. At the time
of writing of this manual, the current file is called Sweep-8. The current sweep files can be found
on our FTP site at the following address:
ftp://ftp.cymbolic.com/downloads/print/test-images/
Because the new series of PlateJet products are capable of many different resolutions, the sweep files
are available in TIFF formats (at specific resolutions), and an EPS format (resolution independent, but
requires that it be RIPped prior to imaging).
Using the Sweep Function
To use the Sweep function of PlateJet Toolkit perform the following steps:
1. Select the Print button on the main menu.
2. In the Print window (see Figure 7-9), select Sweep in the Image Type box at the top left of
the window.
Figure 7-9 PlateJet Toolkit Print Window

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Once Sweep is selected, the Exposure Sweep section at the bottom left of the window becomes
active. This is where the type of sweep and settings are entered. Additionally, the Image
Placement and Printing Options sections are available so that you can set up the appropriate values
to use.
When using Sweeps, it is suggested that no values be entered into the Image Placement section
of the Print window.
The Media Size settings in the Printing Options window MUST be set to the actual media
size. This is so that PJTk can determine how many Sweep images will fit on the media.
The Resolution and Print Polarity settings must also be set correctly in the Printing Option
window.
To enable the Print button, you must first select the image file that you wish to use for printing
your sweep. The Gretag Sweep8_xxxx.tif file (where xxxx represents your printing
resolution) can be used for all types of Sweeps, and is very useful in determining image quality.
To evaluate the results of these Sweeps, please consult the Evaluating Image Quality section that
follows the Sweep definitions.
Exposure Sweep
The Exposure Sweep is used to determine the proper exposure value for the media / resolution
combination that you are using. Normally, the T-Wave system is capable of exposures between 450
and 1300 units, but this value may vary significantly from machine to machine due to differences in
backscan sensor alignment and calibration.
This test image has been tested at 150 lpi at both 2000 dpi and 4000 dpi, and works well at both
resolutions. It is recommended that the test image be used at 150 lpi. The test image has a series of
oval shapes that contain a 3x3 pixel dot grid, surrounded by 50% halftone dots. To set proper
exposure, the 3x3 pixel dot ovals should visually appear to be the same density as the surrounding
half tone dots. If the oval is lighter, the exposure level is too high. If the oval is darker, the exposure
level is too low.
To perform an Exposure Sweep, do the following in addition to the general settings described
earlier:
1. Select Exposure Level Series in the Sweep Type menu
2. Set the Initial Exposure Level, (normally 450-800 units)
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7-21
3. Set the Number of Exposures (normally 8-12, depending on the width of your media. The
sweep image is 2 wide). Ensure that the maximum exposure value does not become
significantly higher than necessary, as overpowering the laser can eventually damage it. Starting
with lower values to determine the approximate exposure range required is suggested rather than
running the laser until maximum power is reached.
4. Set the Exposure Level Increment (normally 25-50 units, depending on how close you believe
you are to the optimum level)
Once these settings are entered, press the Print button, and load media normally into the PlateJet.
Spinner Phase Offset Sweep
The Spinner Phase Offset Sweep is used to adjust the synchronization of the optics plate spinner to
the cross-scan spinner. Changing the relationship of these two spinners effectively tilts the laser
stripe on the media surface, making it effectively wider or narrower.
The optimum setting may not necessarily be for the stripe to be perfectly vertical on the plate.
Depending on resolution and media type, it may be necessary to tilt the stripe slightly to fill in the
spaces in between scan lines. In such situations, a Spinner Phase Offset Sweep will show two
optimum settings, one on either side of the point where the stripe is travelling perfectly vertically on
the plate.
To perform the Spinner Phase Offset Sweep, set the following in addition to the general settings
described earlier:
Select Spinner Phase Offset Series in the Sweep Type menu.
Set the Initial Phase Offset (check the current Spinner Phase Offset setting in the EEPROM,
and set a value that results in the current value being in the middle of the Sweep range you are
planning to expose)
Set the Number of Exposures (normally 8-12, depending on the width of your media. The
sweep image is 2 wide by 13 high)
Set the Phase Offset Increment (normally in steps of 1 or 2 units, as this is a very precise
setting. Note that decimal increments are not allowed)
Set the Exposure Value to be used in the Print Options section of the window1
Notes:
1
See the section on Determining Proper Spinner Phase Offset for recommended exposure values
7-22
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Spinner Speed Scaling Sweep

The Spinner Speed Scaling Sweep function is used to exactly match the speed of the laser stripe on
the media to the speed of the pixel pattern that is travelling backwards within the stripe. When these
two elements are synchronized perfectly, the pixel pattern effectively stand still on the media,
creating the sharpest image. This setting should theoretically never change, as it is a function of the
magnification of the stripe on the media surface. However, it is a good idea to run this sweep to
verify the setting is ideal for your conditions. Additionally, there are circumstances where it may be
desirable for this number to be different than the optimum setting.
To perform the Spinner Speed Scaling Sweep, set the following in addition to the general settings
described earlier:
Select Spinner Speed Scaling Series in the Sweep Type menu.
Set the Initial Scaling Factor (check the current Spinner Scale Factor setting in the EEPROM,
and set a value that results in the current value being in the middle of the Sweep range you are
planning to expose)
Set the Number of Exposures (normally 8-12, depending on the width of your media. The
sweep image is 2 wide)
Set the Scaling Factor Increment (normally in steps of 0.25 units, as this is a very precise
setting.)
Set the Exposure Value to be used in the Print Options section of the window1
Evaluating Image Quality
Determining proper exposure, spinner phase, and spinner speed settings is actually quite simple. The
Sweep8 image supplied on our FTP site has a number of features that can be used for analyzing all
aspects of the PlateJet image quality.
The following sections detail each aspect of image quality that should be inspected. The last section
describes the order in which tests should be run for setting up a PlateJet.
Setting Exposure
The Exposure setting must be determined for each combination of media type and output resolution.
Exposure is determined by printing an Exposure Sweep using the Gretag Sweep image. Use the
following list to help determine the proper setting.
Notes:
1
See the section on Determining Proper Spinner Speed Scaling Factor for recommended exposure values
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7-23
1. Examine the Exposure Patch first

The visual density of the center portion should be equal to (or very slightly lighter than) the
outer portion when properly exposed
When viewed with a 50x or 100x scope, the exposure patch should look like a checkerboard,
with the black and white sections being exactly equal in size
When read with a plate densitometer, the exposure patch should read very close to 50%
2. Examine the Pixel Pattern section (unlabeled as such, but it is directly below the exposure
patch)
The top half of this section is an 8-pixel checkerboard for use as a reference
The 3, 4, 5, and 6 pixel sections below should be the same visual density as the 8-pixel
reference. Note that the 2-pixel section may or may not be the same density, depending on
media type and processing conditions.
When viewed with a 50x or 100x scope, the 4, 5, and 6 pixel sections should look like a
checkerboard, with the black and white sections being exactly equal in size. Depending on
media type, the 3 pixel and 2 pixel sections may not be as perfect as the other sections.
3. Check the background to ensure proper cleaning without compromising the solids
For Negative type plates (where the exposed area is dark and carries ink), check to ensure
that the background area is not fogged (i.e. that the background is the lightest color
possible, the same as an unexposed, processed plate). If overexposed, the background will
get darker, and start to carry ink on press
For Positive type plates (where the non-image areas are exposed so that they do not carry
ink), check to ensure that the background area is perfectly clean, and that no emulsion
remains. The background color will get lighter as you approach the proper exposure, and
plateau slightly before the correct exposure setting. An underexposed plate will have a
dirty background, which will carry ink on press. Ideally, use the lowest exposure that
ensures a perfectly clean background (or very slightly higher to compensate for possible
process variation in the future).
Check to ensure that the plate is not overexposed. Overexposure will cause the image area to
be compromised by the leakage light. If this happens, the foreground will start to get lighter
than an unexposed and processed plate. Comparing the density of the area within the gripper
bar to the density of the image area will help determine if the plate is overexposed (compare
it to an unexposed and processed plate if you are using a manual PlateJet Sapphire). If the
image area is lighter, reduce the exposure.
7-24
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Determining Proper Spinner Phase Offset

The proper Phase Offset setting is partially determined by the T-Wave optical hardware, and is
partially media and resolution dependent. Ideally, the Phase offset should be tested and optimized for
the most common resolution that the customer uses, or the middle resolution, if they use multiple
resolutions.
When performing this type of sweep, it is easiest to determine the proper setting where a marginal
exposure value is used. By using a marginal value, it is easier to visually see changes in effective
exposure with your unaided eye. The best Phase Offset value will result in the highest exposure
(darkest exposure on negative plates, lightest exposure on positive plates).
When performing a Phase Offset sweep, you may see the density of the plate rise, fall, and rise again,
producing two humps rather than one. This is normal, and indicates that the optimum Phase Offset
happens when the laser stripe is slightly tilted on the plate. Usually this happens more when lower
printing resolutions are selected. Choose either one of the two Phase Offsets that resulted the highest
exposure.
To confirm your setting, print an additional image at a proper exposure level and evaluate the
Along-Scan line quality. Examine the width of the lines and spaces in the smallest crosshair target
at the bottom of the plate (this is a series of 5 lines and spaces, each should be the same width, which
is 3 pixels). When the proper Phase Offset setting is used, the vertical lines and spaces should be
almost exactly the same width (at proper exposure levels; underexposed plates should not be
evaluated this way).
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7-25
Determining Proper Spinner Speed Scaling Factor

Spinner Speed Scaling is completely dependent on the T-Wave optical hardware, and should not
change with media or resolution. However, the factory-supplied default value should be verified
upon installation, and checked whenever optical adjustments are made.
To determine the proper setting to use, examine the Cross-Scan line quality on the smallest
crosshair target at the bottom of the plate (this is a series of 5 lines and spaces, each should be the
same width, which is 3 pixels). When the proper setting is used, the lines and spaces will be the same
width (at proper exposure levels; underexposed plates should not be evaluated this way), and the line
edges should be straight and sharp. If the lines appear scalloped, the setting is incorrect.
If determining which of several settings is best by using the cross-scan line quality is difficult,
examine other small features such as 1% and 2% dots (negative plates) or 98% and 99% dots
(positive plates). The best spinner speed scaling setting will also result in the best reproduction of
these features.
Image Quality Testing Sequence
For best results, perform the Image Sweep testing in the following order. This is important because
some of the settings interact with other settings. Using this sequence will ensure that all variables are
addressed properly.
1. Exposure Sweep (coarse setting)
2. Focus Setting, if required (examine exposure sweep image created above for density uniformity
in the underexposed areas)
3. Spinner Phase Offset Sweep (slightly underexpose the plate)
4. Spinner Speed Scaling Factor Sweep (use correct exposure)
5. Exposure Sweep (fine-tuning)
End of Section
7-26
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Section Eight: Linear Drive System Maintenance

Replacing the Westwind Spinner
The Spinner is located on the Micropositioner Stage as shown in Figure 8-1. The Spinner includes
the Westwind self generating air bearing motor, tachometer, spinner cube and cables connectors
attached to a mounting plate. The following tools will be needed: 3mm and 8mm hex keys, small
straight screw driver, wire cutter, cable ties.
Figure 8-1 Replacing the Spinner Motor Assembly

To replace the Spinner Motor Assembly perform the following steps:
2. Open the right column door using an 8mm hex key.
3. Move the Spinner assembly to the away end.
4. Disconnect the motor drive and tachometer cables.
5. While supporting the spinner motor body with your hand, remove the 4 bolts on the bore
clamping bracket using a 3.0mm hex key.
6. Install the new spinner insure that the spinner motor is pushed firmly against its mount, then
secure the four mounting bolts.
7. Reconnect the Westwind drive and tachometer cables.
8. Reattach any cable ties that were removed.
9. Close the right column door.
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8-1
Replacing the Linear Motor Micropositioner Coil Assembly

1. As shown in Figure 8-2, remove the flex cable module cover.
Figure 8-2 Flex Cable Module Cover Removal

2. As shown in Figure 8-3, disconnect the limit, motor cable and encoder connectors from the flex
cable board assembly
Figure 8-3 Flex Cable Board Connector Removal

8-2
45563-B
Linear Drive System Maintenance
3. Remove the six inch long Magnetic Track if necessary. See "Replacing the Magnetic Track
Assembly" on page 8-4.
4. As shown in Figure 8-4, remove the two attaching screws from the utility plate assembly and
separate it from the carriage.
Figure 8-4 Utility Plate Assembly Removal

5. As shown in Figure 8-5, remove ten retaining screws from the utility plate wire cover.
Figure 8-5 Utility Plate Wire Cover Removal
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8-3
6. As shown in Figure 8-6, remove three retaining screws from the motor coil assembly.
Figure 8-6 Motor Coil Assembly Removal

7. Separate the old motor coil assembly from the utility plate.
8. Route the new motor coil assembly cables through the utility plate and fasten the coil in place
using three screws with Loctite 222 (purple) or equivalent. Torque the screws to 2.0 N-m (18 inlb.).
9. Install the utility plate cover using ten screws (do not use Loctite).
10. Install the utility plate assembly onto the carriage assembly using two screws with Loctite 222
(purple) or equivalent. Align the edges of the utility plate flush with the edges of the tip plate and
torque the screws to 8.5 N-m (75 in-lb.).
11. Connect the limit, motor and encoder connectors to the flex cable board assembly and secure the
cables to the top plate using plastic cable ties.
Replacing the Magnetic Track Assembly

1. With the air supply on, slide the carriage assembly clear of the six inch long Magnetic Track
Assembly.
2. As shown in Figure 8-7, making sure to hold the magnet track firmly, remove the three attaching
screws and carefully pull the track away from the beam.
8-4
45563-B
Figure 8-7 Magnetic Track Assembly

3. Remove the shims or washers from the beam.
4. Position the three linear motor shims in place on the beam with a small amount of RTV silicon to
hold them in place.
5. Carefully position the new magnet track in place on the beam.
6. Fasten the magnet track in place using three screws with Loctite 222 (purple) or equivalent.
7. Insert a .50 cm (+/- .04 cm) shim between the end magnets of the adjacent tracks to maintain
consistent magnet spacing for the linear motor coil. Align the top edge with the adjacent
track and torque the screws to 2.0 N-m (18 in-lb.).
Replacing the 0.25 Diameter Magnet

1. With the air supply ON, slide the carriage assembly clear of the limit magnet bore on the side of
air beam.
2. Apply a small amount of silicon adhesive into the limit magnet bore.
3. As shown in Figure 8-8, with the white dot end of the magnet inward, press the magnet into the
bore until the face is flush with the beam.
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8-5
4. Clean excess silicon from surfaces.
Figure 8-8 Magnet (.250 Diameter) Installation
Replacing the Linear Scale Head Assembly

1. Remove the utility plate assembly. See "Replacing the Linear Motor Micropositioner Coil
2. As shown in Figure 8-9, remove the two screws holding the Linear Scale Head and spacer to the
top plate.
8-6
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Figure 8-9 Linear Scale Head Removal

3. Install the new Linear Scale Head with spacer to the top plate using two screws with Loctite 222
(purple) or equivalent. Do not tighten the screws at this time.
4. Connect the Linear Scale Head Connector to the flex cable board assembly.
5. Align the Linear Scale Head as described in "Aligning the Linear Scale Head" on page8-8.
6. Install the utility plate assembly.
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See "Replacing the Linear Motor Micropositioner Coil
8-7
Aligning the Linear Scale Head

1. As shown in Figure 8-10, insert the alignment spacer (provided with the Linear Scale Head)
between the Linear Scale Head and the encoder tape on the beam.
Figure 8-10 Linear Scale Head Alignment

2. Gently press the encoder read head against the spacer and beam.
3. Torque the Linear Scale Head retaining screws to 0.70 N-m (6 in-lb.).
4. Carefully remove the spacer.
5. Power ON the Linear Scale Head.
6. A green light on the Linear Scale Head should turn on, if not, adjust the gap between the Linear
Scale Head and the encoder tape again until the encoder shows a green light.
7. With the air supply ON, slide the carriage (by hand) along the entire length of the beam and make
sure that the Linear Scale Head shows a green light all the way (excepting where the read head
passes the limits and index, where it will turn red).
8. Adjust as necessary to maintain an Linear Scale Head green light for full travel.
8-8
45563-B
Replacing the Linear Scale RG2 Encoder Tape

1. As shown in Figure 8-11, remove the mechanical stop from one end of the air beam.
Figure 8-11 Encoder Tape Installation

2. With the air supply ON slide the carriage assembly to the end of the beam and carefully slide it
off. While removing the carriage assembly be careful not to scratch the air bearing
surfaces.
3. Carefully peel the RG2 encoder tape off the beam.
4. Clean the beam with alcohol to remove any residue left by the RG2 encoder tape.
5. Peel away the backing from one end of the new RG2 encoder tape (about 3 or 4 inches).
6. Carefully position the end of the encoder tape against the machined register edge on the air beam,
3 inches from the end of the beam.
7. Carefully press the tape along the rest of the beam while peeling the backing away. Make sure to
line the edge against the machined register. Make sure the tape is flat to the beam and not
overlapping the machined register, otherwise the encoder will not read properly.
8. Making sure air supply is ON, carefully replace the carriage assembly on the beam.
9. Install the mechanical stop.
10. Power ON the encoder.
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8-9
11. Check that the Linear Scale Head has a green light. If not, remove the utility plate as described in
"Replacing the Linear Motor Micropositioner Coil Assembly" on page 8-2. Then loosen and
realign the Linear Scale Head as described in "Aligning the Linear Scale Head" on page 8-8.
Replacing the 14-Conductor Flex Cable

2. Carefully disengage the strain relief snap-in pins and disconnect the 14 conductor flex cable from
its connector on the flex cable board assembly.
Figure 8-12 14 Conductor Flex Cable Replacement

3. Cut the plastic end ties and pull the cable from the nylon mesh cable sleeve.
4. Insert the new 14 conductor flex cable through the nylon mesh cable sleeve, make sure the bare
leads are facing up and toward the flex cable module.
5. Slide the connector clip of the circuit board connector over the end of the flex cable.
6. Slide the end of the flex cable fully into the connector and engage the clip to secure it.
7. Press in the strain relief snap-in pins.
8. Install plastic tie wraps at the ends of the nylon mesh cable sleeve.
9. Install the flex cable module cover.
8-10
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Replacing the 25-Conductor Flex Cable

Figure 8-13 25 Conductor Flex Cable Replacement

2. Carefully disengage the strain relief snap-in pins and disconnect the 14 conductor flex cable from
its connector on the flex cable board assembly.
3. Disconnect the 25 conductor flex cable connector from the flex cable board assembly.
4. Cut the plastic end ties and pull the cable through the nylon mesh cable sleeve.
5. Insert the new 25 conductor flex cable through the nylon mesh cable sleeve and plug it into the
connector on the board.
6. Connect the 14 conductor flex cable to the circuit board as discussed in "Replacing the 14Conductor Flex Cable" on page 8-10.
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8-11
Replacing the Bonded Air Pressure Tube

2. Carefully disengage the strain relief snap-in pins and disconnect the two flex cables from the flex
cable board assembly.
3. Remove the retaining screws from the bonded tube and disconnect it from the air supply barb.
Figure 8-14 Bonded Tube Removal

4. Cut the plastic end ties and pull the tube through the nylon mesh cable sleeve.
5. Insert the new bonded tube through the nylon mesh cable sleeve with the reworked end towards
the flex cable module.
6. Connect the bonded tube to the air supply barb and secure the bonded tube in place using two
screws.
7. Connect the two flex cables and secure the strain relief snap-in pins to the flex cable board
assembly as discussed in "Replacing the 25-Conductor Flex Cable" on page 8-11.
8-12
45563-B
Replacing the Flex Cable Board Assembly

2. Disconnect the limit, motor cable and encoder connectors from the flex cable board assembly.
3. Carefully disengage the strain relief snap-in pins and disconnect the two flex cables from the flex
cable board assembly.
4. Remove the two attaching screws and disconnect the bonded tube from the air supply barb.
5. Remove the jack screws holding the three connectors to the bottom of the sheet metal base.
Figure 8-15 Flex Cable Board Connector Removal

6. As shown in Figure 8-16, remove the three retaining screws and separate the flex cable board
assembly from the sheet metal base.
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8-13
Figure 8-16 Flex Cable Board Assembly Removal

7. Install the flex cable board assembly in the sheet metal base using three retaining screws with
Loctite 222 (purple) or equivalent.
8. Install the jack screws on the connectors through the bottom of the sheet metal base.
9. Connect the bonded tube to the air supply barb.
10. Secure the bonded tube in place using two screws.
11. Connect the two flex cables and secure the strain relief snap-in pins to the flex cable board
assembly as described in "Replacing the 25-Conductor Flex Cable" on page 8-11.
12. Connect the limit, motor cable and encoder connectors to the flex cable board assembly.
8-14
45563-B
Replacing the Home and Away Limit Switches

The following tools are needed to perform this procedure;
1. Remove the utility plate assembly. See "Replacing the Linear Motor Micropositioner Coil
2. As shown in Figure 8-17, remove the attaching screw from the limit assembly and pull the wires
from the utility plate.
Figure 8-17 Home and Away Limit Switch Assembly

3. Route the wires of the limit assembly through the utility plate.
4. Install the limit on the utility plate using one attaching screw with Loctite 222 (purple) or
equivalent.
5. Install the utility plate assembly onto the carriage assembly. See "Replacing the Linear Motor
Micropositioner Coil Assembly" on page 8-2.
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8-15
Replacing the Start of Image RGM22S Reference Mark

The following tools are needed to perform this procedure;
There are two Reference marks, however the PlateJet Sapphire uses only one of them.
1. With the air supply ON slide the carriage assembly clear of the reference mark on the beam.
2. As shown in Figure 8-18, Using a slotted screwdriver or similar tool carefully impact the edge of
the reference mark to break the adhesive bond.
Figure 8-18 Reference Mark Location

3. Carefully remove any adhesive residue left on the beam.
4. As shown in Figure 8-19, install the new reference mark on the beam with Loctite Super Bonder
495 instant adhesive or equivalent.
Figure 8-19 Reference Mark Replacement
8-16
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Replacing the Westwind Prism Spinner Driver Board (Thermal PlateJet Only)
The Prism Spinner Driver Board is located in the lower left front section of the lower frame. It is
mounted on the right side of the upper shelf. This board is found in the Thermal PlateJet only. The
following tools are needed to perform this procedure; 3mm and 8mm hex keys, small straight screw
driver.
3. Open the lower front panel using an 8mm hex key.
4. Locate the Driver Board and disconnect cables P1 (motor), P2 (Alt.), and P100 (ribbon cable).
5. Using a 3mm hex tool, remove the four securing screws holding the board to the shelf and
remove the complete board assembly.
6. Install the Westwind Prism Spinner Driver Board by reversing the above steps.
Replacing the Linear Motor Micropositioner Controller Assembly

The Linear Motor Micropositioner Controller Assembly is located in the left front side of the lower
frame section. It is mounted on the left side of the upper shelf. The following tools are needed to
perform this procedure; 2.5mm and 8mm hex keys, small straight screw driver.
3. Open the bottom Panel using an 8mm hex key and locate the Micropositioner Controller
Assembly.
4. Disconnect the six cables located on the left side of the Linear Motor Micropositioner Controller
Assembly chassis.
5. Using a 2.5mm hex tool, remove the four screws and washers attaching the chassis to the shelf.
The screws are accessed from the bottom of the shelf.
6. Remove the Linear Motor Micropositioner Controller Assembly.
7. Install the Linear Motor Micropositioner Controller Assembly by reversing the above steps.
Testing the Air Pressure Switch

The Air Pressure Switch is located in behind the Instrument and Control panel see Figure 10-2. The
following tools are needed to perform this procedure: Digital Voltmeter (DVM), and 8mm hex key.
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8-17
2. Remove the back bottom right panel using an 8mm hex key.
3. Connect a DVM to the air pressure switch terminals and select Ohms on the DVM.
4. With 80psi measuring on the SYSTEM gauge, change the MICROPOSITIONER air pressure to
60psi using the Micropositioner air pressure. Make a note at what level the switch contacts
transfer from open to close. The contacts of the air pressure will be open below the 57psi
Setpoint and close above it. If it is not working at the correct value1, then replace the air pressure
switch.
5. Install the back bottom right panel using an 8mm hex key.
Adjusting the Linear Motor Micropositioner Air Bearing Pressure

The following tools are needed to perform this procedure: 8mm hex key. To adjust the Linear Motor
Micropositioner air bearing pressure, perform the following steps:
1. Turn the power off to the PlateJet
2. Remove the back right lower panel using an 8mm hex key.
3. With 80psi on the SYSYEM pressure gauge, unlock the air pressure regulator by pulling up on
the knob and turn it until 60psi is set on the MICROPOSITIONER gauge. Figure 10-1 on page
10-1 shows the location of the air pressure regulator.
4. Push down on the knob to lock the regulator. Check the MICROPOSITIONER gauge to make
sure the needle has not moved off the 60psi mark.
5. Install the back right lower panel using an 8mm hex key.
Setting the Start of Line and Start of Image

The Start of Line and Start of Image are set using the EEPROM Window in PlateJet Toolkit. This
window contains the Cross-scan Offset and Along-scan Offset parameters as described below:
Cross-scan Offset - This parameter is also referred to as Start of Image. This value is in inches and
indicates where the first line of data will be placed on the media as shown in Figure 8-20.
Notes:
1
Variations of a few psi are of no concern. There is only concern if the setpoint is too close to the Micropositioner operating
pressure of 60psi. A setpoint close to 60psi may prevent the Micropositioner from moving and/or plotting.
8-18
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Figure 8-20 Offset Parameters

Along-scan Offset - This parameter is also referred to as the Start of Line. This value is in inches and
indicates where in the arc the image starts as shown in Figure 8-20. This number is typically fairly
large since it is measuring from the top of the arc.
See the PlateJet Sapphire Maintenance Manual for more details.
End of Section
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8-19
8-20
45563-B
Section Nine: Media Transport Maintenance

PlateJet Sapphire Media Transport
The Media Guide DC Motor runs on 24VDC and operates at a speed of 39rpm through a built in gear
train. The motor operates the Media Guide cage that rotates along the inside of the internal drum.
Figure 9-1 shows the location of the Media Guide Assembly. Limit switches define the limits between
fully IN1 and fully OUT.
Figure 9-1 The Media Guide Assembly
Replacing the Media Guide Motor

To replace the Media Guide Motor, you will need the following tools: 8mm hex key, 2.5mm hex key,
7/16 hex key, and small wire cutter.
2. Open the right column door of the PlateJet using an 8mm hex key.
3. Cut any cable ties securing the media guide motor cable.
4. Disconnect the Media Guide Motor cable P50.
Notes:
1
IN places the roller of the Media Guide at the bottom of the internal drum and fully OUT, places the roller at the top (park
position)
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9-1
5. Rotate the Media Guide cage by hand until the flex coupling clamping screw is facing down for
easy access.
6. Loosen the clamping screw (7/16 hex key) on the motor shaft end so the motor shaft is free to
slide out.
7. Remove the Media guide Motor Assembly, including the mounting bracket1.
8. Remove the motor from the mounting bracket (2.5mm hex key).
9. Install the new Media Guide Motor to the mounting plate.
10. Push the motor shaft into the flex coupling and install the Media Guide Motor Assembly to the
AWAY end plate.
11. Tighten the flex coupling clamping screw. Be sure to tighten the coupling set screws onto the flat
on the shaft.
12. Connect the Media Guide Motor connector.
13. Secure the motor cable with cable ties, if required.
15. Test the operation of the motor.
16. Close the right column door using an 8mm hex key.
Replacing the Media Guide Limit Switches
The limit switches are used by the Main Processor Board to control the travel of the Media Guide
cage. Figure 9-2 shows the location of the Media Guide limit switches. The following tools are
needed to perform this procedure; 8mm and 1.5mm hex keys, needle nose pliers.
Notes:
1
The mounting bracket is attached to the AWAY end plate by four screws.
9-2
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Media Transport Maintenance
Figure 9-2 Media Guide Limit Switches

To replace the Media Guide Limit Switch(es) the following tools are needed; 1.5mm and 8mm hex
keys, small needle nose pliers
3. Pull back on the top door release lever as shown in Figure 9-3.
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9-3
Figure 9-3 Top Front Door Release Lever

4. Lift the front top door of the PlateJet and place the support struts in place, see Figure 9-4.
Figure 9-4 Front Door Strut Location
9-4
45563-B
5. Place a sheet of media on the tray, with a few inches of the media overlapping the internal drum.1
6. Using small needle nose pliers gently pull off the two terminal connectors attached to the
switch(es).
7. Remove the two screws (1.5mm hex key) holding the limit switch(es).
8. Install the new limit switch(es) with the two screws from the old assembly.
9. Connect the two push-on terminal connectors2 to the switch(es).
10. Remove the protective sheet of media from the media tray.
12. Test the operation of the switch(es).
13. Close the right column door using an 8mm hex key.
14. Close the top front panel of the PlateJet. Make sure that the latches click closed when the panel
is lowered. Push on the top coners of the panels to ensure closure.
Replacing the Vacuum Pump

See Figure 9-5 for the location of the Vacuum Pump. The following tools are needed to perform this
procedure: 6mm and 8mm hex keys.
Figure 9-5 Vacuum Pump Location

Notes:
1
2
This is a precaution against any screws or small tools from falling inside the tray.
Connect the wires to the common (COM) and normally-closed (NC) terminals.
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9-5

3. Remove the bottom left back panel (as viewed from the back) using an 8mm hex key.
4. Remove the bottom right back panel (as viewed from the back) using an 8mm hex key.
5. Disconnect the cable to the two Main Exhaust Fans.
6. Disconnect the vacuum pump cable connector J45 from the back of the Instrument Control &
Power Panel, see Figure 10-2.
8. Pull the vacuum pump power cable from the cable tray.
9. Pull out the four clear and single yellow hoses from the vacuum pump manifold.
10. Using a 6mm hex tool, remove the four screws and washers attaching the vacuum pump to the top
isolator plate.
11. Remove the vacuum pump from the PlateJet.1
12. Install the vacuum pump by reversing the above steps.
Replacing the Vacuum Solenoid Assembly

See Figure 9-6 for the location of the Vacuum Solenoid Assembly. The following tools are needed to
perform this procedure: 4mm and 8mm hex keys, and small wire cutter.
Figure 9-6 Vacuum Solenoid Location
Notes:
1
The PlateJet Sapphire has an access through the frame. Open the left column door and remove the six screws (some may
have ten). The plate can be removed from the machine and hooked into place to provide a level working surface.
9-6
45563-B

3. Remove the rear bottom left panel (as viewed from the back) using an 8mm hex key.
4. Disconnect the two cable connectors, P46 and P47 from the Vacuum Solenoid assembly.
5. Pull out the twenty yellow vacuum hoses from the internal drum manifold.
6. Pull out the two clear vacuum hoses from the vacuum pump manifold.
7. Using a 4.0mm hex key, remove the two screws attaching the vacuum solenoid assembly to the
bracket.
8. Remove the Vacuum Solenoid Assembly.
9. Install the Vacuum Solenoid Assembly by reversing the above steps.
Replacing the Vacuum Switch

As shown in Figure 10-2 the vacuum switch is located directly behind the VACUUM gauge on the
Instrument Control & Power Panel. The following tools are needed to perform this procedure: 8mm
hex key, 12mm open end wrench, medium straight slot screw driver, Teflon tape.
To replace the Vacuum Switch perform the following steps:
3. Turn off the air to the PlateJet.
4. Remove the bottom right back panel using an 8mm hex key.
5. Disconnect the two lead wires from the back of the vacuum switch using a straight slot screw
driver.
6. Remove the vacuum switch from the T-connector fitting at back of the VACUUM gauge by
rotating the switch counter-clockwise with a 12 mm open ended wrench (or small adjustable
wrench).
7. Clean any Teflon tape residue from the T-connector fitting.
8. Apply Teflon tape to the threaded end of the new vacuum switch to ensure a tight leak-free
connection.
9. Install the new vacuum switch to the T-connector fitting at the back of the VACUUM gauge by
rotating the switch clockwise and tighten it with a small adjustable wrench.
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9-7
10. Connect the two lead wires from the back of the vacuum switch using a straight slot screw
driver.1
11. Install the bottom right back panel using an 8mm hex key.
12. Turn the air on to the PlateJet and set it to 80psi as measured by the SYSTEM gauge.
13. Plug the power cord into the wall outlet.
15. Test the operation of the vacuum switch.
Testing the Vacuum Switch

As shown in Figure 10-2, the vacuum switch is located directly behind the VACUUM gauge on the
Instrument Control & Power Panel. The following tools are needed to perform this procedure; 8mm
hex key, Digital Volt Meter (DVM).
1. Remove the back bottom right panel using an 8mm hex key.
2. Connect a DVM to the vacuum switch terminals. The vacuum switch is located as shown in
Figure 10-2.2
3. Load a piece of media.
4. Disconnect the vacuum hose to the vacuum vent solenoid.3
5. Cover the end of the disconnected vacuum hose with your thumb to control the level of vacuum
in the system. Monitor both the vacuum gauge and the DVM as the vacuum level decreases.
Make a note at what level the switch opens. The switch should open at 7 in-hg as indicated by a
change from 0 to 5VDC on the DVM. If it is not working at this value, then replace the vacuum
switch.
6. Install the back bottom right panel.
Replacing the Vacuum Gauge

The VACUUM gauge is located as shown in Figure 10-2. The following tools are needed to perform
this procedure; 8mm hex key, 3/8 and 12mm open end wrench, Teflon tape.
To replace the Vacuum Gauge perform the following steps:
1. Remove the vacuum switch. See Replacing the Vacuum Switch on page 9-7.
Notes:
1
2
3
Polarity is not important. The wires can be attached to either connection.

The vacuum switch has normally open contacts that close when a certain vacuum is achieved.
Air will leak into the vacuum line and the vacuum reading should decrease.
9-8
45563-B
2. Disconnect the vacuum line from the T-connector fitting.

disconnects.
The vacuum line is on quick
3. Remove the T-connector fitting from the back of the VACUUM gauge. Keep this T-connector
fitting, it will be used with the new VACUUM gauge.
4. Remove the mounting bracket from the VACUUM gauge by removing the two 3/8 nuts and lock
washers from the mounting bracket with 3/8 open end wrench.
5. Remove the VACUUM gauge through the front of the Instrument Control & Power Panel.
6. Install the new VACUUM gauge through the front of the Instrument Control & Power Panel.
7. Install the VACUUM gauge to the mounting bracket with the two 3/8 nuts and lock washers
using 3/8 nut driver.
8. Clean any Teflon tape residue from the T-connector fitting and apply new Teflon tape.
9. Install the T-connector fitting to the back of the VACUUM gauge.
10. Install the vacuum switch. See Replacing the Vacuum Switch on page 9-7.
11. Test the operation of the VACUUM gauge.
Adjusting Media Skew

The media skew adjustments involve aligning the media to the internal drum. The GeoRad test file
image, as shown in Figure 9-7, is used for this adjustment. It can be downloaded from our FTP Site at
ftp.cymbolic.com.
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9-9
Figure 9-7 GeoRad Test File Image
Adjusting Image Skew

Image skew occurs when the media on the PinBar assembly is not parallel to the internal drum. The
PinBar assembly may need to be rotated to align the media with the drum. Figure 9-8 illustrates the
location of the set screw used to rotate the PinBar assembly. The following tools are required: 1.5mm
and 4mm hex keys.
Figure 9-8 PinBar Adjustment Point
9-10
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To minimize skew perform the following steps:

1. Image the GeoRad test image file and process the plate.1
2. Measure from the bottom edge of the plate (at the location indicated by the two arrows labeled
Sapphire Skew Reference Point as shown in Figure 9-9), to the bottom line on the GeoRad.
The two measurements are equal when no skew of the plate in the drum occurs.
Figure 9-9 Correcting for Image Skew

3. Determine the direction the set screw should be rotated. As shown in Figure 9-10, the direction
of rotation is dependent on the slope of the skew. A positive slope requires the set screw to be
rotated counter clockwise (CCW), and a negative slope requires the set screw to be rotated
clockwise (CW).
4. Loosen the four PinBar securing bolts, located on top of the PinBar
5. While pulling back on the PinBar handle, rotate the set screw to remove the screw. One rotation
of the set screw will move skew 0.5 mm.
6. While pulling back on the PinBar handle, tighten the four PinBar securing bolts, located on top of
the PinBar
7. Confirm operation of the registration system, repeating steps 1 - 3.
Notes:
1
The minimum plate size for this adjustment is 18 cs.
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9-11
Figure 9-10 Correcting for Image Skew
End of Section
9-12
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Section Ten: Electronic System Maintenance

Foreword
The Instrument Control & Power Panel is located as shown in Figure 10-1 and Figure 10-2.
Figure 10-1 Instrument Control & Power Panel -- Front View
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10-1
Figure 10-2 Instrument Control & Power Panel -- Rear View
Replacing the Internal SCSI Cable

The internal SCSI cable is located in the cavity behind the Instrument Control & Power Panel. The
following tools are required in this procedure: 8mm hex key.
To replace the Internal SCSI Cable perform the following steps:
3. Unplug the power cord from the wall outlet.
5. Disconnect the internal SCSI cable from the SCSI U2 Connector on the inside of the Instrument
Control & Power Panel.
6. Disconnect the internal SCSI cable from J13 on the Main Processor Board Assembly, as shown in
Figure 10-6.
7. Connect the new internal SCSI cable J13 on to the Main Processor Board Assembly.
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Electronic & Electrical System Maintenance
8. Connect the other end of the SCSI-U2 cable to the SCSI Wide Splice Connector on the inside of
the Instrument Control & Power Panel.
13. Test the operation of the internal SCSI by plotting an image.
Replacing the SCSI-U2 Splice Connector

The Low Voltage Differential SCSI (Ultra 2) Splice Connector is located as shown in Figure 10-2. The
following tools are required in this procedure: 8mm hex key.
To replace the SCSI-U2 Splice Connector perform the following steps:
4. Disconnect the main SCSI cable from the Instrument Control & Power Panel.
6. Disconnect the internal SCSI cable from the SCSI-U2 Splice Connector on the inside of the
Instrument Control & Power Panel.
7. Remove the SCSI Wide Splice Connector from the Instrument Control & Power Panel.
8. Install the new SCSI Wide Splice Connector to the Instrument Control & Power Panel.
9. Connect the internal SCSI cable to the SCSI Wide Splice Connector on the inside of the
Instrument Control & Power Panel.
11. Connect the main SCSI cable to the Instrument Control & Power Panel.
15. Test the operation of the SCSI Wide Splice Connector by plotting an image.
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10-3
Replacing the Air Pressure Switch

The air pressure switch, as shown in Figure 10-2, is located directly behind the air pressure regulator of
the Instrument Control & Power Panel. The following tools are required in this procedure: 8mm hex
key, small straight slot screw driver, and a small adjustable wrench.
To replace the Air Pressure Switch perform the following steps:
5. Disconnect the two lead wires from the back of the air pressure switch using a straight slot screw
driver.
6. Remove the air pressure switch from the air pressure regulator by rotating the switch counterclockwise with a small adjustable wrench.
7. Clean any Teflon tape residue from the air pressure regulator.
8. Apply Teflon tape to the threaded end of the new air pressure switch to ensure a tight leak-free
connection.
9. Install the air pressure switch to the air pressure regulator by rotating the switch clockwise and
tighten it with a small adjustable wrench.
10. Connect the two lead wires from the back of the air pressure switch using a straight slot screw
driver.1
12. Turn on the system air and set it to 80psi as measured by the SYSTEM gauge.
15. Test the operation of the air pressure switch.
Replacing the Air Pressure Regulator

The air pressure regulator is located as shown in Figure 10-2. The following tools are required in this
procedure: 8mm hex key, small adjustable wrench, and Teflon tape.
To replace the Air Pressure Regulator perform the following steps:
Notes:
1

10-4
45563-B
1. Remove the air pressure switch. See Replacing the Air Pressure Switch on page 10-4.
2. Disconnect all air lines to the air pressure regulator. These are mounted with quick disconnects.1
3. Remove the air pressure regulator by turning it counter-clockwise with an adjustable wrench.
4. Remove all Y air line connectors from the air pressure regulator.2
5. Apply Teflon tape to the Y connectors and attach them to the new air pressure regulator.
6. Apply Teflon tape to the threaded end of the air pressure regulator to ensure a tight leak-free
connection and install it to the same location at the back of the MICROPOSITIONER gauge.
7. Connect all air lines to the air pressure regulator. These are mounted with quick disconnects.3
8. Install the air pressure switch to the back of the air pressure regulator by rotating the switch
clockwise and tighten it with a small adjustable wrench.
driver.1
10. Turn on the system air and set it to 80psi as measured by the SYSTEM gauge.
11. Using the air pressure regulator, set the Micropositioner air pressure to 60psi as measured by the
MICROPOSITIONER gauge.
12. Install the bottom right back panel.
16. Check the quality and geometric accuracy of the images.4
17. Replacing the Micropositioner Gauge
Replacing the Micropositioner Gauge

The Micropositioner gauge is located as shown Figure 10-2. The following tools are required in this
procedure: 8mm hex key, 3/8 nut driver, small adjustable wrench, and Teflon tape.
To replace the Micropositioner Gauge perform the following steps:
1. Remove the air pressure switch. See Replacing the Air Pressure Switch on page 10-4.
2. Disconnect all air lines to the air pressure regulator. These are mounted with quick disconnects.1
Notes:
1
Note the location of all the air lines that are attached to the air pressure regulator. The input and output lines must not be interchanged.
2
3
4
The Y connectors will be used on the replacement air pressure regulator.

Install the air lines to the air pressure regulator in the correct order. The input and output lines must not be inter-changed.
The air pressure has a significant effect on image quality and geometric accuracy because it supports the spinner carriage.
45563-B
10-5
3. Remove the air pressure regulator by turning it counter-clockwise with an adjustable wrench.
4. Remove the mounting bracket from the Micropositioner gauge by removing the two 3/8 nuts and
lock washers from the mounting bracket with 3/8 nut driver.
5. Remove the Micropositioner gauge through the front of the Instrument Control & Power Panel.
6. Install the new Micropositioner gauge through the front of the Instrument Control & Power Panel.
7. Install the Micropositioner gauge to the mounting bracket with the two 3/8 nuts and lock
washers using 3/8 nut driver.
8. Apply Teflon tape to the threaded end of the air pressure regulator to ensure a tight leak-free
connection and install it to the same location at the back of the Micropositioner gauge.
9. Connect all air lines to the air pressure regulator. The air lines are on quick disconnects.2
10. Install the air pressure switch to the back of the air pressure regulator by rotating the switch
clockwise and tighten it with a small adjustable wrench.
driver.3
12. Turn on the system air and set it to 80psi as measured by the System gauge.
13. Using the air pressure regulator, set the Micropositioner air pressure to 60psi as measured by the
Micropositioner gauge.
Replacing the System Gauge

The System gauge is located as shown in Figure 10-2. The following tools are required in this
procedure: . 8mm, 3/8 nut driver, small adjustable wrench, and Teflon tape.
To replace the System Gauge perform the following steps:
2. Turn off the system air to the PlateJet.
5. Disconnect the air lines from the back of the system gauge. The air lines are on a quick
disconnects.
6. Remove the T-connector fitting by turning it counter-clockwise with an adjustable wrench.
Note the location of all the air lines that are attached to the air pressure regulator. The input and output lines must not be interchanged.
2
3
Install the air lines to the air pressure regulator in the correct order. The input and output lines must not be inter-changed.
10-6
45563-B
7. Remove the mounting bracket from the system gauge by removing the two 3/8 nuts and lock
washers from the mounting bracket with 3/8 nut driver.
8. Remove the system gauge through the front of the Instrument Control & Power Panel.
9. Insert the new system gauge through the front of the Instrument Control & Power Panel.
10. Install the system gauge to the mounting bracket with the two 3/8 nuts and lock washers using
3/8 nut driver.
11. Apply Teflon tape to the threaded end of the T-connector fitting and install it to the back of the
system gauge with an adjustable wrench.
12. Connect the air lines to the T-connector fitting at back of the system gauge. The air lines are on a
quick disconnects.
14. Turn on the system air and set it to 80psi as measured by the system gauge.
Replacing the Toggle Switches

The Spinner ON/OFF1 and Multipass Test Enabled/Disabled Toggle Switches are located as shown in
Figure 10-2. The following tools are required in this procedure: 8mm hex key, small adjustable
wrench, wire cutter, solder, soldering iron (possible an extension cord), 1/8 diameter heat shrink
tubing.
To replace these switches perform the following steps:
2. Turn the air off to the PlateJet.
5. Cut away the shrink tubing from the switch terminals.
6. Unsolder the wires from the switch terminals.
7. Using a small adjustable wrench, remove the two switches from the Instrument Control & Power
Panel.
8. Install the new switch onto the Instrument Control & Power panel.
9. Cut two short lengths of 1/8diameter shrink tubing and slip them over the wires.
10. Solder the wires to the two top terminals of the switch.
45563-B
10-7
11. Slip the shrink tubing over the terminals.

12. Using soldering iron, shrink the tubing onto the terminals.
15. Turn the air on to the PlateJet and set it to 80psi as measured by the System gauge.
17. Test the operation of the switch.
Replacing the Power Circuit Breaker Switch

The Power Circuit Breaker Switch is located as shown in Figure 10-2. The following tools are required
in this procedure: 3mm and 8mm hex keys, needle nose pliers.
To replace the Power Circuit Breaker Switch perform the following steps:
5. Remove the AC distribution cover by first releasing the three thumb screws at the bottom of the
cover and then loosening the two hex head screws at the top, using an 3mm hex key. The cover
can then be simply slipped off.
6. Disconnect the four wires, in back of the circuit breaker switch, with a pair of needle-nose pliers.
7. Remove the switch through the front of the Instrument Control & Power Panel.
8. Install the new circuit breaker switch CB1 through the front of the Instrument Control & Power
Panel.
9. Install the wires by pushing them on with a pair of needle-nose pliers.
10. Install the AC distribution protective cover.
14. Test the switch by turning the power on the PlateJet.
10-8
45563-B
Replacing the 230VAC Vacuum Pump Solid State Relay

The 230VAC Vacuum Pump Solid State Relay is located as shown in Figure 10-2. The following tools
are required in this procedure: 3mm and 8mm hex keys, Xcelite 9/16 nut driver.
To replace the 230VAC Vacuum Pump Solid State Relay perform the following steps:
4. Remove the bottom right back panel.
cover and then loosening the two hex head screws at the top. Then slip the cover off.
6. Remove the four wires from the relay.
7. Remove the two black plastic inserts in front of relay securing bolts, as shown in Figure 10-2.
8. Using a nut driver, remove the two nuts and washers attaching the relay to the panel.
9. Install the new relay to the back of the Instrument Control & Power Panel.
10. Install the two black plastic inserts in front of relay securing bolts
11. Connect the wires to the relay.
17. Test the operation of the relay by turning on the Vacuum Pump.
Replacing the EMI Filter

The EMI Filter is located as shown in Figure 10-2. The following tools are required in this procedure:
3mm and 8mm hex keys, 7/32 nut driver, and small needle nose pliers.
To replace the EMI Filter perform the following steps:
45563-B
10-9
cover and then loosening the two hex head screws at the top using an 3mm hex key. The cover
6. Disconnect the five wires from the EMI Filter by pulling them off with a pair of needle-nose
pliers.
7. Using a 7/32 nut driver, remove the four nuts and washers attaching the EMI Filter to the panel.
8. Install the new EMI Filter to the back of the panel.
9. Connect the five wires.
14. Turning the power on to the PlateJet will test the EMI Filter.
Replacing the Transient Suppressor

The Transient Suppressor is located as shown in Figure 10-3. The following tools are required in this
procedure: 3mm and 8mm hex keys, 3/8 nut driver.
To replace the Transient Suppressor perform the following steps:
cover and then loosening the two hex head screws at the top using an 3mm hex key. The cover
6. Disconnect the three wire sets from the Transient Suppressor by pulling them off with a pair of
needle-nose pliers.
7. Using a 3/8 nut driver, remove the two nuts and washers attaching the transient suppressor to the
panel.
8. Install the new transient suppressor to the back of the panel.
9. Connect the three wire sets to the transient suppressor.
10-10
45563-B
11. Install the bottom right back panel.

Figure 10-3 Locating the Lower Frame Components
Replacing the Switching DC Power Supply

See Figure 10-3 for the location of the Switching DC Power Supply. The following tools are required in
this procedure: 2.5mm, 5mm and 8mm hex keys,
To replace the Switching DC Power Supply perform the following steps:
3. Remove the rear bottom right and left panels using an 8mm hex key.
4. Using a 2.5mm hex tool, remove the top and bottom shield brackets.
45563-B
10-11
5. Remove connector J43 (press locking tab at the bottom) from the back of the Instrument, Control
& Power Panel, as shown in Figure 10-2.
6. Pull the AC power cable (for the DC power supply) out of the cable tray.
7. Remove connector J20 (press locking tab) from the PS I/O Board assembly. See Figure 10-5 for
the location of connector J20.
8. For Thermal laser systems remove connector J90 (press locking tab) from the Laser Controller
Box. See Figure 10-4 for the location of connector J90. For Visible laser systems remove it from
the visible bracket.
Figure 10-4 Laser Controller Box Location

9. Pull the DC power cable out of the cable tray.
10. Using a 5mm hex tool, remove the four screws attaching the DC power supply to the side wall.
11. Using a 5mm hex tool, loosen (only) the two top screws attaching the DC power supply to the
side wall.
12. Remove the Switching DC Power Supply by lifting the assembly so that the hooks lift off the
holes in the frame.
13. Install DC power supply by reversing the above steps.
10-12
45563-B
Replacing the PS I/O Board Assembly

See Figure 10-5 for the location of the PS I/O Board Assembly. The following tools are required to
perform this procedure;
To replace the PS I/O Board Assembly perform the following steps: Turn the power off to the PlateJet.
2. Remove the rear bottom right panel using an 8mm hex key.
3. Disconnect all the cable connectors from the back of the PS I/O Board assembly as shown in
Figure 10-5.
4. Release the eight spring loaded thumbscrews. A large slotted screwdriver may be required to
loosen the thumbscrews.
5. Remove the PS I/O Board assembly.
6. Install the PS I/O Board assembly by reversing the above steps.
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10-13
Figure 10-5 The PS I/O Board Assembly
10-14
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Replacing the Main Processor Board Assembly

See Figure 10-6 for the location of the Main Processor Board Assembly. The following tools are
required to perform this procedure; 8mm hex key, large slotted screwdriver.
To replace the Main Processor Board Assembly perform the following steps:
3. Remove the rear bottom right panel using an 8mm hex key.
4. Disconnect all the cable connectors from the back of the Main Processor Board assembly as
5. Release the eight spring loaded thumbscrews. A large slotted screwdriver may be required to
loosen the thumbscrews.
6. Remove the Main Processor Board assembly.
7. Install the Main Processor Board assembly by reversing the above steps.
Figure 10-6 The Main Processor Board Assembly
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10-15
Replacing the Operator Control Panel

The Operator Control Panel is located as shown Figure 10-7. The following tools are required in this
procedure: 2.5mm and 8mm hex keys, 7/32 nut driver, and a 4mm Allen Key.
To replace the Operator Control Panel, perform the following steps:
3. Open right column door using an 8mm hex key.
4. Remove the operator controller PCB assembly. Use a 2.5mm hex key to remove the three
securing bolts.
5. Disconnect cable connecting JP1 on the control panel controller PCB.
6. Remove the control panel mount by using a 4mm Allen Key to remove the three screws, then
feed the cable through the opening in the front cover.
7. Remove the plate on the back of the mount using a small Philips screw driver.
8. Remove the control panel from the mount using a 7/32 nut driver.
9. Install the control panel by reversing the above steps.
Figure 10-7 Operator Control Panel Location

10-16
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Replacing the Operator Control Panel Controller PCB

The Control Panel Controller PCB is located directly behind the Operator Control Panel as shown
Figure 10-8. The following tools are required in this procedure: 2.5mm and 8mm hex keys, 3/16 nut
driver, and a small Philips screw driver
To replace the Control Panel Controller Assembly, perform the following steps:
3. Open right column door using an 8mm hex key.
4. Remove the operator controller PCB assembly. Use a 2.5mm hex key to remove the three
securing bolts.
5. Disconnect cables JP1, J250M, and P259 from the control panel controller PCB.
6. Remove the two connector posts at P1 on the control panel controller PCB using a 3/16 nut
driver.
7. Remove the control panel controller PCB from the assembly using a small Philips screw driver.
8. Install the control panel controller PCB by reversing the above steps.
Replacing the Two Main Exhaust Fans

The Two Main Exhaust Fans are located on the back of rear bottom left panel. It is recommended to
replace both fans at the same time. The following tools are required; 2.5mm and 8mm hex keys, small
adjustable wrench, and small wire cutter.
To replace the two main exhaust fans perform the following steps:
3. Remove the rear bottom left panel using an 8mm hex key.
6. Using a 2.5 mm hex key, remove the two fans and finger guards from the panel.
7. Install the Main Exhaust Fans and finger guards by reversing the above steps, replace both fans
as preventative maintenance.
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10-17
Replacing the System Air Filter Assembly

The System Air Filter Assembly is located on the right sidewall in the left cavity of the lower frame, see
Figure 10-8. The following tools are required; 8mm hex key, 10mm open ended wrench.
To replace the System Air Filter Assembly, perform the following steps:
3. Turn off the system air supply to the PlateJet and wait until all the air has bled away.
4. Remove the rear bottom left panel using an 8mm hex key.
6. Disconnect the two red hoses from the air filter assembly.
7. Using a 10mm open-ended wrench, remove the two nuts and washers attaching the air filter
assembly to the right sidewall.
8. Remove the Air Filter Assembly.
9. Install the Air Filter Assembly by reversing the above steps.
Figure 10-8 Air Filter Assembly
10-18
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Replacing the Drum Circulation Fan

The Drum Circulation Fan is located on the inside of the right column door. The following tools are
required; 3mm and 8mm hex keys.
To replace the Drum Circulation Fan, perform the following steps:
4. Disconnect the cable to the Drum Circulation Fan.
5. Using a 3mm hex tool, remove the four screws attaching the fan (and finger guard) to the right
sidewall.
6. Install the Drum Circulation Fan (and finger guard) by reversing the above steps.
End of Section
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10-19
10-20
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Appendix A: Table of Figures

Figure 1-1 Visible Laser Safety Label Locations - Front .............................................................. 1-3
Figure 1-2 Visible Laser Safety Label Locations - Left................................................................. 1-3
Figure 1-3 Thermal Laser Safety Label Locations - Front............................................................ 1-6
Figure 1-4 Thermal Laser Safety Label Locations - Left .............................................................. 1-6
Figure 1-5 Common Safety Label Locations - Back..................................................................... 1-8
Figure 1-6 Error Code Label Locations - Right Door Open .......................................................... 1-9
Figure 2-7 PlateJet Component Layout (Front View) ................................................................... 2-2
Figure 2-8 PlateJet Component Layout (Rear View).................................................................... 2-3
Figure 3-9 The Visible Optics Plate ............................................................................................. 3-8
Figure 3-10 The YAG Laser Optical Schematic ........................................................................... 3-9
Figure 3-11 Visible Laser Interlock Switch Locations................................................................. 3-13
Figure 3-12 The Thermal Optics Plate....................................................................................... 3-14
Figure 3-13 Thermal Laser Interlock Switch Locations .............................................................. 3-18
Figure 4-1 The PlateJet Crate ..................................................................................................... 4-1
Figure 4-2 PlateJet Room ........................................................................................................... 4-4
Figure 4-3 Thumbscrew Location ................................................................................................ 4-5
Figure 4-4 Leveling the PlateJet.................................................................................................. 4-6
Figure 6-1 Replacing the Green YAG Laser ................................................................................ 6-2
Figure 6-2 Replacing the 3.5D Filter Wheel Assembly................................................................. 6-3
Figure 6-3 Replacing the Photodetector Board............................................................................ 6-5
Figure 6-4 The A-O Modulator on the Optics Plate...................................................................... 6-6
Figure 6-5 Replacing the Shutter Assembly ................................................................................ 6-7
Figure 6-6 Location of A-O Modulator Driver ............................................................................... 6-9
Figure 6-7 The Optics plate ....................................................................................................... 6-10
Figure 6-8 Optical Alignment Jigs.............................................................................................. 6-11
Figure 6-9 Viewing the Beam After the Collimating Lens........................................................... 6-12
Figure 6-10 Viewing the A-O Modulator Beam Pattern Using a Business Card ......................... 6-13
Figure 6-11 Adjusting Mirror #1 on the Optics Plate .................................................................. 6-14
Figure 6-12 Adjusting the TILT Plate on the Optics Plate .......................................................... 6-16
Figure 6-13 Offsetting the beam Using the TILT Plate............................................................... 6-16
Figure 6-14 Rotating the Beam Using the TILT Plate Barrel ...................................................... 6-17
Figure 6-15 TILT Plate Rotation ................................................................................................ 6-17
Figure 6-16 The Balanced Modulated Beam Pattern ................................................................. 6-19
Figure 6-17 Setting the Bragg Angle on the Modulator............................................................ 6-19
Figure 6-18 Mounting the Target-1 hole .................................................................................... 6-22
Figure 6-19 Mounting the Assy-Jig 1 hole ................................................................................. 6-23
Figure 6-20 Aligning Mirror #3 ................................................................................................... 6-24
Figure 6-21 Adjusting the Horizontal Position of the Optics Plate .............................................. 6-24
Figure 6-22 Mounting the Assy-Spinner Lens Centering Jig.................................................... 6-26
Figure 6-23 Adjusting for Lens Centration ................................................................................. 6-27
Figure 7-1 Ceramic Washer Locations ........................................................................................ 7-4
Figure 7-2 Heat Sinks Laser Head Mounting Holes .................................................................... 7-5
Figure 7-3 AOM Alignment Shim Location................................................................................... 7-7
Figure 7-4 Prism Spinner Rotation Referencing .......................................................................... 7-9
Figure 7-5 The Cross Scan Spinner .......................................................................................... 7-11
Figure 7-6 Beam Order Adjustment Components...................................................................... 7-12
45563-B
A-1
Figure 7-7 Mounted Focusing Tool............................................................................................ 7-15

Figure 7-8 Image with Dove Prism Stopped .............................................................................. 7-18
Figure 7-9 PlateJet Toolkit Print Window................................................................................... 7-20
Figure 8-1 Replacing the Spinner Motor Assembly...................................................................... 8-1
Figure 8-2 Flex Cable Module Cover Removal ............................................................................ 8-2
Figure 8-3 Flex Cable Board Connector Removal ....................................................................... 8-2
Figure 8-4 Utility Plate Assembly Removal.................................................................................. 8-3
Figure 8-5 Utility Plate Wire Cover Removal ............................................................................... 8-3
Figure 8-6 Motor Coil Assembly Removal ................................................................................... 8-4
Figure 8-7 Magnetic Track Assembly .......................................................................................... 8-5
Figure 8-8 Magnet (.250 Diameter) Installation............................................................................ 8-6
Figure 8-9 Linear Scale Head Removal....................................................................................... 8-7
Figure 8-10 Linear Scale Head Alignment ................................................................................... 8-8
Figure 8-11 Encoder Tape Installation......................................................................................... 8-9
Figure 8-12 14 Conductor Flex Cable Replacement.................................................................. 8-10
Figure 8-13 25 Conductor Flex Cable Replacement.................................................................. 8-11
Figure 8-14 Bonded Tube Removal........................................................................................... 8-12
Figure 8-15 Flex Cable Board Connector Removal ................................................................... 8-13
Figure 8-16 Flex Cable Board Assembly Removal .................................................................... 8-14
Figure 8-17 Home and Away Limit Switch Assembly................................................................. 8-15
Figure 8-18 Reference Mark Location ....................................................................................... 8-16
Figure 8-19 Reference Mark Replacement................................................................................ 8-16
Figure 8-20 Offset Parameters .................................................................................................. 8-19
Figure 9-1 The Media Guide Assembly ....................................................................................... 9-1
Figure 9-2 Media Guide Limit Switches ....................................................................................... 9-3
Figure 9-3 Top Front Door Release Lever ................................................................................... 9-4
Figure 9-4 Front Door Strut Location ........................................................................................... 9-4
Figure 9-5 Vacuum Pump Location ............................................................................................. 9-5
Figure 9-6 Vacuum Solenoid Location......................................................................................... 9-6
Figure 9-7 GeoRad Test File Image .......................................................................................... 9-10
Figure 9-8 PinBar Adjustment Point .......................................................................................... 9-10
Figure 9-9 Correcting for Image Skew ....................................................................................... 9-11
Figure 9-10 Correcting for Image Skew ..................................................................................... 9-12
Figure 10-1 Instrument Control & Power Panel -- Front View .................................................... 10-1
Figure 10-2 Instrument Control & Power Panel -- Rear View..................................................... 10-2
Figure 10-3 Locating the Lower Frame Components............................................................... 10-11
Figure 10-4 Laser Controller Box Location .............................................................................. 10-12
Figure 10-5 The PS I/O Board Assembly................................................................................. 10-14
Figure 10-6 The Main Processor Board Assembly .................................................................. 10-15
Figure 10-7 Operator Control Panel Location .......................................................................... 10-16
Figure 10-8 Air Filter Assembly ............................................................................................... 10-18
End of Section
A-2
45563-B
Appendix B: Installation Checklist

Inspecting and unpacking the PlateJet shipment
Inspect the shipping crate for damage
Unpack the PlateJet crate
Verify contents as per packing slip (attached to the front panel of the crate)
Locating the PlateJet
Move the PlateJet to the room it will be installed in
Locate the PlateJet as per the Site Preparation manual
Remove all latched panels (2 back, 1 front, 2 sides)
Inspecting the internal components for shipping damage
Inspect the Optics Plate
Inspect the Instrument Control & Power Panel
Inspect the DC Power Supply
Inspect the Laser Controller1 or Laser Controller Box2
Inspect the Modulator Driver
Inspect the Main Processor Board Assembly
Inspect the I/O PS Board Assembly
Inspect the Linear Drive Micropositioner Assembly
Inspect the Media Guide Assembly
Inspect the Media Tray Assembly
Inspect the Air Filter
Inspect the Vacuum Pump
Removing the internal packing from the PlateJet
Remove the spinner carriage retaining bracket
Remove the media guide (squeegee) locking bolts
Remove the internal drum end plates retaining bolts and spacers
Remove the shipping brackets (red) from vacuum pump anti-vibration plate
Unsrew the thumb screws that lock the slide door inplace (Thermal only)
Installing the PlateJet-V
Raise the PlateJet onto the four support pads and level the PlateJet
Connect the house air to the AIR IN quick connect at the Instrument Control & Power Panel
Set the house air to 80 psi
Connect the SCSI Wide 15 meter (50) cable to Instrument Control & Power Panel
Check the power at the wall outlet (3-pin only) for 230VAC 10% 47-63Hz single phase (no neutral)
Notes:
1
2
The laser controller is applicable to the Sapphire and Sapphire4.

The laser controller box is applicable to the Thermal PlateJet
45563-B
B-1

Connect the power cord to the PlateJet

Connect the power cord to the wall outlet
Installing the PlateJet-T

Raise the PlateJet onto the four support pads and level the PlateJet
Connect the house air to the AIR IN quick connect at the Instrument Control & Power Panel
Set the house air to 80 psi
Connect the SCSI Wide 15 meter (50) cable to Instrument Control & Power Panel
Check the power at the wall outlet (3-pin only) for 230VAC 10% 47-63Hz single phase (no neutral)
Connect the power cord to the PlateJet
Connect the power cord to the wall outlet
Checking the operation of the PlateJet
Turn the power on to the PlateJet
Check that the laser comes on
Check that the spinner carriage goes to the HOME position
Check that the spinner motor comes on.
Check media loading for all media types and sizes used by the customer
Check the operation of the media guide
Check and record the light output at the laser and media plane
Installing the host computer
Check the host computer for compliance and connectivity
Check the host computer has a dedicated SCSI controller
Connect the SCSI Wide 15 meter (50) cable to host computer SCSI controller
Connect the AC power cord to the wall outlet
Turn on the power to the host computer
Verify in boot-up screen that the SCSI Controller can see the PlateJet
Install the PlateJet Toolkit onto the DESKTOP and the test-image files into a dedicated folder.
Launch the PlateJet Toolkit Utility
Go to the SETUP Window and set the SCSI ID (default is 6) and adapter ID
Go to the PRINTER STATUS menu and check that the PlateJet is on-line
Checking the operation of the PlateJet system
Go to the PlateJet and check that there is READY status
Using PlateJet Toolkit Utility (PRINT menu), simulate an image using a dummy piece of media
Replace all panels
Perform a power series for each media type and resolutions
Check, and if required set the START OF LINE
Check, and if required set the START OF IMAGE
B-2
45563-B
Installation Check List
Training the customer on PlateJet operational and maintenance procedures

Connecting the air line and setting the correct air pressure
Connecting the SCSI cable
Connecting the AC power cord
Turning the power ON and OFF to both the PlateJet and host computer
Reading the vacuum and air pressure gauges
Loading and unloading media
Cleaning the media tray and outside panel surfaces
Recovering jammed media in the internal drum
Using the PlateJet Toolkit utility and test files
Setting the exposure at the host for imaging
Getting sign-off on the PlateJet
Complete the requirements outlined in the Installation Completion Form and get customer sign-off.
End of Section
45563-B
B-3
B-4
45563-B
Appendix C: Special Tools List

PlateJet Sapphire Recommended Tools List
The PlateJet Sapphire special tools required for service procedures are
Part#
39043
38800
37582
38159
38217
45231
Description
Gauge-Readhead
Tool-Focus - Adapter-SCSI 50F-68M
Target-1 hole
Assy-Jig 1 hole
Assy-Spinner lens centering jig
Key-Latch 45226
End of Section
45563-B
C-1
C-2
45563-B
Appendix D: Spare Parts

Spares Common to the 4Up Model
Attached is the spares list for the PlateJet Sapphire. This Appendix is comprised of a Safari
Report .pdf file that encorporates each of the spares kits as follows:
Part #
Description
45870
Assy-Spares Emer/Saph Common
45872
Assy-Spares Sapphire Common
45873
Assy-Spares Emer/Saph 8Up
45874
Assy-Spares Emer/Saph 4-Up
45875
Assy-Spares Emer/Saph Visible
45876
Assy-Spares Emer/Saph Thermal
45877
Assy-Spares Saph Manual
45563-B
D-1
D-2
45563-B
7/25/2000
Bill of Material W/ Cross Reference Information
12:34:57
ASSY# 45870
10
ASSY-SPARES EMER/SAPH COMMONRevision
Comp. #
Description
01394
FUSE-FAST BLO 3A 250V 1/4X11/4
QTY PER
5 EA
Eff.:
Manufacturer
Rev :
6/26/2000
Exp.:
0/0/0000
Page
1
Comercial Part#
Eff.:
6/15/2000
Exp.:
0/0/0000
Exp.:
0/0/0000
Exp.:
0/0/0000
Exp.:
0/0/0000
BOM Notes :
LITTELFUSE
BUSSMAN
20
01407
FUSE-SLO BLO 5A 250V1/4X11/4IN
5 EA
Rev :
312003
AGC-3
Eff.:
6/15/2000
BOM Notes :
LITTELFUSE
BUSSMAN
30
21070
SWITCH-MICRO MINI LOW FORCE
1 EA
Rev :
326005
MDA-5
Eff.:
6/15/2000
BOM Notes :
MICROSOFT
MICROSOFT
MICROSOFT
MICROSOFT
40
21404
AIRMATIC-REGULATOR
1 EA
Rev :
V3L2103D8
V3L2103D8
V3L2103D8
V3L2103D8
Eff.:
6/15/2000
BOM Notes :
NORDGREN
NORGREN
R07-100-RNKA
R07-100-RNKA
ASSY# 45870
50
Comp. #
Description
32407
SWITCH-ROCKER 15A W/SHIELD
QTY PER
Eff.:
Manufacturer
1 EA
Rev :
6/26/2000
Exp.:
0/0/0000
Page
2
Comercial Part#
Eff.:
6/15/2000
Exp.:
0/0/0000
BOM Notes :
ETA
60
36735
GAUGE-VACUUM 30"HG 2" PNL MNT
1 EA
3120F323P7T1W02L15A
VENDOR SPEC-A
Rev :
Eff.:
6/15/2000
Exp.:
0/0/0000
BOM Notes :
MARSH
VARIOUS
140
38757
SWITCH-PRESSURE 60 PSIG
1 EA
J2405 (MEXICO)
VENDOR SPEC-A
Rev :
Eff.:
6/15/2000
Exp.:
0/0/0000
BOM Notes :
HOBBS
150
38779
FILTER-COALESCING 1/4NPT
1 EA
76054
VENDOR SPEC-A
Rev :
Eff.:
6/15/2000
Exp.:
0/0/0000
BOM Notes :
PARKER
200
39145
ASSY-FAN,SINGLE,24V,6P,NO TACH
1 EA
Rev :
11F16ECSB
VENDOR SPEC-A
A
Eff.:
6/15/2000
Exp.:
BOM Notes :
ASSEMBLY-A
BILL OF MATERIALS-A
0/0/0000
ASSY# 45870
210
Comp. #
Description
39146
ASSY-FAN,DUAL,24V,6POS,NO TACH
QTY PER
1 EA
Eff.:
Manufacturer
Rev :
6/26/2000
Exp.:
0/0/0000
Page
3
Comercial Part#
Eff.:
6/15/2000
Exp.:
0/0/0000
BOM Notes :
ASSEMBLY-B
BILL OF MATERIALS-B
240
39269
ASSY-PS I/O INTERCONNECT UNIT
1 EA
Rev :
Eff.:
6/15/2000
Exp.:
0/0/0000
BOM Notes :
ASSEMBLY-B
BILL OF MATERIALS-B
250
39270
ASSY-CONTROLLER UNIT
1 EA
Rev :
Eff.:
6/15/2000
Exp.:
0/0/0000
BOM Notes :
ASSEMBLY-B
BILL OF MATERIALS-C
290
39357
GAUGE-PANEL MOUNT 100 PSIG
1 EA
Rev :
Eff.:
6/15/2000
Exp.:
0/0/0000
Exp.:
0/0/0000
BOM Notes :
MARSH
300
40592
RELAY-SOLID STATE 25A 280V DCC
1 EA
Rev :
J2448
Eff.:
6/15/2000
BOM Notes :
VARIOUS
CRYDOM
VENDOR SPEC-B
D2425
ASSY# 45870
360
Comp. #
Description
39761
ASSY-LINEAR MOTOR ELEC UNIT
QTY PER
1 EA
Eff.:
Manufacturer
Rev :
6/26/2000
Exp.:
0/0/0000
Page
4
Comercial Part#
Eff.:
6/15/2000
Exp.:
0/0/0000
BOM Notes :
ASSY INSTR-A
BILL OF MATERIALS-A
370
39707
CRATE-PCB PROCESSOR PLATEJET
2 EA
Rev :
Eff.:
6/15/2000
Exp.:
0/0/0000
BOM Notes :
CUSTOM VENDOR SPEC-A
380
43253
FILTER-AIR CARDCAGE 336.5X146X
1 EA
Rev :
Eff.:
6/15/2000
Exp.:
0/0/0000
BOM Notes :
MECHANICAL-B
390
38031
SWITCH-VACUUM 7 IN HG NO
1 EA
Rev :
Eff.:
6/15/2000
Exp.:
0/0/0000
BOM Notes :
HOBBS
77342-7
mfg_xref4_1
7/25/2000
12:37:07
ASSY# 45872
10
ASSY-SPARES SAPPHIRE COMMON Revision
Comp. #
Description
45216
ASSY-VACUUM SOLENOID
QTY PER
1 EA
Eff.:
Manufacturer
Rev :
6/26/2000
Exp.:
0/0/0000
Page
1
Comercial Part#
Eff.:
6/15/2000
Exp.:
0/0/0000
Exp.:
0/0/0000
BOM Notes :
BOM
20
42405
KNOB-FRONT PANEL
1 EA
Rev :
Eff.:
6/15/2000
BOM Notes :
MECHANICAL-A
30
42339
ASSY-PS,PFC,28/24/12/15V,800W
1 EA
Rev :
Eff.:
6/15/2000
Exp.:
0/0/0000
Exp.:
0/0/0000
BOM Notes :
BOM
40
45882
ASSY-F/S OPERATOR PANEL
1 EA
Rev :
Eff.:
6/15/2000
BOM Notes :
BOM
SEE ASSY INSTRUCT 42354
50
43974
FILTER-AIR 1-1/4X5-1/2X6-5/16
2 EA
Rev :
Eff.:
6/15/2000
Exp.:
0/0/0000
BOM Notes :
UNIVERSAL AIR FILTER CO
CUSTOM VENDOR SPEC-A
mfg_xref4_1
7/25/2000
12:38:08
ASSY# 45873
20
ASSY-SPARES EMER/SAPH 8UP
Comp. #
Description
39124
ASSY-VACUUM PUMP
QTY PER
1 EA
Revision
Eff.:
Manufacturer
Rev :
6/26/2000
Exp.:
0/0/0000
Page
1
Comercial Part#
Eff.:
6/15/2000
Exp.:
0/0/0000
Exp.:
0/0/0000
BOM Notes :
ASSEMBLY-B
BOM
30
39341
ASSY-SQUEEGEE MOTOR 24V
1 EA
Rev :
Eff.:
6/15/2000
BOM Notes :
ASSEMBLY-A
BILL OF MATERIALS-A
mfg_xref4_1
7/25/2000
12:40:25
ASSY# 45874
10
ASSY-SPARES EMER/SAPH 4-UP
Comp. #
Description
39883
ASSY-MOTOR MEDIA GUIDE
QTY PER
1 EA
Revision
Eff.:
Manufacturer
Rev :
6/26/2000
Exp.:
0/0/0000
Page
1
Comercial Part#
Eff.:
6/15/2000
Exp.:
0/0/0000
BOM Notes :
ASSEMBLY-B
BILL OF MATERIALS-A
mfg_xref4_1
7/25/2000
12:41:59
ASSY# 45875
10
ASSY-SPARES EMER/SAPH VISIBLE Revision
Comp. #
Description
39300
ASSY-SPINNER/MULTIPASS SWITCH
QTY PER
1 EA
Eff.:
Manufacturer
Rev :
6/26/2000
Exp.:
0/0/0000
Page
1
Comercial Part#
Eff.:
6/15/2000
Exp.:
0/0/0000
BOM Notes :
ASSEMBLY-A
BILL OF MATERIALS-A
20
41121
ASSY-SHUTTER w/PLUG
1 EA
Rev :
Eff.:
6/15/2000
Exp.:
0/0/0000
Exp.:
0/0/0000
BOM Notes :
ASSEMBLY-A
30
36981
MODULATOR-A-0 200MHZ GR/BL
1 EA
Rev :
Eff.:
6/15/2000
BOM Notes :
CRYSTECH
CRYSTECH
CRYSTAL TECHNOLOGY INC.
40
38176
ASSY-WESTWIND SPINNER MOTOR
1 EA
Rev :
Eff.:
3200-126
99-48146-14
VENDOR SPEC-A
6/15/2000
Exp.:
0/0/0000
Exp.:
0/0/0000
BOM Notes :
ASSEMBLY-C
50
38346
ASSY-DRIVER AOM 200/75M
1 EA
Rev :
Eff.:
6/15/2000
BOM Notes :
SEE 38320 FOR INFO
TEST SPEC-A
ASSY# 45875
60
ASSY-SPARES EMER/SAPH VISIBLE Revision
Comp. #
Description
39186
ASSY-PCB PHOTODETECTOR
QTY PER
1 EA
Eff.:
Manufacturer
Rev :
6/26/2000
Exp.:
0/0/0000
Page
2
Comercial Part#
Eff.:
6/15/2000
Exp.:
0/0/0000
Exp.:
0/0/0000
BOM Notes :
39186 rev E.zip
70
37465T
LASER-DOUBLED YAG 100mW
1 EA
Rev :
Eff.:
6/15/2000
BOM Notes :
N/A
mfg_xref4_1
7/25/2000
12:42:45
ASSY# 45876
10
ASSY-SPARES EMER/SAPH THERMALRevision
Comp. #
Description
39477T
F/S - LASER DIODE ARRAY
QTY PER
1 EA
Eff.:
Manufacturer
Rev :
6/26/2000
Exp.:
0/0/0000
Page
1
Comercial Part#
Eff.:
6/15/2000
Exp.:
0/0/0000
BOM Notes :
BOM
ASSEMBLY INSTRUCT-A
20
39478
ASSY-SPINNER DOVE PRISM
1 EA
Rev :
Eff.:
6/15/2000
Exp.:
0/0/0000
BOM Notes :
CUSTOM VENDOR SPEC-1
BILL OF MATERIAL-1
30
39494
ASSY-SHUTTER LD
1 EA
Rev :
Eff.:
6/15/2000
Exp.:
0/0/0000
Exp.:
0/0/0000
BOM Notes :
BOM
ASSEMBLY-C
130
42373
ASSY-DRIVER AOM
1 EA
Rev :
Eff.:
6/22/2000
BOM Notes :
BILL OF MATERIALS-A
140
39651
ASSY-DOVE SPINNER DRIVER
1 EA
Rev :
Eff.:
6/15/2000
BOM Notes :
WESTWIND AIR BEARINGS INC
D1580-61
Exp.:
0/0/0000
ASSY# 45876
150
Comp. #
Description
45463
ASSY-BLOWER OPTICS LD
QTY PER
1 EA
Eff.:
Manufacturer
Rev :
6/26/2000
Exp.:
0/0/0000
Page
2
Comercial Part#
Eff.:
6/22/2000
Exp.:
0/0/0000
BOM Notes :
BOM
ASSEMBLY INSTRUCT-A
160
45200
SW-INTLK DPST 0.1A,250V,MOM,WH
1 EA
Rev :
Eff.:
6/15/2000
Exp.:
0/0/0000
BOM Notes :
CHERRY
170
37758
ROLLER-SQUEEGEE
1 EA
Rev :
F78-00A
VENDOR SPEC-A
B
Eff.:
6/15/2000
Exp.:
0/0/0000
BOM Notes :
MECHANICAL-B
180
38726
TRACK-14"L X 11" TRAVEL SS
1 PR
Rev :
Eff.:
6/15/2000
Exp.:
0/0/0000
Exp.:
0/0/0000
BOM Notes :
MCMASTER-CARR
190
39775
ASSY-LASER CONTROL UNIT
1 EA
Rev :
12155A24
VENDOR SPEC
Eff.:
6/15/2000
BOM Notes :
ASSEMBLY-B
BOM
ASSEMBLY INSTRUCT-A
ASSY# 45876
200
Comp. #
Description
45203
FUSE-SLOW BLOW,2A,250V,5X20 MM
QTY PER
5 EA
Eff.:
Manufacturer
Rev :
6/26/2000
Exp.:
0/0/0000
Page
3
Comercial Part#
Eff.:
6/15/2000
Exp.:
0/0/0000
Exp.:
0/0/0000
BOM Notes :
BUSSMAN
LITTLEFUSE
210
39650
ASSY-SPINNER MIRROR LD
1 EA
Rev :
GDC-2A
218.002
VENDOR SPEC
1
Eff.:
6/15/2000
BOM Notes :
WESTWIND AIR BEARINGS INC
220
42364
ASSY-WIRING THERMISTER
1 EA
Rev :
Eff.:
CUSTOM VENDOR SPEC-1

6/22/2000
Exp.:
0/0/0000
Exp.:
0/0/0000
BOM Notes :
ASSEMBLY-B
BOM
230
45881
ASSY-PHOTODETECTOR LD
1 EA
Rev :
Eff.:
6/22/2000
BOM Notes :
BOM
ASSEMBLY INSTRUCITONS-A
240
45971
ASSY-AOM W/ MOUNT LD
1 EA
Rev :
Eff.:
6/22/2000
Exp.:
0/0/0000
BOM Notes :
BOM
mfg_xref4_1
7/25/2000
12:43:54
ASSY# 45877
10
ASSY-SPARES SAPH MANUAL
Comp. #
Description
37330
RAIL-TRACK ROLLER
QTY PER
Revision
Eff.:
Manufacturer
2 EA
Rev :
6/26/2000
Exp.:
0/0/0000
Page
1
Comercial Part#
Eff.:
6/15/2000
Exp.:
0/0/0000
BOM Notes :
INA
20
44930
CAM-CLAMPING BAR PINBAR
2 EA
LFS 32-730 C/ANS

Rev :
Eff.:
6/15/2000
Exp.:
0/0/0000
BOM Notes :
MECHANICAL-B
30
42377
PAD-CLAMPING BAR PINBAR
2 EA
Rev :
Eff.:
6/15/2000
Exp.:
0/0/0000
BOM Notes :
MECHANICAL-A
40
45679
PIN-8MM LOCATING PINBAR
2 EA
Rev :
Eff.:
6/15/2000
Exp.:
0/0/0000
BOM Notes :
MECHANICAL-A
mfg_xref4_1
Appendix E: Wiring Diagrams

Cables Common to Thermal and Visible (46184)
The attached pages provide the wiring diagrams common to the Thermal and Visible PlateJet Sapphire.
45563-B
E-1
E-2
45563-B
Wiring Diagrams
Cables for the Visible System (46182)

The attached pages provide the wiring diagrams common to the Thermal and Visible PlateJet Sapphire.
45563-B
E-3
E-4
45563-B
Wiring Diagrams
Cables For the Thermal System (46183)

The attached pages provide the wiring diagrams for the Thermal PlateJet Sapphire.
45563-B
E-5
E-6
45563-B

SapphireService (46181 B)

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PlateJet Sapphire

Gretag Imaging Group

COPYRIGHT 2000 Gretag Imaging Group

RESTRICTION ON DISCLOSURE, USE, OR DUPLICATION OF PROPRIETARY INFORMATION

European Community - EMC

Section Two: Product Description ............................................................................2-1

Section Three: Theory of Operation .........................................................................3-1

PlateJet Sapphire Service Manual

AOM Focusing Lens and Shutter Assembly................................................................ 3-11

Section Four: Installing PlateJet ...............................................................................4-1

Section Five: PlateJet Packaging Removal..............................................................5-1

Section Six: The Visible Optics Plate .......................................................................6-1

Adjusting the A-O Modulator for Optimum Diffraction Efficiency.................................. 6-17

Section Seven: The Thermal Optics Plate................................................................7-1

Section Eight: Linear Drive System Maintenance ...................................................8-1

PlateJet Sapphire Service Manual

Replacing the Start of Image RGM22S Reference Mark .............................................. 8-16

Section Nine: Media Transport Maintenance ...........................................................9-1

Section Ten: Electronic System Maintenance .......................................................10-1

Appendix A: Table of Figures................................................................................... A-1

Appendix D: Spare Parts .......................................................................................... D-1

Appendix E: Wiring Diagrams .................................................................................. E-1

PlateJet Sapphire Service Manual

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Section One: Introduction

DIODE PUMPED FREQUENCY DOUBLED YAG

(YTTRIUM ALUMINUM GARNET)

PlateJet Sapphire Service Manual

Safety Labels Visible PlateJet

Figure 1-1 Visible Laser Safety Label Locations - Front

Figure 1-2 Visible Laser Safety Label Locations - Left

PlateJet Sapphire Service Manual

VORSICHT: LASERSTRAHLUNG IM GE|FFNETEN ZUSTAND UND NICHT FUNKTIONIERENDER

DIREKTE BESTRAHLUNG MUA

Laser Safety and Warnings for Thermal PlateJet Service Personnel

(ALUMINUM GALLIUM ARSENIDE SEMICONDUCTOR)

CAUTION: USE OF CONTROL OR ADJUSTMENTS OR PERFORMANCE OF PROCEDURES

Laser Safety Labels

PlateJet Sapphire Service Manual

Figure 1-3 Thermal Laser Safety Label Locations - Front

Figure 1-4 Thermal Laser Safety Label Locations - Left

PlateJet Sapphire Service Manual

Common Safety and Miscellaneous Labels

Figure 1-5 Common Safety Label Locations - Back

Label 31104 shown in Figure 1-5 is a mains flash symbol.

Figure 1-6 Error Code Label Locations - Right Door Open

PlateJet Sapphire Service Manual

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Section Two: Product Description

Applicable to the Visible PlateJet.

PlateJet Sapphire Service Manual

Figure 2-7 PlateJet Component Layout (Front View)2

Applicable to the Thermal PlateJet .

PlateJet Sapphire Specifications

Doubled-YAG Green Laser (532 nm wavelength)

Figure 2-8 PlateJet Component Layout (Rear View)2

PlateJet Sapphire Service Manual

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Section Three: Theory of Operation

PlateJet Sapphire Service Manual

The fixed scale is in the form of a tape with an adhesive backing.

Care and Handling

Main Processor Board Assembly