Kodak DirectView CR 500 - Troubleshooting Guide

CR500 Trouble Shooting Guide
Follow steps below to solve problem
1 Talk to the customer and have them describe the problem.

2 When did the problem start ?
3 How often does it occur ?
4 Does it occur on all cassette sizes ?
5 What does the Error Log show (recent, frequent error codes) ?
6 What has been done so far ?
7 See if customer description translates to one of the Top 10 Problems ( listed below ), if not goto step 10.
8 Look up corresponding Error Code on Error Description tab.
9 Trouble shoot per the Error Description suggestion, goto step 12.
10 Check Error Log for repeating codes, see manual for remedy or go to step 11.
11 Complete CALL FOR HELP tab questions, send to Pat Hanley.
12 Feed back solution info to SCAN.
Customers Descriptions Pop-up Error Translation
Screen doesn't come out of cassette when scanned 961-12265 See # 1 of Top 10 Problems
Screen doesn't return to cassette, have to manually retrieve from erase area. 12266-00000 See # 3 of Top 10 Problems
Screen doesn't return to cassette, returns after hitting continue button on pop-up message 963-12267 See # 4 of Top 10 Problems
Screen doesn't return to cassette, can see screen in cassette opening of scanner 963-12302 See # 2 of Top 10 Problems
Screen not fully in cassette, some portion hanging outside of closed cassette door n/a See # 10 of Top 10 Problems
Top 10 CR500 Problems

Official Error Description Error Code
1 Screen Start timeout, screen did not enter scanner 12265

2 Slow Scan stopped, position error while not scanning 12302
3 Screen did not fully enter Erase Assembly 12266
4 Screen did not return to cassette 12267
5 Roller Pair 3 Cam Motor timeout 12263
6 Roller Pair 2 Cam Motor timeout 12262
7 Slow Scan frequency locked range error while not scanning 12301
8 Slow Scan frequency locked range error while scanning 12101
9 Slow Scan stopped, position error while scanning 12102
10 Screen not fully in cassette on return n/a No Error Code generated for this problem
CR500 Common Error Codes
cannot home cassette guides 10031
cannot activate cassette load switch 10032
cannot clamp the cassette correctly 10033
cannot retract feed pin 10034
cannot home feed motor 10035
retrying clamp cassette with guides 10037
retrying extract screen from cassette 10038
Slow scan ER1 frequency locked range error (scanning) 12101

Slow scan stopped ER2 position error limit (scanning) 12102
Slow scan ER3 frequency lock motion stalled (scanning) 12103
Slow scan ER1 frequency locked range error (transport) 12301
Slow scan stopped ER2 position error limit (transport) 12302
Slow scan E3 frequency lock motion stalled (transport) 12303
Slow scan +24v malfunction during screen transport 12307
RP1 cam timeout 12261

screen start sensor blocked 12264
no screen start, screen did not enter reader 12265
screen not fully in erase assembly 12266
screen failed to return to the cassette 12267
all erase lamps malfunctioned 13009
MSC initialization failed 14015

MSC initialization successful 14016
MSC initialization started 14017
side door opened 14018
possible light leak 16010

possible light leak during autozero, imaging system contains out of range noise 16013
cassette task timeout 30041

load plate timeout, did not receive a load screen command 30042
MSC fatal error state 30043
MSC undefined error 30044
Transient 24v loss (happens on occasion) 30048
entered service diagnostics 54001

exited service diagnostics 54002
unable to enter service diagnostics 54003
MCPU application software download complete 54010
MSC application software download complete 54011
Slow Scan boot and application software download complete 54012
Slow Scan application software download complete 54013
Slow Scan parameters download complete 54014
des
12261 Roller Pair 1 Cam Motor Timeout -- A motor and drive pulley rotate a cam which opens and closes the roller pair. A flag on the cam
shaft is used with an optical emitter/detector sensor to determine the location of the cam. The cam shaft is linked to the motor by a
drive belt. This error will occur if the detector does not sense the rotation of the cam shaft before the prescribed time expires.
This error does not alert the customer in anyway of a problem, it is an Error Log entry only.
Cause Action
Belt broken or came off pulleys Replace broken belt or investigate why belt came off pulley. Check
alignment of pulleys, mounting of motor and cam shaft
Broken gear Replace broken gear, if it is the drive gear it is replaced as an

assembly with the motor pinned to it.
Defective motor, wiring harness or circuitry on MSC Bd Trouble shoot using diagnostics and replace the appropriate part
If error is intermittent the cause may be a RP1 cam flag/sensor Replace RP1 cam sensor, torque lightly until sensor is secure.
tolerence issue or the sensor mounting screw may be over DO NOT OVER TIGHTEN
torqued.
Cause Action

If error is intermittent the cause may be a RP2 cam flag/sensor Replace RP2 cam sensor, torque lightly until sensor is secure.
tolerence issue or the sensor mounting screw may be over DO NOT OVER TIGHTEN
torqued.
Cause Action

12265 Screen Start Timeout, Screen did not enter scanner -- This error will occur when the screen is not detected by the Screen Start
Sensor within the prescribed time. The Screen Start Sensor is located between Roller Pair 1 and the Scan Line. The scanner will try
to extract the screen from the cassette up to three times, the first two failures will result in a 10038 error code (retrying to extract
screen from cassette) the third failure to extract the screen from the cassette will result in a pop-up error message on the customers
display indicating a 12265 error.
Cause Action
No screen in cassette Insert screen in cassette
Screen under the transport pad in cassette Insert screen correctly such that it is on top of the transport pad
Static attraction between the screen and the cassette Clean both sides screen with Kodak Min-R Screen Cleaner Wipes. TL-
5280094
Curled or non-flat screens Check curl and flatness using field service gage, replace screens
if out specification.
Screen Start Sensor defective Check operation of Screen Start Sensor using diagnostics, replace
if necessary.
12266 Screen did not full enter the Erase Assembly -- This error indicates that while moving in the scan direction the trail edge of the screen
did not pass the Erase Lamp photo detector. This error will cause a pop-up message indicating a 12266 error, however, does not
alert the customer to manually remove the screen from the erase chimney. The error recovery does not return the screen to the
cassette, it will remain in the erase assembly. This can cause subsequent 12265 (no screen in cassette) or 12300 series (transport
error due to 2 screens in scanner) errors.
Cause Action
Erase lamps flicker but do not fully illuminate Verify lamp and ballast wire connections are tight and secure, if
problem persists replace lamps or ballast as necessary
Erase photo detector not aligned in hole in erase guide Adjust
Erase photo detector covered by debris Clean
If error is intermittent the cause may be a RP1 or RP2 cam Replace RP1 & RP2 cam sensor, torque lightly until sensor is secure.
flag/sensor tolerence issue or the sensor mounting screw may DO NOT OVER TIGHTEN
be over torqued.
12267 Screen did not return to cassette -- This error indicates that while the screen was returning to the cassette either the trail or the lead
edge did not pass under the Start of Scan sensor. This error will cause of pop-up message on the customer display indicating a
12267 error occurred
Cause Action
Screen jam in the erase assembly Check erase assembly RP3 nip for proper operation
be over torqued.
12101 Slow Scan frequency locked range error while scanning -- This error indicates that the prescribed speed range has been exceeded
while scanning a screen. This is an Error Log entry only and is not displayed to the customer. The scanned image will be in spec.
and no image artifacts should result from this error. It should be considered as a warning that the slow scan system may have a
problem in the future.
Cause Action
System tolerance None
12102 Slow Scan Stopped, position error while scanning -- This error indicates that the Slow Scan Motor stopped prematurely during its
move instruction while scanning a screen. This will result as a pop-up message on the customers display indicating the error and
that the scanned image may be unusable.
Cause Action
Screen jam in part of transport path used to scan image Check for an obstruction in the path for the specific size of the
screen for which the error occurred. Horizontal line image artifacts
may be a clue to the location of the obstruction
Defective Slow Scan Motor Using diagnostics check Slow Scan current and velocity profiles
12103 Slow Scan Stopped, frequency lock motion stalled error while scanning -- This is the most severe error indicating that the Slow Scan
Motor stopped abruptly during its move instruction while scanning a screen. This will result as a pop-up message on the customers
display indicating the error and that the scanned image may be unusable.
Cause Action
Screen jam in part of transport path used to scan image Check for an obstruction in the path for the specific size of the
screen for which the error occurred. Horizontal line image artifacts
may be a clue to the location of the obstruction
12301 Slow Scan frequency locked range error while not scanning -- This error indicates that the prescribed speed range has been
exceeded while not scanning a screen. This is an Error Log entry only and is not displayed to the customer. No image artifacts will
result from this error. It should be considered as a warning that the slow scan system may have a problem in the future.
Cause Action
System tolerance None

12302 Slow Scan Stopped, position error while not scanning -- This error indicates that the Slow Scan Motor stopped prematurely during its
move instruction while scanning a screen. This will result as a pop-up message on the customers display indicating the error.
No image artifacts will result from this error.
Cause Action
Screen jam in part of transport path down stream from were Check error log to see if the error is specific to 1 cassette, if so
the image is scanned or during the return of the screen to the check cassette for obstruction or door open failure.
cassette.
Screen jam near cassette entrance due to a skewed screen This can be verified by removing the top cover of the scanner, then
returning to the cassette. watching a screen return into a cassette (top cover removed) which
frequently shows the problem. As the screen moves into the cassette
the trail edge of the screen may pucker upward, indicating the screen
edge has hit the side wall of the cassette due to skew. Mod 2 fixes
a known skew problem.
Screen jam near cassette entrance due to cassette door being This can be verified by removing the top cover of the scanner, then
pushed closed by trail edge of returning screen. watching a screen return into a cassette (top cover removed) which
frequently shows the problem. As the screen moves into the cassette
the trail edge of the screen may pick up the door and push it closed,
stopping the screen at the cassette entrance outside the door and
stopping the Slow Scan motor. With the cassette removed from the
scanner, the screen will stick out approx. 0.400 inches from the
cassette interface face plate. This problem is fixed by software
included in Mod 3 and Mod 4. If the problem exists with the Mods
installed, it may be a specific to a defective cassette door identified
in the error log.
RP1 drive roller bearing not seated in bore Clean and lubricate (light silicone grease) the RP1 drive roller
shaft in the area of the bearings, reassemble in bore.
12303 Slow Scan Stopped, frequency lock motion stalled error while not scanning -- This is the most severe error indicating that the Slow
Scan Motor stopped abruptly during its move instruction while not scanning a screen. This will result as a pop-up message on the
customers display indicating the error.
Cause Action
Screen jam in part of transport path down stream from were Check error log to see if the error is specific to 1 cassette, if so
the image is scanned or during the return of the screen to the check cassette for obstruction or door open failure.
cassette.
RP1 drive roller bearing not seated in bore Clean and lubricate (light silicone grease) the RP1 drive roller
shaft in the area of the bearings, reassemble in bore.
13009 This error occurs when electrical current is not sensed in the lamp ballast circuit. Use diagnostics to actuate the lamp, the relay will
click when the circuit is turned ON. The lamps should light up approx 1-2 seconds later.
Cause Action
Relay clicks but lamps don't turn ON. May be caused by a bad Replace lamps as a pair.
lamp. If one lamp is bad ,neither will light.
Relay does not click when lamp turn on is initiated. Check for signal at the relay, if none check wiring, MSC BD is the
source of the signal. Replace relay, MSC Bd or repair wiring as
necessary.
be over torqued.
Screen Screen not fully in cassette on return, some part of the screen is outside of the cassette enterance. During the screen return RP1 will
Return transport the screen into the cassette leaving it approx 1 inch outside of the cassette, the motion of the Feed Motor will cause the
Error Transport Pad inside the cassette to carry the screen fully into the cassette and lock the cassette door.
Viewing the operation of the CR500 with the top cover off and the top of a problem cassette removed is a good way to observe this
problem.
Cause Action
Transport Pad not carrying screen into cassette If carrier pad is worn or has debris (gray appearance) inbedded in it,
there may not be enough friction to transport the screen into the
cassette the final 1 inch. Replace the Transport Pad or Cassette.
Screen has excessive non-flatness (bowl shaped or domed) Loss of screen contact with the Transport Pad results in less friction
between the screen and pad, the slippage may cause part of the
screen to be left outside of the cassette. Replace the non-flat screen.
Answer the questions below and have the information ready when making your call for help.
Name of site?
Location (city, state) ?
S/N of CR500 with problem ?
Mod #'s installed ?
Actuation Count ?
What is the problem?
When was the CR installed?
When did the problem start?
How often does it occur?
What are the software versions? (read from diag screen to get actual versions downloaded and running
on embedded boards)
What do the error logs show?
What has been done so far?
If the problem is an image artifact, is it in the artifact database?
Are all screen sizes effected by the artifact?
Common to one cassette?
Has the Total Quality Tool (TQT) been run?
For help call Pat Hanley 585-477-2581 or Lotus Notes ins. # 319406
CR500 Scan Sequence
In normal operation mode, insert a cassette then watch and listen for the following sequence of events.
1. Beep once.
2. Turn on the system LED.
3. If guide home sensor is not blocked, run guide motor home until it is.
4. Run guide motor to close guides until guide load sensor is blocked. Leave the guide motor energized
at 75% power to hold the guides shut.
5. Run side actuator motors to engage side actuators. Leave motors energized at 50% power to hold
the side actuators in position.
6. Run the pin motor to extend the feed pin into the cassette. Leave the motor energized to hold it in
that position.
7. Run roller pair one cam motor until roller pair one is closed.
8. Read the barcode on the cassette.
9. Run the slow scan motor at the appropriate speed for the cassette size.
10. Turn on the screen start sensor.
11. Run the feed motor to move the pin towards the mouth of the cassette and push the screen out of th
cassette into roller pair one.
12. Stop the feed motor and remove power from it.
13. When the screen start sensor sees the leading edge of the screen, note the time.
motor.
15. Turn off the screen start sensor so its light does not interfere with the scan.
16. Flash the system LED to show data transfer is in progress.
17. Wait until the leading edge of the screen has reached roller pair two. This occurs 5201 to 8710 ms
after the leading edge passes the screen start sensor, depending upon the screen size.
18. Run the roller pair two cam motor to close roller pair two.
19. Once roller pair two is fully closed, turn on the erase lamps.
20. Once roller pair two is fully closed, run the roller pair one cam motor to open roller pair one.
21. Wait until the trailing edge of the screen passes the scan line. This occurs , 18030 to 25330 ms after
the leading edge passes the screen start sensor, depending upon the screen size.
22. Stop flashing the system LED. The scan is complete.
23. Start the erase motor running at the appropriate speed for the cassette size.
24.
25. Run
When the roller
the pairedge
trailing threepasses
cam motor until roller
the erase screenpair threestop
sensor is closed.
and remove power from the erase moto
For some plate sizes, we allow the screen to move a little farther into the erase unit before we stop the
erase motor.
26. Stop the slow scan motor.
27. Wait an appropriate amount of time for the last part of the screen to be fully erased.
28. Run the roller pair one cam motor to close roller pair one. All three roller pair are now closed.
29. If the screen had a high exposure, run the erase motor and slow scan motor slowly in the reverse
direction to provide extra erase exposure to the screen.
30. Turn on the screen start sensor.
31. Run the slow scan and erase motors at high speed until the screen has completely passed the screen
start sensor.
32. Stop and remove power from the erase motor.
33. Turn off the erase lamps.
34. Wait a while for the tail of the screen to get through roller pair.
35. Run the pin motor to extend the pin yoke to receive the pin block.
36. Increase the holding current of the side actuator motors to 100%.
37. Run the feed motor to move the feed pin to the lock (over travel) position. Stop and hold it there wit
full motor current.
38. Stop the slow scan motor.
39. Run the pin motor to retract the pin from the cassette. Leave the pin motor energized to hold the pi
in the retracted position.
40. Run the feed motor to move the pin to the home position ad remove power from the feed motor.
41. Run the side actuator motors to disengage the side actuators then remove power from the side
actuator motors.
42. Run the guide motor until the guide home sensor is blocked. Remove power from the guide motor.
43. Beep two times.
44. Run all three cam motors until the respective roller pairs are open.
45. Run the slow scan motor to seat the drive belt.
46. Turn off the system LED.
47. Remove power from the slow scan motor.
Screen Curl and
Flatness Info
Flatness
Specification
Mod Description Mod Kit Production Start Date MFG to Blacken Active/
Part # S/N Range Mod # Inactive
1 Version 3.60.09 CP10 Software. (Selective Mod) 6F5614 337, 343 & Greater 2/19/2004 YES Inactive
2 Erase Timing Belt changed from P/N 936096 to P/N 559174. 6F5894 359 & Greater 2/27/2004 YES Active
(Mandatory Mod)
3 Version 3.60.09 CP12 Software. (Mandatory Mod) 6F6032 336, 378 & Greater 3/5/2004 YES Active
4 Version 3.60.09 CP15 Software, Parts for Erase Lamp 6F6301 550 & Greater 5/17/2004 YES Active
Update, Erase Assembly, Top Cover Update, Access Cover
Addition, and Slow Scan Update. (Mandatory Mod)
5 Reserved for Version 4.1 S/W but not used. No Inactive
6 MS Software Security Patch 02-04-03 6F9272 5/17/2004 No Active
7 MS Software Security Patch 04-04-03 6F9273 5/17/2004 No Active
8 Addition of UHMWPE tape to edge of Erase Lamp Housing 6F9686 =/>590 for US
=/>3000 for KEPS 6/9/2004 YES Active
9 Addition of Cowling Part No. 6F9015 9F1416 =/> 800 for US

=/> 3200 for KEPS` Yes Active
Glossary
customer description Words the customer may use to describe a problem.
pop --up error Error message displayed on customers monitor
pop --up message Message displayed on customers monitor
screen lead edge Screen edge that leaves the cassette first regardless of transport direction, this
is the edge nearest the cassette door
screen trail edge Screen edge that leaves the cassette last regardless of transport direction, this
is the edge furthest from the cassette door
RP Roller Pair, example RP1, transport rollers in the Slow Scan assembly
Debris Artifact A negative density artifact, the debris may be a dust fiber, fingerprint, spot,
verticle or horizontal line. Debris artifacts can be removed by cleaning with a lint
free cloth or for more stubborn problems cleaning with Kodak Min-R Screen
Cleaning Wipes.
Depression Line Defect (DLD) The appearance of a depression in the phosphor surface when viewed in
reflected light at some angle. The depression line or lines are in the direction of
transport and correlate to heavy localized scratches on the backside of the
screen. This defect by itself will not cause an image artifact and the screen
does not need to be replaced.
Depression Line Artifact (DLA) A plus density line or lines in an image in the direction of transport that correlate
to heavy localized scratches on the backside of the screen. Some form of
chemical contamination on the screen surface is required for the artifact to be
seen. If the artifact is permanent the screen should be replaced.
Stub Line Artifact This is a horizontal line (perpendicular to the direction of transport) artifact in an
image caused by a momentary screen speed change, such as the lead edge of
the screen hitting an obstacle in the screen transport path. It should appear as
an edge to edge positive density line. The position of the line on the image will
correlate to where the lead edge of the screen was when the stub occurred.
May be caused by excessive positive lead edge screen curl or problem in the
transport path.
Horizontal White Line Artifact A negative density artifact (perpendicular to the direction of transport) that may
not be uniform edge to edge 2 to 5 mm in width. This may be debris (try
cleaning screen) or screen speed loss caused by chemical contamination. If
cleaning does not remove artifact, replace screen.
Verticle White Line Artifact A negative density artifact (parallel to the direction of transport) that may not be
uniform top to bottom 2 to 5 mm in width. This may be debris (try cleaning
screen) or screen speed loss caused by chemical contamination. If cleaning
does not remove artifact, replace screen.
Calibration Artifact A vertical line or lines (parallel to the direction of transport) running top to
bottom in the image. May be positive or negative density, and will correlate to
the collector profile of a specific screen size. My be caused by calibrating with a
dirty or chemically damaged screen or dust particles in the optics (usually top or
bottom aperature of the collector).
Chemical Artifact An image artifact that causes a permanent speed loss on the screen. May be in
the shape of a fingerprint, puddle, streak or swipe mark in a non-vertical or non-
horizontal direction.
Horizontal White
Line Artifact
Microsoft Photo
Editor 3.0 Picture
Chemical Artifact 1 Chemical Artifact 2

Kodak DirectView CR 500 - Troubleshooting Guide

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Kodak DirectView CR 500 - Troubleshooting Guide

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CR500 Trouble Shooting Guide

Follow steps below to solve problem

1 Talk to the customer and have them describe the problem.

Customers Descriptions Pop-up Error Translation

Top 10 CR500 Problems

1 Screen Start timeout, screen did not enter scanner 12265

Slow scan ER1 frequency locked range error (scanning) 12101

RP1 cam timeout 12261

all erase lamps malfunctioned 13009

MSC initialization failed 14015

possible light leak 16010

cassette task timeout 30041

entered service diagnostics 54001

Broken gear Replace broken gear, if it is the drive gear it is replaced as an

Broken gear Replace broken gear, if it is the drive gear it is replaced as an

Broken gear Replace broken gear, if it is the drive gear it is replaced as an

Erase photo detector not aligned in hole in erase guide Adjust

Erase photo detector covered by debris Clean

System tolerance None

Location (city, state) ?

S/N of CR500 with problem ?

Mod #'s installed ?

What is the problem?

When was the CR installed?

When did the problem start?

How often does it occur?

What do the error logs show?

What has been done so far?

If the problem is an image artifact, is it in the artifact database?

Are all screen sizes effected by the artifact?

Common to one cassette?

Has the Total Quality Tool (TQT) been run?

5 Reserved for Version 4.1 S/W but not used. No Inactive

6 MS Software Security Patch 02-04-03 6F9272 5/17/2004 No Active

7 MS Software Security Patch 04-04-03 6F9273 5/17/2004 No Active

9 Addition of Cowling Part No. 6F9015 9F1416 =/> 800 for US

pop --up error Error message displayed on customers monitor

pop --up message Message displayed on customers monitor

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