The latest Polyscience Chiller Operators Manual has been posted on the Chiller page: Operators Manual for Refrigerated Recirculating Chillers.

The cable parts page has been updated: Thermal head cable 10-4149A replaces cables 10-3517A and 10-3516A.

The S to F speed upgrades now require a water cooling upgrade. See the FCOs page for details.

When you set up a heat exchanger, make sure that you set caselow to 16 and casehigh to 32.

For full details, see Installation and Maintenance: Heat Exchanger for Trendsetter VLF or download it from the Heat Exchanger page.

Download the updated procedure here: Installation and Maintenance: Heat Exchanger for Trendsetter VLF or on the Heat Exchanger page.

The Trendsetter VLF Operator Guide is now available in simplified Chinese on the Reference page.

Controlled release 4.0 has been withdrawn and will be replaced by version 4.1. See the Control/settings page for details.

The parts kit and the tool kit for the shaft encoder upgrade have been updated to reflect the new style Heidenhain encoders. For details, go to the FCOs page or the Upgrades page.

The Trendsetter VLF Operator Guide is now available in Spanish. To download the operator guide, go to the Reference page.

The parts information for the Trendsetter VLF table cylinders and supporting hardware has been updated. See the Cylinder page for details.

The Trendsetter VLF Operator Guide is now available in German. To download the operator guide, go to the Reference page.

The CSC-PSS contact information for CAP has been updated on the Escalation page. The e-mail address has changed and separate phone numbers for Australia and Shanghai are now available.

The following information was added to the Heat Exchanger page on TechPlanet:

• The interface in the Polyscience chiller has a jumper across pins 1 and 9 which is used as a cable detect signal by the Trendsetter. The heat exchanger does not require an interface cable to the Trendsetter, but the firmware still expects a cable detect jumper on the interface. A jumper plug (Creo part number 220-01149A) has been created to provide the cable detect signal by connecting pins 1 and 9. This plug connects to the Chiller connector on the debris removal cabinet or to the interface on the Trendsetter if there is no debris unit installed. If the jumper plug was not shipped with one of the early heat exchanger shipments, then order a jumper plug. As a temporary measure, connect a jumper between pins 1 and 9 on the connector or mask status #25 in the firmware (mask on 25, nvs save status 1).
• The water filter has an O-ring to seal it. When replacing the filter, be careful not to damage the O-ring and make sure that the filter housing is tight when it is re-installed. A damaged O-ring may result in a slow leak. Optionally, you can lubricate the O-ring with Dow-Corning high vacuum grease to provide a better seal—Lytron coats the O-ring with this grease in the factory.

The escalation process and contacts have been updated. See the Escalation page for details.

See the Control/settings page for details.

When upgrading a device to use a heat exchanger instead of a chiller, first determine what the maximum and minimum temperature values are for that site. To view the temperature values, see the document posted on the Heat Exchanger page.

The English and Dutch user guides have been updated and are available on the Reference page.

An interim firmware version is available for customer sites that are currently experiencing problems—version 2.02 build 13. Version 2.02 is an updated version of 2.00 build 53 and supports the DM picker. The next controlled release is scheduled for 2005-Q2.

If firmware versions 2.00 build 50 to 2.02 build 13 are installed and the machine is running positive plates, set the parameters temp b2 and temp b3 to 4. This controls the number of swaths to hold focus to ensure that the emulsion on the edges of the plates are exposed and will be cleaned off the plate. The default for both of these parameters is 0. The symptom is focus error detected at 0 inches while imaging. An examination of the plate shows that there is a focus artifact at the edge of the plate.

See the FCOs page and the Heat Exchanger page for details.

This affects Thermal 1.x heads with head firmware version 1.93, 1.95, or 1.96 and LVD hardware version 4 or later

If all of the above conditions apply, and the device has more than one media setup, when you switch media the stroke tables may become corrupted and display all 33s. This can cause image artifacts or banding.

If the device you are working on meets all the conditions above and has more than one media setup, even if you are not experiencing image artifacts or banding, complete the following workaround:

Workaround

1. Check the stroke table by typing stroke.
2. Check the head firmware version and LVD hardware version by typing head version. You're looking for a Thermal 1.x head with:
   • head firmware version 1.93, 1.95, or 1.96
   and
   • LVD hardware version is 4 or later
3. Repair the stroke tables and prevent future corruption by using the following commands:
   • MPE: Type set head r6 0.
   • MCE, and newer MPE platforms where r6 does not exist: Type set head lvreverse 0.
4. MPE only: type nvs save head.
5. Reset the device.

The 33s in the stroke tables are active and have not been saved, so resetting the device will clear them. After resetting the device the head will perform a stroke cal automatically on the first plot as each media is selected.

A permanent solution will be rolled out in the next two weeks.

The 2MB MPE boards (503-00075A) are interchangable with the regular 1MB MPE boards (10-3692B). There are no firmware changes or changes to the firmware loading procedures between these boards. The 2MB boards will be installed in new devices, but can be replaced with 1MB MPE boards in the field. No versions of the Trendsetter VLF firmware requires a 2MB MPE board.

The Trendsetter VLF specifications document has been updated. See the new specifications on the Overview page.

A new page has been posted containing information on the Lytron MCS50 series heat exchanger.

See Subscan variability on imaged plates on the Troubleshooting page.

New English and Dutch Operator Guides have been posted. See the Reference page for details.

Overstress on the detent mechanism and drum pulley can cause the detent pin to crack and eventually break off. See the troubleshooting item for a procedure that will adjust the detent pin gap and relieve the overstress.

Do not attempt to upgrade the table on machine serial numbers B1 through B19 without contacting the PSS in Product Development, Al Edge, first. It is a complicated upgrade procedure because the frame is a slightly different design from later models. See the Upgrades page for the parts and procedure.

On the recent version of the PolyScience chiller, which is a grey model rather than black, there is an error in the interface connector on the back. The interface has a cable detect that signals the device firmware to turn the coolant pump and the compressor on/off, but some chillers have the incorrect interface installed. See the Chiller Troubleshooting page for a workaround that will fix the cable detect and give some control over the chiller. A field change order (FCO) will be issued later to provide a permanent fix.

Do not upgrade machines to CR2.0. Please wait for the next controlled release before installing new firmware. If CR2.0 is required for a particular reason, contact the Product Support Specialist (Al Edge) to get a recommendation.

When imaging a Creo Positive Thermal Plate (PTP) on the S-speed Trendsetter 5880 at 75 rpm (as specified in the media calculator), resonance frequency has been observed. To avoid any problem with resonance, increase 5880 drum speed on S-speed devices to 90 rpm. The CTP Media Imaging Performance Database is being updated to reflect this new drum speed specification.

A customer requires the ability to load 81.5" plates, which are larger than the current spec and capability. An upgrade kit has been released to install guides that allow proper loading of the larger plate. For details, see FCO CA02367.

Machines with serial numbers BB01 to B019 cannot be upgraded to the shaft (Heidenhain) encoder. A post on the frame blocks access to the encoder, and the drum pin cannot be removed. For photos of the problem, see FCO D992.

On V-speed devices, the carriage can stall if a retrace occurs during plotting. The solution is to change the carriage psteps parameter to 90. For details, see the troubleshooting note, Carriage motor stalls during retrace.

The CD for Controlled Release version 2.0 (March 2003) contained Service Shell v2.4 instead of v2.4 SP1. A new version of the CD (21-0142D) has been released to correct this error.

If you have already installed CR2.0, download Service Shell v2.4 SP1 from the Service Shell Downloads page on TechPlanet. If you haven't yet installed CR v2.0, the part number to order the correct CD, plus details including the 2.4 SP1 release notes, are on the TS VLF Controlled Release v2.0 page.

Requirements for debris removal and ventilation have been added to the Site Preparation document, along with guidelines for assessing power quality and floor vibration. The floor layout diagrams have been updated, and the document is now in a more customer-friendly format. See the Installation page.

When upgrading the Trendsetter VLF MPE firmware to version 2.00 from a previous version (e.g., 1.51 or 1.53), the autoloader startup command must be used instead of nvs upgrade. This command makes room for the new bay state parameters, and sets up all the new autoloader specific parameters. The following is taken from Section 3 of the release notes (please read them!):

... Note:  If this firmware is being installed on a machine that was running base TS VLF firmware (e.g., 1.53), you must run the command autoloader startup ...
    If it is a TSV base machine, set val pbin 0.

Whenever a reed magnet sensor is replaced, order part number 10-5065A. Do not use 15-3063 - it sometimes causes intermittent failures. See the Sensors and Switches page for details.

The leadscrew hanger bearing is received from the vendor without any grease. It has a light rust inhibitor only. For maintenance, it is important that the bearing is packed with grease. A procedure for lubricating this bearing has been added to the Procedures page and also to PM maintenance.

Creo MPE devices are no longer being shipped with metal oxide varistors (MOVs) and spark gaps between line and ground. The MOV assembly (part number 10-3616B) should be removed from units in the field at the next PM visit. Serial numbers B892 and later already have the MOV assembly removed. See FCO CA01804 for details.

The installer file for Service Shell v2.4 SP1 is generating an error message when NVS parameters are backed up. The message will read:

• Timeout waiting for:
• OK
• From this command
• stg verify flash

To avoid this problem, download the updated Service Shell v2.4 SP1 Firmware Upgrade Script from the Service Shell Downloads page and install it on any machine where the Firmware installer file release date is prior to 15 Aug 2003.

The Version 2.8 thermal head has moved to Full Production on Trendsetter VLFs that are running either KPG Thermal Gold or Spectratech 830-n plates worldwide. Both plates are approved for use with FM20. All customers who purchased the V-speed upgrade after January 2003 and are running KPG Thermal Gold or Spectratech 830-n plates are entitled to a free speed upgrade to V2.8. It is recommended that the upgrade be done at the next PM. The upgrade requires a drum speed change on VLF devices to 292RPM (50" drum) or to 260RPM (58" drum).

Non-Quantum Trendsetter VLFs have moved to Full Production worldwide. Since Early Production in January 2003, the performance of non-Quantum Trendsetter VLFs has been comparable to that of Quantum devices. There is no evidence to suggest that reliability is being compromised.

A link to the test files master page, which includes ATP12a and ATP12b files, is now available under Acceptance on the Installation page, and under Software Tools on the Parts/tools page. The links are only available online inside the firewall (not on TechPlanet CDs or on the Extranet).

In response to customer requests, the VLF Core Team has undertaken an initiative to improve how scheduled maintenance is documented and tracked across all VLF devices. One part of the initiative is to ensure that every device is checked for safety and overall operation first, before each assembly is assessed and cleaned/fixed. Once the PM work is finished, the customer is given a list of what has been done and asked to sign off on it. The advantage to Creo is that once the signed PM documents are filed centrally, we have a complete maintenance history for each machine.

The VLF team has recently updated the PM documents to align with these principles. There is now a customer checklist that is to be filled out by the service engineer during a PM visit, signed by the customer, and left on site. It is complemented by a detailed document that gives full instructions for the service engineers, elaborating on each step in the customer checklist and covering what to look for, full procedures and parts. Other output device teams have agreed to prepare and release customer PM checklists for their product lines in the near future.

The Trendsetter VLF PM checklist has been released and translated into Dutch, French, German, Italian, Spanish, and Swedish. The documents are posted under Planned Maintenance on the Maintenance page

Controlled Release version 2.0 is now available for the Trendsetter VLF (FCO CA00573). This controlled release updates MPE firmware to Version 2.00, which combines Trendsetter VLF and Autoloader firmware into one code. The release also enables imaging at V2.8 speed on the Trendsetter VLF and use of the P33 (entry-level) head. All machines should be upgraded at the next PM visit. For details, see Controlled Release version 2.0 on the Control-Settings page.

Trendsetter 4557, 5064, 5080, 5467 and 5880 (non-Quantum) are now shipping with the P33 non-Quantum thermal imaging head. The base model has the head set at S-speed and is shipped with a chiller. Upgrades are available - for details, see ECO CA00527.

There is now a single configurable UDRC-BP upgrade kit, 02-4468, for all devices. Kits 05-0156 and 05-2042 are no longer available.

To order the UDRC-BP for a Trendsetter VLF, fill out the order form on the Debris Removal site's Installation page and e-mail it to Order Management at UDRC.Order@creo.com. Order Management will use the information to assemble the correct parts kit for the device. [Do not use this form to order parts for UDRC servicing or filter replacement.]

An incorrect bend in the hotlink cable can cause plot errors. Symptoms include no plotting on plate, and no error messages. When first troubleshooting a plot problem, replace this cable before replacing the backplane.

For more details, refer to the troubleshooting item: Bad hotlink cable (10-4968B or 10-3518B) can cause plot problems on TS VLF, available on the Troubleshooting page of the Thermal 1/1.7 site.

On VLF devices that have a 1.x thermal head, an error has been reported where part of a swath is missing on the plate, and a full swath may also be missing. This occurs randomly during a plot and may require replacement of the LC-BP and the coaxial (hotlink) cables. For details of the problem, see Missing a Partial Swath.

Fretting on contacts between the cable and sensor causes a loss of connection. At next failure, a new cable and sensor should be installed to improve reliability. For details, see FCO E897.

Controlled Release version 1.1 is now available for the Trendsetter VLF (FCO F008). All machines should be upgraded to the latest controlled release version at the next PM visit. For details, see Controlled Release version 1.1 on the Control-Settings page.

This fix is for all Trendsetter VLF base machines prior to B692. See ECO E788 for details of this procedure.

Some customers find the UDRC too noisy. The UDRC kit now includes longer hoses and cables so that the unit can be placed farther away from the device operator. See FCO E921 for details of the new attachments.

At sites where customers use positive plates, avoid a firmware upgrade unless it is absolutely necessary. An artifact has been seen lately on Trendsetter VLFs and Trendsetter Spectrums, and it is suspected that it affects all MPE-based devices. The artifact is an unimaged strip, 0.5 to 1.0 mm wide, visible on positive plates at the away end of the plate. The solution to the problem is to downgrade to an earlier version of the MPE firmware.

If you must do a firmware upgrade because you are replacing a thermal head, or for some other reason, see the troubleshooting note for tests to verify that the plates will be free of the problem and for a possible workaround if the problem does occur.

The first Controlled Release CD is now available for the Trendsetter VLF (FCO E878). A Controlled Release is a package of software/firmware components that have been tested for compatibility with each other and with Trendsetter VLF hardware. All machines should be upgraded to the latest controlled release version at the next PM visit. For details, see Controlled Release version 1.0 on the Control-Settings page.

The 15 separate Trendsetter VLF specifications have now been consolidated into 2 specifications: 72-3715A for the Trendsetter VLF Quantum Series and 72-3716A for the Trendsetter VLF (Entry-Level) Series. All five drum sizes (4557, 5067, 5080, 5467, 5880) are listed in each specification along with the three imaging speed options (S, F, and V). See the Overview page for links to the new documents. The Packaging Series is now obsolete; it has been replaced by the S (standard) speed Quantum.

To prevent bending of the table up switch bracket (57-6492B) on 5880 machines, it must be installed 30mm to the right of the bracket position for 5080 machines. This involves drilling two new holes in the table support frame (57-1474D). See FCO E710 for instructions.

Four extra counterweight brackets (57-7289A) are added to the main counterweight to eliminate problems with the 5080 and 5880 table being unbalanced when running large plates. FCO E797 releases the updated upgrade kit and revised procedure, replacing the documents released under FCO E345 and FCO E679.

Creo has a contract with Rx Monitoring Services in Manchester, NH (603-666-6606 ext201) to provide Power & Environmental Site Surveys for the NAFTA region. The monitoring service includes voltage, current, temperature, humidity, dust and air pressure. Rx will provide the equipment to be installed at the customer site (for a maximum of 10 days), monitor it and send an e-mail report.

Air pressure monitoring is the latest addition to the Power & Environmental Site Survey. See Installing the Rx Air Pressure Sensor for details.

The table up switch bracket is susceptible to bending, so a new bracket design has been implemented. At next failure, install 57-6492B. See FCO E612 for details.

A blanking plate has been added for the water cooling connection on 20W heads that are upgraded to the UDRC-B debris removal system. Order the new kit #05-2042, which replaces 05-0239. See FCO E712 for details. For information on the upgrade, see FCO E399(R1).

The one-page listing of Trendsetter VLF models and speeds has been updated, along with the thermal exposure heads list, the throughput comparison tables, and the V2.5 upgrade suitability guidelines. See the Overview page.

The toolkit needed to perform an upgrade to a Heidenhain encoder is available in the regions. See the list of 90-1191 owners for contact information. For details about the shaft encoder upgrade, refer to FCO D992.

Use the "drum tick" command to help troubleshoot encoder issues. For detailed instructions, see Firmware Engineering's drum tick page.

5080 tables that have been retrofitted with head guards using kit 05-2029 are unbalanced when running large plates. ECO E679 releases kit 05-2041, containing extra counterweights, for upgrades to 5080 and 5880 tables. The old kit 05-2029 is obsolete. See FCO E679 for details.

ECO E399 releases field upgrade kit 05-0239 to add the UDRC-B debris removal system to F-speed machines, at the request of DUs.
Before ordering a kit, please refer to the updated site questionnaire, 72-3656B (72-3656A is now obsolete)

A new troubleshooting note has been posted that deals with the causes of and possible solutions to Image skewing. See the Troubleshooting page for details.

If the cabinet is turned on within 30 seconds of being turned off, the debris nozzle vacuum sensor may not calibrate correctly. As a result, the vacuum sensor readings are too low and error message 10064 is generated. The most likely occurrence is when a new plot initiates immediately after the 10-minute automatic shut-off. See the Troubleshooting note for details.

Please send all failed carriage motor boards back to Vancouver for analysis, attention of Angus Gillon (who will distribute to electrical engineers).

Address:
Angus Gillon - VLF Product Support Specialist
Annacis Island
1608 Cliveden Avenue
Delta, B.C. Canada
V3M 6P1

The purpose of this upgrade is to prevent ablative media from entering the optical cavities and to reduce maintenance costs. See ECO E346 for details.

The orange upgrade case that is supplied for the shaft encoder upgrades, includes the components of two different BOMs:

• 05-0195 - the parts including the Heidenhain encoder
• 90-1191 - the tools needed to perform the upgrade (including 92-0670 - the gauge used for GC correction after the upgrade)

If you are upgrading more than one machine at a customer site, you must order an extra 05-0195 kit for every additional machine. After completing the upgrade, the orange case can be stored in a central location within your district and replenished with a 05-0195 kit to be ready for the next upgrade.
See the Trendsetter VLF AL Tools page for photographs identifying the individual BOMs.

This ECO addresses the need and implementation of safety head guards on all Trendsetter VLF tables - both production and field machines. See FCO E345 for details.

Pulley end drum balancer reliability problems - see FCO E269 for details.

To prevent the LEC and Backbone from dropping onto the engine when the air supply fails, check valves are installed that will maintain the pressure in the cylinders until the air supply is restored. See the FCO page for details - E286.

To solve imaging errors and maintenance costs for the glass encoders, they must be replaced with Heidenhain shaft encoders on the next failure. See the FCO page for details.

These guidelines include three major considerations for recommending V2.5 field upgrades: Media type; Image data format; and Workstation hardware/software. Use for F to V2.5 upgrades as well as V2.0 to V2.5 upgrades to determine if workstation hardware or software will need to be replaced to match the speed of the Trendsetter VLF. Speed limitations of media types and image data formats are also included. See the Procedures page.

The type of thermal head, speed factor, essential features, and upgrade eligibility for each Trendsetter VLF model is outlined in the Models & Speeds Table on the Overview page. The Creo Trendsetter VLF comes in five sizes (4557, 5067, 5080, 5467, and 5880) and three speed models (Packaging, F, and V). Due to speed increases in 2000 and 2001, there are three possible speeds for V models in the field (V1.7, V2.0, and V2.5).

Trendsetter VLFs are presently shipping with three different thermal exposure heads, depending on the model: Packaging Series, F, and V. Click on the Trendsetter VLF Thermal Exposure Heads link on the Overview page for thermal head part numbers and descriptions.

The site questionnaires and procedures for V2.5 speed upgrades are now available on the Procedures page. V2.5 allows the 224-pixel Thermal Head 1.7x to image at up to 2.5 times the imaging speed of the F-speed 20W air cooled Thermal Head 1.0. The site questionnaire must be completed in advance to determine all the components required at the site.

• Upgrade F to V2.5
• Site Questionnaire for F to V2.5 Upgrade Planning
• Water Cooled Head Upgrade
• V2.5 Speed Upgrade for Trendsetter VLFs
• Upgrade V to V2.5
• Site Questionnaire for V to V2.5 Upgrade Planning
• V2.5 Speed Upgrade for Trendsetter VLFs

The filter assembly on the Trendsetter VLF has been changed.
Trendsetter VLF filter assembly - 50-2369A (includes pressure gauge).

ECO E150 - On the LEC backbone assembly, the LEC hinge rod comes out of the hinge assembly. When the leading edge clamp extends or retracts, the hinge rod works itself out over time. See the Procedures Page for details on how to fix this in the field.

A new Debris Removal Upgrade document has been posted. It is a combination of the old Debris Removal Installation document, the Airjet Plate Installation document, and the Debris Removal Nozzle Installation document. See the Procedures page.

The ‘Adjusting the Balance Actuation Assemblies’ document has been revised and updated. This document is available on the Procedures page.

Firmware version 1.50 has been released. View the Release Summary for the details of this release.
To upgrade a Trendsetter VLF to firmware version 1.50, it must have a MPE and ALE board with E revision Xilinx chips. To determine what revision board you have, use the command >>fw dir

A new procedure has been posted that describes how to align the plate flyoff sensor. See the Procedures page.