When installing the GENINE board, the plastic film MUST be removed from the heat sinking compound on the back of the board. Failure to remove this film can lead to unexpected resets or premature failure of this board. For devices built between 1 April 2004 and 20 July 2004, please verify that the GENINE board has been installed correctly. See Checking GENINE board installation on the Trendsetter VLF Procedures page

This is a next visit FCO. Because the existing picker arm support strut does not lock, FCO CA04999 replaces the support strut and adds a locking pin to prevent the strut from slipping while the picker arm is held in the up position for servicing. See the FCOs page for details.

The support arm for the picker arm does not lock and is easily dislodged. This creates a safety hazard for personnel doing maintenance on the picker. See the Safety Alert document on the Safety page for details. A FCO for the solution to this problem will follow.

On 5880 machines, the p-door may sometimes slam against the table when the table is in the up position, even though the p-door has fixed orifices to control its open/close sequences. Pneumatic components have been added to the Autoloader connection kit to provide additional control of the p-door speed, and should be installed when there is a possibility of damaging the table. For details on the upgrade, see FCO CA03424.

If a customer changes to a more scratch-sensitive type of media, they may decide to order a Delicate Media (DM) picker upgrade. The two field upgrade kits, 518-00415A (L to R) and 518-00416A (R to L) are being added to the price sheet and will be available only through Order Management, not through Service Logistics. For details on performing the upgrade, see FCO CA02406.

The CD for Controlled Release version 2.1 (March 2003) contained Service Shell v2.4 instead of v2.4 SP1. A new version of the CD (21-0143E) has been released to correct this error.

If you have already installed CR2.1, download Service Shell v2.4 SP1 from the Service Shell Downloads page on TechPlanet. If you haven't yet installed CR v2.1, the part number to order the correct CD, plus details including the 2.4 SP1 release notes, are on the TS VLF AL Controlled Release v2.1 page.

Several slip sheet removal units were built with a fixed safety cover over the roller area. The design has been changed to allow the cover to be opened for operator access. This upgrade only applies to Trendsetter VLF Autoloaders from BA026 to BA033. See FCO CA01198 for the procedure and upgrade kit.

If the debris cabinet needs to be located at the back of the device and the hose is too short, order the 7.6 m (25 ft) data cable/hose kit - part number 518-00323A BOM. This information is also available on the Installation page on this site, and under Attachment Kits on the Debris Removal site.

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, part numbers for full-sized floor layout drawings added, and the document is now in a more customer-friendly format. See the Installation page.

When a series of CANbus-related errors appears, it may indicate that the problem is not isolated to a single GENINE board, but is due to interference (noise) disrupting the CANbus signal to the PDB. See Stepper Motor 2 cable not detected (error message 23323) for a case study of how a diagnosis was made using a scope.

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.

Visual Quick Reference Guides are now available in English, French, German, Italian and Japanese. These charts show operators how to clean the edge detection strip and plate roller, empty the slip sheet bin, replace the air intake filter and compressed air supply filters, load the MCU or SCU, and image a plate in either manual or bypass mode. At the next PM visit, provide a Quick Reference Guide to any customer who does not yet have one. See FCO CA01783 for part numbers.

Older slip sheet bins (non-GT SSR) may fail to reset the counter properly if the MPE firmware is upgraded to V2.0. The new firmware is looking for a bag sensor that was introduced on the GT SSR bin. The recommended action is to revert to MPE firmware 1.18 until the next firmware release is available, which will fix the problem. If a site needs to use MPE firmware V2.0 for other reasons, a bag sensor must be installed. See FCO CA01744 for details.

Due to a problem with the slip sheet counter not resetting to zero on the old-style SSR units, we recommend NOT upgrading to MPE firmware version 2.00 on machines with serial numbers BA112 and earlier. Stay with Version 1.15 or 1.18 until the next release is ready. This is not an issue for Trendsetter VLF Autoloaders from BA113 on. They should all have MPE firmware v2.00 installed.

Exception:   If an older VLF TS Autoloader requires MPE firmware v2.00 to support V2.8 speed imaging, P33 imaging, the Delicate Media (DM) Picker option or the Processor Interface option, then a SSR bag sensor kit will need to be installed (P/N 512-00065A).

The Version 2.8 thermal head has moved to Full Production on Trendsetter VLF Autoloaders 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 VLF Autoloaders 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.

The pneumatic rotary actuators on the slip sheet picker develop some internal leakage during the first 150,000 or so cycles. Since the speed controls are unable to accommodate this leakage and still provide adequate torque, the speed control orifice has been changed. On the next failure, upgrade the speed controls for the slip sheet picker rotary actuators. See FCO E968 for details.

The toolkit for installing the table active cups assembly is now ready. Order part number 512-00018A from Service Logistics.
See FCO CA00855 for details about the upgrade, including the procedure.

On machines earlier than serial number B807, the carriage drive board (10-3761B) has been failing in the field due to bad connector contacts and other reasons. The board has been redesigned for the MCU, SCU, L-conveyor and RS-conveyor. At the next site visit, install the new board (503C01525B) and replace the power and motor cables. See FCO CA00433 for details.

For machines BA001 to BA0050 only, the table vacuum may not be capable of holding large plates on the table during the load/unload sequence. The table active cups assembly should be installed at the next failure, with upgrade priority given to sites that run very large plates. See FCO CA00855 for details.

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).

The rollers on the Slip Sheet Removal (SSR) unit may wear out due to abrasion from the slip sheets. When the SSR rollers fail at sites with high plate throughput, replace the entire unit with the new GT SSR unit (11-1074A for R-L, 11-1075A for L-R). At sites with low plate throughput, just replace the roller assembly (57-7720B) in the existing slip sheet bin. For details, see FCO E450.

The Version 2.1 Controlled Release CD is now available for the Trendsetter VLF AL (FCO CA00830). This controlled release updates MPE firmware to Version 2.00, which combines Trendsetter VLF and Autoloader firmware into one code. The release also enables operation at V2.8 speed and fixes small plate flyoff during loading. All machines should be upgraded at the next PM visit. For details, see Controlled Release version 2.1 on the Control-Settings page.

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 Autoloader PM checklists for each option (MCU with S-Conveyor, MCU with L-Conveyor, SCU with S-Conveyor, SCU with L-Conveyor) have been released and translated into Dutch, French, German, Italian and Swedish. The documents are posted under Planned Maintenance on the Maintenance page.

The Version 2.0 Controlled Release CD is now available for the Trendsetter VLF AL (FCO F009). A Controlled Release is a package of software/firmware components that have been tested for compatibility with each other and with Trendsetter VLF AL hardware. All machines should be upgraded to the latest controlled release version at the next PM visit. For details, see Controlled Release version 2.0 on the Control-Settings page.

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 AL, 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.

On PDB version 10-4112G-B and earlier, the resistors are too close to the board surface and have a small chance of causing a fire. Four of them should be removed at the next visit. For details, see FCO E723.

The relays on the MCU Safety Interface Board, which have a vent in the top of their casing, have been replaced with a sealed type to reduce the risk of damage during cleaning. At the next failure, board 10-4697B should be upgraded to 10-4697C. Board functionality is unchanged. For details, see FCO E725.

The M8x30 SHCS screws that hold the MCU cassette latch pins may come loose. At the next visit, please apply Loctite 262 to the screws. See FCO E889 for details.

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.

If the motor for the slipsheet rollers is not responding, the circuit breaker may have tripped due to motor overcurrent from a paper jam. See the troubleshooting note for details on how to reset the breaker.

The first Controlled Release CD is now available for the Trendsetter VLF AL (FCO E877). A Controlled Release is a package of software/firmware components that have been tested for compatibility with each other and with Trendsetter VLF AL 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.

Labels 74-3358A and 74-3359A need to be applied to the MCU jog button panels on machines prior to BA079. See FCO E540 for details.

If the MCU does not respond and error number 22329 displays, one of the MCU cassettes may not be locked into position properly. Open the back door and reseat all 4 cassettes. See the 22329 troubleshooting page for details.

Strange behavior of the carriage, including stalling and excessive motor temperature, could be caused by faulty capacitors on the carriage drive board (10-3761B). Before replacing the board or motor, follow the steps in the troubleshooting note Overcurrent in Carriage Drive Boards.

If MPE Firmware 1.20 or later is installed, use the firmware command cal picker to check 'media X sst' (slip sheet threshold), 'val pvth' (plate vacuum threshold), or 'val ssvth' (slip sheet picker/Wedgemaster vacuum threshold), Otherwise, use the manual procedures.

If the Wedgemaster fails to go all the way up, the optical sensor is probably not being interrupted properly. A troubleshooting tip is now available with photos showing how to correct the problem.

After picker or S-Conveyor cables are replaced, the motor will run in reverse if the pins have not been connected in the right order. A troubleshooting tip is now available with photos showing how to correct the wiring.

Occasional problems with the drive belt skipping teeth and the picker jaws failing to rotate have been eliminated with version D of the slip sheet picker. At next failure, replace the ss picker with the new assembly (50-1743D-A). For details of the improvements, see FCO E628.

A procedure is available for checking the air supply without using a test gauge. See Checking the Air Supply without a Test Gauge for details.

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.

All machines in the field must be upgraded with this kit. See E496 for details.

Cable 10-4703A was built incorrectly and installed on several machines before the flaw was discovered. For details on which machines are affected and how to fix the problem, see FCO E465.

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

To help understand how the new regulator system on the VLF TS AL works, Don MacKay has provided a detailed description of its operation.
See the Regulator Principle of Operation  Technical Bulletin.

This upgrade includes a new Pcup arm and bigger lift cylinder for more reliable operation. The addition of a limit switch also prevents the firmware from moving the picker when it is on its service strut. Upgrade all machines in the field with firmware version 1.12 or higher.
See the FCO page for details.

Rework all machines in field with the following priorities:

• High priority units (Europe) -
  BA#003,004,005,010,012,013,016,017,018,021-024, 029,031,034,037,038,039,041,043,045-048,051,053,055-057,060.
• Lower priority units -
  BA#009,011,014,015,019,020,025,026,027,028, 030,032,033,036,040,042,044,054,058

See the Upgrades page for details on performing the safety panel retrofit.

The orange upgrade case that is supplied for the shaft encoder upgrades includes the components of three 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 Tools page for photographs identifying the individual BOMs.

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.

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.

Due to the instability of the power supplies on the Genine and PDB boards, all boards must be replaced using upgrade kit 05-0224 during the next site visit. All old boards must be returned for rework/upgrade.

The filter assemblies on the VLF Autoloader have been changed. The two new assemblies are:
Base Trendsetter VLF filter assembly - 50-2369A (includes pressure gauge)
VLF Autoloader regulator assembly - 50-2367A (lower pressure loss over regulator)

Web-based training (WBT) has been released for the VLF Autoloader WBT. This training course is a prerequisite to attending the installation or maintenance courses. See the Reference page for the link to the WBT.

When picker Genine boards are replaced, the pressure sensors must be re-calibrated. See the Procedures page for details.

Several machines in the field have had the belts skip because of too low tension causing the slip sheet picking to fail. To adjust the wedgemaster belt tension, see the troubleshooting procedure: Wedgemaster belt skipping.

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.

To check the state of a Genine board via the workstation, use one of two possible commands: >>SIO or >>LIST VERSION.
To reset the Genine boards: Type >>SIO RESET - Please note that this command does reset the Genines, but does NOT clear the Genines' memory. Power the entire system down to clear the Genine's memory.