Trendsetter VLF AL - Planned Maintenance Procedure

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Planned Maintenance Procedure

Strictly confidential, for internal use only. If you print the checklist out, be careful not to leave it at a customer site.
Planned maintenance (PM) is to be performed only by Creo service personnel or by trained and certified operators.

To print out the PM instructions below, click on the print icon at the top of the page.

Before going to the site:

Run an activity report to list all calls and dispatches for the device since the last PM (or install date if this is the first PM ever). Review the report for outstanding issues to help you prepare for the PM.
Find out when the processor chemistry will be changed. To properly assess image quality, the processor should be serviced and filled with fresh chemistry 24 to 48 hours before the PM visit.

Safety and Exterior

Objectives: Check safety first! Determine that all TS VLF AL components are safe to operate and to work on. Walk around the entire device to examine the exterior and surroundings for damage and any issues that may require further investigation or repair.
Time needed: 10 minutes (Device can be returned to customer any time.)

Safety and Exterior Evaluation	What to Do	What to Look For	Procedure Parts
Guard rail gate lock	Visually inspect.	The gate should be locked securely and not bypassed.
Front safety panels	Visually inspect.	The guard rail and front safety panels should be intact.
Right e-stop switch	Depress the switch.	Check that the workstation message is correct.
Table drop leaf	Lean in and open the drop leaf.	The picker lights should go out.
Left e-stop switch	Depress the switch.	Check that the picker lights go out and that the workstation message is correct.
SSR safety cover	Visually inspect.	The flip-up cover should be intact and the safety interlock should not be bypassed.
SSR bin door	Visually inspect.	The bin door should be intact and the safety interlock should not be bypassed.
Panel interlocks	Open each panel.	Ensure that the safety interlocks are operating correctly.	Isolating the faulty door sensor
Rear safety panels	Visually inspect.	The rear safety panels should be intact on the hood and the track support arms.
Picker lights	See if the picker lights are on.	Picker lights are normally on in automatic mode. If they are off, the AL safety loop should be open or the Trendsetter VLF should be in manual mode.
Track lights	See if the track lights are on.	Track lights are normally on (or flashing) in both automatic and manual modes. If they are off, there is a problem.
Chariot path	Inspect the floor.	Look for excessive wear.
Chiller fluid leaks	Check floor at the side of the TS VLF and chiller.	Ensure that there are no external fluid leaks.
Debris cabinet hose	Check exterior hose.	Ensure that it is not being crushed or broken.
Panels, skins, and table	Visually inspect the overall condition of all surfaces.

System Operation

Objectives: Determine that the Trendsetter VLF is operating correctly. Watch and listen. Note irregularities for further investigation.
Time needed: 10-20 minutes (Device can be returned to customer within 5 minutes.)

System Operation	What to Do	What to Look For
Operator feedback	Speak with the operators and prepress manager.
Operator training	Make sure the operators understand how to operate the device safely.
Backup settings #1	Backup the following info: list version list stats laser mask head mask set drum set carriage wsearch set mode 1 edge picker ale set sys list plate nvs dump diff fsave all	Compare to latest controlled release # of resets, 'on' time, images, and retraces 'laser on' time Is anything masked? Is anything masked? chkfly enabled? Static pressure Static pressure
	Send a file from the workstation to start the full sequence of operation.
Cassette door
Picker door
Picker movement
Picker operations
Slip sheet picker
SSR rollers
SSR compactor
Table cups
Plate drop onto table
Y-axis movement
Y-axis gripper
P-door	Watch and listen.	Smooth, symmetrical and quiet movement.
Table vacuum ports/cups	Watch and listen.	Holds plate, without slipping, during the load and unload.
Table movement	Watch and listen.	Smooth, symmetrical and quiet movement.
Electronic registration	Watch green light and listen.;	Quick and solid registration.
Plate loading onto drum	Watch and listen.
Edge detection	Listen and watch monitor.	Finds edge quickly, on first try.
Carriage operation	Listen.	Listen for any irregular noises.
Plot operation	Listen and watch monitor.	Listen for retraces and any irregular noises.
Plate unload from drum	Watch and listen.
Conveyor operation

Imaging

Time needed: 2 hours, 15 minutes (Device can be returned to Production within 25 minutes.)

Note: To properly assess image quality, the processor should have been serviced and filled with fresh chemistry within the last 24 to 48 hours.

Time needed: 2 hours, 15 minutes (Device can be returned to customer within 25 minutes.)
For this procedure you will need:

Splot or ServiceShell and all related scripts
Related cleaning and installation procedures:
Lens cleaning kit (Lens cleaning kit: 04-0012B BOM)

For full details, refer to Thermal 1.x Exposure Head Preventative Maintenance

Imaging	What to Do	What to Look For	Procedure Parts
NVS settings	Back-up NVS. In Splot or ServiceShell, run: savecfg.spt
Reference plot	Run the standard test plot agreed to by the customer.	Examine customer's image reference plot. Agree on a test plot that fits with what LPI and quality of jobs the customer is doing (FM/AM Proofing, linework, or high quality).
Reference stroke cal	Create a Stroke cal reference. In Splot or ServiceShell, run: strokcal.spt. Wait for the graph to appear.	Examine the strokecal.spt graph in ServiceShell. This will give a baseline as to the health of the head. Compare to the factory or previous graphs and keep for reference.	Refer to the sample graphs at the end of the Thermal 1.x Exposure Head Preventative Maintenance .
Laser power	Check the laser power. Type: `>>mode media` x(x=media in use) `>>laser on >>laser` Record the current value that the head draws at the specified wpower. Record laser on time in hours. Type: `>>set head nomlsrcur` The current should be less than nomlsrcur. Type: `>>head power sum` (use `>>head power full` if firmware version is earlier than 1.62v) `>>laser off`	Check the laser output of the head at the wpower for the media that is used. Note and record the current draw when the laser is on. If the laser current approaching the `>>set head nomlsrcur` value, it is a good indication the head is nearing end of life. Check the power at the nosepiece and compare to the power on the Media spreadsheet for the given media.	CTP Media Imaging Performance Database
Sum and focus error	Check the sum and focus error. Load a plate on the drum. Type `>>head install on`	Check that the sum value is around 1000 units and the error is near 0 (see note, below). A sum lower than 1000 can indicate debris buildup on the final lens. If the lens is clean and the error is not 0 ± 25 units, reinstall the head as per the head install document. Note: The error may be different on a Spectrum device.
	Remove the head	Device must be powered down. All laser safety procedures must be followed.	TH1.0: Thermal 1.0 Head Installation Procedure TH1.7: Thermal 1.7 Head Installation Procedure
Safety	Warning: Follow Laser Safety Procedures during the next step.
Debris removal nozzle	Clean the debris removal nozzle using the correct procedure. See: Importance of lens cleaning and debris removal	The pressure tap in the vacuum nozzle needs to be clean of debris in order for the debris removal system to work properly.	TH1.7 Debris Removal Nozzle Cleaning Procedure
Lens	Clean the lens using the correct procedure. See: Importance of lens cleaning and debris removal	Leaving streaks can seriously impact imaging quality.	TH1/1.7 Lens Cleaning Procedure (77-0125A) Note: make sure you order the lens cleaning kit (Lens cleaning kit: 04-0012B BOM).
	Install the head	Follow the head installation procedure. Check that the sum value is around 1000 units and the error is near 0 If the lens is clean and the sum is lower than 1000, you may need to adjust the surface reflectivity	TH1.0: Thermal 1.0 Head Installation Procedure TH1.7: Thermal 1.7 Head Installation Procedure
New stroke cal	Generate a new stroke cal. In Splot or ServiceShell, run: strokcal.spt Wait for the graph to appear.	Generate a new stroke graph and compare it to the stroke reference graph (Step 3) to determine any changes as a result of the nozzle or lens cleaning.	Refer to the sample graphs at the end of the Thermal 1.x Exposure Head Preventative Maintenance .
	Compare stroke graphs. Type `>>set head Bpmaxerr xxx`	Compare the strokecal graph obtained in the previous step to the sample graphs (at the end of the Thermal Head 1.x Planned Maintenance) and determine if any parameter adjustments are necessary.	Thermal 1.x Exposure Head Preventative Maintenance
Contrast script	Run the contrast script. In Splot or Service Shell run: getcontr.spt If adjustments are required, type: `>>set head Bposn xxx`	Compare the graph obtained to the sample graphs at the end of the Thermal Head 1.x Planned Maintenance. Determine if any adjustments are necessary. Note: This may cause a change in the strokecal graph. If changes were made to the Bposn value, repeat Steps 27 to 28.	Thermal 1.x Exposure Head Preventative Maintenance
Laser power	Verify the laser power. Type: `>>mode media` x(x=media in use) `>>laser on >>laser` Record the current value that the head draws at the specified wpower. Record laser on time in hours. Type: `>>set head nomlsrcur` The current should be less than nomlsrcur. Type: `>>head power sum` (use `>>head power full` if firmware version is earlier than 1.62v) `>>laser off`	Verify the laser output of the head at the wpower for the media that is used. Note and record the current draw when the laser is on. If the laser current approaching the `>>set head nomlsrcur` value, it is a good indication the head is nearing end of life. Check the power at the nosepiece and compare to the power on the Media spreadsheet for the given media.	CTP Media Imaging Performance Database
ECOs/FCOs and firmware	Check that all ECOs/FCOs have been implemented on the thermal head. To see the current firmware version of the head, type: `>>head` or `>>list version`	A list of FCOs can be seen at the FCOs page of the Thermal 1/1.7x TechPlanet site. Also check that all firmware upgrades have been carried out.
Shutter	Test the operation of the lens shutter. Type: `>>shutter open >>shutter close` Another test option is to type `>>focus cal reflect` and listen to the shutter rapidly opening and closing.	If possible, listen to the sound and check that operation is normal. Clean the shutter, if necessary.	Thermal 1/1.7 Shutter Sensor Replacement Procedure
NVS settings	Final NVS save. In Splot or ServiceShell, run: saveconfig.spt	Generate a final strokecal graph and a THXXXX.cfg file that can be used for future reference. This script takes approximately 6 minutes to run. Leave the THXXXX.cfg file on the workstation for future reference.

	What to Do	Procedure Parts
Carriage	Allow 15 minutes, 5 minutes to return device to customer
Carriage rails	Lubricate.	Lubricating the Carriage Tracks and Leadscrew Lubricating the leadscrew hanger bearing
Carriage lead screw	Lubricate.

Dehumidifer Unit (DHU)	What to Do	What to Look For	Procedure Parts

DHU

Each device will have a head-mounted Dehumidifier Unit (DHU).

Power down the device and purge all air from the system.
Replace the filter (PN 55-1219).
Turn the air on and power up the device.

CAUTION: If the differential pressure indicator displays red you need to examine the bowl to determine if the device has been tripped by moisture or oil in the line. You must replace the DHU (part number 05-0244) once it has been tripped, then investigate why the DHU tripped. Rectify air quality before reinstalling the new DHU.

Note: If the device has a desiccant box: upgrade the Desiccant pack to a DHU (kit #05-0244). For details, see the Dehumidifier Unit FCO E246 information.

Dehumidifier Unit (DHU) Installation Procedure

**If the pressure indicator is red, the DHU MUST be replaced and the air system examined for contaminants.**

**If the Trendsetter VLF AL still has a desiccant box, upgrade to a DHU (kit #05-0244).**

	What to Do	What to Look For	Procedure Parts
Debris Removal Unit	Allow 15 minutes, 5 minutes to return device to customer
Check sensor	Turn on the debris cabinet. Block the front of the nozzle with cardboard.	A warning should appear on the workstation, and the vacuum motor should whine louder.
Filter	Check condition.
Hose	Check that all clamps are secure. Inspect the vacuum hose.	Inspect for wear along the hose tray, and for crushing along the floor.
Chiller	Allow 30 minutes, 5 minutes to return device to customer		Neslab/Polyscience External Chiller Planned Maintenance
Leaks	Remove the side panels and visually inspect the internal system for leaks.		Neslab/Polyscience External Chiller Planned Maintenance
Condenser and air vents	Remove the front filter element. Wash it with water and mild detergent. Vacuum the grills, vents and condenser.	Excessive buildup of dust and debris.	Neslab/Polyscience External Chiller Planned Maintenance
Pump strainer/fluid filter	Drain off some of the chiller fluid. Remove the sediment bowl or strainer. Clean and re-install the filter.		Neslab/Polyscience External Chiller Planned Maintenance
Pump motor	Add 30-35 drops of electric motor oil to each motor bearing.		Neslab/Polyscience External Chiller Planned Maintenance
Fluid	Top up the fluid to the correct level.		Neslab/Polyscience External Chiller Planned Maintenance
Image Quality
Image quality #2	Run another test plot and inspect the results.

Trendsetter VLF

Objectives: Check everything, then go back and repair or adjust as required.
Time needed: 2 hours (Device can be returned to Production within 15 minutes.)

Trendsetter VLF	What to Do	What to Look For	Procedure Parts
Power Box
Keyswitch	Check operation in both positions. Leave in 'mech hazard' position for the rest of the Trendsetter VLF section of the PM.
MOV	Test the MOV on the PDB and replace as required.		10-3562
Genine 0	Visually inspect the lights on the board..
Cooling fans	Check for adequate flow and lack of excessive noise.
Fan Box
	Open the panel.
Intake air filters	Replace filters.
Compressed air filters	Replace filters.
Air dump	Test functionality.
Air supply pressure	Test compressed air supply.	It should be >90psi@20scfm. Turn on the pcups, ss picker vac, and air knives. Watch the gauge.
Air leaks	Check for leaks around regulator.
	Close the panel.
Engine
	Open the hood.
Time engine #1
P-door actuators	Check for loose fasteners, leaks and smooth symmetrical operation.
Drum and LEC	Clean and inspect.
Drum straps	Check and tighten all strap fasteners.
Drum belt	Visually inspect the condition and tension of the belt.
Encoder disk	Clean the disk (glass encoder only).
	If the disk is excessively dirty, consider doing a shaft encoder upgrade - kit #05-0195 (FCO D992).
Rollers	Clean with a damp, lint-free rag.
Roller actuators	Check for leaks.
Roller pressure	Check pressure to the cylinders. It should be 55-60psi.
Roller movement	Check for smooth, symmetrical movement.
Roller rotation	Should rotate freely by hand with the backbone up.
TEC actuators	Check for leaks.
TEC pressure	Check pressure to the cylinders. It should be ~30psi.
TEC magnets	Clean off any debris.
TEC rod ends			Trendsetter VLF PM Procedure
TEC lock/unlock			Trendsetter VLF PM Procedure
TEC sensors	Visually inspect.	If any cable sockets are loose, replace the sensor.	10-1065A
Backbone sensors			Trendsetter VLF PM Procedure
LEC hinge	Inspect for wear and dust.
LEC actuators	Check for loose fasteners, leaks and smooth operation.
Backbone actuators	Check for loose fasteners, leaks and smooth operation.
	Shut off the power. Remove the conveyor and SSR to gain access to the sides of the Trendsetter VLF. Remove the side panels. Power on the device.
Carriage fan	Check for dirt and adequate flow.
Carriage belt	Check for wear and tension.
Main manifold	Check for leaks and overall condition.
AL manifold	Check for leaks and overall condition.
Table vacuum generator	Replace the filters.
Balance weight actuators	Check for leaks, looseness, and release tip.
Balance weight hall sensors			Trendsetter VLF PM Procedure
Balance weights	Lubricate the release tips, engagement rings, and balance races.
Balance weight release alignment			Trendsetter VLF PM Procedure
Balance weight smooth operation			Trendsetter VLF PM Procedure
	If the balance detent arm or detent spring do not operate smoothly, install kit #05-0233 (FCO E269).
Time engine			Trendsetter VLF PM Procedure
Table, P-door, Y-axis
Guard rail gate	Adjust as required.
Table drop leaf	Visually inspect.	Check for easy release and solid latching.
Arborite	Inspect the surface.	Check for missing or protruding darts.
X-axis tape	Replace if damaged.
Table flatness	With the table up, place a cassette rail front to rear across the table in four places. Adjust as required.
Adjustable bumpers	With the table down, adjust all four bumpers to contact the top panels evenly. Replace if worn.
Leading edge	Check with a straight edge.	Should be flush and flat to the table surface.
	Type "ale init" to position the drum. Raise the table.
Table to LEC distance	Check the distance with a ruler at both ends of the drum. It must be parallel.		table alignment procedure
Table tangent to drum	Check the distance with a ruler at both ends of the drum.		table alignment procedure
Table dampers	Check for leaks and looseness. Adjust as required.
Plate drop	Check the plate drop distance. Adjust plate stop only.
Y-axis gripper operation	Check that the gripper moves from p-door to table and back smoothly.	It should grip the plate at the home and away positions. If the p-door angle is changed, recheck the plate drop.
Y-axis gripper alignment	Check the alignment of the gripper.	It should be parallel to the plate.
Y-axis home	Check the home position.	The plate should be 1-2mm away from the plate stop.
	Put all Trendsetter VLF panels back on, and close the hood.

Autoloader Components

Time needed: 2.5 hours (Device can be returned to customer within 15 minutes.)

Autoloader Components	What to Do	What to Look For	Procedure Parts
Picker and Track
	Open the cassette doors.
Track belt	Visually inspect the condition and tension of the belt.
Picker height to plenum	Move the picker to the pick position. Measure the plenum to picker distance on both sides of the picker. Record the values. (Leave the picker cover on.)
	Move the picker to the table center and remove the skin.
Genine 2	Visually inspect the lights on the board.
Manifold	Inspect the manifold assembly for leaks and overall condition.
Picker deck vacuum generator filter	Remove and inspect the filter. Replace as required.
P-cups	Check for proper movement and overall condition.
Lift arm	Check for proper movement and overall condition.
Lift arm actuator	Check for leaks and loose fasteners.
Vacuum cups	Check for proper movement and overall condition.	Cracking or excessive wear	50-2126B
	Lift the picker onto the prop to access the underside.
Eject/pusher fingers	Check for proper movement and overall condition.
Eject finger actuators	Check for leaks and loose fasteners.
Slip sheet picker (wedgemaster)	Check for proper movement and overall condition.
Slip sheet picker actuator	Check for leaks and loose fasteners.
Slip sheet picker cups	Check for proper movement and overall condition. Check the alignment of the icup and the ocup.		50-1743B
Slip sheet picker belts	Visually inspect the condition and tesnsion of each belt.
Slip sheet picker vacuum	Check the vacuum threshold settings.
Slip sheet picker vacuum generator	Remove and inspect the filter. Replace as required.
	Lower the picker and install the skins (covers).
Multiple Cassette Unit (MCU)
For details of the MCU PM, see the PM procedure for MCU (with SSR, straight or L conveyor)
Single Cassette Unit (SCU)
For details of the SCU PM, see the PM procedure for SCU (with SSR, straight or L conveyor)

Workstation

Objectives: Test the system thoroughly before leaving the site! Update any/all firmware and Print Console. Note updates under Service Commands on the customer's PM Checklist.
Time needed: 2 hours (Device can be returned to customer within 60 minutes.)

Refer to the Control-Settings page for details of controlled releases.

Workstation	What to Do	Procedure Parts
SCSI cable	Visually inspect the overall condition of the SCSI cable and connections. Replace as required.
Service Shell software	Update to the current Controlled Release version.	current version
Print Console software	Update to the current Controlled Release version.	current version
Head firmware	Update to the current Controlled Release version.	current version
MPE firmware	Update to the current Controlled Release version.	current version
Genine firmware	Update to the current Controlled Release version.	current version
PDB firmware	Update to the current Controlled Release version.	current version
Backup settings #2
	Test operation.

Service Comments

Complete the "Service Comments" section of the Trendsetter VLF AL Planned Maintenance Checklist that applies to the customer site. Links to the checklists for all four configurations are on the Maintenance page.

For the customer's information, make a note in the "Service Comments" section of:

All FCOs that were installed
All firmware and Print Console updates that were installed
All parts that were replaced
Any safety features that were disabled or bypassed
Any operating environment issues

Customer Acceptance

To complete the PM, the Trendsetter VLF AL Planned Maintenance Checklist must be signed off by the customer and returned to Creo.