Thermal 3 Head - Planned Maintenance Procedure

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Thermal 3: Planned Maintenance Procedure

Strictly confidential. Do not leave at a customer site.
Planned maintenance (PM) is to be performed only by Creo service personnel or by trained and certified operators.

Time needed: 1.5 hours (Device can be returned to customer within approximately 40 minutes)

External check | Imaging check | Internal check | Sample script results

Requirements:

TH3 shipping kit (514-00097A KIT, SHIPPING, 2400DPI, TH3)
Lens cleaning kit: Lens cleaning kit: 04-0012B BOM
Coolant connector O-ring: 59-3415
External chiller coolant filter kit: 500-01665A
Air bearing filter kit: Air bearing kit 332-00027 (photo)

Related procedures:

Removing the Thermal 3 Head from the carriage (Magnus VLF): See section 7.3 in TH3 Head Lifting Crane
Cleaning the Thermal 3 Final Lens and Debris Removal Nozzle
Configuring a Workstation for GMCE/TH3

Before you start

Print this document	Click the print icon at the top of the page.		Print it in landscape format.
Safety	Before you start, make sure you are familiar with all device and laser safety concerns.		For more information see Laser safety information.

External checks

External Checks	Action	Look For	Procedure or Parts
Back up the NVS settings.	In Service Shell, run: NVSDump.spt	N/A
Perform a visual check.	Visually inspect the outside of the head and the surrounding area.	Note the amount of debris buildup on the nozzle and surrounding area. Check for any device-specific issues.
Check the coolant and the coolant reservoir.	Visually inspect the coolant. Visually inspect the reservoir.	Check that coolant levels are good and that there is no leakage. Ensure that the flow from the reservoir is adequate. Check the reservoir for signs of contamination and floating debris.
Check the coolant connector O-rings.	Visually inspect the O-ring on the hose and the O-ring on the head.	Check that there is no damage to the connectors. Check that there is a good seal. Ensure that there are no leaks. Replace the O-ring, if necessary (part number 59-3415).	Use a paper towel while disconnecting the hose to ensure that you don’t spill any coolant. Picture of the coolant O-Ring (part number 59-3415)
Clean the chiller air filter.	Clean the air filter on the front of the chiller.	The air filter in the front of the chiller may be blocked with dust, reducing the effectiveness of the chiller.
Replace the external chiller coolant filter.	Replace coolant filter assembly 500-01665A on the rear of chiller.	Failure to replace this filter every 6 months will limit coolant flow, which may cause overheating.	Use kit number 500-01665A Replace the O-ring, if needed (part number 59-3415)
Replace the air bearing filter on the air manifold.	Replace the filter. Air bearing kit 332-00027 (photo)	N/A	Use kit number 332-00027
Check the temperature and voltage levels.	Turn on the laser. Type `>>temp`. Check that all temperature levels are within range. If they are not, troubleshoot as needed. Type `>>volt`. Check that all voltage levels are within range. If they are not, troubleshoot as needed.	All voltage and temperature levels should be within range.
Check that the head and device are running the latest controlled release.	Check the CR version against the latest released version on TechPlanet.	If necessary, upgrade to the latest controlled release.	Magnus VLF Controlled releases for all CTP
Test the remote connection and configuration functions.	Perform a RAS check: Contact the Response Center (RC) and request that they dial in.	Confirm the connection, passwords, IP addresses, and so on. If any relevant information has changed, notify the RC.
Verify the processor setup.	Ensure the processor meets operating specifications.	Check the setup specifications using the appropriate documentation.	Media-specific Standard Operating Procedure Media-specific technical note CTP Media Imaging Performance Database
Safety	Warning: Follow all Laser and Mechanical Safety Procedures during the next steps.
	Remove the head from the carriage.	Turn off the device. All laser and mechanical safety procedures must be followed.	To remove the head from the device you must use the lifting jig. See TH3 Head Lifting Crane
Inspect and clean the debris removal nozzle.	Clean the debris removal nozzle.	Inspect the debris removal hoses and ensure that there isn’t any cracking or wear. Clean the whisker jet orifice. Note: It is not possible to clean the debris removal nozzle if the head is on the device.	Cleaning the Thermal 3 Final Lens and Debris Removal Nozzle
Inspect and clean the final lens.	Clean the final lens and surrounding area. You will need the lens cleaning kit (Lens cleaning kit: 04-0012B BOM). See Importance of lens cleaning and debris removal.	Leaving streaks can seriously impact imaging quality. Note: It is not possible to clean the final lens if the head is on the device.	Cleaning the Thermal 3 Final Lens and Debris Removal Nozzle
	Install the head.	Re-attach the debris removal nozzle. Re-install the head using the head installation procedure. Load a plate. Type `>>head install on` on check that the sum and error are correct. Error: ±20 Sum: approx. 750 If the sum is not near 750 and the lens is clean, run `foc cal rcvrgain` to correct the value.	Th3 Debris Removal Nozzle Installation Procedure TH3 Installation Media-specific technical note

Imaging checks

Note: If you are using a laptop, the results will be automatically stored there. You will need to copy them to the workstation.

Imaging Checks	Action	Look for	Procedure or Parts
Back up the NVS settings.	In Service Shell, run: NVSDump.spt	N/A
Upgrade the head firmware to version 1.04.06.	Download and install the necessary files from the TH3 Head Firmware Version 1.04.06 page. Enter the command `>>bpd setup` Enter the command `>>ldd setup`	N/A
Record the image count.	Using the device parameter `imagestats`, record the image count in the service log. Ensure that the level of debris is consistent with the number of images made on the device.	If there is more debris than you would expect, plan to proactively inspect and clean the debris removal system, nozzle, and thermal head final lens more frequently.
Generate a reference plot.	Run the standard test plot (Kodak Plate Test Target). If the CPTT is not available, run a Plot 1008.	If there are problems with image quality, refer to the appropriate media technical note. Troubleshoot as needed.	Media-specific technical note Thermal 3 troubleshooting
Generate a reference stroke cal.	Create a stroke cal graph. In Service Shell, run: BeamBalance.spt and BeamProfile.spt.	Examine the BeamBalance.spt graph in Service Shell. This gives a baseline of the health of the head. Compare to previous graphs and keep for reference. Check the BBSProfile.spt graph for stuck pixels and any changes in the beam profile. Troubleshoot as needed (refer to the Thermal 3 troubleshooting page).	Sample BeamBalance.spt graphs Sample BBSProfile.spt graphs

Sample Script Graphs

Script name	Good	Poor/Fail	Notes
BBSProfile.spt		bbsprofile_stuck_pixel.png
BeamBalance.spt	BeamBalance_good.pdf	BeamBalance_poor_1.pdf BeamBalance_poor_2.pdf BeamBalance_poor_3.pdf BeamBalance_failed_1.pdf BeamBalance_failed_2.pdf	If you get results that look like failed_1 or failed_2, escalate to your PSS.