- SCHYIEW

DotMate 1500 · ·
DotMate 7500 Plus

.....
t

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 © July, 1997. ScanView. All rights reserved.
No part of this publication may be copied or in any other way reproduced, nor
may it be stored in a retrieval system, without the prior written permission of
ScanView A/S.

The information in this manual is subject to change without notice. ScanView

A/S assumes no responsibility or liability for any errors or inaccuracies that 'may
appear in this book.

DotMate 7500, DotMate 7500 Plus, RipMate, RipManager and DotMonitor are
trademarks of ScanView. Other manufacturers' trademarks are used in an edit
orial fashion, with no intention of infringement.

Head office U.S. Subsidiary

ScanView A/S ScanView, Inc.
Meterbuen 6 330 Hatch Drive, Suite A
DK2740 Skovlunde Foster City, CA 94404
Denmark U.S.A.
Tel: (+45) 44 53 61 00 Tel: (+ll 4153786360
Fax: (+45) 44 53 61 08 Fax: (+l) 4153786368

This equipment has been tested and1'ouna to comply with the limits for a
Class A digital device, pursuant to part 15 of the FCC Rules. These limits are
designed to provide reasonable protection against harmful interference when the
equipment is operated in a commercial environment.
This equipment is supplied with a shielded cable. It must be operated with a
shielded cable in order to meet FCC Class A emission limits.
This equipment generates and can radiate radio frequency energy and, if not
installed and used in accordance with the instruction manual, may cause
harmful interference, to radio communications. Operation of this equipment in a
residential area is likely to cause harmful interference, in which case the user will
be required to correct the interference at his or her own expense.

Manual edition: 2
Firmware version: 3.01

PN 7322501302

2 Service Manual • DotMate 7500/7500 Plus Edition 2 • July 199

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 DM7500P(PLUS) Technical training

Agenda:

Mon. Introduction
(9:0017:00) Brochure's+ Functional specifications uml.2 1.5

Generel info Imagesetter um2.l 2.15

sml.1 1.9
Media Transport, sensors etc.
Optical System
Generel info Processor Overhead sm7.33 7.43
Chemistry & film
Tuesday Service programs Dot sm3.l 3.26
(9:0017:00) Terminal
Processor Service
Installation um5.9 8.11 sm2.1 2.17
RipMate and exposure calibration

Wednesday. Parts replacements and Adjustments sm4.0001 4.415

(9:0017:00) sm5.1 5 .13

Thursday. Parts replacements and Adjustments

(9:0017:00) Electronics IM and Processor sm7.1 7.33
,· Downloading firmware.

Friday Maintenance Easy Maintenance guide

(9:0017:00) DM7500(plus)
Technotes
Troubleshooting
Follow up and questions

Evaluation

um: User manual

sm: Service manual

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 1 • GENERAL INFORM-ATION

' Contents

About the service manual :1•3

About the DM 7500 and DM 7500 Plus 1 •3
Service manual revision and revision 1 •4
list. Physical specifications 1 •5
Optional equipment 1 •5
General cautions 1 •5
Laser safety '. 1•5
Laser warnings 1 •6
Media transport : .. 1 •6
system Media flow 1•7
diagram Exposure 1 •8
system 1 •9
Optical system 1 •10
Green Quality
Standard modulerequired
equipment (optional
andequipment)
recommended 1•11
Service kit 1 •12
Error reporting 1 •12
I Error report form 1 •13

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mrnn 1 • GENERAL INFORMATION

About the Service Manual

This manual serves as a technical service and maintenance manual for

the DotMates 7500SA/7500P and 7500SA/P Plus. Its purpose, linked
with the technical training courses provided by ScanView, aim to give
the service engineer the indepth knowledge of the function and con
struction of the DotMate and the skills neccessary to perform repair
and maintenance operations.

About the DotMate 7500 and 7SOOP Plus

The DotMate 7500 and 7500 Plus are stand alone imagesetters in their
SA and SA Plus configuration and fully integrated imagesetter and pro
cessor when configured as a P and P Plus model.
The imagesetter unit has an internal drum of high end quality and
precision with flexible exposure formats, fast exposure times, flexible
choices of resolution and flexible media widths.
The processor unit is a high quality rapid access processor, 100%
computercontrolled and rnonitored.
The DotMate 7500 and 7500 Plus interface to RipMate, a software
RIP based on Harequin Script Works, but with additional features added
by ScanView.

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 SCANflEW
1 • GENERAL INFORMATION

Service Manual Revision System

Revisions to this manual will show the most recent revision number
and date issued on the bottom of each page. Each section will show the
latest revision of the contents of that section. A master revision list
showing the revision status of each section is shown below

To assist in the identification of which part of the new section has been
revised, a vertical line on the left hand side of the affected page or pages
will define the area of revised text. Additionally, the cover letter sent
with the manual revision will name the revised page or pages.

For ease ofreference, Service Manuals will have their own edition num
ber; a number which will be the number of the latest section edition.

Revision List

Edition Date

Section • General Information 2 July 1997

Section 2 • Installation 2 July 1997

Section 3 • Service program 2 July 1997

Section 4 • Part replacement 2 July 1997

Section 5 • Adjustments and testing 2 July 1997

Section 6 • Cleaning and maintenance 2 July 1997

Section 7 • Diagrams and layouts 2 July 1997

Section 8 • Trouble shooting 2 July 1997

Section 9 • Not allocated

Section 10 • Parts list and spare parts policy 2 July 1997

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SCANYIEII 1 • GENERAL INFORMATION

Physical Specificat'ions
Data interface: SCSI2
Dimensions DM 7500SA/7500SA Plus 145 x 115 x 80 cm (57" x 45" x 32")
(LxWxH) DM 7500P/7500P Plus 145 x 115 x 160 cm (57" x 45" x 63")
Weight: DM 7500SA/7500SA Plus 250 kg. (550 lbs.)
DM 7500P/7500P Plus
600 kg. (1320 lbs.)
Max. power consumption:
2.6 kW, 200 240VAC
Rated frequency:
50/60 Hz

Optional Equipment
lmagesetter: • Bacher Control 2000 punch registration system.
Additional input and takeup cassettes
Processor: • Green quality module (GQunit).

General Cautions

Cautions! c... Turn off power Before connecting or disconnecting cables.

Before carrying out service or adjustment operations.

r.- Use nonreflective tools while working in the drum area with the laser turned on.

r.- Always check that the actual media width in "media management" corres
sponds to the actual media being used.

Laser Safety

Cautions! c... The DotMate 7500 and 7500 Plus are class l laser products and contain a
laser, which under normal working conditions is totally shielded by the cab
inet. When the panels are removed, an interlock system automatically
switches off the laser, and optics unit, thus ensuring no risk of radiation.

c... To override the interlock system, a "defeater" female connector is fitted

to the male connector situated behind the left hand side door. Only
authorized service personnel may override the interlock system.

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 1 • GENERAL INFORMATION

Laser Warnings
Warnings adjacent to
the interlock switches
inside the cabinet
�1
..----! _,
DANGER·LASERRAOIATION
WHENOPENANO!ITTERLOCKS
DEFEATED AVOIOEXPOSURETO
BEAM

ve1l¥i���JiH�!���
ATTENTION-RA't'ONNEMENT

OANGEREUSEAUFAISCEAU

'u �----- ACHTUNG-WARNUNGVORLASERSTRAHLEN

0EIOFFENEMGEHAUSEUNO
AUSGESCALTETEMSICHERHEITSSCHALTER
OIREKTEBESTRAHLUNG
VERMEIDEN

This warning appears AVOIOEXPOSURf.L.ASERAAOIATIONISEMITTEO

FROMTHISAPERTUREWHENINTEFI..OCKSAREOEFEATED
on the drum assembly. EXPOSITIONOANOEREUSE·UNAAYONNEMENTLASERESTEMIS
PARCETTEOOVERTURELORSOUELASECURITEESTNEUTRAI.ISEE

Media Transport System

DotMate 7500SA/7500SA Plus DotMate 7500P/7500P Plus

• from the input cassettte • from the input cassettte
• through the input cassette and around the drum • through the input cassette and around the
• through the output module drum
• through the buffer module • through the output module
• into the take-up cassette • through the front and rear conveyors
• into the processor or take-up cassette

(the DM 7500SA/7500SA Plus fitted with the on-line

processor option, have the same front and rear con-
veyor system)

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 mrnn 1 • GENERAL INFORMATION

Media Flow

Load media
c
I
I

_.I
Expose media I

c
Feed new media
into drum and
exposed media
into conveyor or
takeup cassette

Cut media

Feed exposed,
cut film, into the
processor

�·
Dev. Fix. Water

Feed exposed
film, into the
takeup cassette

,,
Feed processed
film, into the
output tray

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 scurnw 1 • GENERAL INFORMATION

Exposure System

The exposure system of the DotMate 7500/7500 Plus consists of a spin

ner and optical unit placed on a carriage assembly. The carriage moves
from zero to the left hand position during media exposure. It is driven
by a spindle (or lead screw) connected to a step motor.

Filter Aperture
step motor step motor Rotating mirror
Spinner
Optical unit

Step motor
Carriage sled

Spindle

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 mmn 1 • GENERAL INFORMATION

Optical System

The optical system consists of a laser driver board to which is mounted

the 670 nm, visible red laser diode. The laser beam first passes through a
collimator lens, which ensures parallel distribution of the beam. It then
passes through a filter in the filterwheel; the filter selection depending
on the selected laser intensity. From here the light enters the beam ex
pander where a negative lens difuses the beam. At the rear of the beam
expander, the selected aperture determines the spot size of the beam
before it is passed through the beam expanders positive lens, which
once again collimates the beam. On exiting the beam expander, the
beam is centered through the focus lens and is subsequently passed on
to the rotating mirror of the spinner.

Filter motor Aperture motor

Filter wheel
Aperture switch
Filter switch
Focus adjust

Laser board

Laser diode Focus lens

Collimator lens Aperture iris

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 1 • GENERAL INFORMATION
t

Green Quality module (optional)

The GQunit has two installation options. "On line", were the GQunit is connected to a
mains water supply and drain. (In this mode, fresh water is automatically supplied during
water changes). "Offline" were the unit is disconnected from the mains water supply and
drain and water changing is carried out remote from the DotMate.

The diagram below shows the GQunit in the "online" mode. The water tank is built onto a
trolley, which can be rolled out of the DotMate. The trolley has an internal recirculation
pump which can also be used for emptying the water tank. The UV reactor unit is moun
ted on the frame of the DotMate, above the water tank.

The tube from the processor water tank overflow pipe is redirected to the UV reactor, (on
DotMate's without a GQ unit, the overflow tube is connected to the main drain). The water
slowly flows down a hinged tray in the UV reactor and absorbs ultraviolate light. During the
flow through the UV reactor, a slight vacuum is applied via an activated carbon filter, which
removes the hydrogen sulphide generated.

After UV exposure, the water enters the GQunit water tank via a buffer. The buffer which
has a capacity of 3 1/min, is used for storing water, for example, when the overflow pipe is
removed for emptying the processor water tank. The water then flows down through a
pipe into the silver cartridge. The water rises through the cartridge, precipitating the silver
sulphide. The water then exits the cartridge through a filter cloth, into the water tank and
is directed from the water tank by the recirculation pump to the processor wash tank.

Extem&I water

[I
inlet (magnet
valve)

Alrfilte,
(Acirvlll•d Air outlet
oari>oo)

••�w mso,
I
• ::.,
Overflow pipe

Rac1rculat1onpump

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 1 • GENERAL INFORMATION

Standard Equipment Required and Recommended

Oscilloscope (2 channels, DSO type, <50MHz, xy mode)

Magnifying glass (5 lOx)
Densitometer (ie. Xrite with resolution of 1/10, measuring up to 05.0
Peak stand microscope lOOx
Measuring cups for mixing chemistry
Thermometer
Fluke 85 multimeter (or comparable quality)
Soldering iron
PLCC removal tool
Rachet offset kit (ie. Xcelite XL 75) Socket
set (Hazet, or comparable quality)
Magnet (for retrieving screws, etc) ie. Hazet 19762
Openended spanners; 13, 10, 8, 7, 6, 5, 5.5 and 4 mm.
Allen key set (ie. Wera 950 PKL 7)
Exelite screwdriver handle (ie. Junior 992)
1.5 mm hexagon key for Exelite screwdriver handle
Screwdrivers:
Round head (ie. Wera); 2, 2.5, 3 mm
Cross point (ie. Hazet); 835PZO, 835PZl, 835PZ2
Ordinary (ie. Hazet); 8291, 8292, 8293
Screwdriver with screw retainer (ie. Quick wedge 1258 118)
Long nose pliers (round)
Long nose pliers (flat)
Wire cutter (ie. Bernstein 30652), max 1.5 diameter
Electricians screwdriver
Tweezers (ie. Bemstein5117, 5145)
Small hammer (approx. lOOg. head)
Torch (ie. Sicom Mitylite)
Dentists mirror
Scissors
Hobby knife
Diverse:
Spindle grease
Chalk
Acetone
WD40spray
Loctite (red 222, blue 243)

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 scurnw 1 • GENERAL INFORMATION

Service Kit

Complete set of alien keys (European standard)

2 Interlock defeater
Connector extractor tool
DotMate 7500/7500 Plus service manual

Error Reporting

The aim of the Error Report is to give ScanView A/Sa standard error
reporting medium where all the necessary information is given to Scan
View's Support Department to enable the assessment of defects to be
made in a rational and effective way.

A master copy of this error report is shown on the following page and
should be used to take all the necessary copies.

Of particular importance, is the allocation of a CRN (Confirmation of

Return Number). This number is obtained by contacting ScanView
(Support departments hotline, telefaxing or using the BBS) and must
be included on all error reports.

Exchange parts must be returned to ScanView within 3 weeks of the

invoice date.

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 scurnw
DOTMATE ERROR REPORT

ScanView dealer: Report person:

Date:

DotMate serial Number; Hardware problem: _ Software prob�em:

Hardware problem:
Measurements/calibrations made to verify the problem:

Action taken to correct error.

Exchange equipment
to correct error: _

Serial no. of the item: _

Description of the error:

DotMate firmware version:

System Configuration: _
(This block for ScanView use)
Description:

Warranty _ Warranty exchange Service Service exchange

CRN _

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 2

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 2 • INSTALLATION

Contents

Preinstallation requirements 2•3

DotMate 7500 and 7500 Plus dimensions 2•4
Minimum floor space 2•4
Unpacking and installing the DotMate 7500SA and 7500SA Plus 2•5
Unpacking 2•5
Installation 2•6
Unpacking and installing the DotMate 7500P and 7500P Plus 2•7
Unpacking : 2•7
Installation 2•9
DM 7500P/7500P Plus Water wagon installation (optional GQunit) . 2•14
Offline configuration 2•14
Online configuration 2•15
Setting up the processor= Part 1 2•17
Calibration of the processor temperature sensors 2•17
Setting up the processor • Part 2 2•17
Adjusting the air flow alarm 2•17

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mmn 2 • INSTALLATION

Pre-installation Requirements

Electrical wall outlet: 200-240 VAC, 50-60 Hz

Fuses: This equipment is provided with fuses in the
phase only, not in the neutral. If connected to
a power system that uses phase to phase con
nection to achieve one of the indicated volt
ages, make sure that the connection is carried
out in accordance with national and local
regulations.
Water supply: Water pressure from 1.510 bar, (not needed if
the GQunit is in the offline configuration. The
Drain: drain to be placed no higher than 40 cm above
floor level, (not needed if the GQunit is in the
offline configuration.
Exhaust: Not a requirement, but the DotMate may be
connected to an external exhaust system.
Electrical connection: Fit the appropriate plug as shown below:

Europe (1x220 V + 0 + "'*'")

Blue 0
Yellow/green

Brown

USA (2x110 V + "'*'")

Or countries with similar voltage
Line 1 White

Green

Line l Black

Cautions!� The DotMate 7500/7500 plus are Class 1 electrical equipment. For
personal safety it must be connected to a protective ground, (earth)
in accordance with national and local regulations.

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 SCAN VIEW
2 • INSTALLATION

DotMate 7500SA/P and 7500SA Plus/P Plus Dimensions

DM 7500SA/7500SA Plus
Net weight: 250 kg.
Gross weight: 300 kg.

DM 7500P/7500P Plus
"""""� 145cm -... Net weight: 600 kg.
Gross weight: 650 kg.

115 cm

160 cm

�/
--------
Minimum Floor Space

Minimum requirements:
• 70 cm at the sides to allow for opening of the side doors and processor
side panels and for service access.
• 100 cm at the front for mounting and removing the input and takeup
cassettes and for service access.
• 220 cm in height to allow for opening the processor cover.

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 scumw 2 • INSTALLATION

Unpacking and installing the DotMate 7500SA and 7500SA Plus

Unpacking
1 • Check the TipNTell/ExacTip and/ or Shockwatch indicators on the
container before unpacking.
Note: if the indicators show that the container has been subject to mis
handling or has been tipped, note this on the Bill of Lading and contact
your freight forwarder.
2• Using a screwdriver, remove the ClipLok brackets securing the top and
four side panels of the shipping container and remove the panels.
3• Remove the foil packing around the DotMate.
4• Remove the items detailed on the packing list.
5• Open the left and righthand side doors C and D (fig. 1).

Left-hand side
door Right-hand side
D door
c

Fig.1

6 • Locate the four lock brackets securing the DotMate to the pallet and loosen
the four bolts A (fig. 2).
7 • Loosen the locknuts B and slide the four lock brackets away from the
adjustable feet so that the DotMate is free of the pallet.
8 • Close the left and righthand side doors C and D.

�: � i
Loc k
Bolt Locknut
A B

J Adjustable
foot

Lock brackets
are accessible when the two
side doors are open
Fig. 2

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 SCAHIEW
2 • INSTALLATION

9 • Lay thecontainer side with the two wedgeshaped fitments down to

form a ramp, as shown in fig. 3. '
10 • Screw up four the adjustable feet until the DotMate is supported on its
wheels, and carefully roll the complete unit down the ramp.

Fig. 3

Installation
1 • Open/remove the following panels in accordance with section 4
(access covers and panels):
Top panel F, front cover B and foot panel E (fig. 4).
Front cover
Top panel
B ------------ F

Foot panel
E Fig.4

2 • Screw down the adjustable feet until the weight of the unit is off the
wheels.
3 • Using a spirit level level on the top of the imagesetter, adjust on the
adjustable feet until the complete unit is level in both directions
(fore and aft).
4 • Lock the adjustable feet.

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scumw 2 • INSTALLATION

5 • Connect the mains cable to the DotMate power socket and 'the
mains connection on the back panel (fig. 5).
6 • Connect the SCSI cable and the RS 232 cables between the DotMate
and the RIP and lay the cables in the cutout in the frame (fig. 6).

SA viewed from the back

Main power
RS 232 SCSI
Fig. 5 Fig. 6

Unpacking and installing the DotMate 7500P and 7500P Plus

Unpacking
1 • Check the TipNTell/ExacTip and/ or Shockwatch indicators on
the container before unpacking.
Note: if the indicators show that the container has been subject
to mishandling or has been tipped, note this on the Bill of Lading
and contact your freight forwarder.
2 • Using a screwdriver, remove the Clip Lok brackets securing the top
and four side panels of the shipping container and remove the panels.
3 • Remove the foil packing around the DotMate.
4 • Remove the righthand side panel J and lefthand side panel K (fig. 7).

Right-hand side
panel
J
(left-hand K)

Fig. 7

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 2 • INSTALLATION

5 • Remove the following boxes:

Box A, containing the carbon filter for the processor.
Box B, containing the silver cartridge for the water wagon, (only with
the optional GQunit).
Box C, containing:
Wrench for overflow pipes.
Water inlet hose.
Five filters (including 1 spare).
Spare parts kit.
Damper for water wagon (only with the optional GQunit).
GQ stabilizer (only with the optional GQunit).
Box D, containing the drip trays.
6 • Remove the items detailed on the packing list.
7 • Remove the four bolts A securing the two wooden supports under
neath the processor frame (fig. 8) and remove the supports.

Left-hand side
panel Bolts A
K
(right-hand J)

Lock
brackets, see
fig. 9

Wooden
supports Fig. 8

8• Open the left and righthand side doors C and D, locate the two
lock brackets securing the imagesetter unit to the pallet and loos
en the two bolts A (fig. 9).
9 • Loosen the locknuts B and slide the two lock brackets away from
the adjustable feet .
10 • Close the left and righthand side doors C and D.

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 2 • INSTALLATION

Bolt A Lock bracket

Locknut
B

Adjustable
foot
Fig. 9

11 • Lay the container side with the two wedgeshaped fitments down
to form a ramp, as shown in fig. 10.
12 • Screw up the four adjustable feet until the DotMate is supported
on its wheels, and carefully roll the complete unit down the ramp.

Fig.10

13 • In some cicumstances it may be necessary to separate the image

setter from the processor before installation can be carried out. If
separation is required, see section 4 before continuing.

Installation
• Open/remove the following panels in accordance with section 4
(access covers and panels):
Front cover B, foot panel E, right and lefthand side doors C and D,
processor cover I, and left and righthand side panels J and K.
2 • Screw down the four adjustable feet until the weight of the unit is
off the wheels.

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scumw
2 • INSTALLATION

3 • Using a spirit level level on the top of the processor and imageset •
ter, adjust on the adjustable feet until the complete unit is level in
both directions (fore and aft).
4 • Lock the adjustable feet.
5 • Remove bolt B securing the UV unit lock (fig. 11).

i Bolt B
( '�
»>

6 • Fit the three overflow pipes into the tanks using the wrench supplied,
(red for developer, blue for fixer and transparent for wash) fig. 12.

Before remounting the

overflow pipe, make sure
the 0-ring is placed on the
threaded part of the pipe.
Fig.12

7 • Ensure that the deloper, fixer and water racks are secure in the
tanks (the two clips on the right hand side of the tank compart
ment wall secure them in place (fig. 13).

Fig.13

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 2 • INSTALLATION

8 • Fit the 20µ developer, fixer and water filters, (PN 960 45 013 80) by un
screwing the glass bowl and fitting the filter element with the center
of the element over the raised portion in the bottom of the bowl.
9 • Refit the glass bowl securely, ensuring that the top of the element
engages with the raised portion in the top of the filter housing (fig. 14).
10 • Ensure that the developer circulation flow valve is set in the position
shown.
Developer Developer Fixer
filter circulation filter
flow valve

Fig.14

11 • To be able to set the DIP switches in the following two operations,

the types of installation have to be known. The types are as follows:
On-line: Connected to mains water and drain. .
Off-line: No mains water or drain connections.

With GQ-unit Without GQ-

unit
On-line Ye Yes
s
Off-line N
Normal use o
12 • Remove the four bolts on the electronics box cover and remove the
cover (Fig. 15).

DotMate 7500P/7500P Plus viewed

from the righthand side

Electronics box RA Interface board

cover

Fig.15

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2 • INSTALLATION

13 • Set the DIP switches on the RA Interface board (fig. 16) in accordance
with the settings shown in section 7. (Default is with the GQunit). '

I
,w,

Fig.16

Interface board SW 1

1 : Imagesetter installed ON =yes

2 : GQ installed ON =yes
3 : Silver saver unit installed ON =yes
4, 5, 6 and 7 are not used
8: EEPROM OFF = normal mode
ON = reset at power on resets to
factory values)

M27 Plug for imagesetter communication

M28 Plug for DotMate service program
Jl Jumper in position 2 3 ensures RS 232 level on both M27
andM28

14 • Measure the mains voltage at the wall outlet and note the value.
15 • With reference to fig. 17, .connect the TAP wire to the relevant auto
trans former connection using the voltage noted from step 14. Place
iton:
210Vifthe voltage noted is between 200 215V.
220Vifbetween 215 225V.
230V if between 225 235V.
240V if between 235 245V
Note: before connecting the DotMate make sure that the mains
installation is in accordance with the preinstallation requirements.
16 • Connect the mains cable to the DotMate power socket and the
mains connection on the back of the imagesetter unit (fig. 18).
17 • Connect the power and RS 232 cables from the imagesetter to the
processor (fig. 18).

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2 • INSTALLATION

Auto-transformer

Mains power
connection
lmagesetter to
TAP wire processor
-wire# 302 power
connection

Fig.17 Fig.18

18 • Connect the SCSI cable and the RS 232 cables between the Dot
Mate and the RIP (fig. 19).

Fig.19

19 • If the optional GQunit is fitted, refer to the "Installation of the

Water Wagon (Optional GQ Unit)" on the following pages.
20 • If the optional GQunit is not fitted, connect the hoses as follows:
(fig. 20).
water hose from the mains water tap to the connection on the
bottom of the pump compartment.
Drain hose from the bottom of the wash bath to the drain.

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 SCHYIEW
2 • INSTALLATION

Water
connection

Fig. 20

DM 7500P/7500P Plus - Water Wagon installation (Optional GQ-unit)

Off-line configuration
1 • Remove the lid of the water wagon.
2 • Fit the silver cartridge, (PN 960 45 014 80), mount the damper (anti
splash device) on top of the silver cartridge, secure it in position with
the damper lock and refit the lid of the water wagon, (complete
with buffer), ensuring that the pipe on the cover feeds into the hole
in the silver cartridge (fig. 21). ·
3 • Fit the lµ water filter, (PN 960 45 014 30).

Lid, (with buffer)

Filter
Damper lock

Damper

Silver cartridge

Fig. 21

4 • Fill the tank with water, through the hole in the lid, between the
two upper marks on the tank (fig. 22).
Note: do not exceed 3 liters of water per minute, otherwise the
silver cartridge will be damaged and its function impaired.

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2 • INSTALLATION

Override switch = ......:!+ Do not fill above

this level
......:+t Low level

Fig. 22

5 • Place the water hose over a drain, connect the power cord (the
pump starts) and empty the water wagon.
6 • When the pump stops at the "low level" mark on the tank, press
the override switch on the side of the water wagon to continue
pumping. When the tank is empty, disconnect the power cord.
Note: do not run the pump dry, therefore disconnect the power
cord as soon as the tank is empty.
7 • Fill the tank with water again (not exceeding 3 liters per minute),
up to the middle mark.
8 • Position the water wagon in the processor, connect the water hose
and connect the power cord (fig. 23).
9 • Lower the UV section to its horizontal position so that the rubber
gasket engages with the water wagon.

Lower to the
UV section
horizontal position

(
Water hose
connection
i1 �
Power socket

Fig. 23

On-line configuration.
1 • If the water wagon is to be an on-line configuration, (connected dir
ectly to be the mains water supply and drainage), connect the hoses
from the mains supply to the inlet valve and from the water wagon
to the drain.
CAUTION: Make sure that all connections are tight and secure and
that the installation complies with local and national regulations.

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 mrnn 2 • INSTALLATION

2 • Remove the lid of the water wagon.

3 • Fit the silver cartridge, (PN 960 45 014 80), mount the damper (anti
splash device) on top of the silver cartridge, secure it in position with
the damper lock and refit the lid of the water wagon, (complete
with buffer), ensuring that the pipe on the cover feeds into the hole
in the silver cartridge (fig. 24).
4 • Fit the lµ water filter, (PN 960 45 014 30)

Lid, (with buffer)

Damper lock

Damper -

Silver cartridge Filter

Fig. 24

5 • Position the water wagon in the processor and connect the water
hose and power cord (fig. 25).
6 • Lower the UV section to its horizontal position so that it engages
with the water wagon.

Lower to the
UV section
horizontal position

(
Water hose
connection
-
1' Power socket

Fig. 25

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 scumw 2 • INSTALLATION

Setting up the processor - Part 1

For settingup the processor, which includes the following operations, see
Section 4 • DM 7500/7500P Plus Operators Manual.

• Preparation.
• Startingup.
• Filling the processor.

Calibration of the processor temperature sensors

For calibrating the temperature sensors, see section 3 of this service

manual.

Setting up the processor - Part 2

For the final steps in settingup the processor, which includes the fol
lowing operations, see Section 4 • DM 7500/7500P Plus Operators
Manual.

• Setting the processing parameters.

• Loading media and cassettes.
• Specifying media and cassettes in RipManager.
• Producing a test job.

Adjusting the air flow alarm

For adjusting the airflow alarm, see section 5 of this service manual.

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3 • SERVICE PROGRAM

Contents

Imagesetter service program for Windows NT

(DM's 7500SA/7500P and 7500SA Plus/7500P Plus) Using the DotMate 3
Imagesetter service program Main menu
Standby 3
Test exposure menu Cassette and media 3
menu Processor menu 3
Authorized Service Technician (AST) user menu 3
.' 3
3
Standby
Test exposure menu Cassette and media
menu Processor menu
User menu
Preferences
Manual feed and cut menu
Punch, (only models with optional punch) Debug mode 3
Emulate spinner encoder signals . . . . . 3
· , ..
3
General tool menu 3
Adjust 3
Version parameters 3
Download firmware 3
Processor service program (DM 7500P/7500P Plus) 3
Using the DotMate Processor service program 3
Opening the program 3
Main menu 3
Preference 3
Debug 3
Communication settings 3
Main panel 3
Maintenance 3
Processor calibration 3

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 SCANVIEIT
3 • SERVICE PROGRAM

Contents

Processor I/0 test 3•22 ·

Imagesetter simulating 3•23
Appendix 1
Processor calibration example 3•24
Appendix2
Imagesetter simulation example 3•26

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3 • SERVICE PROGRAM

lmagesetter service program for Windows NT (DM's 7500/7500 Plus)

This section describes the use of the DotMate service program which
is used to service and trouble shoot the DotMate 7500SA/7500SA Plus
and Dotmate 7500P/7500P Plus.

Page Layout
stations

Ethernet connection

I
�
C3
.
SCSI
y

Q
DM 7500SA
DM 7500SA Plus
lmagesetter
service
program

Proce�sor
.._......
�
service

l =J
RS232 C3 program

lmagesetter
lmagesetter � service
RS232 program
DM 7500P
DM 7500P Plus

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3 • SERVICE PROGRAM

Using the DotMate lmagesetter service program

To use the DotMate service program, plug the imagesetter monitor cable
into the serial port (IS) and connect it to the serial communications port
of the RIP PC, (or any other PC running a standard terminal program).

Start the Windows Terminal program (DotMate monitor) on the RIP PC

in the RipMate group, (the communication is to 9600 Baud, 8 bit data,
1 stop bit and no parity). Press the spacebar and the following message
will appear:

Drawer 1: Cassette xxx xx rn

Takeup Cass xx rn

On line menu
M : Main menu {off line)
On line

At any stage, a return to the previous menu level can be made by pres
sing Q (quit). N (next) and P (previous) are used for selecting from a list
(cassette and media lists, for example) and for increasing/decreasing a
particular value (for example, the length of media in each cassette).

Main menu (M)

To enter the main menu, press M at the initial prompt. The choices
available are as follows:
S : Standby
T Test Exposure menu
C Cassette and media menu
P : Processor menu
u : User

Q Quit this menu {online)

Standby (S)
This command facility is used to put the DotMate in standby mode,
(the spinner is off).
Select S to enter the Standby mode and the spinner will stop operating.
To return to the operate mode, press S again.

Test Exposure menu (T)

This command facility allows exposing and printing of specified test
jobs directly onto the DotMate instead of going through the RIP. This is

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useful when finding the correct exposure or when troubleshooting.

Select T to enter the Test exposure menu and the following will be
shown:

Off Line : Test exposure menu 1. 2

T Test pattern
Q : Quit this menu (On line)

Test pattern (T) prompts for the resolution, width, height and number
of scanlines, speed grade and the laser effect of the job. (Press return to
continue with the next submenu).

Test pattern exposure:

Off Line : Resolution in dpi: 1.2 .1

N: Next
P : Previous
Q Quit this menu

Resolution : 2540 dpc : 1000 dpm : 100000

Off Line : Width (scanline) 1.2 .2 .2
N Next
P Previous
Q Quit this menu

Width : 560 mm
Off Line : Height (across scanline) 1. 2. 2. 3
N Next
P Previous
Q Quit this menu

Height 320 mm

Off Line Speedgrade 1.2.2.4

N : Next
P Previous
Q Quit this menu

Speedgrade : 1

Off Line : Exposure 1.2.2.5

N : Next
P Previous
Q Quit this menu

Exposure : 3 0

Upon pressing return at the last prompt, the DotMate begins exposing
the desired test pattern.

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3 • SERVICE PROGRAM

Cassette and media menu (C}

This command facility is used to load new media or unload media al
ready in the DotMate and to eject media in the drum to the takeup
cassette or online processor.

Select C to enter the Cassette and media menu and the following will be
shown:
Off line Cassette and media menu
Drawer 1 cass xxx xx m. media xxx xxx mm.

u : Unload
L : Load
E : Eject
F Form feed
Q Quit this menu (On line)

When selecting Unload, U, the unload function will go through the fol
lowing motions:
unload
moving guide in

backward feeding
off line Cassette and media menu
Drawer 1 cass xxx xx m.
media xxx xxx mm.

When selecting Load, L, the program prompts selection of the cassette

and media that is to be used.
Upon entering these choices, the load function will go through the fol
lowing motions:

Off line : Cassette name

N Next cassette
P Previous cassette
Q Quit this menu

If Eject Eis selected, the last job is moved into the takeup cassette or on
line processor, together with an extra length of media (set in the preferen
ces menu): the media is then cut and fed into the takeup cassette or on
line processor.
Note: always perform an "Eject" before removing the takeup cassette.

Processor menu (P} • DotMate 7500P/7500P Plus

This command facility allows the operation of the following sub menu
functions:

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Select P to enter the Processor menu and the following will be shown:

0: Operate
D : Refill developer
F : Refill fixer
W: Water inlet valve
P : Processor status

Q Quit this menu (On line)

Operate/Stop represents a toggle function. Pressing O .once starts the

processing function, where the media is fed through the processor (use
ful if the DotMate has been turned off and on again with film inside).
Pressing O again stops the processing.
Refill fixer is a toggle function. Upon pressing F, new fixer is pumped
into the fixer tank. Pressing F again stops the pump.
Refill developer is a toggle function. Upon pressing D, new developer is
fed into the developer tank. Pressing D again stops the pump.
Water inlet valve is a toggle function. Upon pressing W, fresh water is
pumped into the water tank. Pressing W again closes the valve.
Processor status displays the current status of the processor.

User menu (U)

This menu is entered via the relevant passwords explained in the fol
lowing paragraph:

Authorized Service Technician (AST) user menu (U)

The user (U) password Super for the enduser will give limited program
access to the menus relevant for the use, (see user manual).

Caution C_. It is not recommended to alter any of the settings unless you are
fully competent to do so. Changing a setting wihout the necessary
competence could mean misalignment of the complete system.

The user (U) password AST (Authorized Service Technician), gives access
to all the menus in the program and enables change/saving of the
machine parameters in the adjust menu.

On selection of AST, the following will appear:

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You are now an authorized service technician

Off line : main menu
S :*Standby
T : Test and expopsure menu
c : Cassette and media menu
p Processor menu
u User
R : Preferences menu
F : Manual feed and cut menu
D Debug mode
E Emulate spinner (scanner) encoder signals
G : General tool menu
A : Adjust

Standby (S)
This command facility is used to put the DotMate in standby mode,
(the spinner is off).

Select S to enter the Standby mode and the spinner will stop operating.
To return to the operate mode, press S again.

Test Exposure menu (T)

This command facility allows exposing and printing of specified test
jobs directly onto the DotMate instead of going through the RIP. This is
useful when finding the correct exposure or when troubleshooting.
Select T to enter the Test exposure menu and the following will be
shown:
(The sub menu's can be found on earlier in this section).

S : Exposure sweep
T : Test pattern 1.2
Q Quit this menu (On line)

Cassette and media menu (C)

This command facility is used to load new media or unload media already
in the DotMate and to eject media in the drum to the takeup cassette.

Select C to enter the Cassette and media menu and the following will be
shown:
U : Unload
L: Load
E : Eject
F: Form feed

Q Quit this menu (On line)

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3 • SERVICE PROGRAM

Processor menu (P)

0 Operate
D :Refill developer
F : Refill fixer
w Water inlet valve
p : Processor status

Q Quit this menu ( on line )

s : Simulate processor
R RA debug mode
c Conveyor speed
J Job setup and start

Simulate processor allows the exposing of a job without the processor

actually running.
RA debug mode puts the imagesetter in a processor debugging mode.
This is useful when troubleshooting.
Conveyor speed displays the speed of the conveyor.
Job setup and start starts an imaginary job on the processor, without
any film from the imagesetter, thus checking the processor without the
imagesetter.

User menu (U)

Enter the relevant passwords (see Super User U and Authorized Service
Technician AST). AST allows access to the menu's; Preferences P, Manual
feed and cut menu F, Debug mode D, Emulate spinner (scanner) encoder
signals E, General tool menu G and Adjust A.

Preferences (R)
This command facility is used to set userdefined parameters, as shown
in the submenu below.

Select R to enter the Preferences menu and the following will be shown:

M Minimum feed length

E Extra feed on eject
O Output device
T Max. length in takeup cassette
C Conveyor speed for online processor
D: Default
preference

Q Quit this menu

Note: The preference menu can be used to reboot the software by ente
ring the menu and quiting again.

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Manual feed and cut menu (F)

This command facility is used to manually set media parameters as def

ined in the sub menu below.

Select F to enter the Manual feed and cut menu and the following will be
shown:

Manual feed and cut

Manual feed and cut menu
F Forward feed
J: Forward feed with conveyor
B Backward feed
T Tense film
R: Release film
M Mini tension film
c Cut
L Car left to stop
Z Car right to stop (zero)
D: Buffer/conv forward feed
I Buffer/conv backward feed
G Car guide in/out
S : Select output (online or takeup)
Y: Clear jam status
K: Self test
P : Punch menu

Q Quit this menu

Forward feed feeds media in/into the drum.

Forward feed with conveyor feeds media in/into the drum and simul
taneously feeds any film in the takeup cassette or front conveyor.
Tense film tensions media in the drum.
Release film releases media in the drum.
Mini tension film slowly tensions the media in the drum.
Cut performs a cut of the media.
Car left to stop moves the carriage fully to the left.
Car right to stop (zero) moves the carriage fully to the right.
Buffer/conv forward feed and Buffer/conv backward feed selects
forward or backward feed in the buffer or front conveyor (for service
purposes).
Car guide in moves the righthand guide in.
Select output allows selection of the takeup cassette or online proces
sor.
Clear jam status clears the internal status on jam and media in the take
up cassette.
Self test establishes if the DotMate has media loaded. It can also be
used to test the sensors.
Punch menu, see the following paragraph.

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3 • SERVICE PROGRAM

Punch menu (P)

This command facility is a submenu of the Manual feed and cut menu
and allows the selection of the optional punch system menu.

Select P to enter the Punch menu and the following will be shown:

s Select and punch

:
p Punch
v Vacuum
0 Prepare
B : Battery load test

Q Quit this menu

Debug mode (D)

This command facility allows the monitoring of the entire exposure process
which will assist in trouble shooting. With the Debug mode turned on,
system information will accompany every command that is selected.

Select D to enter the Debug mode and the exposure process will be monitored.

Emulate spinner encoder signals (E)

This command facility will enable working on the imagesetter with the
spinner turned off. Spinner function will then be simulated from the soft
ware, which allows testing.

Select E to enter the Emulate spinner encoder signals mode and the spinner
will stop operating. To return to the operate mode, press E again.
Note: a reboot of the PC will cause the program to return to the default set
ting which is spinner on in normal mode.

General tool menu (G)

This command facility informs of the status of all sensors and switches and is used to
manually set other machine parameters, other than media parameters, as defined in the
submenu on the following page.

Select E to enter the General tool menu and the following will be shown:

O : Manual optic control

E Exposure
P Peripheral status

1 Encoder step
2 Spinner ref
Q Quit this menu

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•
mrnn

Manual optic control manually moves the filter and aperture to specified
settings.
Exposure sets an unmodulated exposure.
Peripheral status gives the status of all sensors and switches in the
system. (An excellent tool for fault finding)
Encoder step and Spinner ref (ScanView reserved)

Adjust (A)

Caution � It is not recommended to alter any of the settings unless you are
fully competent to do so. Changing a setting wihout the necessary
competence could mean misalignment of the complete system.

This command facility gives an overview of all settings of the imagesetter

(ie. drum diameter, y offset, etc). It also allows adjustment of the settings
shown in the menu below:
Select A to enter the Adjust menu and the following will be shown:

D: Drum diameter
H Media height =
Y Y_offset_mm =
I : Index_offset_angle
V: Version parameters
c : Configuration
M: Motor parameters
P Parameter defaults
S Save parameters
A Show all parameters
Q Quit without saving parameters
Drum diameter is the calculated drum diameter. (Do not change).
Filter sets the filter number for a required exposure setting. (It is automat
ically set in relation to job exposure during normal operation). Media
height specifies the maximum height (length) of cut film. Y_offset_mm is
the value of the zero offset (across scanline, y offset) for set ting the start
exposure point on the media. (See Y offset adjustment, section
5).
lndex_offset_angle is the value of the zero offset (scanline direction,
index offset) setting the start exposure point on the media. (See index off
set adjustment, section 5).
an extra job after the DotMate has not been in use for a period of time.
(The film "bows" making a portion unusable).
Version parameters see the paragraph below.
Configuration allows for overiding certain error codes.

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Motor parameters see the paragraph below.

Parameter defaults (ScanView reserved).
Save parameters is saving of parameter defaults.
Show all parameters shows all parameter values.

Version parameters (P)

This command facility is a submenu of the Adjust menu and shows and/or
allows adjustment of the following settings:

Select V to enter the Version parameter menu and the following will be shown:

F : Filter and laser Function = x

T: Transport and tense Function = x
s : Spot table = x
Z : Punch zone mm= x

Punch zone is a submenu of Version parameters and allows the selection of

the following commands:

Select Punch control:

O JobControlled
1 : Always Punch
2 : Never Punch
Punch : x
Select Punch center control:
O JobControlled centering
1 : Always center on Punch
2 : Never center on Punch
Punch : x

Motor parameters (M)

This command facility is a submenu of the Adjust menu and sets the para
meters for the systems motors.

Select M to enter the Motor parameters menu. In the submenu appearing,

select S for Spinner to display the spinner function selections.

For the DM7500, select 2: spinner and driverboard for 29412 RPM
For the DM 7500 Plus, select 3: spinner and driverboard for 41667 RPM

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Download firmware
To download the firmware, use the following procedure:

1 • In RipManager, select DotMate from the pulldown menu.

2 • Select Update firmware.
3 • Turn off the DotMate.
4 • Set dip switch 4 to on on the control board.
5 • Boot the DotMate and download the firmware.
Note: this operation takes approximately 1 minute.
6 •Turnoff the DotMate and set dip switch 4 to off.
7 • Boot the DotMate.

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 mmn 3 • SERVICE PROGRAM

Processor service program

This section describes the use of the DotMate processor service pro
gram which is used to service and trouble shoot the DotMate 7500P/
7500P Plus.

The DotMate imagesetter service program and the DotMate processor

service program handle communication to and from the processor and
imagesetter respectively and use RS232 connections.

The processor program is a dedicated program running under Wind

ows NT at 4800 baud, whereas the imagesetter program resides in the
imagesetter CPU and must be called from Windows terminal program
at 9600 baud.

Page Layout
stations

Ethernet connection
I
�
C=l
A
SCSI Processor
service
y program

RS232

RS232

lmagesetter
service
program

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3 • SERVICE PROGRAM

Using the DotMate Processor service program

• To open the processor service program, double click on Processor

Service in the RipMate window.

R ipM ate 2. 20 Revert to Ripwatch

Factor�
Settings

ripSplit
�
Install Log
Manager

2 • The following window will appear. This is a window that is intend

ded to warn wouldbe users of the consequences of unqualified
activation of the functions of the program. Select Yes if you are
authorized and wish to continue.

Starting ...

I This is the Processor Service Program I

Using this program.
service technicians I
superuser can activate
functions that may
destroy the processor.

This may happen. if the

functions are activated in
incorrect order.

Are you sure you are authorized and

want to run this service program ?

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3 • SERVICE PROGRAM

3 • The Stat (status) icon and lmagesetter Service window will appear,
Doubleclicking first on the Stat icon will activate the status panel.

Status
D Prnc1:i,i,in\1 D Motor Hard L<rnded
D h:edin9 Mi1terial D Vh1ter cnanqe Hequirt:d
D Developer Temperature D Vh1ti:r ch. in pro\1rei;i;
D Fixer Temperuture O Al9ai: Killt:r ni:quirt:d

ERROR-------- Air Hiter:··

1 ALARM
D
, Main Motor Overluad Silver OK
D Liquid Level Filter. UV OK
D Interlock Silver Unit:
Tubes> OK

FAIL
D Air Flow TEMPERATURES����
D Water Wagon
Developer 33 'C
O UV Tubes Fixer> 32 'C
D Silvi:r Recovery Unit Drver. 39 'C

This shows the current status of the processor, i.e;

BUSY Processing: shows that a job is being run from the image
setter.
Feeding: shows that there is media entering the processor.
Developer/Fixer temperature: shows that the chemistry temp
eratures are too low or too high.
ERROR Main motor overload: shows that a jam or other malfunc
tion has occurred in the chemistry racks, gears or dryer unit.
Liquid level: shows that the developer or fixer levels are too low.
Interlock: indicates that the processor cover is open.
FAIL shows that the indicated part or unit is malfunctioning (refer
to Section 8 • Troubleshooting).
INFO Motor hard loaded: shows that a jam or other malfunction
has occurred in the chemistry racks, gears or dryer unit.
The remaining functions are as indicated by the text.
TEMPERATURES
Shows the current temperatures of the developer and fixer
and the temperature in the dryer.

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 3 • SERVICE PROGRAM

The lmagesetter Service window below is the main menu for the
processor service program. It allows selection of the setting, service,
calibration, test and simulation functions of the processor.

Ill lmageSetter Service a

4 • In the pulldown menu of the lmagesetter Service window, select

ion of freference and then Startup, will show the following menu:

.Eile Service

Switch Qeveloper on
../ Open Statuswindow

When No Startup Warning is activated the processor will be auto

matically turned on when starting the processor service program.
When Switch �eveloper on is activated, the processor will auto
matically switch on when starting the processor service program.
When Open Status window is activated, the Stat (status) window
will automatically open when starting the processor service pro
gram.

5 • In the pulldown menu of the lmagesetter Service window, select

ion of freference and then �ebug, will show the menu on the fol
lowing page. This window is reserved and must only be used by
ScanView personnel. However, the individual boxes can be
checked to ensure that they are not activated. If a box is activated,
please contact ScanView's support department.

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 3 • SERVICE PROGRAM

O firmware warnings
O Silver Recovery Status
DDriveStatus
DReplenishmentSt11tus

DTemperatureStatus
0 .
0 .
0 .

Remember to launcc OBWIN.EXE

6 • In the pulldown menu of the lmagesetter Service window, select

ion of ]!reference and then RS 232 line, will show the following
menu:

file .S.ervice

J,,inie Settings

Deactivate .Connect in order to be able to activate J,ine Settings.

Activate .!.ine Settings and the Communication Settings window will
open.
Set the parameters required, click on Save and then Connect.

I Baud Rate
01200 02400

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 3 • SERVICE PROGRAM

7 • In the hnagesetter Service window, selection of Main panel ... will

open the following window.
This window allows the processor to be switched On or Off, set the

OFFO I

Ret111� Developer
D Fixer
D
Water D

Operate, Rewash or Stop mode, or Refill may be activated for the

developer and fixer. The Water refill is only possible if the machine
is connected to mains water.

8 • In theProcessor Service window, selection of Service... will open the

Maintenance window:

Air Fiiter, Time used = 6%

Air Filter

UV tubes
UV Tubes l\im"J
Silver Filter {ereaJ
Silver Fiiter [timeJ
W1>lerfa:rea)
Wash Water Silver
Silver Unit
SR Unit Silver

OK

The left hand column is used for replacement of the silver unit and the
air filter. For DotMates with the optional GQunit, the left column can
also be used for the UV tubes, silver filter, water change and algae kil
ler. Click on the relevant button and the computer will be informed
that the part has been replaced and the parameters will be automati
cally reset for that part.
The right hand column is used to obtain the status of the operating
time, or silver filter (area) and water (area) of the relevant part. All sele
ctions with the exception of SR Unit Silver and Air Filter apply only
to DotMates with the optional GQunit.

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 scurnw
3 • SERVICE PROGRAM

9 • In the lmagesetter Service window, selection of Calibration... will

open the Processor Calibration window:

PROCESSOR CALIBRATION
ml Prog DEV
NEW:- 20

NOW:- 32
NEW:- 30

NOW:- 40 'C 1·· .

NEW:- 20 'C' Dryer
1031

OK

Note: before starting calibration, the temperatures specified by the

manufacturers of the developer and fixer should be set in the IS/PS
Sim ... window first, as shown in step 12. This is to ensure the great
est accuracy is obtained when calibrating temperatures.

Temperature. For temperature calibration, in the lefthand column,

proceed as follows:
Note: the Now values are the actual temperatures in the tanks.
• A 1530 minute period should elapse from processor startup to
this step in order for the temperatures in the tanks to stabilize.
• Using a thermometer, measure the temperature in the developer
and fixer tanks and dryer unit.
• Type the values obtained with the thermometer into the New
value boxes and click on Developer, Fixer and Dryer in order to
accept the typed input.
Note 1: if the values obtained with the thermometer have a dif
ference of more than 5° from the values in the Now boxes, type
in a value that is only 5° different in the New boxes.
Note 2: settingup calibration is carried out in conjunction with
the IS/PS Sim ... (lmagesetter/processor simulation).
• Wait approximately 10 minutes for the temperature in the tanks
to stabilize.
To get a better understanding of the process, an example is shown
in Appendix 1 at the back of this section.

Replenish. For replenish calibration, in the righthand window,

proceed as follows:

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 sornn
3 • SERVICE PROGRAM

• Place the suction hose for the chemistry to be calibrated into a

measuring glass (at least 21).
• Click on Start DEV and Start FIX and the pump will run for one
minute.
• Enter the amount taken from the glass in mL and click on Prog
DEV/Prog FIX to enter the amount into the computer.
To set Motorload Limit, key in 1500 mA and click on Set limit.
The actual motor load in mA is displayed in the Motor load window.

10 • In the lmagesetter Service window, selection of 1/0 Test... will open

the following window.
DEVELOPER 1/0 TEST
PWMQutput

DI I
Input Flags Qutput Flags
OIL 1 (DEV): 00000111 bin orseeiierl llrwe
OIL 2 (GQ/SSJ:
Status Flags:
00000000 bin
00000110 bin
o·o;;_;�·j��er Heater
D Dev Circulation 01··sR·1
D
Pump
Dev Replenish
D Fixer Heater
Pump
AD values D Fix Circulation Pump Iacho
Drive Load: D Fix Replenish Pump Speed (Hz):
Dev Temp: 149 D Water Circ. Pump
Fix Temp: 148 D Water Valve
Dryer Temp: 99 D Dryer Heater
UV Load: 65 D Dryer Fan
SR Current: 51 D Water Wa"on
SR Voltage: O UV Tubes

_. In this test it is possible to start functions which

may damage parts in the machine if the functions
are activated in the wrong order. (For example,
Caution! starting the fixer heat without liquid in the tank).

Input Flags DIL 1 (DEV):· shows the switch settings on the RA

interface board (see section 7).
DIL 2 (GQ/SS):· shows the switch settings on the sil
ver saver board (see section 7).
AD values show the return status of the unit.
Output Flags Start the indicated function by clicking in the relev
ant box.

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 3 • SERVICE PROGRAM

PWM Output (Pulse width modulation)

Drive: a number between O (stop) and 255(max.
speed) will run the processor motor.
SR: (Silver recovery unit) a number between O and
256 will set voltage and current in the SR unit. The
values can be seen in the relevant AD values boxes.
Tacho shows the motor speed in Hz.
Update Tick Every 15 seconds (count down from 15 to 0) all levels
will be updated in the window. If you do not want to
wait, click on Now.

12 • In the lmagesette. Service window, selection of IS/PS Sim ... will open
the following window.

�IFixTcmp (ntiOx AOXmodc I

�E:=
l��====!
Chemlst,y

Width DcvTimc IDcvRcpl 1rixRepl

�� 150 150 �. Cassette

I START JOB J1��Black 11�1"t 1 . .

1 J_b .

I CANCEL JOB . I OK

This window allows setting the Chemistry temperatures that you

require, dependent on the type of film being used and the AntiOx
and AOX mode.
The Cassette and Job values in the two lower sets of windows are
controlled by RipManager.
Anti Ox The amount of developer, 03000 mL per hour in
AntiOx mode.
AOX Mode 0 = time and square of material
1 = time or square of material
2 = as O and 0.25 times the amount in softoff mode,
3 = as 1 and 0.25 times the amount in softoff mode 2.

To get a better understanding of setting the AOX mode parameters,

an example is shown in Appendix 2 at the back of this section.

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 3 • SERVICE PROGRAM

Appendix 1

Processor calibration example

Example of temperature setting

Example: a temperature of 32° is required in the fixer tank.

• Open the IS Sim ... window and type in 32 in the Fixlemp box.

� !FixTemp AntiOx AOX mode 1

,�11..
� 32
Width DevTime IDevRepl IIFixRepl
��150 150 Cassette
�
,��Black IIL e �gth Ii! Job
4

OK

• Click on Chemistry and then OK and close the IS Sim ... menu.
• Wait 1530 minutes for the temperatures in the tanks to stabilize.
• Let us assume that a value of 25° is measured with the thermometer.
• Click on Calibration ... in the Processor Service menu. A value of 32°
should be shown in the fixer Now window.

PROCESSOR CALIBRATION

Temperature,
NOW:- 33 'C
1300 ml Prog DE.V
NEW:- 20 'C

�I NOW:- 32
NEW:- 20

NOW:- 40
NEW:- 20

• As the difference of the required value of 25° measured with the

thermometer and the required value set in IS Sim ... has a differ
ence greater than 5°, type in 30 in the fixer New box, (25+5 =30.
• Click on Fixer and then OK.

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 3 • SERVICE PROGRAM

Appendix 1

• Wait for approximately 10 minutes and measure the temperature

with the thermometer again. The temperature is now 30°.
• Click on Calibration ... in the lmagesetter Service menu. A value of
32° should still be shown in the Now box.
• Type in 30 in the fixer New box.

Temperature,
... ..
Replenish
:•, .
I
NOW: 33
:� I Developer I
Start DEV 1300 ml Prog DEV
NEW: 20
I I
I I I
NOW: 32
NEW: 30 :� I Fixer
I
Start AX 1300 ml ,� Prog FIX

NEW:
NOW: 40 ·c
1w-,- I I Motor Load�liMotor Load Limit
1 031 mA 1500 mA Sel Limil II I
20 'C Dryer

OK

• Click on Fixer and then OK.

• Wait for approximately 10 minutes and the tank should now heat
up to the required 32° when measured with the thermometer and
the fixer Now window should also read 32°.

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 SCHVIEW
3 • SERVICE PROGRAM

Appendix 2

lmagesetter simulation example

Example of AOX mode setting

Example: a value of 200 mL is required.

Image Setter Simulating

AOX mode O
without processing film = 200 mL
replenish due to oxidation when processing film, 100 mL = 300 mL total
replenish due to oxidation when processing film, 500 mL = 700 mL total
standby = 200 mL

AOXmode 1
• without processing film = 200 mL
replenish due to oxidation when processing film, 100 mL = 200 mL total
replenish due to oxidation when processing film, 500 mL = 500 mL total
standby = 200 mL

AOXmode 2
without processing film = 200 mL
replenish due to oxidation when processing film, 100 mL = 300 mL total
replenish due to oxidation when processing film, 500 mL = 700 mL total
standby = 50 mL

AOXmode 3
without processing film = 200 mL
replenish due to oxidation when processing film, 100 mL = 200 mL total
replenish due to oxidation when processing film, 500 mL = 500 mL total
standby = 50 mL

When setting is complete, click OK and the menu will close.

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(1)
u
(1)

3
�
(1)

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SCAHIEW
4 • PART REPLACEMENT

Contents

Sub Section 4•100 General 4•102 to 4•105

Sub Section 4•200 Imagesetter 4•202 to 4•291
Sub Section 4•300 Processor 4•302 to 4•341
Sub Section 4•400 - Optional Equipment 4•402 to 4•415

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mrnn 4 • PART REPLACEMENT

Contents

General Sub Section 4• 100

Access panels:
DotMate 7500SA/7500SA Plus 4•102
DotMate 7500P/7500P Plus 4•103
Separating the imagesetter and processor (DM 7500P/7500P Plus) 4•104
Removing the processor cover (DM 7500P/7500P Plus) 4•105

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•• 4 • PART REPLACEMENT

Access Panels - DotMate 7500SA/7500SA Plus

Covers and panels

A Front shield
B Front cover
c Right hand side door
D Left hand side door
E Foot panel
F Top panel
G Back panel

Tools and materials required

No tools or material are required.

Cautions c. The DotMate 7500/7500 Plus are class I laser products and contain a
laser, which under normal working conditions is totally shielded by
the cabinet. When the cabinet of the imagesetter unit is opened, the
interlock system automatically switches off the laser.
c To override the interlock system, a female "defeater" connector is fit
ted to the male connector on the inside of the lefthand side door of
the imagesetter unit.
Only authorized service personnel may override the interlock system.

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 scurnw

Access Panels - DotMate 7500SA/7500SA Plus

How to open/remove

• Front shield A slides both upwards and downwards on rails. Release

'catches on the undersides of the two handgrips lock the shield in
the central, raised or lowered positions. Simply press the release
catches to move the shield in the desired direction.
2 • Front cover B is a hinged panel, supported in the open position by
two gasfilled struts. First remove the top panel F and then open
the front cover by pressing the two catches underneath the cover
and lifting up at the bottom.
3 • Right· and left-hand side doors C and D are hinged doors and are
opened by simply swinging towards the rear of the imagesetter.
4 • Foot panel Eis secured by four flanges on the mainframe. First rem
ove the top panel F, open the front cover Band remove the foot
panel by simply lifting up and away.
5 • Top panel F is a loose fit on the top of the imagesetter. Remove by
simply lifting away.
6 • Back panel G is secured by two flanges on the mainframe. Remove
by simply lifting up and away.

How to shut/refit

7 • Closing/refitment of the panels and covers are carried out in the

reverse order to that of opening/removal.
Note: the lefthand side panel D cannot be closed with the inter
lock defeater fitted.

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 4 • PART REPLACEMENT

Access Panels - DotMate 7500SA/7500SA Plus

Top panel
F
Status panel

Back panel
G

Front shield
A

Right-hand side
.....:--+I---- door
c
Left-hand side/
door
D

Front cover
B
On/off switch

Front cover release cat-

Foot panel ches (each side)
E

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 •

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•
4 • PART REPLACEMENT

Access Panels - DotMate 7500P/7500P Plus

Covers and panels

A Front shield
B Front cover
c Righthand side door
D Lefthand side door
E Foot panel
H Conveyor cover
Processor cover Right
hand side panel
K Lefthand side panel
L Processor back panel

Tools and materials required

No tools or material are required.

Cautions c.,. The DotMate 7500/7500 Plus are class I laser products and contain a
laser, which under normal working conditions is totally shielded by
the cabinet. When the cabinet of the imagesetter unit is opened, the
interlock system automatically switches off the laser.
c. To override the interlock system, a female "defeater" connector is fit
ted to the male connector on the inside of the left hand side door of
the imagesetter unit.
Only authorized service personnel may override the interlock system.

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Access Panels - DotMate 7500P/7500P Plus

How to open/remove

• Front shield A slides both upwards and downwards on rails. Release

catches on the undersides of the two handgrips lock the shield in
the central, raised or lowered positions. Simply press the release
catches to move the shield in the desired direction.
2 • Front cover B is a hinged panel, supported in the open position by
a gas filled strut. First remove the processor cover I and then open
the front cover by pressing the two catches underneath the cover
and liftting up at the bottom.
3 • Right- and left-hand side doors C and D are hinged doors and are
opened by simply swinging towards the rear of the imagesetter.
4 • Foot panel E is secured by four flanges on the mainframe. First raise
the processor cover I, open the front cover B and remove the foot
panel by simply lifting up and away.
5 • Conveyor cover H is located underneath the processor cover I. First
raise the processor cover and then simply lift the conveyor cover
away.
6 • Processor cover I is a hinged cover, supported in the open position
by a gasfilled strut. Open by simply lifting up at the front.
7 • Right- and left-hand side panels J and K are secured by two flanges
on the mainframe. Remove by simply lifting up and away.
8 • Back panel L is secured by two flanges on the mainframe. Remove
by simply lifting up and away.

How to shut/refit

9 • Closing/refitment of the panels and covers are carried out in the

reverse order to that of opening/removal.
Note: the righthand side panel D cannot be closed with the inter
lock defeater fitted.

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 4 • PART REPLACEMENT

Access Panels - DotMate 7500P/7500P Plus

Processor cover
I
Conveyor cover
Status panel H
(underneath the
processor cover)

Processor
back panel
L

Front shield
A

......:- Right-hand side

panel
J
(left-hand K)

Left-hand side /
door Right-hand side
D door
c
Front cover
On/off switch B
Front cover release
Foot panel
catches (each side)
E

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 4 • PART REPLACEMENT

Separating the lma_gesetter and Processor

(DotlVlate 7500P/7500P Plus)

Purpose

All of the service operations contained in this manual can be carried

out with the DotMate 7500P /7500P Plus as an integral unit. However,
for logistical reasons, i.e. moving to other premises, etc. it may be easier
to separate the imagesetter from the processor.

Tools and materials required

Spirit level
Standard equipment (section 1).

Caution! ,... Only authorized service personnel may override the interlock
system, (if activated).

,... Turn off power • Before connecting or disconnecting cables.

• Before carrying out service operations.

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 mmn

Separating_ the lmagesetter from the Processor

(DotMate 7500P/7500P Plus)

How to remove

1 • Raise the processor cover I (see covers and panels DotMate

7500P /7500P Plus) by simply lifting up.
2 • Open the left and righthand side doors C and D (see covers and
panels).
3 • Remove the lefthand side panel J (see covers and panels), so that
there is access to the GQunit and imagesetter/processor connectors.
4 • Lift the UV light unit to a horizontal position. '
5 • Disconnect the water hose snapon connector from the water inlet
valve on the processor.
6 • Disconnect the power cord on the side of the water wagon and move
the water wagon away from the processor.
7 • Remove the main power connector, processor power connector and
RS 232 connector from the back of the imagesetter unit.
8 • Remove the four nuts, washers and bolts A (located on the back wall
of the imagesetter unit)
9 • Carefully slide the imagesetter away from the processor.

How to refit

10 • Position the imagesetter up against the processor and align the four
bolt holes as closely as possible.
11 • Using a spirit level, adjust the imagesetter in both directions (fore
and aft) until it is level, by adjusting on the four adjustable feet.
12 • Using a spirit level, adjust the processor in both directions (fore and
aft) until it is level, by adjusting on the four adjustable feet.
Note: lock the feet when adjustment is complete by screwing up the
locknut.
13 • Fit the four bolts, washers and nuts A.
14 • Connect the main power connector, processor power connector and
RS 232 connector to the back of the imagesetter unit.
15 • Position the water wagon in the processor and connect the power
cord.
16 • Reconnect the water hose snapon connector.
17 • Lower the UV light unit ensuring that the rubber gasket seats correc
tly on the water wagon.
18 • Refit the lefthand side panel J, processor cover G and close the left
and righthand side doors C and D.

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 4 • PART REPLACEMENT

Separating the lma�setter from the Processor

{DotMate 7500P/7500P Plus)

UV light unit Right-hand side

door C
Left-hand side
door D

Fig.1

GQ-unit

Bolts, washers
and nuts A
(x4)

Fig. 2

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SCAN VIEW
4 • PART REPLACEMENT

Removing the Processor Cover

{DotMate 7500P/7500P Plus)

Function

This instruction is a continuation of the previous instruction, separat

ing the imagesetter from the processor.

If the imagesetter has been separated from the processor, it also may be
necessary to remove the processor cover if access for installation of the
DotMate 7500P/7500P Plus is limited.

Technical data

Tools and materials required

Circlip removal tool

Standard equipment (section 1).

Caution! r� Only authorized service personnel may override the interlock

system.

r� Turn off power • Before connecting or disconnecting cables.

• Before carrying out service operations.

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 mmn

Removing the Processor Cover

(DotMate 7500P/7500P Plus)

How to remove
1 • Ensure that the processor cover I is raised.
2 • Remove the processor back panel L (fig. 1) by lifting up and away.
3 • Remove the circlips A retaining the damper arms on both sides of
the processor cover (fig. 2) and slide off the damper endfork.
4 • Lower the processor cover I and remove the three bolts and wash
ers B on the right and lefthand brackets securing the processor
cover hinges (fig. 3)
5 • Slide the bracket away as shown and carefully lift away the proces
sor cover.

How to replace

6 • Mount the processor cover I onto the processor.

7 • Mount the left and right hand brackets and fit the three bolts and
washers B.
8 • Lift up the processor cover and refit the damper endforks onto
each side of the processor cover and fit the circlips C.

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 4 • PART REPLACEMENT

Removing the Processor Cover

(DotMate 7500P/7500P Plus)

Processor back
panel L

CirclipA
(x2)

Damper

Fig.1

Processor cover hinge

Processor cover hinge

viewed from the top

bracket

Bolts B

Fig. 2

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 4 • PART REPLACEMENT

Contents

lmagesetter Sub Section 4• 200

Hardware drawer:
Electronics module:
Control board (960 55 002 20) 4•2
Driver board (960 55 001 60) 4•2
Backplane (960 55 000 80) : (960 40 4•2
Electronics cooling fan 002 20) : (960 55 001 00) 4•l
LED board 4•2
Power supply: (960 45 000 70)
5V, +/12V 4•2
24V (960 55 001 70) 4•2
Line filter, 6A (960 55 001 80) 4•2
Capacitor, 2 µF (960 55 002 00) 4•2
Pages reserved for future use 4•210 to 4•215
Transport modules:
Input module (SA/P & SA Plus/P Plus) .. (960 55 000 10) 4•2
Step motor (960 55 003 00) : (960 55 4•2
Drive belt, outer 003 10) 4•2
Drive belt, inner (960 40 001 30) 4•2
Sensor, drum in (960 55 003 30) 4•2
Sensor, cassette (960 40 001 40) 4•2
Input cassette DC motor. (960 55 002 80) 4•2
Pages reserved for future use 4•223 to 4•226
Output module (SA/P & SA Plus/P Plus) . (960 55 000 20) 4•2
Step motor, knife (960 40 002 00) 4•2
Step motor, rollers (960 40 002 00) 4•2
Drive belt, knife (960 55 003 20) 4•2
Drive belt, rollers (960 40 001 20) 4•2
Microswitches, knife right (960 40 001 90) 4•2
Microswitch, knife left (960 40 001 90) 4•2
Sensor, drum out (960 40 001 50) 4•2
Pages reserved for future use 4•234 to 4•237

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 scum,

Contents

Buffer module (SA/SA Plus) (960 55 000 30) 4•2

Step motor, right (960 40 002 00) 4•2
Step motor, left (960 40 002 00) 4•2
Sensor, buffer top (960 40 001 50) 4•2
Sensor, buffer side (960 55 003 40) 4•2
Microswitch, takeup cassette (960 55 003 50) 4•2
Pages reserved for future use 4•243 to 4•247
Front conveyor (SA/P & SA Plus/P Plus) .. (960 55 000 40) 4•248
Step motor, right (960 40 002 00) 4•248
Step motor, left (960 40 002 00) 4•249
Step motor, conveyor (960 55 003 00) 4•250
Sensor, buffer top (960 40 001 50) 4•251
Sensor, buffer side (960 55 003 40) 4•252
Sensor, in (960 40 001 40) 4•253
Microswitch, takeup cassette (960 55 003 50) 4•254
Pages reserved for future use 4•255 to 4•258
Rear conveyor (SA/P & SA Plus/P Plus) .. (960 55 000 50) 4•259
DC motor (960 55 002 90) 4•260
Sensor, in (960 40 001 50) 4•261
Sensor, out (960 40 001 50) 4•262
Pages reserved for future use 4•263 to 4•268
Optics module:
Spinner. (960 55 002 10) 4•269
Filter step motor (960 55 002 50) 4•270
Aperture (iris) step motor (960 55 002 60) 4•271
Microswitch, aperture (iris) (960 40 002 90) 4•272
Microswitch, filter (960 40 002 90) 4•273
Pages reserved for future use 4•274 to 4•278
Carriage module:
Spindle step motor (960 45 001 70)
Microswitch, right � (960 40 001 90)
Microswitch, left (960 40 001 90)

4• 201 b Service Manual • DotMate 7500/7500 Plus . Edition 2 • July 1997

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mmn
4 • PART REPLACEMENT

Contents

Media guide strain gauges (960 55 002 70) .'4•281

Optics protection board (960 55 000 90) 4•282
Temperature stabilizer board (960 55 001 10) 4•283
Pages reserved for future use 4•284 to 4•286
Media Guide Module
DC motor (960 55 002 90) 4•287
Microswitches (960 40 001 90) 4•288
Pages reserved for future use 4•289 to 4•290
Cooling/Filter module:
Air filters (960 55 001 40) 4• 291

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 4 • PART REPLACEMENT

P/N 960 55 002 20 Control Board

Function

The control board houses the SCSI controller, flashproms and NVRAM
and is mounted inside the electronics drawer.

Technical data

Tools and materials required

PLCC removal tool.

Caution! c... Only authorized service personnel may override the interlock
system, (if activated).

c... Turn off power • Before connecting or disconnecting cables.

• Before carrying out service operations.

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 Control Board

How to replace

Removal
1 • Remove the foot panel E (see covers and panels) by simply lifting up and
away.
2 • Disconnect the SCSI and RS232 connectors from the electronics drawer.
3 • Remove two retaining screws securing the SCSI, RS232 and spare RS232
connectors to the electronics drawer front panel.
4 • Remove the ten countersunk alien screws securing the electronics drawer
front panel and remove the panel.
5 • Unscrew the two alien screws A on the control board end plate.
Note: the end plate disengages/engages the board connector from its mat
ing connector on the backplane. It is therefore important that the two alien
screws are unscrewed either together or alternately a few turns at a time.
This ensures that the board connector disengages/ engages evenly.
6 • Carefully slide the control board out enough to disconnect the coax cable
from J3, (being careful not to let the cable catch up on control board com
ponents), then completely remove the board from its tray.
7 • Remove the NVRAM from the old board using the PLCC removal tool and
fit them onto the new control board. (The NVRAM preserves the para
meter settings and machine constants for the DotMate 7500SA/P and
7500SA Plus/P Plus).
Note: parts of the data on the NVRAM are factory adjustments and on file
at ScanView. Iffor any reason this data is lost, contact ScanView, quoting
your DotMate serial number.

Assembly
8 • Fit a new control board by positioning the board onto its tray and sliding
in enough to connect the coax cable to J3. Push the board further in as
far as the backplane connector.
9 • Carefully screw in the two alien screws A on the end plate until the board
and backplane connectors are mated, (see the note in step 5 above).
10 • Refit the electronics drawer front panel using the ten countersunk alien
screws.
11 • Refit the two screws on the SCSI, RS232 and spare RS232 connectors.
13 • Reconnect the SCSI and RS232 connectors.
12 • If no further replacement operations are required, refit the foot panel Eby
hooking the four lugs on the panel over the brackets on the imagesetter
and lower into place.

Adjustments required
No adjustments are required.

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 4 • PART REPLACEMENT

Control Board

See section 7 for a more detailed

view of the control board

Electronics drawer front Allen screws

panel A
(x2)

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 mmn 4 • PART REPLACEMENT

P/N 960 55 001 60 Driver Board

Function

The driver board controls the DotMate's step motors and sensors and is
mounted inside the electronics drawer.

Technical data

Tools and materials required

No special tools are required, only standard equipment (section 1).

Caution! r..- Only authorized service personnel may override the interlock
system, (if activated).

r,-. Turn off power • Before connecting or disconnecting cables.

• Before carrying out service operations.

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 mrnn

Driver Board

How to replace

Removal

1 • Remove the foot panel E (see covers and panels) by simply lifting
up and away.
2 • Disconnect the SCSI and RS232 connectors from the electronics
drawer.
3 • Remove two retaining screws securing the SCSI, RS232 and spare
RS232 connectors to the electronics drawer front panel.
4 • Remove the ten countersunk alien screws securing the electronics
drawer front panel and remove the panel.
5 • Unscrew the two alien screws A on the control board end plate.
Note: the end plate disengages/ engages the board connector from
its mating connector on the backplane. It is therefore important that
the two alien screws are unscrewed either together or alternately a
few turns at a time. This ensures that the board connector diseng
ages/ engages evenly.
6 • Carefully slide the driver board out from its tray.

Assembly

7 • Fit a new driver board by positioning the board onto its tray and
sliding in to the backplane connector.
8 • Carefully screw in the two alien screws A on the end plate until the
board and backplane connectors are mated, (see the note in step 5
above).
9 • Refit the electronics drawer front panel using the ten countersunk
alien screws.
10 • Refit the two screws on the SCSI, RS232 and spare RS232 connectors.
11 • Reconnect the SCSI and RS232 connectors.
12 • If no further replacement operations are required, refit the foot
panel E by hooking the four lugs on the panel over the brackets on
the imagesetter and lower into place.

Ajustments required
No adjustments are required.

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 4 • PART REPLACEMENT

Driver Board

See section 7 for a more detailed

view of the driver board

Electronics drawer front Allen screws

panel A
(x2)

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 SONYIEW
4 • PART REPLACEMENT

P/N 960 55 000 80 Backplane

Function

The backplane is the interface for the cabling, control board and driver
board.

Technical data

Tools and materials required

No special tools are required, only standard equipment (section 1).

Caution! r.- Only authorized service personnel may override the interlock
system, (if activated).

c.. Turn off power • Before connecting or disconnecting cables.

• Before carrying out service operations.

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Backplane

How to replace

Removal
1 • Remove the foot panel E (see covers and panels) by lifting up and away.
2 • Remove the two alien screws A and pull the hardware drawer partially out.
3 • Remove the five allen screws Band remove the halfpanel.
4 • Disconnect the SCSI and RS232 connectors from the electronics drawer.
5 • Remove two retaining screws securing the SCSI, RS232 and spare RS232
connectors to the electronics drawer panel.
6 • Remove the ten countersunk alien screws screws securing the electron
ics drawer front panel and remove the panel.
7 • Remove the control board (see control board removal and fitting).
8 • Remove the driver board (see driver board removal and fitting).
9 • Disconnect connectors J7, J8, J9, no, n 1, nz, ]13, n4, ]15, n 7, ns, ns,
]20, J21, J22, J23, J24, J25, J26, J27 and J28 on the back plane.
10 • Remove the eight alien screws C (four each side), securing the top panel
of the electronics drawer and remove the panel.
11 • Remove the twelve alien screws D securing the back plane to the elec
tronics drawer and lift the backplane away.

Assembly
12 • Mount the new backplane and refit the twelve alien screws D.
13 • Refit the top panel of the electronics drawer using the the eight alien
screws C (four each side).
14 • Reconnect connectors J7, J8, J9, no, Jll, nz, ]13, n4, ]15, Jl 7, ns, ns,
J20, J21, J22, J23, J24, J25, J26, J27 and J28 to the backplane.
15 • Refit the driver board, (see driver board removal and fitting).
16 • Refit the control board, (see control board removal and fitting).
17 • Refit the electronics drawer front panel using the ten cross point screws.
18 • Refit the two screws on the SCSI, RS232 and spare RS232 connectors.
19 • Refit the halfpanel using the five alien screws B.
20 • Reconnect the SCSI and RS232 connectors.
21 • Push the hardware drawer back in to the Dotmate and refit the two alien
screws A.
22 • If no further replacement operations are required, refit the foot panel E
by hooking the four lugs on the panel over the brackets on the imageset
ter and lower into place.

Adjustments required
No adjustments are required.

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 4 • PART REPLACEMENT

Backplane

J28 J14 J22 J18 J19 J24 J25 J26 J27 J9 J21 J12 J8

UH II Ii Hl81HU II HU llillll!iilH 0UIIHHHIIHH HUIGGUUUllillllllHIIH 0 ill lllilllliHHUilHUHillHUIIH

I:[7 . TI .. , TI
08�

[1 . T
Bl8H
mm
� 0 0

n
J23 J11 J17 J13 J20 J7 J10 J15

See section 7 for a more detailed

view of the backplane
Electronics drawer front
panel
Allen screws
Backplane
c
Hardware drawer (x8)

Allen screws B Electronics drawer front Allen screws

(x5) panel A
(x2)

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 4 • PART REPLACEMENT

P/N 960 40 002 20 Electronics Cooling Fan

Function

The cooling fan is located inside the hardware drawer, on the right
hand side of the electronics module.
It supplies cooling air to the control board and driver board inside the
electronics module.

Technical data

Tools and materials required

No special tools are required, only standard equipment (section 1).

Caution! ... Only authorized service personnel may override the interlock
system.

C... Turn off power • Before connecting or disconnecting cables.

• Before carrying out service operations.

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Electronics Cooling Fan

How to replace

Removal

1 • Remove the foot panel E (see covers and panels) by lifting up and
away.
2 • Remove the two alien screws A and pull the hardware drawer part
ially out.
3 • Remove the five alien screws B and remove the half panel.
4 • Remove the foot panel E (see access panels and covers).
5 • Remove the four alien screws C and washers securing the electron
ics module and lift the module out enough so that cooling fan can
be removed.
Note: be carefull not to damage cables and connectors on the
backplane.
6 • Disconnect the connector to the cooling fan.
7 • Remove the four alien screws securing the fan and remove the fan.

Assembly

8 • Fit a new cooling fan and secure using the four alien screws.
9 • Reconnect the connector to the fan.
10 • Refit the electronics module using the four alien screws A.
11 • Push the hardware drawer back in to the Dotmate and refit the two
alien screws A.
12 • Ifno further replacement operations are required, refit the foot
panel E by hooking the four lugs on the panel over the brackets on
the irnagesetter and lower into place.

Adjustments required

No adjustment is required.

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 4 • PART REPLACEMENT

Electronics Cooling Fan

Allen screws
c
(x4)

Half panel

Cooling fan

\
Allen screws B
(x5)

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 4 • PART REPLACEMENT

P/N 960 55 001 00 LED Board

Function

The LED board controls the status and function switches to the oper
ator and is located underneath the status panel on the front cover.

Technical data

Tools and materials required

No special tools are required, only standard equipment (section 1).

Caution! r.- Only authorized service personnel may override the interlock
system, (if activated).

C_.. Turn off power • Before connecting or disconnecting cables.

• Before carrying out service operations.

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 mrnn

LED Board

How to replace

Removal

• Remove the top panel F (DM 7500SA/7500SA Plus) or the proces

sor cover I (DM 7500P/7500P Plus) and raise the front cover B (see
covers and panels) by pressing the two catches underneath the
cover and lifting up at the bottom.
2 • Disconnect the two connectors Jl and JPl on the LED board.
3 • Remove the ten allen screws securing the board to the cover and
lift the board away.

Assembly

4 • Mount the new LED board and refit the ten allen screws.
5 • Reconnect connectors Jl and JPl to the board.
6 • If no further replacement operations are required, lower the front
cover B.

Adjustments required

No adjustments are required.

4•206b Service Manual •· DotMate 7500/7500 Plus Edition 2 • July 1997

A ./, C"\
manual DotMate 7500.indd 112 06/06/2016 01:17:49 p.m.
 4 • PART REPLACEMENT

LED Board

Connector J1
Connector JP1

0 :··········;·······: 0 .........•
�
0
L..�--��
I
�o=E:D

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 mrnn 4 • PART REPLACEMENT

P/N 960 45 000 70 (5V, +/-12V) Power Supplies

P/N 960 55 001 70 (24V)

Function

The 5\1, +l12V and 24V power supplies supply power to the DotMate.

Technical data

PIN 960 45 000 70 (5\1, +I 12V)

PIN 960 55 001 70 (24V)

Tools and materials required

No special tools are required, only standard equipment (section 1).

Caution! _. Only authorized service personnel may override the interlock

system, (if activated).

c� Turn off power • Before connecting or disconnecting cables.

• Before carrying out service operations.

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 scnmw

Power Supplies, (SV,+/-12 & 24V)

How to replace

Removal

1 • Open the lefthand side door C (see covers and panels).

2 • Disconnect the main power connector, processor power connector
and RS232 connector on the back of the imagesetter unit.
3 • Remove the foot panel E (see covers and panels) by lifting up and
away.
4 • Disconnect the SCSI and RS232 connectors from the electronics
drawer.
5 • Remove the two alien screws A and pull the hardware out far
enough to gain access to the power supplies.
6 • Disconnect connectors Jl and J2 on the SV and +/12V power
supply and/ or loosen the screws on the connectors of the eight
leads on the 24V power supply and remove the leads.
7 • Remove the four alien screws B from the SV, +/12 and/or 24V
power supply (the screws are located on the outside of the left
hand side wall of the hardware drawer) and remove the power
supply.

Assembly

8 • Mount the SV, +/ 12 and/ or 24V power supplies and refit the four
alien screws B.
9 • Reconnect connectors Jl and J2 on the SV and +/12V power
supply and/or the eight leads on the 24V power supply.
10 • Push the hardware drawer back in and refit the two alien screws A.
11 • Reconnect the SCSI and RS232 connectors.
12 • Reconnect the main power connector, processor power connector
and RS232 connector on the back of the imagesetter unit.
13 • If no further replacement operations are required, close the left
hand side door D and refit the foot panel E by hooking the four
lugs on the panel over the brackets on the imagesetter and lower
into place.

Adjustments required

No adjustments are required.

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 4 • PART REPLACEMENT

Power Supplies, (SV,+/-12 & 24V)

24V power supply

Power supplies
alien screws 5V & +/ 12V power supply
B
on the outside of
this wall

SCSI and RS232 connectors

Allen screws A

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 scumw 4 • PART REPLACEMENT

P/N 960 55 001 80 Line Filter

Function

The line filter removes electrical interference from the system.

Technical data

6A

Tools and materials required

No special tools are required, only standard equipment (section 1).

Caution! r, Only authorized service personnel may override the interlock

system, (if activated).

c. Tum off power • Before connecting or disconnecting cables.

• Before carrying out service operations.

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Line Filter

How to replace

Removal

1 • Open the lefthand side door C (see covers and panels).

2 • Disconnect the main power connector, processor power connector
and RS232 connector on the back of the imagesetter unit.
3 • Remove the foot panel E (see covers and panels) by lifting up and
away.
4 • Disconnect the SCSI and RS232 connectors from the electronics
drawer.
5 • Remove the two alien screws A and pull the hardware out far
enough to gain access to the line filter.
6 • Disconnect the four connectors on the line filter.
7 • Remove the four allen screws B from the filter and lift it away.

Assembly

8 • Fit a new line filter using the four alien screws B.

9 • Reconnect the four connectors.
10 • Push the hardware drawer back in and refit the two alien screws A.
11 • Reconnect the SCSI and RS232 connectors.
12 • Reconnect the main power connector, processor power connector
and RS232 connector on the back of the imagesetter unit.
13 • Ifno further replacement operations are required, close the left
hand side door D and refit the foot panel E by hooking the four
lugs on the panel over the brackets on the imagesetter and lower
into place.

Adjustments required

No adjustments are required.

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 4 • PART REPLACEMENT

Line Filter

Allen screws
B

...... , _...._::.,.::-1
=:€ ro:
{t \ :
\ ...._ � c 1 I I
_ - - -- ' I j

Line filter

SCSI and RS232 connectors

Allen screws A

Edition 2 • July 1997 Service Manual • DotMate 7500/7500 Plus 4•208c

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 scurnw 4 • PART REPLACEMENT

P/N 960 55 002 00 Capacitor, 21,1F

Function

The 2µF capacitor controls the speed of the main fan motor.

Technical data

Tools and materials required

No special tools are required, only standard equipment (section 1).

Caution! c. . Only authorized service personnel may override the interlock

system.

c. Turn off power • Before connecting or disconnecting cables.

• Before carrying out service operations.

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 scurnw

Capacitor 21,1F

How to replace

Removal

1 • Open the lefthand side door C (see covers and panels).

2 • Disconnect the main power connector, processor power connector
and RS232 connector on the back of the imagesetter unit.
3 • Remove the foot panel E (see covers and panels) by lifting up and
away.
4 • Disconnect the SCSI and RS232 connectors from the electronics
drawer.
5 • Remove the two alien screws A and pull the hardware drawer out
far enough to gain access to the the capacitor.
6 • Disconnect the four connectors on the capacitor.
7 • Remove the nut Band lockwasher (on the righthand outer wall of
the hardware drawer) and lift the capacitor away.

Assembly

8 • Fit a new capacitor using the nut B and lockwasher.

9 • Reconnect the four connectors.
10 • Push the hardware drawer back in and refit the two alien screws A.
11 • Reconnect the SCSI and RS232 connectors.
12 • Reconnect the main power connector, processor power connector
and RS232 connector on the back of the imagesetter unit.
13 • If no further replacement operations are required, close the left
hand side door D and refit the foot panel E by hooking the four
lugs on the panel over the brackets on the imagesetter and lower
into place.

Adjustments required

No adjustments are required.

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 4 • PART REPLACEMENT

Capacitor, 2µF

2µF capacitor

Nut B

SCSI and RS232 connectors

Allen screws A

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 surnn 4 • PART REPLACEMENT

P/N 960 55 000 10 Input Module

Function

The input module guides the film into the drum while retaining it
throughout its transportation to the buffer module (DM 7500SA/7500SA
Plus) or front conveyor (DM 7500SA/7500SA Plus with online proces sor
option.

Technical data

Tools and materials required

No special tools are required, only standard equipment (section 1).

Caution! c� Only authorized service personnel may override the interlock

system.

r, Turn off power • Before connecting or disconnecting cables.

• Before carrying out service operations.

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Input Module

How to replace

Removal

• Remove the top panel F (DM 7500SA/7500SA plus) or the processor

cover I (DM 7500P/7500P Plus) and raise the front cover B (see
covers and panels) by pressing the two catches underneath the cover
and lifting up at the bottom.
2 • Remove the input cassette if fitted.
3 • Disconnect the connector to the module.
4 • Remove the four lock pins A (two each side) securing the input
module by turning until the locating pin on the lock pin is in line
with the slot in the input module. The lock pin will now be released
from the module by the spring pressure.
5 • Remove the two close tolerance bolts B (one each side) securing the
input module.
6 • Remove the module by carefully lifting it away from the drum.

Assembly

7 • Carefully lower the input module into drum and line the six locating
holes in the module with the adjacent holes in the drum.
8 • Fit the four lock pins A by lining up the locating pins with the slots in
the module. Push the lock pins in against the spring pressure and
turn approximately 1/2 turn (clockwise or counterclockwise) until
the bolts are locked.
9 • Fit the two close tolerance bolts B and washers.
Note: do not overtighten these bolts
10 • Refit the connector to the input module.
11 • If no further replacement operations are required, lower the front
cover B.

Adjustments required

No adjustments are required.

4•216b Service Manual • DotMate 7500/7500 Plus Edition 2 • July 1997

,I"'(')
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 4 • PART REPLACEMENT

Input Module

Lock
pin
A

Lock Close
pin tolerance
A bolt
B
Close
tolerance
bolt
B

Connector

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 mmn 4 • PART REPLACEMENT

P/N 960 55 003 00 Input Module Step Motor

Function

The input module step motor powers the input module that transports
the media from the input cassette into the drum.

Technical data

Tools and materials required

No special tools are required, only standard equipment (section 1).

Caution! .,.. Only authorized service personnel may override the interlock
system.

_. Turn off power • Before connecting or disconnecting cables.

• Before carrying out service operations.

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 uumw

Input Module Step Motor

How to replace

Removal

• Remove the top panel F (DM 7500SA/7500SA Plus) or the proces

sor cover I (DM 7500P/7500P Plus) and raise the front cover B (see
covers and panels) by pressing the two catches underneath the
cover and lifting up at the bottom.
2 • Remove the input cassette if fitted.
3 • Remove the input module (section 4)
4 • Disconnect the connector to the step motor.
5 • Remove the three allen screws A and washers securing the motor
to the module.
6 • Lift the two drive belts from the motor gear wheel and remove the
motor.

Assembly

7 • Mount the new step motor and fit the two drive belts over the
motor gear wheel.
8 • Fit the three alien screws and washers A (finger tight only see the
following step.
9 • Position the motor so that the tension of the outer drive belt has
approximately 12 mm of free play. Tighten the three alien screws
A on the motor.
10 • Connect the motor connector.
11 • Refit the input module (section 4).
12 • If no further replacement operations are required, lower the front
cover B.

Adjustments required

No adjustments are required.

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 4 • PART REPLACEMENT

Input Module Step Motor

Step motor
gear
Inner drive belt

Outer drive belt

Fig.1 Fig. 2

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P/N 960 55 003 10 Input Module Drive Belt (Outer)

Function

The drive belt (outer) transfers power from the step motor to the small
roller of the input module.

Technical data

Tools and materials required

Standard equipment (section 1).

Caution! c. Only authorized service personnel may override the interlock

system, (if activated).

c. Turn off power • Before connecting or disconnecting cables.

• Before carrying out service operations.

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 scurnw

Input Module Drive Belt (Outer)

How to replace

Removal

• Remove the top panel F (DM 7500SA/7500SA Plus) or the proces

sor cover I (DM 7500P/7500P Plus) and raise the front cover B (see
covers and panels) by pressing the two catches underneath the
cover and lifting up at the bottom.
2 • Remove the input cassette if fitted.
3 • Remove the input module (section 4)
4 • Loosen the three alien screws A and washers securing the motor to
the module.
5 • Lift the outer drive belt from the motor and lower roller gear
wheels.

Assembly

6 • Mount the new drive belt onto the motor gear wheel first.
7 • Turn the belt in a counterclockwise direction so that the belt
forms a figure of eight and fit it over the lower roller gear wheel.
Note: ensure that the belt crosses over as shown in fig. 2.
8 • Position the motor so that the tension of the outer drive belt has
approximately 12 mm of free play. Tighten the three alien screws
A on the motor.
9 • Refit the input module (section 4).
10 • If no further replacement operations are required, lower the front
cover B.

Adjustments required

No adjustments are required.

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 4 • PART REPLACEMENT

Input Module Drive Belt (Outer)

Step motor
�gearwheel

Outer drive belt

Lower roller
gear wheel
Fig.1

Step motor

Allen rews
As �-- - -= =-��-:t�P�
(x4)

Outer drive belt Outer drive belt Inner drive belt Fig. 2
tensioner

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P/N 960 40 001 30 Input Module Drive Belt (Inner)

Function

The drive belt (inner) transfers power from the step motor to the large
roller of the input module.

Technical data

Tools and materials required

1/20" allen key for tensioner adjusting screw

Standard equipment (section 1).

Caution! c� Only authorized service personnel may override the interlock

system (if activated).

C� Turn off power • Before connecting or disconnecting cables.

• Before carrying out service operations.

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 mmn

Input Module Drive Belt (Inner)

How to replace

Removal

• Remove the top panel F (DM 7500SA/7500SA Plus) or the proces

sor cover I (DM 7500P /7500P Plus) and raise the front cover B (see
covers and panels) by pressing the two catches underneath the
cover and lifting up at the bottom.
2 • Remove the input cassette if fitted.
3 • Remove the input module (section 4)
4 • Loosen the locknut (fig. 1) and unscrew the adjustment screw until
the tensioner is not pressing down on the belt.
5 • Loosen the three alien screws A and washers securing the motor to
the module.
6 • Lift the outer drive belt from the motor and lower roller gear wheels.
7 • Lift the inner drive belt from the motor and middle roller gear wheels.

Assembly

8 • Mount the new inner drive belt onto the motor and middle roller
gear wheels.
9 • Refit the outer drive belt onto the motor gear wheel first.
10 • Turn the belt in a counterclockwise direction so that the belt
forms a figure of eight and fit it over the lower roller gear wheel.
Note: ensure that the belt crosses over as shown in fig. 2
11 • Position the motor so that the tension of the outer drive belt has
approximately 12 mm of free play. Tighten the three alien screws
A on the motor.
12 • Screw the adjustment screw in until the white plastic ball on the
bottom of the screw begins to move into the body of the screw.
13 • Tighten the locknut on the tensioner.
14 • Refit the input module (section 4).
15 • If no further replacement operations are required, lower the front
cover B.

Adjustments required

No adjustments are required.

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 4 • PART REPLACEMENT

Input Module Drive Belt (Inner)

Step motor
- gear wheel
Inner drive belt
Lock nut

Middle roller
gear wheel
Adjustment
Outer drive belt screw
--------------:·/
Lower roller
,,,�_ ,: Tensioner
gear wheel ----,;,{.,_--,':':
\'�:::::',' Fig.1

Step motor

Allen screws -- -

(xA4) -------------

Outer drive belt Outer drive belt Inner drive belt Fig. 2
tensioner

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 4 • PART REPLACEMENT

P/N 960 55 003 30 Input Module Sensor, Drum In

Function

The drum in sensor informs the system when the film has entered the
rollers in the input module and when the input cassette is out of film.

Technical data

Mechanical sensor

Tools and materials required

No special tools are required, only standard equipment (section 1).

Caution! � Only authorized service personnel may override the interlock

system, (if activated).

� Turn off power • Before connecting or disconnecting cables.

• Before carrying out service operations.

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Input Module Sensor, Drum In

How to replace

Removal

• Remove the top panel F (DM 7500SA/7500SA Plus) or the proces

sor cover I (DM 7500P /7500P Plus) and raise the front cover B
(see covers and panels) by pressing the two catches underneath
the cover and lifting up at the bottom.
2 • Remove the input cassette if fitted.
3 • Remove the input module (section 4).
4 • Disconnect the connector to the sensor.
5 • Remove the two allen screws A from the side of the sensor bracket
and lift the sensor bracket, complete with sensor, away.

Assembly

6 • Fit the new sensor bracket and sensor using the two allen screws A.
7 • Reconnect the connector.
8 • Refit the input module (section 4).
9 • If no further replacement operations are required, lower the front
cover B.

Adjustments required

No adjustments are required.

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 4 • PART REPLACEMENT

Input Module Sensor, Drum In

Allen screws
A

Feed A sensor

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 mmn 4 • PART REPLACEMENT

P/N 960 40 001 40 Input Module Sensor, Cassette

Function

The cassette sensor informs the system when no input cassette is fitted.

Technical data

Mechanical sensor

Tools and materials required

No special tools are required, only standard equipment (section 1).

Caution! r..- Only authorized service personnel may override the interlock
system.

C.. Turn off power • Before connecting or disconnecting cables.

• Before carrying out service operations.

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 mrnn

Input Module Sensor, Cassette

How to replace

Removal

• Remove the top panel F (DM 7500SA/7500SA Plus) or the proces

sor cover I (DM 7500P/7500P Plus) and raise the front cover B (see
covers and panels) by pressing the two catches underneath the
cover and lifting up at the bottom.
2 • Remove the input cassette if fitted.
3 • Remove the input module (section 4)
4 • Disconnect the connector from the sensor.
5 • Remove the sensor from its bracket by pressing the plastic tab
upwards with one finger and pushing away.

Assembly

6 • Fit the new sensor by pressing it into its bracket until the tabs
engage.
7 • Reconnect the connector.
8 • Refit the input module (section 4).
9 • If no further replacement operations are required, lower the front
cover B.

Adjustments required

No adjustments are required.

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 4 • PART REPLACEMENT

Input Module Sensor, Cassette

Press the tabs

together

Sensor

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 4 • PART REPLACEMENT

P/N 960 SS 002 80 Input Cassette DC Motor

Function

The cassette step motor powers the input cassette that feeds media into
the input module.

Technical data

Tools and materials required

No special tools are required, only standard equipment (section 1).

Caution! c.- Only authorized service personnel may override the interlock
system, (if activated).

r.- Turn off power • Before connecting or disconnecting cables.

• Before carrying out service operations.

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 scurnw

Input Cassette DC Motor

How to replace

Removal

1 • Open the righthand side door C (see covers and panels).

2 • Remove the input cassette if fitted.
3 • Disconnect the connector to the input cassette step motor.
4 • Remove the two nuts and washers A.
5 • Remove the step motor.

Assembly

6 • Fit the new step motor using the two nuts and washers A.
7 • Reconnect the connector to the step motor.
8 • If no further replacement operations are required, close the right
hand side door C.

Adjustments required

No adjustments are required.

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 4 • PART REPLACEMENT

Input Cassette DC Motor

DC motor

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 4 • PART REPLACEMENT

P/N 960 55 000 20 Output Module

Function

The output module receives the media from the drum and tensions it
during transportation through the drum.

Technical data

Tools and materials required

No special tools are required, only standard equipment (section 1).

Caution! c. Only authorized service personnel may override the interlock

system.

fllr Turn off power • Before connecting or disconnecting cables.

• Before carrying out service operations.

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Output Module

How to replace

Removal
• Remove the top panel F (DM 7500SA/7500SA Plus) or the processor
cover I (DM 7500P/7500P Plus) and raise the front cover B (see covers
and panels) by pressing the two catches underneath the cover and lift
ing up at the bottom.
2 • Open the left and righthand side doors C and D (see covers and
panels).
3 • Remove the takeup cassette if fitted.
4 • Remove the buffer module (DM 7500SA/7500SA Plus) or front convey
or (DM 7500P/7500P Plus or online DM 7500SA/7500SA Plus), sect
ion 4.
5 • Disconnect the connector to the output module.
6 • Remove the two lock pins A (one each side) securing the output mod
ule by turning until the locating pin on the lock pin is in line with the
slot in the input module. The lock pin will now be released from the
module by the spring pressure.
7 • Remove the two close tolerance bolts B (one each side) securing the
output module.
8 • Remove the module by carefully lifting it away from the two dowel
pins C on the drum.

Assembly
9 • Carefully lower the output module into drum, over the two dowel
pins C and line the four locating holes in the module with the adjacent
holes in the drum.
10 • Fit the two lock pins A by lining up the locating pins with the slots in
the module. Push the lock pins in against the spring pressure and turn
approximately 1/4 turn (clockwise or counterclockwise) until the
bolts are locked.
11 • Fit the two close tolerance bolts B and washers.
Note: do not overtighten these bolts
12 • Refit the output module connector.
13 • Carry out a pressure roller adjustment and tension the system (section 5).
14 • Refit the buffer module (DM 7500SA/7500SA Plus) or front conveyor
(DM 7500P/7500P Plus), section 4.
15 • If no further replacement operations are required, close the right and
and lefthand side doors C and D and lower the front cover B.

Adjustments required
Pressure roller adjustment (section 5).
Tension the system (section 5).

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 4 • PART REPLACEMENT

Output Module

Connector �

Close
tolerance
bolt
B

Lock
pin
A

Close
tolerance
bolt
B

Lock
pin
A

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 scumw 4 • PART REPLACEMENT

P/N 960 40 002 00 Output Module Step Motor, Knife

Function

The knife step motor powers the knife that cuts the media after exiting
the drum.

Technical data

Tools and materials required

No special tools are required, only standard equipment (section 1).

Caution! c... Only authorized service personnel may override the interlock
system, (if activated).

C... Turn off power • Before connecting or disconnecting cables.

• Before carrying out service operations.

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 SCUVIEW

Output Module Step Motor, Knife

How to replace

Removal

• Remove the top panel F (DM 7500SA/7500SA Plus) or the proces

sor cover I (DM 7500P/7500P Plus) and raise the front cover B (see
covers and panels) by pressing the two catches underneath the
cover and lifting up at the bottom.
2 • Open the left and righthand side doors C and D (see covers and
panels).
3 • Remove the takeup cassette if fitted.
4 • Remove the buffer module (DM 7500SA/7500SA Plus or front con
veyor (DM 7500P/7500P Plus or online DM 7500 SA/7500SA Plus),
section 4.
5 • Remove the output module (section 4).
6 • Disconnect the connector to the motor and remove the cable tie
wrap from the cable.
7 • Remove the two allen screws A and washers and remove the
motor.

Assembly

8 • Mount the new step motor and fit the drive belt over the motor
gearwheel.
9 • Fit the two allen screws and washers A.
10 • Push the motor fully to the left to tension the drive belt and
tighten the two allen screws A.
11 • Reconnect the connector and fit a new cable tie wrap.
12 • Refit the output module (section 4).
13 • Refit the buffer module (DM 7500SA/7500SA Plus) or front convey
or (DM 7500P/7500P Plus), section 4.
14 • If no further replacement operations are required, close the right
and lefthand side doors C and D and lower the front cover B.

Adjustments required

No adjustments required.

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 4 • PART REPLACEMENT

Output Module Step Motor, Knife

Screws A

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 mrnn 4 • PART REPLACEMENT

P/N 960 40 002 00 Output Module Step Motor, Rollers

Function

The step motor powers the rollers of the output module that tensions
the media in the drum and transports it into the knife system.

Technical data

Tools and materials required

No special tools are required, only standard equipment (section 1).

Caution! � Only authorized service personnel may override the interlock

system, (if activated).

� Turn off power • Before connecting or disconnecting cables.

• Before carrying out service operations.

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Output Module Step Motor, Rollers

How to replace

Removal

• Remove the top panel F (DM 7500SA/7500SA Plus) or the proces

sor cover I (DM 7500P/7500P Plus) and raise the front cover B (see
covers and panels) by pressing the two catches underneath the
cover and lifting up at the bottom.
2 • Open the left and righthand side doors C and D (see covers and
panels).
3 • Remove the takeup cassette if fitted.
4 • Remove the buffer module (DM 7500SA/7500SA Plus) or front con
veyor (DM 7500P/7500P Plus or online DM 7500 SA/7500SA Plus),
section 4.
5 • Remove the output module (section 4).
6 • Disconnect the connector to the motor and remove the cable tie
wrap from the cable.
7 • Remove the three alien screws A, washers and bushes and remove
the motor.

Assembly

8 • Mount the new step motor and fit the drive belt over the motor
gearwheel.
9 • Position the three bushes and fit the three alien screws A and
washhers (finger tight only see the following step.
10 • Tension the drive belt as shown in fig. 1 and tighten the three
motor alien screws A.
11 • Reconnect the connector and fit a new cable tie wrap.
12 • Refit the output module (section 4).
13 • Refit the buffer module (DM 7500SA/7500SA Plus) or front convey
or (DM 7500P/7500P Plus), section 4.
14 • If no further replacement operations are required, close the right
and lefthand side doors C and D and lower the front cover B.

Adjustments required

No adjustments are required other than tensioning the drive belt.

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 4 • PART REPLACEMENT

Output Module Step Motor, Rollers

Step motor

Drive belt

Fig. 1

Screws A

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 SCAN VIEW
4 • PART REPLACEMENT

P/N 960 55 003 20 Output Module Drive Belt, Knife

Function

The drive belt for the knife transfers power from the step motor to the
knife assembly.

Technical data

Tools and materials required

No special tools are required, only standard equipment (section 1).

Caution! fllr Only authorized service personnel may override the interlock
system.

C_ . Tum off power • Before connecting or disconnecting cables.

• Before carrying out service operations.

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Output Module Drive Belt, Knife

How to replace

Removal

• Remove the top panel F (DM 7500SA/7500SA Plus) or the proces

sor cover I (DM 7500P /7500P Plus) and raise the front cover B (see
covers and panels) by pressing the two catches underneath the
cover and lifting up at the bottom.
2 • Open the left and righthand side doors C and D (see covers and
panels).
3 • Remove the takeup cassette if fitted.
4 • Remove the buffer module (DM 7500SA/7500SA Plus) or front con
veyor (DM 7500P/7500P Plus or online DM 7500 SA/7500SA Plus),
section 4.
5 • Loosen the two alien screws A securing the knife step motor and
move the motor to the right in order to loosen the drive belt.
6 • Remove the two posidrive screws B and remove the belt cover.
7 • Lift the drive belt away.

Assembly

8 • Mount the new drive belt over the gear wheels at either end of the
module, under the two tensioners and into the knife· block.
Note: the two ends of the belt should touch each other in the knife
block (fig. 1).
9 • Fit the extra piece of belt supplied with the new belt over the two
ends in the knife block and fit the belt cover using the two posi
drive screws B.
10 • Tension the drive belt by moving the step motor fully to the left
and tighten the two alien screws A.
11 • Refit the output module (section 4).
12 • Refit the buffer module (DM 7500SA/7500SA Plus) or front convey
or (DM 7500P/7500P Plus), section 4.
13 • If no further replacement operations are required, close the right
and lefthand side doors C and D and lower the front cover B.

Adjustments required

No adjustments are required other than tensioning the drive belt.

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 4 • PART REPLACEMENT

Output Module Drive Belt, Knife

Knife block

Drive belt
Extra piece of
belt Fig.1
Belt cover

Belt cover

Screws B
Tensioner (x2)
Screws A

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 SCAN VIEW
4 • PART REPLACEMENT

P/N 960 40 001 20 Output Module Drive Belt, Rollers

Function

The roller drive belt transfers power from the step motor to the rollers
on the output module.

Technical data

Tools and materials required

No special tools are required, only standard equipment (section 1).

Caution! c. Only authorized service personnel may override the interlock

system.

c. Turn off power • connecting or disconnecting cables.

Before
• Before carrying out service operations.

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 SCANflEIT

Output Module Drive Belt, Rollers

How to fit

Removal

Note: the drive belt can be replaced without having to remove the
output module. Access is from the lefthand side, behind the left-
hand side door.

• Open the lefthand side door D (see access panels and covers).
2 • Loosen the three allen screws A attaching the step motor to the
module.
3 • Move the motor downwards and remove the drive belt.

Assembly

4 • Fit the new drive belt.

5 • Align the motor to tension the drive belt as shown in fig. 1 and
tighten the three allen screws A.
6 • If no further replacement operations are required, close the left
hand side door D.

Adjustments required

No adjustments are required other than tensioning the drive belt.

4• 231 b Service Manual • DotMate 7500/7500 Plus

Edition 2 • July 1997
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 4 • PART REPLACEMENT

Output Module Drive Belt, Rollers

Step motor

(\0
23 mm of play�: /!.< »-> Drive belt

Drive gear
Fig.1

Step motor

Motor �
attachment�
screws A

Drive belt

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 scumw 4 • PART REPLACEMENT

P/N 960 40 001 90 Output Module M/Switches, Knife

Function

There are two identical microswitches on the output module and are
mounted at both ends of the module. They limit the travel of the knife
at the left and righthand positions.

Technical data

Leaf type microswitch

Tools and materials required

No special tools are required, only standard equipment (section 1).

Caution! c_. Only authorized service personnel may override the interlock
system, (if activated).

c_. Turn off power • Before connecting or disconnecting cables.

• Before carrying out service operations.

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 SCANJIEW

Output Module M/Switches, Knife

How to replace

Note: replacement of the two microswitches is identical, therefore

only one is explained in this instruction.

Removal

• Remove the top panel F (DM 7500SA/7500SA Plus) or the proces

sor cover I (DM 7500P /7500P Plus) and raise the front cover B
(see covers and panels) by pressing the two catches underneath
the cover and lifting up at the bottom.
2 • Open the left and right hand side doors C and D (see covers and
panels).
3 • Remove the takeup cassette if fitted.
4 • Remove the buffer module (DM 7500SA/7500SA Plus) or front con
veyor (DM 7500P/7500P Plus or online DM 7500 SA/7500SA Plus),
section 4.
5 • Remove the output module (section 4).
6 • Disconnect the connector to the microswitch.
7 • Remove the two crosspoint screws and lock washers and remove
the microswitch.

Assembly

8 • Fit the new microswitch using the two crosspoint screws and
lock washers.
9 • Reconnect the connector.
10 • Refit the output module (section 4).
11 • Refit the buffer module (DM 7500SA/7500SA Plus) or front convey
or (DM 7500P /7500P Plus) section 4.
12 • If no further replacement operations are required, close the right
and lefthand side doors C and D and lower the front cover B.

Adjustments required

No adjustments required.

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 4 • PART REPLACEMENT

Output Module M/Switches, Knife

M icroswitch
(right-hand) Module viewed from the back

Microswitch
(left-hand)

Module viewed from the front

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 rnrnn 4 • PART REPLACEMENT

P/N 960 40 001 50 Sensor, Drum Out

Function

The drum out sensor informs the system when the film has exited the
drum and reaches the output module.

Technical data

Mechanical sensor

Tools and materials required

No special tools are required, only standard equipment (section 1).

Caution! � Only authorized service personnel may override the interlock

system.

� Turn off power • Before connecting or disconnecting cables.

• Before carrying out service operations.

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Sensor, Drum Out

How to replace

Removal

• Remove the top panel F (DM 7500SA/7500SA Plus) or the proces

sor cover I (DM 7500P /7500P Plus) and raise the front cover B
(see covers and panels) by pressing the two catches underneath
the cover and lifting up at the bottom.
2 • Open the left and righthand side doors C and D (see covers and
panels).
3 • Remove the takeup cassette if fitted.
4 • Remove the buffer module (DM 7500SA/7500SA Plus) or front con
veyor (DM 7500P/7500P Plus or online DM 7500 SA/7500SA Plus),
section 4.
5 • Remove the output module (section 4).
6 • Disconnect the connector to the sensor.
7 • Remove the two alien screws A from the sensor bracket and lift
away, complete with bracket.

Assembly

8 • Fit the new sensor, together with bracket, using the two alien
screws A.
9 • Reconnect the connector to the sensor.
10 • Refit the output module (section 4).
11 • Refit the buffer module (DM 7500SA/7500SA Plus) or front con
veyor (DM 7500P/7500P Plus), section 4.
12 • If no further replacement operations are required, close the right
and lefthand side doors C and D and lower the front cover B.

Adjustments required

No adjustments are required.

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 4 • PART REPLACEMENT

Sensor, Drum Out

Screws A

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 SCANVIEW
4 • PART REPLACEMENT

P/N 960 55 000 30 Buffer Module

(SA/SA Plus only)

Function

The buffer module receives the cut media and transports it to the take
up cassette.

Technical data

Tools and materials required

No special tools are required, only standard equipment (section 1).

Caution! c... Only authorized service personnel may override the interlock
system.

c... Tum off power • Before connecting or disconnecting cables.

• Before carrying out service operations.

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 4 • PART REPLACEMENT

Buffer ModulE
(SA/SA Plus only:

Dowel
<, pins
B

pins Connector
B
,,,.----........ Lock pins
. ��� A
:::..------

Lock pins
A

Drum
light shield Screws
c
(x4)
Take-up cassette
light shield

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NT

UIE
nly:

!38c
manual DotMate 7500.indd 185 06/06/2016 01:18:16 p.m.
 scurnw 4 • PART REPLACEMENT

P/N 960 40 002 00 Buffer Module Step Motors BL

(SA/SA Plus only) (SJ

Function

There are two identical step motors on the buffer module, both moun
ted identically but located on the righthand side and middle of the
module. The step motors power the buffer module that transports the
cut media from the output module into the takeup cassette.

Technical data

Tools and materials required

No special tools are required, only standard equipment (section 1).

Caution! c. Only authorized service personnel may override the interlock

system.

c. Turn off power • connecting or disconnecting cables.

Before
• Before carrying out service operations.

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\IT
somn

srs Buffer Module Step Motors

1ly) (SAISA Plus only)

How to replace

Note: replacement of the two motors is identical, therefore only

one is explained in this instruction.

Removal

• Remove the top panel F and raise the front cover B (see covers and
panels) by pressing the two catches underneath the cover and lift
ing up at the bottom.
2 • Open the left and righthand side doors C and D (see covers and
panels).
3 • Remove the takeup cassette if fitted.
4 • Remove the buffer module (section 4).
5 • Disconnect the connector to the motor.
6 • Remove the four alien screws and washers and remove the motor.

Assembly

1 • Mount the new step motor and fit the drive belt over the motor
gearwheel.
8 • Fit the four alien screws and washers (finger tight only see the
following step.
9 • Tension the drive belts as shown in fig. 1 and tighten the four alien
screws.
10 • Reconnect the connector.
11 • Refit the buffer module (section 4).
12 • If no further replacement operations are required, close the right
and lefthand side doors C and D and lower the front cover B.

Adjustments required

No adjustments are required other than tensioning the drive belt.

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 4 • PART REPLACEMENT

Buffer Module Step Motor!

(SAIS� Plus only:

Step motor
/

: 0

23 mm of play • \ ;' - Drive belt

.s->

Drive gear
Fig.1 Fig. 2

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NT

or!
nly:

!39c
manual DotMate 7500.indd 189 06/06/2016 01:18:17 p.m.
 mrnn 4 • PART REPLACEMENT

P/N 960 40 001 50 Buffer Module Sensor, Buffer Top

(SA/SA Plus only)

Function

The top buffer module sensor regulates the speed of the media ensur
ing that a constant media buffer height is maintained in the buffer
module, thus ensuring that the media feeds correctly and not offline
through the module.

Technical data

Mechanical sensor

Tools and materials required

No special tools are required, only standard equipment (section 1).

Caution! r.,. Only authorized service personnel may override the interlock
system, (if activated).

r.,. Turn off power • Before connecting or disconnecting cables.

• Before carrying out service operations.

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NT 4 • PART REPLACEMENT
scumw
-t
'op P/N 960 40 001 50 Buffer Module Sensor, Buffer Top
nly) (SA/SA Plus only)

Function

The top buffer module sensor regulates the speed of the media ensur
ing that a constant media buffer height is maintained in the buffer
module, thus ensuring that the media feeds correctly and not offline
through the module.

Technical data

Mechanical sensor

Tools and materials required

No special tools are required, only standard equipment (section 1).

Caution! c, Only authorized service personnel may override the interlock

system, (if activated).

C.- Turn off power • Before connecting or disconnecting cables.

• Before carrying out service operations.

40a Edition 2 • July 1997 Service Manual • DotMate 7500/7500 Plus 4•240a
manual DotMate 7500.indd 191 06/06/2016 01:18:18 p.m.
Buffer Module Sensor, Buffer Top
(SA/SA Plus only)

How to replace

Removal

• Remove the top panel F and raise the front cover B (see covers and
panels) by pressing the two catches underneath the cover and lift
ing up at the bottom.
2 • Open the left and righthand side doors C and D (see covers and
panels).
3 • Remove the input cassette if fitted.
4 • Disconnect the connector to the sensor.
5 • Remove the sensor from its bracket by pressing the plastic tabs
together and lifting away.

Assembly

6 • Fit the new sensor by pressing it into its bracket until the plastic
tabs engage.
7 • Reconnect the sensor connector.
8 • Tension the drive belts as shown in fig. 1 and tighten the four alien
screws A.
9 • Refit the input cassette.
10 • If no further replacement operations are required, close the right
and left hand side doors C and D and lower the front cover B.

Adjustments required

No adjustments are required.

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 4 • PART REPLACEMENT

Buffer Module Sensor, Buffer Top

(SA/SA Plus only)

Press the tabs

together

Sensor

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 mrnn 4 • PART REPLACEMENT

P/N 960 55 003 40 Buffer Module Sensor, Side

(SA/SA Plus only)

Function

The side sensor regulates the speed of the rollers in the buffer module
to ensure that the media feeds correctly and not offline through the
buffer module.

Technical data

Mechanical sensor

Tools and materials required

No special tools are required, only standard equipment (section 1).

Caution! _. Only authorized service personnel may override the interlock

system, (if activated).

c. Turn off power • Before connecting or disconnecting cables.

• Before carrying out service operations.

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 mmn

Buffer Module Sensor, Side

(SAISA Plus only)

How to replace

Removal

• Remove the top panel F and raise the front cover B (see covers and
panels) by pressing the two catches underneath the cover and lift
ing up at the bottom.
2 • Open the left and righthand side doors C and D (see covers and
panels).
3 • Remove the takeup cassette if fitted.
4 • Remove the buffer module (section 4).
5 • Disconnect the connector to the sensor.
6 • Remove the two alien screws A, washers and bushes from the sensor.

Assembly

7 • Fit the new sensor using the two alien screws A, washers and bushes.
8 • Reconnect the sensor connector.
9 • Adjust the sensor (section 5).
10 • Refit the buffer module, (section 4).
11 • If no further replacement operations are required, close the right
and lefthand side doors C and D and lower the front cover B.

Adjustments required

Sensor adjustment (section 5).

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 4 • PART REPLACEMENT

Buffer Module Sensor, Side

(SA/SA Plus only)

Sensor

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 4 • PART REPLACEMENT

P/N 960 55 003 50 Buffer Module M/switch (Take-up Cas.)

(SA/SA Plus only)

Function

The buffer module microswitch (takeup cassette) informs the system

when the a takeup cassette is not fitted.

Technical data

Roller type

Tools and materials required

No special tools are required, only standard equipment (section 1).

Caution! � Only authorized service personnel may override the interlock

system.

c.. Turn off power • Before connecting or disconnecting cables.

• Before carrying out service operations.

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Buffer Module M/switch {Take-up Cassette.)
(SA/SA Plus only)

How to replace

Removal

• Remove the top panel F and raise the front cover B (see covers and
panels) by pressing the two catches underneath the cover and lift
ing up at the bottom.
2 • Open the left and righthand side doors C and D (see covers and
panels).
3 • Remove the takeup cassette if fitted.
4 • Remove the buffer module (section 4).
5 • Disconnect the connector to the microswitch.
6 • Remove the two posidrive screws B and lockwashers and lift the
microswitch away.

Assembly

7 • Fit the new microswitch using the two posidrive screws B and
lockwashers.
8 • Reconnect the microswitch connector.
9 • Refit the buffer module, (section 4).
10 • If no further replacement operations are required, close the right
and left hand side doors C and D and lower the front cover B.

Adjustments required

No adjustments are required.

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 4 • PART REPLACEMENT

Buffer Module M/switch (Take-up Cassette.)

(SA/SA Plus only)

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 4 • PART REPLACEMENT

P/N 960 55 000 40

Front Conveyor
(DM 7500P/P Plus and on-line SAISA Plus only)

Function

The front conveyor receives the cut media and transports it to the take
up cassette or the processor (or the online processor if a DM 7500SA/
7500SA Plus with the online processor option fitted), depending on
which mode has been selected.

Technical data

Tools and materials required

No special tools are required, only standard equipment (section 1).

Caution! c.. Only authorized service personnel may override the interlock
system, (if activated).

c. . Tum off power • Before connecting or disconnecting cables.

• Before carrying out service operations.

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 scum,

Front Conveyor
(DM 7500P/P Plus and on-line SA/SA Plus only)

How to replace

Removal
• Remove the top panel F (DM 7500SA/7500SA Plus) or the processor cover I
(DM 7500P/7500P Plus) and raise the front cover B (see covers and panels) by
pressing the two catches underneath the cover and lifting up at the bottom.
2 • Open the left and righthand side doors C and D (see covers and panels).
3 • Remove the takeup cassette if fitted.
4 • Disconnect the connectors to the module.
5 • Remove the two lock pins A (one each side) securing the drum light shield by
turning until the locating pin on the lock pin is in line with the slot in the
input module. The lock pin will now be released from the module by the
spring pressure.
6 • Rotate the light shield downwards so that it rests on the takeup cassette light
shield.
7 • Release the two lock catches (one each side) securing the takeup cassette
light shield.
8 • Carefully pull the light shield, together with the front conveyor, away from the
drum, so that the telescopic rails are fully extended.
Note: the module is located on the drum by two dowel pins B on each side of
the front of the drum flanges.
9 • Remove the alien screw C from the side of each rail and carefully lift the front
conveyor away.
Note: the front conveyor slides out from under the drum on telescopic rails.
10 • Remove the four alien screws D securing the light shield to the module and
remove the shield.

Assembly
11 • Fit the light shield to the front conveyor using the four alien screws C.
12 • Carefully position the front conveyor onto the extended telescopic rails and
secure with the two alien screws B.
13 • Push the front conveyor fully in, locating it onto the four dowel pins A.
14 • Snap the two lock catches back into place so that the takeup cassette, light
shield and front conveyor are secure.
15 • Reconnect the two connectors to the front conveyor.
16 • Rotate the drum light shield upwards and fit the two lock pins A by lining up the
locating pins with the slots in the module. Push the lock pins in against the
spring pressure and turn approximately 1/2 turn (clockwise or counterclockwise)
until the bolts are locked.
17 • Ifno further replacement operations are required, close the right and left
hand side doors C and D and lower the front cover B.

Adjustments required
No adjustments are required.

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 4 • PART REPLACEMENT

Front Conveyor
(DM 7500P/P Plus and on-line SA/SA Plus only)

Dowel
pins
B

Screw /
c Lock pins
(1 ech side) A

Lock pins -
A

Drum
light shield Screws
D
Take-up cassette (x4)
light shield

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 SCANVIEW
4 • PART REPLACEMENT

P/N 960 40 002 00 Front Conveyor Step Motors (Rollers)

{DM 7500P/P Plus and on-line SA/SA Plus only}

Function

There are two identical step motors on the front conveyor, both moun
ted identically but located on the righthand side and middle of the
conveyor.

The step motors power the conveyor that transports the cut media from
the output module into the takeup cassette or the processor (or the on-
line processor if a DM 7500SA/7500SA Plus with the online proces sor
option fitted), depending on which mode has been selected.

Technical data

Tools and materials required

No special tools are required, only standard equipment (section 1).

Caution! c. Only authorized service personnel may override the interlock

system, (if activated).

c. Turn off power • Before connecting or disconnecting cables.

• Before carrying out service operations.

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Front Conveyor Step Motors (Rollers}
(OM 7500P/P Plus and on-line SA/SA Plus only)

How to replace

Note 1: replacement of the two motors is identical, therefore only

one is explained in this instruction.
Note 2: the front conveyor slides out from under the drum on tele
scopic rails.

Removal

• Remove the top panel F (DM 7500SA/7500SA Plus) or the proces

sor cover I (DM 7500P /7500P Plus) and raise the front cover B (see
covers and panels) by pressing the two catches underneath the
cover and lifting up at the bottom.
2 • Open the left and right hand side doors C and D (see covers and
panels).
3 • Remove the take up cassette if fitted.
4 • Remove the front conveyor (section 4).
Note: it is only necessary to pull the front conveyor out far enough
so that the telescopic rails are fully extended.
5 • Disconnect the connector to the motor.
6 • Remove the four allen screws A and washers and remove the
motor.

Assembly

7 • Mount the new step motor and fit the drive belt over the motor
gearwheel.
8 • Fit the four allen screws A and washers (finger tight only see the
following step.
9 • Tension the drive belts as shown in fig. 1 and tighten the four allen
screws A.
10 • Refit the front conveyor (section 4).
11 • Ifno further replacement operations are required, close the right
and lefthand side doors C and D and lower the front cover 8.

Adjustments required
No adjustments are required.

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 4 • PART REPLACEMENT

Front Conveyor Step Motors (Rollers)

(DM 7500P/P Plus and on-line SA/SA Plus only)

Step motor

Drive belt
2-3 mm of play

Drive gear
Fig.1 Fig. 2 Fig.1

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 mrnn 4 • PART REPLACEMENT

P/N 960 40 002 00 Front Conveyor Step Motors (Conveyor)

(DM 7500P/P Plus and on-line SA/SA Plus only)

Function

The step motor powers the rollers in the front conveyor that transports
the cut media through the conveyor to the processor (or the online
processor if a DM 7500SA/7500SA Plus with the online processor option
fitted).

Technical data

Tools and materials required

No special tools are required, only standard equipment (section 1).

Caution! r. - Only authorized service personnel may override the interlock

system.

r.- Turn off power • Before connecting or disconnecting cables.

• Before carrying out service operations.

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I\/\ 4
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Front Conveyor Step Motors (Conveyor)
(DM 7500P/P Plus and on-line SA/SA Plus only)

How to replace

Note: the front conveyor slides out from under the drum on tele
scopic rails.

Removal

• Remove the top panel F (DM 7500SA/7500SA Plus) or the proces

sor cover I (DM 7500P /7500P Plus) and raise the front cover B
(see covers and panels) by pressing the two catches underneath
the cover and lifting up at the bottom.
2 • Open the left and righthand side doors C and D (see covers and
panels).
3 • Remove the takeup cassette if fitted.
4 • Remove the front conveyor (section 4).
Note: it is only necessary to pull the front conveyor out far enough
so that the telescopic rails are fully extended.
5 • Disconnect the connector to the motor.
6 • Remove the three alien screws A and washers.
7 • Lift off the two drive belts and remove the motor.

Assembly

8 • Mount the new step motor and fit the two drive belts over the
motor gear wheel.
9 • Fit the three alien screws A and washers (finger tight only see the
following step.
10 • Position the motor so that there is 23 mm of free play on the drive
belts. Tighten the four alien screws A.
11 • Reconnect the connector.
12 • Refit the front conveyor (section 4).
13 • Refit the takeup cassette.
14 • Ifno further replacement operations are required, close the right
and lefthand side doors C and D and lower the front cover B.

Adjustments required

No adjustments are required.

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 4 • PART REPLACEMENT

Front Conveyor Step Motors (Conveyor)

(DM 7500P/P Plus and on-line SA/SA Plus only)

Step motor

Allen
screws A

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'\ 'l LI
manual DotMate 7500.indd 214 06/06/2016 01:18:27 p.m.
 srnmw
4 • PART REPLACEMENT

P/N 960 40 001 50 Front Conveyor Sensor, Buffer Top

(DM 7500P/P Plus and on-line SA/SA Plus only)

Function

The bufer top front conveyor sensor regulates the speed of the media
ensuring that a constant media buffer height is maintained in the conve
yor, thus ensuring that the media feeds correctly and not offline.

Technical data

Tools and materials required

No special tools are required, only standard equipment (section 1).

Caution! c� Only authorized service personnel may override the interlock

system, (if activated).

C� Turn off power • Before connecting or disconnecting cables.

• Before carrying out service operations.

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 SCHllEIT

Front Conveyor Sensor, Buffer Top

d
(DM 7500P/P Plus and on-line SA/SA Plus only)

How to replace

Note: the front conveyor slides out from under the drum on tele
scopic rails.

Removal

• Remove the top panel F (DM 7500SA/7500SA Plus) or the proces

sor cover I (DM 7500P/7500P Plus) and raise the front cover B (see
covers and panels) by pressing the two catches underneath the
cover and lifting up at the bottom.
2 • Open the left and righthand side doors C and D (see covers and
panels).
3 • Remove the takeup cassette if fitted.
4 • Remove the front conveyor (section 4).
Note: it is only necessary to pull the front conveyor out far enough
so that the telescopic rails are fully extended.
5 • Disconnect the connector to the front conveyor sensor.
6 • Remove the sensor from its bracket by pressing the plastic tabs
together and lifting away.

Assembly

7 • Fit the new sensor by pressing it into its bracket until the plastic
tabs engage.
8 • Reconnect the sensor connector.
9 • Refit the front conveyor (section 4).
10 • Refit the takeup cassette.
11 • Ifno further replacement operations are required, close the right
and lefthand side doors C and D and lower the front cover B.

Adjustments required

No adjustments are required.

4• 251 b Service Manual • DotMate 7500/7500 Plus Edition 2 • July 1997

manual DotMate 7500.indd 216 06/06/2016 01:18:27 p.m.
 4 • PART REPLACEMENT

Front Conveyor Sensor, Buffer Top

(DM 7500P/P Plus and on-line SA/SA Plus only)

Press the tabs

together

Sensor

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 scumw 4 • PART REPLACEMENT

P/N 960 55 003 40 Front Conveyor Sensor, Side

(DM 7500P/P Plus and on-fine SA/SA Plus only)

Function

The side sensor regulates the speed of the rollers in the front conveyor
ensuring that the media feeds correctly and not offline through the
conveyor.

Technical data

Tools and materials required

No special tools are required, only standard equipment (section 1).

Caution! c.. Only authorized service personnel may override the interlock
system, (if activated).

,.. Tum off power • Before connecting or disconnecting cables.

• Before carrying out service operations.

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 mrnn

Front Conveyor Sensor, Side

(DM 7500P/P Plus and on-line SA/SA Plus only)

How to replace

Note: the front conveyor slides out from under the drum on tele
scopic rails.

Removal

• Remove the top panel F (DM 7500SA/7500SA Plus) or the proces

sor cover I (DM 7500P /7500P Plus) and raise the front cover B
(see covers and panels) by pressing the two catches underneath
the cover and lifting up at the bottom.
2 • Open the left and right hand side doors C and D (see covers and
panels).
3 • Remove the takeup cassette if fitted.
4 • Remove the front conveyor (section 4).
Note: it is only necessary to pull the front conveyor out far enough
so that the telescopic rails are fully extended.
5 • Disconnect the connector to the sensor.
6 • Remove the two alien screws A, washers and bushes and remove
the sensor.

Assembly

7 • Fit the new sensor using the two alien screws A, washers and bushes.
8 • Reconnect the sensor connector.
9 • Refit the front conveyor (section 4).
10 • Adjust the sensor (section 5).
11 • Refit the takeup cassette.
12 • If no further replacement operations are required, close the right
and lefthand side doors C and D and lower the front cover B.

Adjustments required

No adjustments are required.

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 4 • PART REPLACEMENT

Front Conveyor Sensor, Side

(DM 7500P/P Plus and on-line SA/SA Plus only)

Sensor

Screw A

Adjustment
screw

Screw A

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P/N 960 40 01 40 Front Conveyor Sensor, In

{DM 7500P/P Plus and on-line SA/SA Plus only)

Function

The frontin sensor informs the system that the media is being fed
through the front conveyor.

Technical data

Mechanical sensor

Tools and materials required

No special tools are required, only standard equipment (section 1).

Caution! � Only authorized service personnel may override the interlock

system, (if activated).

c. Turn off power • Before connecting or disconnecting cables.

• Before carrying out service operations.

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 SCAN VIEW

Front Conveyor Sensor, In

(DM 7500P/P Plus and on-line SA/SA Plus only)

How to replace

Note: the front conveyor slides out from under the drum on tele
scopic rails.

Removal

• Remove the top panel F (DM 7500SA/7500SA Plus) or the proces

sor cover I (DM 7500P /7500P Plus) and raise the front cover B
(see covers and panels) by pressing the two catches underneath
the cover and lifting up at the bottom.
2 • Open the left and right hand side doors C and D (see covers and
panels).
3 • Remove the takeup cassette if fitted.
4 • Remove the front conveyor (section 4).
Note: it is only necessary to pull the front conveyor out far enough
so that the telescopic rails are fully extended.
5 • Disconnect the connector to the sensor.
6 • Remove the sensor from its bracket by pressing the plastic tabs
together and lifting away.

Assembly

7 • Fit the new sensor by pressing it into its bracket until the plastic
tabs engage.
8 • Reconnect the sensor connector.
9 • Refit the front conveyor (section 4).
10 • Refit the takeup cassette.
11 • If no further replacement operations are required, close the right
and lefthand side doors C and D and lower the front cover B.

Adjustments required

No adjustments are required.

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Front Conveyor Sensor, In

(DM 7500P/P Plus and on-line SA/SA Plus only)

Press the tabs

together

Sensor

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P/N 960 55 003 50 Front Conveyor M/switch (Take-up Cas.)

(OM 7500P7P Plus and on-line SA/SA Plus only)

Function

The front conveyor microswitch (takeup cassette) informs the system

when the takeup cassette is not fited.

Technical data

Roller type

Tools and materials required

No special tools are required, only standard equipment (section 1).

Caution! c.,.. Only authorized service personnel may override the interlock
system.

_. Turn off power • Before connecting or disconnecting cables.

• Before carrying out service operations.

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 SCAN VIEW

Front Conveyor Microswitch (Take-up cassette)

(DM 7500P/P Plus and on-line SA/SA Plus only)

How to replace

Note: the front conveyor slides out from under the drum on tele
scopic rails.

Removal

• Remove the top panel F (DM 7500SA/7500SA Plus) or the proces

sor cover I (DM 7500P/7500P Plus) and raise the front cover 8 (see
covers and panels) by pressing the two catches underneath the
cover and lifting up at the bottom.
2 • Open the left and righthand side doors C and D (see covers and
panels).
3 • Remove the takeup cassette if fitted.
4 • Remove the front conveyor (section 4).
Note: it is only necessary to pull the front conveyor out far enough
so that the telescopic rails are fully extended.
5 • Disconnect the connector to the microswitch.
6 • Remove the two posidrive screws 8 and lockwashers and lift the
microswitch away.

Assembly

7 • Fit the new microswitch using thetwo posidrive screws Band lock
washers.
8 • Reconnect the microswitch connector.
9 • Refit the front conveyor (section 4).
10 • Refit the takeup cassette.
11 • If no further replacement operations are required, close the right
and lefthand side doors C and D and lower the front cover 8.

Adjustments required

No adjustments are required.

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 4 • PART REPLACEMENT

Front Conveyor Microswitch (Take-up Cassette)

(l>M 7500P/P Plus and on-line SA/SA Plus only)

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P/N 960 55 000 50 Rear Conveyor

(DM 7500P/P Plus and on-line SA/SA Plus only)

Function

The rear conveyor transports the film from the front conveyor to the
processor.

Technical data

Tools and materials required

No special tools are required, only standard equipment (section 1).

Caution! ,.- Only authorized service personnel may override the interlock
system, (if activated).

,. Turn off power • Before connecting or disconnecting cables.

• Before carrying out service operations.

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 scumw

Rear Conveyor
(DM 7500P/P Prus and on-line SA/SA Plus only)

How to replace

Removal

1 • If a DotMate 7500P/7500P Plus, raise the processor cover I and

remove the conveyor cover G (see covers and panels).
2 • If a DotMate 7500SA/7500SA Plus with the online processor op
tion, remove the top panel F (see covers and panels).
3 • Remove the cable clip on the top of the module.
4 • Disconnect the connector to the module.
5 • Remove the two lock pins A (one each side) securing the rear con
veyor by turning until the locating pin on the lock pin is in line
with the slot in the module. The lock pin will now be released
from the module by the spring pressure.
6 • Pull the conveyor upwards and towards the front of the DotMate
as far as it will go.
7 • Remove the two close tolerance bolts B (one each side) and com
pletely remove the conveyor.

Assembly

8 • Mount the new conveyor onto its guides and fit the two close tol
erance bolts B.
9 • Lower the conveyor down the guides as far as it will go and secure
using the two lock pins A by lining up the locating pins with the
slots in the conveyor. Push the lock pins in against the spring pres
sure and turn approximately 1/2 turn (clockwise or counter
clockwise) until the bolts are locked.
10 • Reconnect the connector to the conveyor.
11 • Refit the cable clip.
12 • If a DotMate 7500SA/7500SA Plus with the online processor op
tion, refit the top panel F (see access panels).
13 • If a DotMate 7500P/7500P Plus, refit the conveyor cover G and
lower the processor cover I.

Adjustments required

No adjustments are required.

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 4 • PART REPLACEMENT

Rear Conveyor
(DM 7500P/P Plus and on-line SA/SA Plus only)

Lock pin
Cable clip A
Sensor

Close
tolerance
Lock pin - bolt
A B

Close /
tolerance
bolt
B

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 scurnw 4 • PART REPLACEMENT

P/N 960 55 002 90 Rear Conveyor DC Motor

(DM 7500P/P Plus and on-line SA/SA Plus only)

Function

The DC motor powers the conveyor that transports the cut media from
the front conveyor into the processor (or the online processor if a DM
7500SA/7500SA Plus with the online processor option fitted).

Technical data

Tools and materials required

No special tools are required, only standard equipment (section 1).

Caution! _. Only authorized service personnel may override the interlock

system, (if activated).

_. Turn off power • Before connecting or disconnecting cables.

• Before carrying out service operations.

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 SCANYIEW

Rear Conveyor DC Motor

(DM 7500P/P Pfos and on-line SA/SA Plus only)

How to replace

Removal

1 • If a DotMate 7500P /7500P Plus, raise the processor cover I and

remove the conveyor cover G (see covers and panels).
2 • If a DotMate 7500SA/7500SA Plus with the online processor op
tion, remove the top panel F (see covers and panels).
3 • Remove the rear conveyor (section 4).
4 • Disconnect the motor connector.
4 • Remove the two alien screws A and washers.
5 • Remove the drive belt from the motor gear and lift the motor away.

Assembly

6 • Position the new motor and fit the drive belt over the gear wheel.
7 • Fit the two alien screws A and washers (finger tight only see the
following step.
8 • Tension the drive belt as shown in fig. 1 and tighten the two alien
screws A.
9 • Reconnect the motor connector.
10 • Refit the rear conveyor (section 4).
11 • If a DotMate 7500SA/7500SA Plus with the online processor opt
ion, refit the top panel F (see access panels).
12 • Ifa DotMate 7500P /7500P Plus, refit the conveyor cover G and
lower the processor cover I.

Adjustments required

No adjustments are required.

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Rear Conveyor DC Motor

(DM 7500P/P Plus and on-line SA/SA Plus only)

Step motor

_ Drive belt

Drive gear
Fig.1

Screws
A

DC motor

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P/N 960 40 001 50 Rear Conveyor Sensor, In

(DM 7500P/P Plus and on-line SA/SA Plus only)

Function

The conveyor in sensor informs the system that the media has entered
the rear conveyor and starts the conveyor.

Technical data

Tools and materials required

No special tools are required, only standard equipment (section 1).

Caution! r..- Only authorized service personnel may override the interlock
system, (if activated).

r..- Turn off power • Before connecting or disconnecting cables.

• Before carrying out service operations.

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Rear Conveyor Sensor, In
(DM 7500P/P Prus and on-line SA/SA Plus only)

How to replace

Removal

1 • If a DotMate 7500P /7500P Plus, raise the processor cover I and

remove the conveyor cover G (see covers and panels).
2 • If a DotMate 7500SA/7500SA Plus with the online processor op
tion, remove the top panel F (see covers and panels).
3 • Remove the rear conveyor (section 4).
4 • Disconnect the sensor connector.
5 • Remove the sensor from its bracket by pressing the plastic tabs
together and lifting away.

Assembly

6 • Fit the new sensor by pressing it into its bracket until the plastic
tabs engage.
7 • Reconnect the sensor connector.
8 • Refit the rear conveyor (section 4).
9 • If a DotMate 7500SA/SA Plus with the online processor option,
refit the top panel F (see access panels).
10 • If a DotMate 7500P /7500P Plus, refit the conveyor cover G and
lower the processor cover I.

Adjustments required

No adjustments are required.

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Rear Conveyor Sensor, In

(DM 7500P/P Plus and on-line SA/SA Plus only)

Press the tabs

together

Sensor

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P/N 960 40 001 50 Rear Conveyor Sensor, Out

(DM 7500P/P Plus and on-hne SA/SA Plus only)

Function

The conveyor out sensor regulates the speed of the media in relation to
the processor.

Technical data

Tools and materials required

No special tools are required, only standard equipment (section 1).

Caution! r9'" Only authorized service personnel may override the interlock
system, (if activated).

c� Turn off power • Before connecting or disconnecting cables.

• Before carrying out service operations.

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 sorn Elf

Rear Conveyor Sensor, Out

(DM 7500P/P Pfos and on-line SA/SA Plus only)

How to replace

Removal

1 • If a DotMate ?SOOP /7SOOP Plus, raise the processor cover I and

remove the conveyor cover G (see covers and panels).
2 • Ifa DotMate 7SOOSA/7SOOSA Plus with the online processor op
tion, remove the top panel F (see covers and panels).
3 • Remove the rear conveyor (section 4).
4 • Disconnect the sensor connector.
5 • Remove the sensor from its bracket by pressing the plastic tabs
together and lifting away.

Assembly

6 • Fit the new sensor by pressing it into its bracket until the plastic
tabs engage.
7 • Reconnect the sensor connector.
8 • Refit the rear conveyor (section 4).
9 • If a DotMate 7SOOSA/7SOOSA Plus with the online processor opt
ion, refit the top panel F (see access panels).
10 • If a DotMate ?SOOP /7SOOP Plus, refit the conveyor cover G and
lower the processor cover I.

Adjustments required

No adjustments are required.

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 4 • PART REPLACEMENT

Rear Conveyor Sensor, Out

(DM 7500P/P Plus and on-line SA/SA Plus only)

Press the tabs

together

Sensor

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 4 • PART REPLACEMENT

P/N 960 55 002 10 Spinner

Function

The spinner rotates the mirror which reflects the laser beam onto the
media.

Technical data

Tools and materials required

No special tools are required, only standard equipment (section 1).

Caution! C.- Only authorized service personnel may override the interlock
system, (if activated).

c... Turn off power • Before connecting or disconnecting cables.

• Before carrying out service operations.

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 -
mmn

Spinner

How to replace

Removal

• Remove the top panel F (DM 7500SA/7500SA Plus) or the proces

sor cover I (DM 7500P/7500P Plus) and raise the front cover B (see
covers and panels) by pressing the two catches underneath the
cover and lifting up at the bottom.
2 • Open the right hand side door C (see covers and panels).
3 • Manually rotate the flywheel until the carriage is in the fully right
hand position.
4 • Disconnect the two connectors on the spinner bracket.
5 • Loosen the four allen screws A securing the two spinner clamps.
6 • Carefully slide the spinner out from the two clamps.
Note: be careful not to scratch the spinner mirror during and
after removal.

Assembly

7 • Carefully mount the new spinner and tighten the four allen screws.
Note: avoid touching the mirror while unpacking and fitting the
spinner.
8 • Reconnect the two connectors to the spinner bracket.
9 • Carry out a zero offset adjustment.
10 • If no further replacement operations are required, close the right
hand side door C and lower the front cover B.

Adjustments required

Zero offset adjustment (section 5).

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 4 • PART REPLACEMENT

Spinner

/
/
/
/
Spinner
Screws A

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 4 • PART REPLACEMENT

P/N 960 55 002 50 Filter Step Motor

Function

The filter step motor is controlled by the filter microswitch and counts
up to the filter required for a particular exposure setting.

Technical data

Tools and materials required

No special tools are required, only standard equipment (section 1).

Caution! r.- Only authorized service personnel may override the interlock
system, (if activated).

• Turn off power • Before connecting or disconnecting cables.

• Before carrying out service operations.

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Filter Step Motor

How to replace

Removal

• Remove the top panel F (DM 7500SA/7500SA Plus) or the proces

sor cover I (DM 7500P/7500P Plus) and raise the front cover B (see
covers and panels) by pressing the two catches underneath the
cover and lifting up at the bottom.
2 • Open the lefthand side door D (see covers and panels).
3 • Manually rotate the flywheel until the carriage is in the fully left
hand position.
4 • Disconnect the connector to the filter step motor.
5 • Remove the two allen screws and washers securing the step motor
to its bracket and remove the step motor.

Assembly

6 • Fit the new step motor using the two alien screws and washers and
adjust the step motor so that its gear and the gear on the optics
unit are meshed and are able to be moved freely without any bind
ing.
7 • Tighten the two alien screws.
8 • Reconnect the connector to the step motor.
9 • Ifno further replacement operations are required, close the left
hand side door D and lower the front cover B.

Adjustments required

No adjustments are required.

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 4 • PART REPLACEMENT

Filter Step Motor

Filter step motor

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 mmn 4 • PART REPLACEMENT

P/N 960 55 002 60 Aperture {Iris) Step Motor

Function

The aperture (iris) step motor adjusts the aperture settings of the op
tical unit

Technical data

Tools and materials required

2 mm alien key with ball head

Standard equipment (section 1).

Caution! c� Only authorized service personnel may override the interlock

system, (if activated).

� Turn off power • Before connecting or disconnecting cables.

• Before carrying out service operations.

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Aperture (Iris) Step Motor

How to replace

Removal

• Remove the top panel F (DM 7500SA/7500SA Plus) or the proces

sor cover I (DM 7500P /7500P Plus) and raise the front cover B (see
covers and panels) by pressing the two catches underneath the
cover and lifting up at the bottom.
2 • Open the lefthand side door D (see covers and panels).
3 • Manually rotate the flywheel until the carriage is in the fully left
hand position.
4 • Disconnect the connector to the aperture step motor.
5 • Remove the two allen screws and washers securing the step motor
to its bracket and remove the step motor.

Assembly

6 • Fit the new step motor using the two allen screws and washers and
adjust the step motor so that its gear and the gear on the optics
unit are meshed and are able to be moved freely without any bind
ing.
7 • Tighten the two allen screws.
8 • Reconnect the connector to the step motor.
9 • Ifno further replacement operations are required, close the left
hand side door D and lower the front cover B.

Adjustments required

No adjustments are required.

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 4 • PART REPLACEMENT

Aperture (Iris) Step Motor

Aperture (iris) step motor

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 rnmn 4 • PART REPLACEMENT

P/N 960 40 002 90 Microswitch, aperture (iris)

Function

The aperture (iris) microswitch stops the step motor at the aperture
zero setting.

Technical data

Tools and materials required

No special tools are required, only standard equipment (section 1).

Caution! c... Only authorized service personnel may override the interlock
system, (if activated).

r, Turn off power • Before connecting or disconnecting cables.

• Before carrying out service operations.

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 scumw

Microswitch, Aperture (Iris)

'
How to replace

Removal

• Remove the top panel F (DM 7500SA/7500SA Plus) or the proces

sor cover I (DM 7500P /7500P Plus) and raise the front cover 8 (see
covers and panels) by pressing the two catches underneath the
cover and lifting up at the bottom.
2 • Open the lefthand side door D (see covers and panels).
3 • Manually rotate the flywheel until the carriage is in the fully left
hand position.
4 • Disconnect the connector to the aperture microswitch.
5 • Remove the two screws securing the microswitch.
6 • Remove the microswitch.

Assembly

7 • Fit the new microswitch using the two screws.

8 • Reconnect the connector to the microswitch.
9 • If no further replacement operations are required, close the left
hand side door D and lower the front cover 8.

Adjustments required

No adjustments are necessary.

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 4 • PART REPLACEMENT

' Microswitch, Aperture {Iris)

Microswitch

• •
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 SCANflEll
4 • PART REPLACEMENT

P/N 960 40 002 90 Microswitch, Filter

Function

The filter microswitch stops the step motor at the required filter set
tings

Technical data

Tools and materials required

No special tools are required, only standard equipment (section 1).

Caution! c... Only authorized service personnel may override the interlock
system.

c... Turn off power • connecting or disconnecting cables.

Before
• Before carrying out service operations.

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 mmn

Microswitch, Filter

How to replace

Removal

• Remove the top panel F (DM 7500SA/7500SA Plus) or the proces

sor cover I (DM 7500P/7500P Plus) and raise the front cover B (see
covers and panels) by pressing the two catches underneath the
cover and lifting up at the bottom.
2 • Open the lefthand side door D (see covers and panels).
3 • Manually rotate the flywheel until the carriage is in the fully left
hand position.
4 • Disconnect the connector to the filter microswitch.
5 • Remove the two screws securing the microswitch.
6 • Remove the microswitch.

Assembly

7 • Fit the new microswitch using the two screws.

8 • Reconnect the connector to the microswitch.
9 • If no further replacement operations are required, close the left
hand side door D and lower the front cover B.

Adjustments required

No adjustments are necessary.

.t
4•273b Service Manual • DotMate 7500/7500 Plus Edition 2 • July 1997
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manual DotMate 7500.indd 264 06/06/2016 01:18:46 p.m.
 4 • PART REPLACEMENT

Microswitch, Filter

Edition 2 • July 1997 Service Manual • DotMate 7500/7500 Plus 4• 273c

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 t
((

manual DotMate 7500.indd 266 06/06/2016 01:18:46 p.m.

 4 • PART REPLACEMENT

P/N 960 45 001 70 Carriage Spindle Step Motor

Function

The spindle step motor drives the spindle that extends and retracts the
carriage.

Technical data

Tools and materials required

Loctite 243 or equivalent

Standard equipment (section 1).

Caution! c� Only authorized service personnel may override the

interlock system.

� It is important that the assembly sequence for refitting the

mounting screwsand set screws is maintained, otherwise mis
alignment of the motor shaft may occur.

c� Tum off power • Before connecting or disconnecting cables.

-t
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Carriage Spindle Step Motor

How to replace

• Remove the top panel F (DM 7500SA/7500SA Plus) or the proces

sor cover I (DM 7500P /7500P Plus) and raise the front cover B
(see covers and panels) by pressing the two catches underneath
the cover and lifting up at the bottom.
2 • Open the lefthand side door D (see covers and panels).
3 • Manually rotate the flywheel until the carriage is in the lefthand
position.
4 • Disconnect the connector from the motor.
5 • Remove the three allen screws A and large washer securing the
brass plate to the flywheel and remove the plate.
6 • Remove and discard the two set screws securing the motor shaft to
the flywheel and remove the flywheel.
7 • Remove and discard the set screw B securing the motor to the
bearing housing coupling.
8 • Remove the four allen screws securing the motor to the bearing
housing and remove the motor.

Assembly

9 • Mount a new motor and using loctite 222, refit the four allen
screws.
10 • Using Loctite 243 or equivalent, fit a new set screw B to secure the
motor to the bearing housing coupling.
11 • Refit the flywheel and using loctite 243 or equivalent, fit two new
set screws.
12 • Refit the brass plate and large washer and secure with the three
allen screws A.
13 • Reconnect the connector.
14 • Ifno further replacement operations are required, close the left
hand side door D and lower the front cover B.

Adjutments required

No adjustments are required

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 4 • PART REPLACEMENT

Carriage Spindle Step Motor

Set screw B - {motor

shaft to bearing housing)
Flywheel

/
Step motor

Allen screws A Brass plate

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 sornn 4 • PART REPLACEMENT

P/N 960 40 001 90 Carriage Microswitches

Function

The right and lefthand microswitches on the carriage control the

maximum carriage travel in both directions.

Technical data

Leaf type

Tools and materials required

No special tools are required, only standard equipment (section 1).

Caution! c.. Only authorized service personnel may override the interlock
system.

r.- Turn off power • Before connecting or disconnecting cables.

• Before carrying out service operations.

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 mrnn

Carriage Microswitches

How to replace

Removal - Carriage microswitch, right

1 • Open the righthand side door C (see covers and panels).

2 • Disconnect the connector to the carriage microswitch.
3 • Remove the the two posidrive screws and lockwashers.
4 • Remove the microswitch.

Assembly - Carriage microswitch, right

5 • Fit the new microswitch using the two posidrive screws and
lockwashers.
6 • Reconnect the connector.
7 • If no further replacement operations are required, close the right
hand side door C.

Removal - Carriage microswitch, left

1 • Open the left hand side door D (see covers and panels).
2 • Disconnect the connector to the carriage microswitch.
3 • Remove the the two posidrive screws and lockwashers.
4 • Remove the microswitch.

Assembly - Carriage microswitch, left

5 • Fit the new microswitch using the two posidrive screws and
lockwashers.
6 • Reconnect the connector.
7 • Ifno further replacement operations are required, close the left
hand side door D.

Adjustments required

No adjustments are required.

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 4 • PART REPLACEMENT

Carriage Microswitches

Carriage left
microswitch

Carriage right
microswitch ·
Carriage viewed from the rear

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manual DotMate 7500.indd 274 06/06/2016 01:18:49 p.m.
 mm n 4 • PART REPLACEMENT

P/N 960 55 002 70 Media Guides Strain Gauges

Function

The media guide strain gauges are located on the left hand media guide
(on the carriage) and stop the DotMate in the event that media falls
away from the drum, thus protecting the optics unit.

Technical data

Tools and materials required

No special tools are required, only standard equipment (section 1).

Caution! c_. Only authorized service personnel may override the interlock
system.

_. Turn off power • Before connecting or disconnecting cables.

• Before carrying out service operations.

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Media Guides Strain Gauges

How to replace

• Remove the top panel F (DM 7500SA/7500SA Plus) or the proces

sor cover I (DM 7500P /7500P Plus) and raise the front cover B (see
covers and panels) by pressing the two catches underneath the
cover and lifting up at the bottom.
2 • Open the left hand side door D (see covers and panels).
3 • Manually rotate the flywheel until the carriage is in the left hand
position.
4 • Disconnect the connector from the lefthand media guide.
5 • Remove the four alien screws A and remove the top part of the
media guide.
6 • Remove the two alien screws B and remove the part of the media
guide with the strain gauges.

Assembly

7 • Remove the four alien screws A from the top part of the new
media guide.
8 • Fit the strain gauge part of the new media guide to the carriage
using the two alien screws B.
Note: remember to fit the cable clip under the lefthand screw.
9 • Fit the curved part of the new media guide using the four bolts A.
10 • If no further replacement operations are required, close the left
hand side door D and lower the front cover B.

Adjutments required

No adjustments are required

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 4 • PART REPLACEMENT

Media Guides Strain Gauges

Top part of media

guide

Allen mews B �
-, Allen screws A

Strain gauge

Allen screws A

Strain gauge

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 sornn 4 • PART REPLACEMENT

P/N 960 55 000 90 Optics Protection Board

Function

The optics protection board shuts off power to the unit in the event of a
paper jam or other malfunction when the media strain gauges are activ
ated.

Technical data

Tools and materials required

No special tools are required, only standard equipment (section 1).

Caution! ,.- Only authorized service personnel may override the interlock
system.

r.- Turn off power • Before connecting or disconnecting cables.

• Before carrying out service operations.

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Optics Protection Board

How to replace

Removal

1 • Open the left hand side door D (see covers and panels).
2 • Manually rotate the flywheel until the carriage is in the fully left
hand position.
3 • Disconnect the two connectors to the optics protection board.
4 • Remove the three allen screws securing the board.
5 • Remove the board.

Assembly

6 • Fit the new board using the three allen screws.

7 • Reconnect the two connectors to the board.
8 • If no further replacement operations are required, close the left
hand side door D.

Adjustments required

No adjustments are required.

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 4 • PART REPLACEMENT

Optics Protection Board

[ID�:
I UB I

U10

Optics protection board

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 4 • PART REPLACEMENT

P/N 960 55 001 10 Temperature Stabilizer Board

Function

The temperature stabilizer board controls the temperature in the inter

ior of the imagesetter.

Technical data

Tools and materials required

No special tools are required, only standard equipment (section 1)

Caution! r.- Only authorized service personnel may override the interlock
system.

r.- Turn off power • Before connecting or disconnecting cables.

• Before carrying out service operations.

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Temperature Stabilizer Board

How to replace

Removal

1 • Open the righthand side door C (see covers and panels).

2 • Disconnect the connector to the temperature stabilizer board.
3 • Remove the two alien screws and lockwashers A securing the board
to the drum casting.
4 • Lift the board away.

Assembly

5 • Mount the board and refit the two alien screws and lockwashers A.
6 • Reconnect the connector to the board.
7 • If no further replacement operations are required, close the right
hand side door C.

Adjustments required

No adjustments are required.

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 4 • PART REPLACEMENT

Temperature Stabilizer Board

Allen screws A

Termperature stabilizer board

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 4 • PART REPLACEMENT

P/N 960 55 002 90 Media Guide DC Motor

Function

The media guide DC motor powers the right hand guide.

Technical data

Tools and materials required

No special tools are required, only standard equipment (section 1)

Caution! r, Only authorized service personnel may override the interlock

system.

c. Turn off power • Before connecting or disconnecting cables.

• Before carrying out service operations.

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 SCAOIEW

Media Guide DC Motor

How to replace

Removal

1 • Open the righthand side door C (see covers and panels).

2 • Disconnect the connector to the DC motor.
3 • Remove the three allen screws A and washers on the two attach
ment brackets.
Note: one allen screw on the motor bracket has a distance piece
underneath.
4 • Remove the allen screw B and washer securing the stop arm and
remove the arm.
5 • Lift the motor and shaft away from the two pinnions.
6 • Loosen the set screw C securing the motor to the shaft.
1 • Remove the four allen screws D and washers and remove the DC
motor.

Assembly

8 • Mount the new DC motor onto its bracket and secure using the
four allens screws D and washers.
9 • Tighten the set screw C.
10 • Mount the motor and shaft over the two pinions and secure using
the three allen screws A and washers on both brackets.
Note: make sure that the distance piece is fitted underneath the
one allen screw on the motor bracket.
11 • Refit the stop arm using the allen screw B and washer.
12 • Reconnect the motor connector.
13 • If no further replacement operations are required, close the right
hand side door C.

Adjustments required

No adjustments are required.

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 4 • PART REPLACEMENT

Media Guide DC Motor

Allen screws
c
(x3)

Allen screws
c
(x3)
/

/ Set screw C

Allen screws
D
(x4)

Screw B DC motor
Stop arm

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 4 • PART REPLACEMENT

P/N 960 40 001 90 Media Guide Microswitch

Function

The two media guide microswitches control the the maximum travel,
both in and out, of the guide.

Technical data

button type

Tools and materials required

No special tools are required, only standard equipment (section 1)

Caution! c� Only authorized service personnel may override the interlock

system.

C� Turn off power • Before connecting or disconnecting cables.

• Before carrying out service operations.

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 scumw

Media Guide Microswitch

How to replace

Note 1: replacement of the two microswitches is identical, therefore

only one is explained in this instruction.

Removal

1 • Open the righthand side door C (see covers and panels).

2 • Disconnect the connector to the microswitch.
3 • Remove the two allen screws and lockwashers securing the micro
switch and remove the microswitch.

Assembly

4 • Mount the new microswitch and secure using the two allen screws
and lock washers.
5 • Reconnect the connector to the microswitch.
6 • If no further replacement operations are required, close the right
hand side door C.

Adjustments required

No adjustments are required.

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 4 • PART REPLACEMENT

Media Guide Microswitch

Microswitch, guide in

Microswitch, guide out

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 mrnn 4 • PART REPLACEMENT

P/N 960 55 001 50 Main Air Filter

Function

The main air filter comprises a charcoal element and front and rear
fibre filters. It cleans the incoming air prior to circulation within the
irnagesetter.

Technical data
PN 960 55 00155 Front fibre filter
PN 960 55 00156 Charcoal filter
PN 960 55 00157 Rear fibre filter

Tools and materials required

No special tools are required, only standard equipment (section 1).

Caution! c.. Only authorized service personnel may override the interlock
system.

c. Turn off power • Before connecting or disconnecting cables.

• Before carrying out service operations.

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 f
Main Air Filter

pHow to replace

Removal

1 • Remove the foot panel E (see covers and panels).

2 • Remove the two thumb screws A securing the filter box.
3 • Lift the box slightly up at the front and remove.
Note: the rear of the filter box is retained by two lugs fitting into
two slots on the fan casing. They are released when the filter box is
lifted up at the front.
4 • Remove the front and rear fibre filters elements.
5 • Remove the charcoal filter element.
Note: it may be necessary to carefully use a screwdriver, or other
suitable tool, to remove the carbon element.

Assembly

6 • Fit a new charcoal filter element into the filter box.

7 • Fit the filter box lugs into their corresponding slots on the fan
casing, and, while holding the box up at the front, place the new
front and rear fibre filter elements on the top of the fan casing so
that they align correctly with filter box.
8 • Lower the filter box and fit the two thumb screws A.
9 • If no further replacement operations are required, refit the foot
panel E by hooking the four lugs on the panel over the brackets on
the irnagesetter and lower into place.

Adjustments required

No adjustment is required.

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, 4 • PART REPLACEMENT

Main Air Filter

Filter box

Thumb screws A

Rear fibre filter <,

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 somn 4 • PART REPLACEMENT

Contents

Processor (DM 7500P/7500P Plus) Sub Section �· 300

CPU board (960 45 012 30) 4•302

RA interface board (960 45 012 40) 4•303
Silver saver board (960 45 012 50) 4•304
/Low voltage transformer (960 45 012 70) 4•305
j Autotransformer (960 45 012 80) 4•306
Line noise filter, 20A (960 45 013 00) 4•307
Solid state relay (960 45 013 20) 4•308
Fuses:
15 A, lOA, 4A and 3A (960 45 013 30/40/50/60) .. 4•309
IA (960 45 019 00) 4•309
Pages reserved for future use 4•310 to 4•315
Dryer rack (960 55 020 40) 4•316
Dryer temperature sensor (960 45 010 80) 4•317
Tank heating element, 750W (960 45 010 50) 4•318
Silver recovery unit : (960 45 010 90) 4•319
Silver recovery unit electrodes (960 45 010 95) 4•320
Pages reserved for future use 4•321 to 4•325
Drive motor. (960 45 011 00) 4•326
Motor encoder (960 45 011 10) 4•326
Blower/dryer assembly (960 45 011 30) 4•327
Blower heating element assembly (960 45 011 40) 4•327
Processor fan (960 45 012 10) 4•328
Airflow board (960 45 012 20) 4•329
Airflow detector board (969 45 012 00) 4•329
Pages reserved for future use 4•330 to 4•335
Filter housing (960 45 013 70 4•336
Circulation pump (960 45 014 00) 4•337
Replenishment pump (969 45 013 90) 4•338
Water inlet valve (969 45 014 10) 4•339
Worm gear (green and black) (960 45 016 51/61) 4•340
Drive belt (960 45 010 70) 4•340
Rack and dryer unit gears (960 45 016 50/60) 4•341

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 mmn 4 • PART REPLACEMENT

P/N 960 45 012 30 RA CPU Board

Function

The CPU board houses the EPROM and controls the function of the
processor.

Technical data

Tools and materials required

PLCC removal tool

Standard equipment (section 1).

Caution! � Turn off power • Before connecting or disconnecting cables.

• Before carrying out service operations.
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 SCHflEll'

RA CPU Board

How to replace

Note: The connector numbers are marked on the cables.

Removal

1 • Remove the lefthand side panel K (see covers and panels) by

simply lifting up and away.
2 • Remove the GQunit if fitted (section 2).
3 • Remove the four bolts securing the electronics cover and remove
the cover.
4 • Disconnect connectors M3 and M4.
5 • Remove the two bolts A securing the board.
6 • Disconnect the board at connector Ml to the interface board and
lift away.
7 • Remove the EPROM (1C3) from the old board using the PLCC
removal tool and fit it onto the new CPU board.
Note 1: make sure that the notch on the EPROM is on the right
hand side, as shown in fig. 1.
Note 2: the CPU board socket is larger than the E PROM, therefore
make sure that the EPROM is mounted so that two sets of socket
holes are free on the right hand side of the socket (fig. 1).

Assembly

8 • Mount the new CPU board onto the insulation wall and into con
nector Ml on the interface board.
9 • Refit the two bolts A.
10 • Check that the jumper settings are as described in section 7.
11 • Reconnect connectors M3 and M4.
12 • Refit the electronics cover using four bolts.
13 • Ifno further replacement operations are required, refit the GQunit.
14 • Refit the lefthand side panel K by hooking the two brackets on the
bottom of the panel over thetwo studs on the side of the processor
and over the lip on the top of the processor.

Adjustments required

No adjustments are required.

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 4 • PART REPLACEMENT

RA CPU Board

Notch on the
2 sets of free
E-PROM
socket holes

E-PROM

Fig.1

CPU board

/
/

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 mmn 4 • PART REPLACEMENT

P/N 960 45 012 40 RA lnterface Board

Function

The interface board controls the communication between the image

setter and the processor.

Technical data

Tools and materials required

No special tools are required, only standard equipment (section 1).

Caution! ,..- Turn off power • Before connecting or disconnecting cables.

• Before carrying out service operations.
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RA lnterface Board

How to replace

Note: The connector numbers are marked on the cables.

Removal

1 • Remove the lefthand side panel K (see covers and panels) by

simply lifting up and away.
2 • Remove the GQunit if fitted (section 2).
3 • Remove the four bolts securing the electronics cover and remove
the cover.
4 • Disconnect connectors M2, M9, Mll, Ml2, Ml3, Ml4, Ml5, Ml6,
Ml 7, Ml8, Ml 9, M20, M21, M22, M23 and M24.
5 • Remove the five bolts A securing the board.
6 • Disconnect the board at connectors Ml (from the CPU board) and
M25 (from the silver saver board) and lift away.
7 • If there is a buzzer mounted on the board, remove it for use on the
new board.

Assembly

8 • If a buzzer was removed from the old board (step 7 above), refit it
to the new board.
9 • Set the DIP switches as described in section 7.
10 • Mount the new interface board onto the insulation wall and into
connectors Ml (from the CPU board) and M25 (from the silver
saver board).
11 • Refit the five bolts A.
12 • Reconnect connectors M2, M9, Mll, Ml2, Ml3, Ml4, Ml5, Ml6,
Ml 7, Ml8, Ml 9, M20, M21, M22, M23 and M24.
13 • Refit the electronics cover using four bolts.
14 • Ifno further replacement operations are required, refit the GQunit.
15 • Refit the left hand side panel K by hooking the two brackets on the
bottom of the panel over the two studs on the side of the processor
and over the lip on the top of the processor.

Adjustments required

No adjustments are required.

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 4 • PART REPLACEMENT

RA Interface Board

Interface board

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 4 • PART REPLACEMENT

P/N 960 45 012 50 Silver Saver Board

Function

The silver saver board controls the level of silver in the fixer tank.

Technical data

Tools and materials required

No special tools are required, only standard equipment (section 1).

Caution! f1lr' Turn off power • Before connecting or disconnecting cables.

• Before carrying out service operations.

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 scurnw

Silver Saver Board

How to replace

Note: The connector numbers are marked on the cables.

Removal

1 • Remove the lefthand side panel K (see covers and panels) by

simply lifting up and away.
2 • Remove the GQunit iffitted (section 2).
3 • Remove the four bolts securing the electronics cover and remove
the cover.
4 • Disconnect connectors M2, M3, M4, MS, M6 and M7.
5 • Remove the two bolts A securing the board to the insulation wall.
6 • Disconnect the board at connector Ml to the interface board and
lift away.

Assembly

7 • Mount the new silver saver board onto the insulation wall and into
connector Ml on the interface board.
8 • Refit the two bolts A.
9 • Set the DIP switches as described in section 7.
10 • Reconnect connectors M2, M3, M4, M5, M6 and M7.
11 • Refit the electronics cover using four bolts.
12 • Ifno further replacement operations are required, refit the GQunit.
13 • Refit the left hand side panel K by hooking the two brackets on the
bottom of the panel over the two studs on the side of the processor
and over the lip on the top of the processor.

Adjustments required

No adjustments are required.

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 4 • PART REPLACEMENT

Silver Saver Board

+ .: 1.., +
-
- Qe
�
r':

B Qc=J
�

D
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Siver saver board

 /

Edition 2 • July 1997 Service Manual • DotMate 7500/7500 Plus 4• 304c

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manual DotMate 7500.indd 312 06/06/2016 01:19:04 p.m.
 SCHVIEW
4 • PART REPLACEMENT

P/N 960 45 012 70 Low Voltage Transformer

Function

The low voltage transformer transforms 220 V to 110 V to the electronics

boards.

Technical data

Tools and materials required

No special tools are required, only standard equipment (section 1).

Caution! c.. Turn off power • Before connecting or disconnecting cables.

• Before carrying out service operations.

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 mrnn

Low Voltage Transformer

How to replace

Removal
1 • Remove the lefthand side panel K (see covers and panels) by
simply lifting up and away.
2 • Remove the GQunit if fitted (section 2).
3 • Remove the four bolts securing the electronics cover and remove
the cover.
4 • Disconnect the eight connectors from the transformer.
5 • Remove the four nuts (on the back of the electronics box) and
four screws securing the transformer and lift away.

Assembly

6 • Mount the new transformer and refit the four screws and nuts.
7 • Reconnect the eight connectors.
8 • Refit the electronics cover using the four bolts.
9 • Ifno further replacement operations are required, refit the GQunit.
10 • Refit the left hand side panel K by hooking the two brackets on the
bottom of the panel over the two studs on the side of the processor
and over the lip on the top of the processor.

Adjustments

No adjustments are required.

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 4 • PART REPLACEMENT

Low Voltage Transformer

Low voltage transformer

Edition 2 • July 1997 Service Manual • DotMate 7500/7500 Plus 4• 305c

'2 -u
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 scumw 4 • PART REPLACEMENT

P/N 960 45 012 80 Auto Transformer

Function

The auto transformer ensures that the processor is suppied with a con
stant 220V.

Technical data

Tools and materials required

No special tools are required, only standard equipment (section 1).

Caution! c� Turn off power • Before connecting or disconnecting cables.

• Before carrying out service operations.

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 mrnn

Auto Transformer

How to replace

Removal

1 • Remove the lefthand side panel K (see covers and panels) by

simply lifting up and away.
2 • Remove the GQunit if fitted (section 2).
3 • Remove the four bolts securing the electronics cover and remove
the cover.
4 • Disconnect the four connectors from the transformer.
5 • Remove the four bolts (on the back of the electronics box) securing
the transformer and lift away.

Assembly

6 • Mount the new transformer and refit the four bolts.

7 • Reconnect the four connectors.
8 • Refit the electronics cover using the four bolts.
9 • If no further replacement operations are required, refit the GQ
unit.
10 • Refit the left hand side panel K by hooking the two brackets on the
bottom of the panel over the two studs on the side of the processor
and over the lip on the top of the processor.

Adjustments

No adjustments are required.

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 4 • PART REPLACEMENT

Auto Transformer

Auto-transformer

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 4 • PART REPLACEMENT

P/N 960 45 013 00 Line Noise Filter, 20A

Function

The 20 amp line noise filter removes electrical interference from the
system.

Technical data

Tools and materials required

No special tools are required, only standard equipment (section 1).

Caution! c. Turn off power • Before connecting or disconnecting cables.

• Before carrying out service operations.

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 mmn

Line Noise Filter, 20A

How to replace

Removal

1 • Remove the lefthand side panel K (see covers and panels) by

simply lifting up and away.
2 • Remove the GQunit if fitted (section 2).
3 • Remove the four bolts securing the electronics cover and remove
the cover.
4 • Remove the four connectors.
5 • Remove the two nuts (on the outside of the electronics box) sec
uring the filter and lift away.

Assembly

6 • Mount the new filter and refit the two nuts.

1 • Reconnect the four connectors.
8 • Refit the electronics cover using four bolts.
9 • Ifno further replacement operations are required, refit the GQunit.
10 • Refit the left hand side panel K by hooking the two brackets on the
bottom of the panel over the two studs on the side of the processor
and over the lip on the top of the processor.

Adjustments

No adjustments are required.

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 4 • PART REPLACEMENT

Line Noise Filter, 20A

Line noise filter

/
/
/

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 SCHYIEW
4 • PART REPLACEMENT

P/N 960 45 013 20 Solid State Relay

Function

The three solid state relays are contact free relays that operate the
heater elements.

Technical data

Tools and materials required

No special tools are required, only standard equipment (section 1).

Caution! ,.... Turn off power • Before connecting or disconnecting cables.

• Before carrying out service operations.

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 mrnn

Solid State Relay

How to replace

Note: replacement of thefour relays is identical, therefore only one

is explained in this instruction.

Removal

1 • Remove the lefthand side panel K (see covers and panels) by

simply lifting up and away.
2 • Remove the GQunit if fitted (section 2).
3 • Remove the four bolts securing the electronics cover and remove
the cover.
4 • Remove the four crosspoint screws securing the four connectors
and remove the connectors.
5 • Remove the nut (on the outside of the electronics box) securing
the relay and lift away.

Assembly

6 • Mount the new relay and refit the nut.

7 • Reconnect the four connectors using the four crosspoint screws.
8 • Refit the electronics cover using four bolts.
9 • Ifno further replacement operations are required, refit the GQunit.
10 • Refit the left hand side panel K by hooking the two brackets on the
bottom of the panel over the two studs on the side of the processor
and over the lip on the top of the processor.

Adjustments

No adjustments are required.

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 4 • PART REPLACEMENT

Solid State Relay

Solid state relay

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 scumw 4 • PART REPLACEMENT

For PN's, see below Fuses

Function

The fuses protect the processor primary and secondary power supply,
developer, fixer and dryer heat and the imagesetter and processor mains
supply.

Technical data

Fuses:
PN 960 45 013 30 15amp
PN 960 45 019 00 lamp
PN 960 45 013 60 3amp
PN 960 45 013 50 4amp
PN 960 45 013 40 lOamp

Tools and materials required

No special tools are required, only standard equipment (section 1).

Caution! c_. Turn off power • Before connecting or disconnecting cables.

• Before carrying out service operations.

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 scurnw

Fuses

How to replace

Removal

1 • Remove the lefthand side panel K (see covers and panels) by

simply lifting up and away.
2 • Remove the GQunit if fitted (section 2).
3 • With reference to fig. 1 and the component placement diagram
(section 7), remove the appropriate fuse or fuses.

Assembly

4 • Fit the new fuse(s).

Note: ensure that the replacement fuse, or fuses, are the same
type and amperage as that marked on the label on the electronics
cover.
5 • If no further replacement operations are required, refit the GQ
unit.
6 • Refit the left hand side panel K by hooking the two brackets on the
bottom of the panel over the two studs on the side of the processor
and over the lip on the top of the processor.

Adjustments required

No adjustments are required.

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 4 • PART REPLACEMENT

Fuses

M-10A
T-15A
(Heat dry.)
(Slow)

FF-4A
(Heat fix)

FF-4A
(Heat dev.)

T-1A
(Blower)

T-1A /
(Power Supply
prim.ary)

T-3A /
(Power supply sec.)

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 4 • PART REPLACEMENT

P/N 960 55 020 40 Dryer Rack

Function

The dryer rack contains the rollers that transport the media after pro
cessing, through the drying process and to the output tray

Technical data

Tools and materials required

No special tools are required, only standard equipment (section 1).

Caution! r� Turn off power • Before connecting or disconnecting cables.

• Before carrying out service operations.

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 SCANllElf

Dryer Rack

How to replace

Removal

1 • Lift up the processor cover I (see covers and panels).

2 • Remove the top I rear panel of the dryer unit by simply lifting
away.
3 • Refer to fig. 1 and loosen the cross point bolt A securing the dryer
unit flange to the processor top plate.
4 • Remove connector B.
5 • Viewing the cassette from the front of the DotMate, slide the dry
ing unit to the left until it is clear of bolt A and lift up on that same
side until the unit can be lifted clear of the gear train on the right
hand side of the processor.

Assembly

6 • Carefully refit the dryer unit, righthand side first, in order to en

gage with the gear train.
7 • Position the left hand flange of the unit under the crosspoint bolt
A and tighten the bolt.
8 • Reconnect connector B.
9 • Refit the combined top and back panel of the dryer unit.
10 • Ifno further replacement operations are required, lower the pro
cessor cover I.

Adjustments required

No adjustments are required.

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 4 • PART REPLACEMENT

Dryer Rack

Top/rear panel

Attachment bolt
Slide dryer unit in A
the direction of
the arrow to clear
bolt A

Connector
B

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 SCAN VIEW
4 • PART REPLACEMENT

PN 960 45 010 80 Dryer Temperature Sensor

Function

The dryer temperature sensor senses the temperature of the air in the
drying unit.

Technical data

Tools and materials required

No special tools are required, only standard equipment (section 1).

Caution! c_. Turn off power • Before connecting or disconnecting cables.

• Before carrying out service operations.

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Dryer Temperature Sensor

How to replace

Removal

1 • Lift up the processor cover I (see covers and panels).

2 • Remove the top/rear panel of the dryer unit by simply lifting away.
3 • Remove the nut, bolt and washer securing the sensor to the inside
wall of the dryer unit.
Note: the washer is fitted between the sensor and the side wall of
the dryer unit.
4 • Remove the cable tie wraps.
5 • Remove connector B and lift away the sensor.

Assembly

6 • Fit a new sensor and secure with the nut, bolt and washer.
Note: fit the washer between the sensor and the side wall of the
dryer unit.
7 • Reconnect connector B.
8 • Fit new cable tie wraps.
9 • Refit the combined top and back panel of the dryer unit.
10 • Ifno further replacement operations are required, lower the pro
cessor cover I.

Adjustments required

No adjustments are required.

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 4 • PART REPLACEMENT

Dryer Temperature Sensor

Sensor Dryer top/back panel

4 mm nut and bolt

(the washer is
between the sensor
and inside wall of
the dryer unit)

��
�o

Connector B

Dryer unit

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 sornn 4 • PART REPLACEMENT

P/N 960 45 010 50 Tank Heating Element

Function

The tank heating elements warm the developer and fixer in the proces
sor tanks.

Technical data

750 W element

Tools and materials required

27 mm openended spanner.
Standard equipment (section 1).

Caution! c.,. Turn off power • Before connecting or disconnecting cables.

• Before carrying out service operations.
 Edition 2 • July 1997 Service Manual • DotMate 7500/7500 Plus 4•318a
21 J I

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 SCAHIEW
t
Tank Heating Element

How to replace

Note: replacement of thetwo heating elements is identical, there

fore only one is explained in this instruction.

Removal

1 • Remove the righthand side panel J (see covers and panels) by

simply lifting up and away.
2 • Drain the contents of the relevant tank into a suitable container
(see the DotMate Easy Maintenance Guide).
3 • Remove the top heater element access panel (two screws) and if
necessary, the side access panel (four cross point screws).
Note: if the side access panel is to be removed, first remove the
fixer filter bowl so that there is access to the screws.
4 • Locate the relevant heating element, (developer or fixer tanks)
located on the right hand side of the processor and remove the
connectors.
5 • Using a 27 mm open ended spanner, remove the nut and withdraw
the heating element.

Assembly

6 • Fit the new heating element and and refit the nut.
7 • Reconnect the connector.
8 • Refit the top heater element access panel and the side access
panel, (if removed in step 3).
9 • Refit the fixer filter bowl.
10 • Replenish the chemistry as necessary in accordance with the
instructions in the DM 7500 operators manual.
11 • Carry out a temperature calibration (DotMate 7500 operators
manual).
12 • If no further replacement operations are required, refit the right
hand side panel J by hooking the two brackets on the bottom of
the panel over the two studs on the side of the processor and over
the lip on the top of the processor.

Adjustments required

Temperature calibration (DotMate 7500P operators manual).

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 4 • PART REPLACEMENT

' Tank Heating Element

' Heating element

access panel (top)

Heating element
(developer)

Heating element
(fixer)

Heating element
access panel (side)

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 scumw 4 • PART REPLACEMENT

P/N 960 45 010 90 Silver Recovery Unit

Function

The silver recovery unit recovers the majority of the silver present in the
fixer.

Technical data

Tools and materials required

No special tools are required, only standard equipment (section 1).

Caution! c. Turn off power • connecting

Before or disconnecting cables.
carrying out service operations.
• Before

c. Wear the necessary protective clothing when handling chemicals.

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 scumw

Silver Recovery Unit

How to replace

Removal

1 • Remove the righthand side panel J (see covers and panels) by

simply lifting up and away.
2 • Drain the fixer, (DotMate Easy Maintenance Guide, Changing the
chemistry).
3 • Remove the two pipe clips from the inlet and outlet connections.
4 •Pullout the connector from the top of the the unit.
5 • Remove the four crosspoint screws securing the unit to the top of
the processor, drop it down throught the hole in the base and lift
the unit away.

Assembly

6 • Lubricate the oring with silicon grease.

7 • Mount the new silver recovery unit and refit the four crosspoint
screws.
8 • Refit the two pipe clips to the inlet and outlet connections.
9 • Push the connector back into the top of the unit.
10 • Replenish the fixer tank (DM 7500 operators manual, Setting up
the processor: Filling the processor).
11 • If no further replacement operations are required, refit the right
hand side panel J by hooking the two brackets on the bottom of
the panel over the two studs on the side of the processor and over
the lip on the top of the processor.

Adjustments required

No adjustments are required.

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 4 • PART REPLACEMENT

Silver Recovery Unit

Connector
Outlet
connection
Inlet
connection

Silver recovery
unit

0
0

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mrnn 4 • PART REPLACEMENT

Function

The silver recovery unit electrodes initiate a chemical reaction within

the Silver Recovery Unit for the recovery of the silver from the fixer.

Technical data

Tools and materials required

No special tools are required, only standard equipment (section 1).

Caution! c. Only authorized service personnel may override the interlock

system.

c. Turn off power • connecting or disconnecting cables.

Before
• Before carrying out service operations.

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 scum,

How to replace

Removal

1 • Remove the righthand side panel J (see covers and panels) by

simply lifting up and away.
2 • Drain the fixer, (DotMate Easy Maintenance Guide, Changing the
chemistry).
3 • Remove the bolts securing the pumps access cover and remove the
cover.
4 • Remove the fixer circulation pump (section 4).
5 • Locate the SRU and the two electrodes on the base and remove the
screws securing the electrical leads to the electrodes.
6 • Place a container underneath the SRU to collect fixer when rem
oving the electrodes during the following operation.
7 • Using a 14 mm spanner, unscrew and carefully remove the two
electrodes.
Note: If the electrodes cannot be removed (are locked fast by cor
rosion), the complete SRU will need to be changed (section 4).

Assembly

8 • Check that arings are fitted to the new electrodes, fit the elect
rodes into the SRU and carefully tighten them.
9 • Refit the electrical leads to the electrodes.
10 • Refit the fixer circulation pump (section 4).
11 • Refit the pumps access cover.
12 • Replenish the fixer tank (DM 7500/7500 Plus Operators Manual,
Setting up the processor: Filling the processor).
13 • If no further replacement operations are required, refit the right
hand side panel J by hooking the two brackets on the bottom of
the panel over the two studs on the side of the processor and over
the lip on the top of the processor.

Adjustments required

No adjustments are required.

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 4 • PART REPLACEMENT

t Silver recovery
unit
(SRU)

---�-------- Fixer circulation

Pumps access
pump
cover

': �·: -�6i

Screwmu,�
electrical leads >A
SRU

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 4 • PART REPLACEMENT

P/N 960 45 011 00/01 Drive Motor and Motor Encoder

Function

The drive motor and encoder supply and control the motive power for
the processor drive shaft, which subsequently drives the rollers for the
developer, fixer, and wash water racks and the dryer unit.

Technical data
PN 960 45 011 00 Drive motor
PN 960 45 011 10 Motor encoder

Tools and materials required

Loctite 243 or equivalent for motor shaft set screw

Standard equipment (section 1).

Caution! c.. Turn off power • Before connecting or disconnecting cables.

• Before carrying out service operations.

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 t
Drive Motor and Motor Encoder

How to replace

Note: If only the motor encoder is to be replaced, it is only necessary

to carry out steps 1 to 5 and 7 for removal and 12 to 16 for refitting.

Removal
1 • Raise the processor cover I and remove the processor back panel H
and righthand side panel J (see covers and panels).
2 • Remove the dryer rack (section 4).
3 • Push down the dryer rack female connector A which is mounted
on the access panel underneath the dryer rack in order to be able
to remove the access panel.
4 • Remove the two screws securing the large panel and the two screws
securing the small motor access panel and lift the panels away.
5 • Remove the connector and the two screws from the motor encoder
attachment bracket and remove the encoder.
6 • Remove the three bolts B securing the motor to its mounting bracket.
7 • Remove and discard the set screw securing the encoder wheel to
the drive motor shaft and remove the wheel.
8 • Lift the motor away from its mounting bracket (at the same time
remove the drive wheel from the shaft) and when there is enough
access, disconnect the two connectors from the motor.

Assembly
9 • Connect the two connectors to the motor, position the motor onto
its bracket while at the same time sliding the drive wheel and drive
belt onto the motor shaft.
10 • Fit the three bolts B to secure the motor and adjust the belt tension
(approx 23 cm of free play) before finally tightening the bolts.
11 • Using loctite 243, fit a new set screw to secure the drive wheel.
12 • Fit the original or replacement motor encoder (as necessary) using
two screws and reconnect the connector.
13 • Mount the encoder wheel to the drive motor shaft and, using loc
tite 243, fit a new set screw.
14 • Push up and secure the female connector A removed in step 3 to
the large access panel and refit both the large and small panels.
15 • Refit the dryer rack (section 4).
16 • Ifno further replacement operations are required, refit the right
hand side panel J, processor back panel H and lower the processor
cover I.

Adustments
No adjustments are required

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 4 • PART REPLACEMENT

Drive Motor and Motor Encoder

Motor encoder bracket Motor encoder Viewed from the top of the processor
attachment screws

Drive motor attach-

ment bolts B (x3)

Drive motor attach-

Drive motor Encoder wheel
ment bracket

Female connector
A Large access panel
covering drive motor
and motor encoder

Small access
panel (for drive
belt adjustment)

Motor drive
belt

Processor with dryer rack removed

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 scurnw 4 • PART REPLACEMENT

P/N 960 45 011 30/40 Blower/DrY.er Assemblv

& Heating Elemen1

Function

The blower I dryer assembly supplies the heat to the dryer unit for
drying the film after processing.

Technical data

PN 960 45 0 ll 30 Blower
PN 960 45 Oll 40 Heating element

Tools and materials required

No special tools are required, only standard equipment (section 1).

Caution! r,-. Turn off power • Before connecting or disconnecting cables.

• Before carrying out service operations.

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 SCHVIEIT

Blower/DrY.�r Assembly
& Heatmg Element

How to replace

Removal

Note: If only the heater element assembly is to be replaced, it is

still necessary to first remove the blower/dryer assembly.
• Raise the processor cover I and remove the processor back panel H
and righthand side panel J (see covers and panels).
2 • Remove the dryer rack (section 4).
3 • Push down the dryer rack female connector A which is mounted
on the access panel underneath the dryer rack in order to be able
to remove the access panel.
4 • Remove the two screws securing both access panels and lift the
panels Oaway.
5 • Remove connector B from the blower assembly (located on the
rear frame of the compartment) and the three ground (earth)
con nections (C) on the base plate.
6 • Remove the four cross point screws D securing the blower/dryer
assembly to the base plate and lift the assembly away.
7 • Remove the dryer from the removed blower I dryer by disconnect
ing the three nuts from the connections on the dryer body and
removing the cross point screw E securing the dryer body to the
blower I dryer assembly.

Assembly

8 • Fit a new or replacement element assembly (as necessary), using

the cross point screw E to secure the assembly to the blower/dryer
and reconnect the three connections using the three nuts.
9 • Fit a new blower/dryer assembly and secure it to the base plate
with the four cross point screws D.
10 • Reconnect connector B and the three ground (earth) connections C.
11 • Push up and secure the female connector A removed in step 3 to
the large access panel and refit both the large and the small panels.
12 • Refit the dryer rack (section 4).
13 • If no further replacement operations are required, refit the right
hand side panel J, processor back panel H and lower the processor
cover I.

Adustments
No adjustments are necessary

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 4 • PART REPLACEMENT

Blower/DrY.er As5embly
& Heating Element

Ground (earth) connections Viewed from the top of the processor

c

\ Dryer
\ \
'=,
"\:, Dryer mount-
ing screw
E

�---'------"I

/
Blower Connector B Blower attachment bolts
D

Female connector
Large access panel
A
covering drive motor

- and motor encoder

Small access
panel (for drive
.n11=.. / belt adjustment)

Processor with dryer rack removed

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 scumw 4 • PART REPLACEMENT

P/N 960 45 012 10 Processor Fan

Function

The processor fan supplies airflow to the processor which ensures that
fumes cannot be fed back into the imagesetter.

Technical data

Tools and materials required

No special tools are required, only standard equipment (section 1).

Caution! -,. Turn off power • Before connecting or disconnecting cables.

• Before carrying out service operations.
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 mrnn

Processor Fan

How to replace

Removal

1 • Lift up the processor cover I (see covers and panels).

2 • Remove the filter cover by lifting up, (it is a loose fit).
3 • Remove the three bolts A securing the panel covering the processor
fan.
4 • Remove the three alien screws B securing the fan assembly and lift it
away enough to give access to the connectors.
5 • Remove the cable tie wraps and disconnect the following fan con
nectors:
Two connectors to capacitor C.
One ground (earth) D.
One connector on the rear of the insulation wall E.
6 • Remove the fan assembly.

Assembly

7 • Position the processor fan assembly and reconnect the two connect
ors to capacitor C, one earth D and one on the rear of the insulation
wall E.
8 • Fit new cable tie wrap.
9 • Refit the three alien screws B securing the fan assembly.
10 • Refit the fan cover panel and secure with three bolts A.
11 • Refit the filter cover.
12 • If no further replacement operations are required, lower the pro
cessor cover I.

Adjustments required

No adjustments are required.

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 4 • PART REPLACEMENT

Processor Fan

Capacitor C Ground (earth) D

Connector E

Processor fan

Fan attachment bolts B

Viewed from the top of the processor

Filter cover

Access cover attachment

screws
A

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 4 • PART REPLACEMENT

P/N 960 45 012 20/00 Air Flow and Air Flow Detector Boards

Function

The airflow board and airflow detector boards control the airflow into
the processor and initiate a warning to the operator when the airflow
falls below a preset value.

Technical data

PN 960 45 012 20 Air flow board

PN 960 45 012 00 Air flow detector board

Tools and materials required

No special tools are required, only standard equipment (section 1).

Caution! r. - Turn off power • Before connecting or disconnecting cables.

• Before carrying out service operations.

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 Air Flow and Air Flow Detector Boards

How to replace

Removal

1 • Lift up the processor cover I (see covers and panels).

2 • Remove the filter cover by lifting up, (it is a loose fit).
3 • Remove the three cross point screws A securing the panel covering
the processor fan, (in some cases, bolts may be fitted).
4 • Remove the three alien screws B securing the fan assembly and lift
it away enough to give access to the boards.
5 • Air flow board removal:
Rotate the grey tube to gain access to the board, remove the con
nector and remove the two crosspoint screws.
6 • Air flow detector board removal:
Remove the cable tie wraps, connectors Ml, M3 and M6 and the
four plastic posts securing the board.

Assembly

1 • Air flow detector board fitting:

Secure the board with the four plastic posts, reconnect connectors
Ml, M3 and M6, and fit new cable tie wraps.
8 • Carry out an air flow alarm level adjustment (section 5).
9 • Air flow board fitting:
Secure the board to the grey tube with the two cross point screws
and reconnect the connector.
10 • Position the air flow fan assembly and refit the three alien screws 8.
11 • Refit the fan cover panel and secure with the three crosspoint
screws A.
12 • Refit the filter cover.
13 • If no further replacement operations are required, lower the pro
cessor cover I.

Adjustments required

Air flow alarm level adjustment (section 5).

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 4 • PART REPLACEMENT

Air Flow and Air Flow Detector Boards

Airflow
Attachment
detector
screws B for
board
processor fan

Air flow board

Rotate the grey

tube to gain
access to the two
air flow board
mounting screws

Viewed from the top of the processor

Filter cover

Access cover attachment

screws
A

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 mrnn 4 • PART REPLACEMENT

P/N 960 45 013 70 Filter Housings

Function

The filter housings contain the filters for the developer, fixer and wash
water (if the optional GQ unit is fitted).

Technical data

Tools and materials required

No special tools are required, only standard equipment (section 1).

Caution! ,... Turn off power • Before connecting or disconnecting cables.

• Before carrying out service operations.

C� Wear the necessary protective clothing when handling chemicals.

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 mmn

Filter Housings

How to replace

Removal

1 • Remove the righthand side panel J (see covers and panels) by

simply lifting up and away.
2 • Identify which filter is to be changed from fig. 1:
Fixer filter, blue hoses.
Developer filter, red hoses.
Water filter, transparent hoses (only with the optional GQ unit).
Note: the replacement procedure for all three filters is the same.
3 • If necessary, drain the contents of the relevant tank into a suitable
container (see the DotMate Easy Maintenance Guide).
4 • Unscrew the glass filter bowl and remove the filter.
5 • Remove the two hose clips from the inlet and outlet connections
and pull off the hoses.
6 • Remove the four allen screws on the top of the processor securing
the filter housing and carefully remove the filter.

Assembly

7 • Position the new filter housing and secure with the four allen
screws.
8 • Refit the inlet and outlet pipes and secure them with the two hose
clips.
9 • Refit the filter element and glass bowl.
10 • Ifno further replacement operations are required, refit the right
hand side panel J by hooking the two brackets on the bottom of
the panel over the two studs on the side of the processor and over
the lip on the top of the processor.

Adjustments required

No adjustments are required.

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 4 • PART REPLACEMENT

Filter Housings

Circulation
Developer flow valve Fixer

0
0

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 scomw 4 • PART REPLACEMENT

P/N 960 45 014 00 Circulation Pump

Function

The circulation pumps circulate the developer and fixer (and wash
water when the optional GQ unit is fitted) in their respective tanks.

Technical data

Tools and materials required

No special tools are required, only standard equipment (section 1).

Caution! " Turn off power • Before connecting or disconnecting cables.

• Before carrying out service operations.

c� Wear the necessary protective clothing when handling chemicals.

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 SCHflElf

Circulation Pump

How to replace

Removal

1 • Remove the righthand side panel J (see covers and panels) by

simply lifting up and away.
2 • Remove the chemistry trolley from the processor.
3 • Remove the five bolts A securing the access cover over the rep
lenishment and circulation pumps.
4 • Identify which pump is to be changed from fig. 1:
Fixer, blue hoses.
Developer, red hoses.
Water, transparent hoses (only with the optional GQ unit).
Note: the replacement procedure for all three pumps is the same.
5 • Drain the contents of the relevant tank into a suitable container
(see the DotMate Easy Maintenance Guide).
6 • Remove the two hose clips from the inlet and outlet connections
and pull off the hoses.
7 • Remove the connector from the pump.
8 • Remove the four allen screws securing the pump and carefully
remove the pump.

Assembly

9 • Position the new pump and secure with the four allen screws.
10 • Refit the inlet and outlet pipes and secure them with the two hose
clips.
11 • Reconnect the connector to the pump.
12 • Refit the pump access panel using the five bolts A.
13 • Position the chemistry trolley in the processor.
14 • Replenish the chemistry as necessary in accordance with the
instructions in the DM 7500/7500 Plus operators manual
15 • If no further replacement operations are required, refit the right
hand side panel J by hooking the two brackets on the bottom of
the panel over the two studs on the side of the processor and over
the lip on the top of the processor.

Adjustments required

No adjustments are required.

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 4 • PART REPLACEMENT

Circulation Pump

Back view

.>
/
/
Fixer

Developer

Side view

Access cover
secured by 5
bolts A

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•
4 • PART REPLACEMENT

P/N 960 45 013 90 Replenishment Pump

Function

The replenishment pumps ensure that the developer and fixer tanks are
automatically replenished with chemistry.

Technical data

Tools and materials required

No special tools are required, only standard equipment (section 1).

Caution! � Turn off power • Before connecting or disconnecting cables.

• Before carrying out service operations.

c. Wear the necessary protective clothing when handling chemicals.

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Replenishment Pump

How to replace

Note: do not run the pumps without chemistry in the tanks.

Removal
1 • Remove the righthand side panel J (see covers and panels) by
simply lifting up and away.
2 • Remove the chemistry trolley from the processor.
3 • Remove the five bolts A securing the access cover over the rep
lenishment and circulation pumps.
4 • Identify which pump is to be changed from fig. 1:
Fixer (blue hoses), Developer (red hoses).
Note: the replacement procedure for both pumps is the same.
5 • Drain the contents of the relevant tank into a suitable container
(see the DotMate Easy Maintenance Guide).
6 • Remove the connector to the pump.
7 • Remove the ground (earth) connection to the pump (on the back
wall of the compartment).
8 • Remove the hose clips from the inlet and outlet connections and
pull off the hoses.
Note: take the necessary safety precautions, as chemistry may
flow out of the removed hoses.
9 • Remove the pump by carefully pulling away from the antivibration
mounts.

Assembly
10 • Fit the new pump into the antivibration mounts.
11 • Reconnect the connector.
12 • Reconnect the ground (earth) connections to the back wall of the
compartment.
13 • Refit the inlet and outlet pipes and secure them with the hose clips.
14 • Refit the pump access panel using the five bolts A.
15 • Position the chemistry trolley in the processor.
16 • Replenish the chemistry as necessary in accordance with the
instructions in the DM 7500/7500 Plus operators manual.
17 • Ifno further replacement operations are required, refit the right
hand side panel J by hooking the two brackets on the bottom of
the panel over the two studs on the side of the processor and over
the lip on the top of the processor.

Adjustments required
No adjustments are required.

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 4 • PART REPLACEMENT

Replenishment Pump

Back view

0
Fixer Developer

Side view

Access cover
secured by 5 »>
bolts A

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 scurnw 4 • PART REPLACEMENT

P/N 960 45 014 10 Water Inlet Valve

Function

The water inlet valve controls the main water supply to the processor.
With the optional GQ unit fitted, it supplies mains water in the online
mode only.

Technical data

2 litres per minute when open and water pressure is between 0.5 and 10
bar.

Tools and materials required

No special tools are required, only standard equipment (section 1).

Caution! c.. Turn off power • Before connecting or disconnecting cables.

• Before carrying out service operations.

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 SCANVIEW

Water Inlet Valve

How to replace

Removal

1 • Remove the righthand side panel J (see covers and panels) by

simply lifting up and away.
2 • Remove the chemistry trolley from the processor.
3 • Remove the five bolts A securing the access cover over the rep
lenishment and circulation pumps.
4 • Shut off and remove the mains water supply to the DotMate.
5 • Disconnect the two connectors on the valve.
6 • If necessary, drain the contents of the water tank into a suitable
container.
7 • Remove the hose clip from the outlet connection and pull off the
hose.
8 • Remove the two crosspoint securing screws (located underneath
the plate), and remove the valve.

Assembly

9 Position the new valve and secure with the two crosspoint screws.
•
10 Refit the outlet hose and secure it with the hose clip.
•
11 Reconnect the two connectors on the valve.
•
12 Reconnect the mains water connection.
•
13 • Refit the pump access panel using the five bolts A.
14 • Position the chemistry trolley in the processor.
15 • If no further replacement operations are required, refit the right
hand side panel J by hooking the two brackets on the bottom of
the panel over the two studs on the side of the processor and over
the lip on the top of the processor.

Adjustments required

No adjustments are required.

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 4 • PART REPLACEMENT

Water Inlet Valve

Side view

0
0

Water inlet valve

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mmn 4 • PART REPLACEMENT

Contents

Optional Equipment Sub Section 4•400

GQ-unit (DM 7500P/7500P Plus)

Circulation pump (960 45 014 00) 4•40
Switch (960 45 014 40) 4•40
Dual voltage board (960 45 014 50) 4•40
Transformer (960 45 014 60) 4•40
Rubber gasket (960 45 016 70) 4•40
Filter housing (960 45 013 70) 4•40
Fuses T250 mA and T800 mA (960 45 015 60/70) 4•40
Pages reserved for future use 4•409 to 4•412

Punch Registration System (DM 7500SA/SA Plus and P/P Plus)

Battery (960 46 000 60) 4•413
Punches, outer (960 55 001 20) 4•414
Punch, middle (960 55 001 30) 4•414
Vacuum motor (960 46 000 10) 4•415

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 mmn 4 • PART REPLACEMENT

P/N 960 45 013 90 Circulation Pump

Function

The circulation pump recirculates the water in the water wagon and
processor water tank.

Technical data

Tools and materials required

No special tools are required, only standard equipment (section 1).

Caution! c_. Turn off power • Before connecting or disconnecting cables.

• Before carrying out service operations.

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Circulation Pump

How to replace

Removal

1 • Remove the lefthand side panel K (see covers and panels) by

simply lifting up and away.
2 • Lift the UV light unit to a horizontal position.
3 • Disconnect the water hose snapon connector from the water
inlet valve on the processor.
4 • Disconnect the power cord on the side of the water wagon and
move the water wagon away from the processor.
5 • Remove the four bolts (two on each side) securing the access panel
covering the circulation pump and lift the panel away.
6 • Empty the water wagon (at least to below the level of the pump).
7 • Disconnect the pump connector on the dual voltage board.
8 • Remove the two hose clips connecting the inlet and outlet hoses to
the pump.
9 • Remove the four mounting bolts securing the pump and lift it
away, at the same time removing the two hoses.

Assembly

10 • Mount the new circulation pump and fit the inlet and outlet hoses.
11 • Refit the four pump mounting bolts.
12 • Tighten the two hose clips.
13 • Reconnect the pump connector to the dual voltage board.
14 • Refit the access panel using the four bolts.
15 • Position the water wagon in the processor and connect the power
cord.
16 • Reconnect the water hose snapon connector.
17 • Lower the UV light unit ensuring that the rubber gasket seats cor
rectly on the water wagon.
18 • Refit the left hand side panel K by hooking the two brackets on the
bottom of the panel over the two studs on the side of the processor
and over the lip on the top of the processor.

Adjustments required

No adjustments are required.

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 4 • PART REPLACEMENT

Circulation Pump

0 0

Power cord socket

Circulation pump

Outlet connection

Mounting
Inlet connection
screws

Side view of water wagon with access panel removed

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 4 • PART REPLACEMENT

P/N 960 45 014 40 Switch

Function

The switch on the optional GQ unit allows the low level sensor to be
overridden when emptying the water wagon.

Technical data

Tools and materials required

No special tools are required, only standard equipment (section 1).

Caution! � Turn off power • Before connecting or disconnecting cables.

• Before carrying out service operations.

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 SCANYIEW

Switch

How to replace

Removal

1 • Remove the lefthand side panel K (see covers and panels) by

simply lifting up and away.
2 • Lift the UV light unit to a horizontal position.
3 • Disconnect the water hose snapon connector from the water
inlet valve on the processor.
4 • Disconnect the power cord on the side of the water wagon and
move the water wagon away from the processor.
5 • Remove the four bolts (two on each side) securing the access panel
covering the circulation pump and lift the panel away.
6 • Remove the two connectors to the switch.
7 • Push the switch out of the side plate.

Assembly

8 • Mount the new switch and connect the two connectors.

9 • Refit the access panel using the four bolts.
10 • Position the water wagon in the processor and connect the power
cord.
11 • Reconnect the water hose snapon connector.
12 • Lower the UV light unit ensuring that the rubber gasket seats cor
rectly on the water wagon.
13 • Refit the lefthand side panel K by hooking the two brackets on the
bottom of the panel over the two studs on the side of the processor
and over the lip on the top of the processor.

Adjustments required

No adjustments are required.

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 4 • PART REPLACEMENT

Switch

Power cord socket

Switch
I

0
Side view of water wagon with access panel removed

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 mmn 4 • PART REPLACEMENT

P/N 960 45 014 50 Dual Voltage Board

Function

The dual voltage board controls the function of the GQ unit.

Technical data

Tools and materials required

No special tools are required, only standard equipment (section 1).

Caution! r.- Turn off power • Before connecting or disconnecting cables.

• Before carrying out service operations.

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 mmn

Dual Voltage Board

How to replace

Removal

1 • Remove the lefthand side panel K (see covers and panels) by

simply lifting up and away.
2 • Lift the UV light unit to a horizontal position.
3 • Disconnect the water hose snapon connector from the water
inlet valve on the processor.
4 • Disconnect the power cord on the side of the water wagon and
move the water wagon away from the processor.
5 • Remove the four bolts (two on each side) securing the access panel
covering the circulation pump and lift the panel away.
6 • Remove connectors Ml, M2, M3, M4, MS, M6 and M7.
7 • Remove the board from the four plastic posts.

Assembly

8 • Mount the new board onto the four plastic posts.

9 • Reconnect connectors Ml, M2, M3, M4, MS and M6.
10 • Refit the access panel using the four bolts.
11 • Position the water wagon in the processor and connect the power
cord.
12 • Reconnect the water hose snapon connector.
13 • Lower the UV light unit ensuring that the rubber gasket seats cor
rectly on the water wagon.
14 • Refit the lefthand side panel K by hooking the two brackets on the
bottom of the panel over the two studs on the side of the processor
and over the lip on the top of the processor.

Adjustments required

No adjustments are required.

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 4 • PART REPLACEMENT

Dual Voltage Board

Power cord socket

Dual voltage
board

0
Side view of water wagon with access panel removed

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 scurnw 4 • PART REPLACEMENT

P/N 960 45 014 60 Transformer

Function

The transformer converts 110 V to 220 V for the circulation pump.

Technical data

Tools and materials required

No special tools are required, only standard equipment (section 1).

Caution! c.. Turn off power • Before connecting or disconnecting cables.

• Before carrying out service operations.

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 sornn

Transformer

How to replace

Removal

1 • Remove the lefthand side panel K (see covers and panels) by

simply lifting up and away.
2 • Lift the UV light unit to a horizontal position.
3 • Disconnect the water hose snapon connector from the water
inlet valve on the processor.
4 • Disconnect the power cord on the side of the water wagon and
move the water wagon away from the processor.
5 • Remove the four bolts (two on each side) securing the access panel
covering the circulation pump and lift the panel away.
6 • Remove connectors M3 and M4.
7 • Remove the four nuts and bolts securing the transformer and lift
the transformer away.

Assembly

8 • Mount the new transformer and secure with the four nuts and
screws.
9 • Reconnect connectors M3 and M4.
10 • Refit the access panel using the four bolts.
11 • Position the water wagon in the processor and connect the power
cord.
12 • Reconnect the water hose snapon connector.
13 • Lower the UV light unit ensuring that the rubber gasket seats cor
rectly on the water wagon.
14 • Refit the left hand side panel K by hooking the two brackets on the
bottom of the panel over the two studs on the side of the processor
and over the lip on the top of the processor.

Adjustments required

No adjustments are required.

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 4 • PART REPLACEMENT

Transformer

0 0

Power cord socket

0
Transformer

Side view of water wagon with access panel removed

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 scurnw 4 • PART REPLACEMENT

P/N 960 45 016 700 Rubber Gasket

Function

The rubber gasket, located on the lower surface of the UV unit, ensures
a water and air tight joint between the UV unit and the water wagon.

Technical data

Tools and materials required

No tools are required.

Caution! c� Turn off power • Before connecting or disconnecting cables.

• Before carrying out service operations.

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Rubber Gasket

How to replace

Removal

1 • Remove the lefthand side panel K (see covers and panels) by

simply lifting up and away.
2 • Lift the UV light unit to a horizontal position.
3 • Disconnect the water hose snapon connector from the water
inlet valve on the processor.
4 • Disconnect the power cord on the side of the water wagon and
move the water wagon away from the processor.
5 • Remove the rubber gasket from the underneath the UV light unit.

Assembly

6 • Fit a new rubber gasket.

7 • Position the water wagon in the processor and connect the power
cord.
8 • Reconnect the water hose snapon connector.
9 • Lower the UV unit ensuring that the rubber gasket seats correctly
on the water wagon.
10 • Refit the lefthand side panel K by hooking the two brackets on the
bottom of the panel over the two studs on the side of the processor
and over the lip on the top of the processor.

Adjustments required

No adjustments are required.

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 4 • PART REPLACEMENT

Rubber Gasket

UV unit

Rubber gasket
/

Water wagon -

DD
a

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 lJ y 1)b

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 mrnn 4 • PART REPLACEMENT

P/N 960 45 013 70 Filter Housing

Function

The filter housing contains the filter for the water in the GQ unit water
tank

Technical data

Tools and materials required

No special tools are required, only standard equipment (section 1).

Caution! c... Turn off power • Before connecting or disconnecting cables.

• Before carrying out service operations.

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 SCAHIEW

Filter Housing

How to replace

Removal

1 • Remove the lefthand side panel K (see covers and panels) by

simply lifting up and away.
2 • Lift the UV light unit to a horizontal position.
3 • Disconnect the water hose snapon connector from the water
inlet valve on the processor.
4 • Disconnect the power cord on the side of the water wagon and
move the water wagon away from the processor. ·
5 • Remove the two hose clips from the inlet and outlet connections
of the filter and pull off the hoses.
6 • Remove the transparent pipe from the filter by sliding off at the
connection.
7 • Unscrew the glass bowl and remove the filter element.
8 • Remove the four allen screws securing the filter housing and
carefully remove the housing.

Assembly

9 • Position the new filter housing and secure with the four allen
screws.
10 • Refit the inlet and outlet pipes and secure them with the two hose
clips.
11 • Slide the transparent pipe from the water tank onto the filter hous
ing connection.
12 • Refit the filter element and screw on the glass bowl.
13 • Position the water wagon in the processor and connect the power
cord.
14 • Reconnect the water hose snapon connector.
15 • Lower the UV unit ensuring that the rubber gasket seats correctly
on the water wagon.
16 • Refit the left hand side panel K by hooking the two brackets on the
bottom of the panel over the two studs on the side of the processor
and over the lip on the top of the processor.

Adjustments required

No adjustments are required.

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 4 • PART REPLACEMENT

Filter Housing

Inlet connection Outlet connection

Transparent pipe
to water tank

Power cord socket

Filter housing

Side view of water wagon with access panel removed

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 4 • PART REPLACEMENT

P/N 960 45 015 60/70 Fuses

Function

The 650 and 800 mA fuses protect the circuits in the optional GQ unit.

Technical data
PN 960 45 015 60 T650mA
PN 960 45 015 70 T800mA

Tools and materials required

No special tools are required, only standard equipment (section 1).

Caution! c. Turn off power • Before connecting or disconnecting cables.

• Before carrying out service operations.

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 SCHVIEll'

Fuses

How to replace

Removal

1 • Remove the lefthand side panel K (see covers and panels) by

simply lifting up and away.
2 • Lift the UV light unit to a horizontal position.
3 • Disconnect the water hose snapon connector from the water
inlet valve on the processor.
4 • Disconnect the power cord on the side of the water wagon and
move the water wagon away from the processor.
5 • Remove the four bolts (two on each side) securing the access panel
covering the circulation pump and lift the panel away.
6 • Remove the relevant fuse(s) from the dual voltage board.

Assembly

7 • Fit a new fuse(s) to the dual voltage board.

8 • Refit the access panel using the four bolts.
9 • Position the water wagon in the processor and connect the power
cord.
10 • Reconnect the water hose snapon connector.
11 • Lower the UV light unit ensr �mg that the rubber gasket seats cor
rectly on the water wagon
12 • Refit the lefthand side pa. by hooking the two brackets on the
bottom of the panel over the two studs on the side of the processor
and over the lip on the top of the processor.

Adjustments required

No adjustments are required.

4•408b Service Manual • DotMate 7500/7500 Plus Edition 2 • July 1997

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 4 • PART REPLACEMENT

Fuses

Dual voltage
board

0
650 mA and
800 mA fuses
located on the
dual voltage
board

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 scumw 4 • PART REPLACEMENT

P/N 960 46 000 60 Punch Battery

Function

The punch battery supplies 6 VDC power to the motor of the vacuum
filter.

Technical data

6VDC, 7A, lead battery

Tools and materials required

No special tools are required, only standard equipment (section 1).

Caution! c... Only authorized service personnel may override the interlock
system.

C... Turn off power • Before connecting or disconnecting cables.

• Before carrying out service operations.

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 SCAN VIEW

Punch Battery

How to replace

Removal

1 • Open the lefthand side door C (see covers and panels).

2 • Disconnect the main power connector, processor power connector
and RS232 connector on the back of the imagesetter unit.
3 • Remove the foot panel E (see covers and panels) by lifting up and
away.
4 • Disconnect the SCSI and RS232 connectors from the electronics
drawer.
5 • Remove the two alien screws A and pull the hardware out far
enough to gain access to the punch battery.
6 • Disconnect the two connectors to the battery.
7 • Remove the two screws B securing the battery holder to the wall of
the hardware drawer and remove the holder.
8 • Lift the battery out of its holder.

Assembly

9 • Fit a new battery into its holder and refit the holder using the two
screws B.
10 • Reconnect the two connectors.
11 • Push the hardware drawer back in and refit the two alien screws A.
12 • Reconnect the SCSI and RS232 connectors.
13 • Reconnect the main power connector, processor power connector
and RS232 connector on the back of the imagesetter unit.
14 • If no further replacement operations are required, close the left
hand side door D and refit the foot panel E by hooking the four
lugs on the panel over the brackets on the imagesetter and lower
into place.

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 4 • PART REPLACEMENT

Punch Battery

Screws B

Dual voltage
SCSI and RS 232 board
connectors
Screws A

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 4 • PART REPLACEMENT

P/N 960 55 001 20/30 Punch Assembly

Function

The three punches mechanically punch the registration holes in the

media.

Technical data
Outer punches PN 960 55 00120
Middle punch PN 960 55 00130

Tools and materials required

No special tools are required, only standard equipment (section 1

Caution! � Turn off power • Before connecting or disconnecting cables.

• Before carrying out service operations.

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 mrnn

Punch Assembly

How to replace

Note: replacement of the three punches is identical, therefore

only one is explained in this instruction.

Removal

1 • Open the righthand side door C (see covers and panels).

2 • Disconnect the punch connector.
3 • Remove the extraction hose fiting by simply pulling out of the
flange
4 • Remove the two bolts A and washers securing the punch to the
flange.
5 • Lift the punch assembly away.

Assembly

6 •
Mount the new punch and fit the two bolts A and washers.
7 •
Reconnect the connector to the punch.
8 •
Fit the extraction hose fitting onto the punch flange.
9 •
Carry out a punch test to ensure that the punches are parallel with
the exposure area (section 5).
10 • If no further replacement operations are required, close the right
hand side door C.

Adjustments required

Punch test and adjustment (section 5).

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 4 • PART REPLACEMENT

Punch Assembly

Extraction hose
fitting

Bolts A Bolts A

Punch

Extraction hose
fitting

Bolts A

Edition 2 • July 1997

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 mmn 4 • PART REPLACEMENT

P/N 960 46 000 10 Vacuum motor

Function

The vacuum motor creates a vacuum in the hoses leading from the
three punches and draws the cut media into a collection container.

Technical data

Tools and materials required

No special tools are required, only standard equipment (section 1).

Caution! � Turn off power • Before connecting or disconnecting cables.

• Before carrying out service operations.

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 SCAHIEW

Vacuum motor

How to replace

Removal

1 • Open the righthand side door C (see covers and panels).

2 • Disconnect the connector from the motor.
3 • Unscrew the extraction hose clip and remove the hose by turning
clockwise and pulling away.
4 • Unscrew the two large retaining clips around the motor assembly
body (remove one screw completely on each clip so that the clips
can be swung away).
5 • Remove the motor assembly.

Assembly

6 • Fit a new motor assembly and refit the two retaining clips.
7 • Refit the extraction hose by turning clockwise while pushing on.
8 • Tighten the hose clip.
9 • Reconnect the connector to the motor.
10 • If no further replacement operations are required, close the right
hand side door C.

•
Adjustments required

No adjustments are required.

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 4 • PART REPLACEMENT

Vacuum motor

Vacuum
motor

Retaining
clips

• Filter
bowl

• Edition 2 • July 1997 Service Manual• DotMate 7500/7500 Plus 4•41Sc

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5
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mrnn
5 • ADJUSTMENTS AND TESTING

Contents

Output module, pressure roller adjustment .'5•2

Output module, tension adjustment 5•3
Zero offset (DM 7500SA/7500SA Plus) 5•4
Zero offset (DM 7500P /7500P Plus) 5•5
System calibration, Part 1 5•6
System calibration, Part 2 5•7
Output module knife 5•8
Buffer module sensor, side (DM 7500SA/7500SA Plus 5•.9
Front conveyor sensor, side
(DM 7500P/P Plus/DM 7500SA/SA Plus, online) 5•10
Air flow alarm level 5•11
Optional Bacher 2000 punch
Punch parallism 5•12
Punch centering 5•13

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 r I � \J :i,./)

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mrnn 5 • ADJUSTMENTS AND TESTING

Output Module (Pressure Roller Adjustment)

Function

This adjustment ensures that the pressure roller on the output system is
positioned correctly in relation to the tensioning roller.

Technical data

The difference between the readings of the two spring balances must
not exceed:

400 mm (15.8 ") format film: 100 g.

550 mm (21.6 ") format film: 30 g.

The variation of the reading on the individual spring balances must

not exeed 70 g. during one revolution of the tensioning roller

Tools and materials required

1.5 mm allen key for set screw

2.5 mm allen key for adjustment screws
5.5 mm spanner for lock nuts
2 spring balances (0-1000 g.)
Piece of 400 m. film (approx. 500 mm long)
Piece of 550 m. film (approx. 500 mm long)
Standard equipment (section 1).

Caution! r.- Only authorized service personnel may override the interlock
system.

C� Turn off power • Before connecting or disconnecting cables.

• Before carrying out service operations.

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Output Module {Pressure Roller Adjustment)

How to adjust

• If access is not already available, open the following panels:

Front cover B, righthand side door C and lefthand side door D.
2 • Remove the input and takeup cassettes.
3 • If a DM 7500SA/7500SA Plus, remove the buffer module. If a DM 7500P /7500P
Plus, pull the front conveyor out (section 4).
4 • Cut a piece of 550 mm. film app. 500 mm long and feed it between the rollers
of the output system, ensuring that it lies at the end of the black roller (fig. 2).
Note: the procedures below are to be repeated with 400 mm film.
5 • Punch 2 holes on the bottom of the film and attach the spring balances to
them.
6 • Anchor the two spring balances with bars, or other suitable items (figs. 1
and2).
7 • Override the interlock system by fitting a key to the master interlock switch
(under the triangular panel of the cabinet, behind the lefthand side door).
8 • Access the DotMate imagesetter service program (section 3) and go into the
Manual Feed and Cut menu.
9 • Hold down the key T for Tense with, for example, a matchstick.
10 • If the difference in the readings on the spring balances exceed 100 g. for the
400 mm film, or 30 g. for the 550 mm film, continue with the next step. If the
difference is within limits, proceed to the note in step 16 and then the instruc
tion Output system tensioning in section 5•3).
11 • Undo the lock nut on screw A (fig. 3) and loosen both screws A and B.
12 • Locate the two adjusting screws D on the output roller, loosen the two lock
nuts E and loosen the two screws until there is no tension on the springs(fig. 2).
13 • Exercise the top roller by lifting it up and down.
14 • Repeat steps 9 and 10 and, if the difference is still too great, adjust as follows:
• If the reading needs to be increased on the lefthand (step motor)
I' side, tighten screw A (fig 3), ensuring that screw Bis still loose.
If the reading needs to be increased on the right hand side, tighten
screw B (fig 3), ensuring that screw A is still loose.
15 • Repeat steps 9 and 10 with both 400 mm and 550 mm films until the readings
are within tolerance.
16 • Gently tighten the loose screw/locknut (the one that has not been adjusted).
Lock both screws with laquer.
17 • To ensure that the values have not changed after screws A and B have been
locked, repeat steps 9 and 10 using 550 mm film.
Note1: During this step, check that the readings on the individual spring
balances do not vary more than 70 g during one revolution of the roller. If
they do, it indicates that a rubber(s) is eccentric and the output module will
have to be replaced.
Note2: If any of the values cannot be achieved, please contact ScanView.
18 • Proceed with the adjustment in the following instruction. (Section 5•3, Out-
put system, tension adjustment).

Service Manual • DotMate 7500/7500 Plus Edition 2 • July 1997

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 5 • ADJUSTMENTS AND TESTING

Output Module (Pressure Roller Adjustment)

Two bars can be placed

under the top frame of the
input module and on the
top of the drum.

Bars, or other suitable items,

set up as shown to anchor
the spring balances

<,
Spring balances

Fig.1

Adjustment
Film to be placed screw
at the end of the D
black roller
Set screw Screw

d·
C

Tense film
LockEnut _ Locknut

..... 0 "' <, Screw

B

Output module bracket

seen from the side Fig. 3

Spring balance

Fig. 2

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somn 5 • ADJUSTMENTS AND TESTING

Output Module (Tension Adjustment)

Function

The tensioning roller on the output module ensures that the loaded
media is correctly tensioned during exposure in the drum.

Technical data

The tensioning of the system must be between 400500 g. Also note the
requirement for the difference between the readings of the two spring
balances:

400 mm (15.8 ") format film:

• Pressure 400500 g.
• Difference between the readings on each side max. 100 g.

550 mm (21.6 ") format film:

• Pressure 400500 g.
• Difference between the readings on each side max. 30 g.

Tools and materials required

2.5 mm allen key for adjustment screws

5.5 mm spanner for lock nuts
2 spring balances (01000 g.)
Piece of 400 m. film (approx. 500 mm long)
Piece of 550 m. film (approx. 500 mm long)
Standard equipment (section 1).

Caution! ,_. Only authorized service personnel may override the interlock
system.

c� Turn off power • Before connecting or disconnecting cables.

• Before carrying out service operations.

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 mmn

Output Module (Tension Adjustment)

How to adjust

Note: ensure that the pressure roller adjustment in instruction (5•2) has
been carried out before proceeding with this adjustment.

• Locate the two adjusting screws Don the output roller, loosen the
two lock nuts E and loosen the two screws until there is no tension
on the springs.
2 • Feed the piece of 550 mm between the rollers of the output system,
ensuring that it lies at the end of the black roller (fig. 2).
Note: the procedures below are to be repeated with 400 mm film.
3 • Hold down the key T for Tense with, for example, a matchstick.
4 • Observe the changing values on the spring balances as they are
tensioned by the film. The final readings obtained on both spring
balances should be between 400500 g. for both format films.
Note: the difference between the readings on the two spring
balances should not exceed:
400 mm (15.8 ") format film: 100 g.
550 mm (21.6 ") format film: 30 g.
Note: If the difference between the readings on the two spring
balances exceed these values, pressure roller adjustement must be
repeated as described on page 5•2.
5 • If the pressure is incorrect, adjustment is achieved by adjusting the
two screws D (using an equal number of turns on both) and repea
ting steps 3 and 4 until the reading is 400500 g for both sides. Note:
these adjustment screws must only be used for increasing the
pressure on the tensioning roller and not for adjustment of the
pressure roller.
6 • Tighten the two lock nuts E and lock them in place with laquer.
Note: if any of the values cannot be achieved, please contact Scan
View.
7 • Refit the buffer module (DM 7500SA/7500SA Plus) or pushin the
front conveyor (DM 7500P/7500P Plus), in accordance with section 4.
8 • Refit the input and takeup cassettes.
9 • Lower the front cover B, close the righthand side door C and left
hand side door D.

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 5 • ADJUSTMENTS AND TESTING

Output Module (Tension Adjustment)

Spring balances

Fig.1

Adjustment Adjustment
screw Film to be placed
at the end of the screw
D D
black roller

Lock nut Lock nut

E E

Fig. 2

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mrnn 5 • ADJUSTMENTS AND TESTING

Zero Offset (DM 7500SA/SA Plus)

Function

The zero offset adjustment is necessary to ensure that exposure starts at

the correct point on the media as it is fed into the drum. Measurement is
made in two planes; across scanline, Y offset and Scanline direction, index
offset. Across scanline, Y offset, is the direction of travel (from right to
left) of the spinner and the optics unit on the carriage. The scanline dir
ection, index offset is the direction of travel of the media in the drum.

Technical data

Across scanline, Y offset 12 mm from the edge of the media

Scanline direction, index offset 45 mm from the edge of the media

Tools and materials required

No special tools are required, only standard equipment (section 1).

Caution! � Turn off power • Before connecting or disconnecting cables.

• Before carrying out service operations.

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 scumw

Zero Offset (DM 7500SA/SA Plus)

How to adjust

• Check that the actual media width in "media management" (RipManager)

corresponds with the media that is being used.
2 • Turn on power and enter the Main menu, M in the DotMate service pro
gram, (section 3).
3 • Select the C, (Cassette and Media menu).
Press L, (Load).
Press F, (Form feed).
Press E, (Eject).
4 • Empty the takeup cassette.
5 • Select the Test Exposure menu, T.
Press T, (Test pattern) to expose film.
Example: Resolution: 2540
Width: 750 mm
Height: 545 mm
6 • Press T, (Test pattern) to expose film again.
7 • Select the C, (Cassette and Media menu).
Press E, (Eject).
8 • Remove the takeup cassette and process the film.
9 • Check that they offset value is 12 mm.
10 • If the distance is incorrect, select A, (Adjust menu) in the service program
and then Y, (Y_offset_mm).
11 • Change the value as necessary to bring the start of exposure to 12 mm
and save.
Note: If the distance is too short, increase the value. If too long, decrease
the value.
12 • Check that the distance from the front end of the film to the start of the
pattern is 45 mm, (index offset).
13 • If the index offset value requires adjustment, select A, (Adjust menu) and
then I, (Index offset angle).
Note: the value 1 ° corresponds to 3.18 mm).
14 • Change the value as necessary to bring the start of exposure to 45 + I - 1
mm and save.
Note: If the distance is too short, decrease the value. If too long, increase
the value.
15 • Check that the distance from the top of pattern A to the top of pattern B is
795 mm +/ 1 mm. (fig. 2).
16 • If adjustment is required, select A, (Adjust menu) and then H, (Film height)
17 • Change the value as necessary to bring the film width to 795 mm + I - 1 mm
and save.
Note: the film width as shown in fig. 2 is in reality the film height.
18 • Repeat from step 3 as necessary, if one, or all of the values cannot be ach
ieved.

Service Manual • DotMate 7500/7500 Plus

Edition 2 • July 1997
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 5 • ADJUSTMENTS AND TESTING

Zero Offset (DM 7500SA/SA Plus)

Film Scanline direction

X-offset

Across scanline
direction,
Y-offset

Fig.1

Index offset
45 mm
(+/1 mm)
A
Test pattern width
Film width
750 mm
795 mm
(+/1 mm)

tT:i�;�: J
12Y-mm

height minus
y-offset, (x2)
Fig. 2
Actual film
height

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 I• '� lJ 7

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scurnw 5 • ADJUSTMENTS AND TESTING

Zero Offset (DM 7SOOP/P Plus)

Function

The zero offset adjustment is necessary to ensure that exposure starts at

the correct point on the media as it is fed into the drum. Measurement
is made in two planes; across scanline, Y offset and Scanline direction,
index offset. Across scanline, Y offset, is the direction of travel (from
right to left) of the spinner and the optics unit on the carriage. The
scanline direction, index offset is the direction of travel of the media in
the drum.

Technical data

Across scanline, Y offset 12 mm from the edge of the media

Scanline direction, index offset 45 mm from the edge of the media

Tools and materials required

No special tools are required, only standard equipment (section 1).

Caution! � Only authorized service personnel may override the interlock

system.

� Turn off power • Before connecting or disconnecting cables.

• Before carrying out service operations.

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 mrnn

Zero Offset (DM 7SOOP/P Plus)

How to adjust

1 • Check that the actual media width in "media management" (RipManager)

corresponds with the media that is being used.
2 • Turn on power and enter the Main menu, M in the DotMate service pro
gram, (section 3).
3 • Select the C, (Cassette and Media menu).
Press L, (Load).
4 • Select the Test Exposure menu, T.
Press T, (Test pattern) to expose film.
Example: Resolution: 2540
Width: 750 mm
Height: 545 mm
5 • Press T, (Test pattern) to expose film again.
6 • Remove the processed film.
8 • Check that they offset value is 12 mm.
9 • If the distance is incorrect, select A, (Adjust menu) in the service program
and then Y, (Y_offset_mm).
10 • Change the value as necessary to bring the start of exposure to 12 mm
and save.
Note: If the distance is too short, increase the value. If too long, decrease
the value.
11 • Check that the distance from the front end of the film to the start of the
pattern is 45 mm, (index offset).
12 • If the index offset value requires adjustment, select A, (Adjust menu) and
then I, (Index offset angle).
Note: the value 1 ° corresponds to 3.18 mm).
13 • Change the value as necessary to bring the start of exposure to 45 +/- 1 mm
and save.
Note: If the distance is too short, decrease the value. If too long, increase
the value.
14 • Check that the cut length is 805 mm +/ 1 mm. (fig. 2).
15 • If adjustment is required, select A, (Adjust menu) and then H, (Film height)
16 • Change the value as necessary to bring the film width to 797 mm+!- 1 mm
and save.
Note: the film width as shown in fig. 2 is in reality the film height.
17 • Repeat from step 3 as necessary, if one, or all of the values cannot be ach
ieved.

Service Manual • DotMate 7500/7500 Plus Edition 2 • July 1997

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 5 • ADJUSTMENTS AND TESTING

Zero Offset (DM 7SOOP/P Plus)

Film Scanline direction

X-offset

Across scanline
direction,
Y-offset

Fig.1

(Film shown with emulsion upwards) Front of film

r
Index offset

I
45 mm
(+/-1 mm)

t Cut length/film height Test pattern width

805 +/-1 mm

L
750 mm

_J
Y-
1-2 mm
'. Test pattern
height
- actual film
height minus
j
y-offset, (x2)
Fig. 2
Actual film
height

Edition 2 • July 1997 Service Manual • DotMate 7500/7500 Plus S•Sc

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manual DotMate 7500.indd 446 06/06/2016 01:19:54 p.m.
S - 5 • ADJUSTMENTS AND TESTING

System Calibration (Part 1)

CANVIEW

This adjustment calibrates the DotMate using the RipMate Calibration

Manager and ensures that a completely calibrated output is achieved.

Part 1 of this adjustment sets the Page Setup, Screening setup and
determines the exposure level.

Function

Technical data

Tools and materials required

Densitometer

Caution! c.. Turn off power • Before connecting or disconnecting cables.

• Before carrying out service operations.
 Edition 2 • July 1997 Service Manual • DotMate 7500/7500 Plus 5•6a
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 mrnn

System Calibration (Part 1)

How to adjust

• Turn on power and start up RipMate and check that the commun
ication between RipMate and DotMate is present by using the Adap
tec SCSI interrogator.
2 • Open the Page Setup window by choosing Page Setup from the RipMate
menu.
3 • In the Resolution box at the top of the window, choose an output resol
ution.
4 • Click on the Screening button to open the Screening Setup dialogue.
5 • Set the desired screen frequency, angle and spot function and click on
OK to return to Page Setup.
6 • Select the desired cassette from Page Setup.
7 • Click on OK to close the Page Setup window.
8 • Select Start Exposure Sweep Mode from the DotMate 7500/7500 Plus
pull down menu.
9 • Select Print Exposure Sweep ... from the Output pulldown menu.
10 • Type in the desired starting value for the exposure sweep in the Start
Value in the Exposure Sweep dialogue, and press the Tab key.
11 • Type in the desired interval between exposure values in the Step
Value in the Exposure Sweep dialogue, and press the Tab key.
12 • Type in the desired end value for the exposure sweep in the End Value
in the Exposure Sweep dialogue, and press the Tab key.
13 • Click on OK to generate the exposure sweep.
14 • When the job has been set and processed, measure the exposure den
sity of each test strip (see the fig on the opposite page).
Note: For conventional media, measure the density in the D Max field.
For film, it should be between 3.8 and 4.2. For hard dotfilm, measure
the dot percentage in the 50.0 field. It should be between 50% and 53%.
15 • If the measured value is not within the tolerance listed in step 14, repeat
steps 9 to 15.
Note: From the test strips, find the exposure value that comes closest
to the exposure density in step 13. Change the Start Value, Step Value
and End value in the Exposure Sweep window as necessary in order to
narrow in the exposure value.
16 • When the exposure value is within the specified tolerance, open the
Page Setup window by choosing Page Setup from the RipMate menu
and then click on the OK button.
17 • In the Exposure box at the bottom of the window, type in the exposure
value you determined in step 15, from the test strip with the correct
density I exposure.
18 • Proceed with Part 2 in the following instruction.

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 5 • ADJUSTMENTS AND TESTING

System Calibration (Part 1)

Edition 2 • July 1997 Service Manual • DotMate 7500/7500 Plus 5•6c

-Lfq i .• �
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manual DotMate 7500.indd 450 06/06/2016 01:19:55 p.m.
 sornn 5 • ADJUSTMENTS AND TESTING

System Calibration {Part 2)

Function

This adjustment calibrates the DotMate using the RipMate Calibration

Manager and ensures that a completely calibrated output is achieved.

Part 2 of this adjustment sets the calibration for device.

'
Technical data

Tools and materials required

Densitometer

Caution! _.. Only authorized service personnel may override the interlock
system.

_.. Turn off power • Before connecting or disconnecting cables.

• Before carrying out service operations.

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 scurnw

System Calibration (Part 2)

How to adjust

Note: ensure that System Calibration Part 1 in the previous instruction

has been carried out before proceeding with this 2nd. part.

1 • Using a densitometer, measure the dot percentages for each tint square
(from 0.0 to 100.0) in the test job (see the fig on the opposite page).
Record the measured value in the box below each square.
2 • From the Output menu in RipMate, choose Calibration Manager.
3 • Click on New. (If you are revising an existing calibration set, click on
its name in the list instead of New).
Note: the Resolution, Dot shape, and Exposure are taken from the
active Page Setup. If they are not the same as the ones you specified,
check that the desired Page Setup is, in fact, active. The Screen freq
boxes will display a range that includes the frequency you specified.
4• From the Meter/Film pulldown menu, choose the entry that corresponds
to the densitometer mode that was used to measure the tint values, and
to the type of output you measured (positive or negative).
5• From the Use for list, choose whether you want the calibration to be
used for output that is positive, negative or both.
6• In the Name field, type in a suitable name if the calibration set is a new
one.
7• Using the tab key to move from field to field, type the measured value for
each tint square into the box below the corresponding tint percent.
8• When all the values have been entered, click on the OK button. The
Calibration [Dot Gain] Manager window will reappear.
9• Click on OK and the new calibration set will be saved.
10 • Open the Page Setup window in the RipMate menu. In the Calibration
Set pull down menu, choose the calibration you just created and click
on the OK button.
11 • From the Output menu, choose Print Calibrated Job.
12 • When the test job has been set and processed, check its density and
dot percentages. If the measured values are not within + I- 1 of the
expected values, continue with the steps below.
13 • From the Output menu in RipMate, choose Print Uncalibrated Job and
repeat steps 112.
14 • If the revised values are still not within +/1 of the expected values,
please refer to the DotMate 7500/7500 Plus Operators Manual, Calibrat-
ion troubleshooting.
15 • Save the Page Setup by choosing Save As ... from the Page Setup menu
and assigning an appropriate name. This will also make it the active
Page Setup.
NOTE: When naming a Page Setup, use only letters and numbers, other
wise an error may result.
16 • Select Stop Exposure Sweep Mode from the DotMate 7500/7500 Plus
pull down menu.

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 5 • ADJUSTMENTS AND TESTING

System Calibration (Part 2)

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Edition 2 • July 1997 Service Manual • DotMate 7500/7500 Plus 5•7c

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manual DotMate 7500.indd 454 06/06/2016 01:19:57 p.m.
scumw 5 • ADJUSTMENTS AND TESTING

Output Module Knife

Function

The knife on the output module cuts the media after it has exited the
drum.

New or replacement modules supplied by ScanView are factory adjust

ed and do not need further adjustment, however, if the efficiency of the
knife begins to deteriorate during use, the blade can be adjusted to
compensate.

Technical data

Tools and materials required

No special tools are required, only standard equipment

Caution! r,, Only authorized service personnel may override the interlock
system.

r,, Tum off power • Before connecting or disconnecting cables.

• Before carrying out service operations.

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 mmn

Output Module Knife

How to adjust

1 • Remove the output module (section 4).

2 • Loosen the two 3 mm alien screws A securing the right hand side
of the back plate of the knife module, (viewed from the back of the
module).
3 • Remove the two 3 mm allen screws B securing the right and side
and remove the back plate.
4 • Loosen the 4 mm alien screw C securing the knife arm.

•
5 • Place a thin strip of film between the guides on the module and
adjust the 3 mm set screw D until the rubber wheel on the knife
wheel exerts a slight pressure on the film guide. Pull the film strip
out, ensuring that there is a slight resistance on the strip.
6 • Tighten the 4 mm alien screw C.
7 • Mount the back cover, refit alien screws B and tighten alien screws A.
8 • Refit the output module (section 4).

Service Manual • DotMate 7500nSOO Plus Edition 2 • July 1997

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 5 • ADJUSTMENTS AND TESTING

Output Module Knife

Back view of
output module

• Allen screws B

, Knife block

4 mm alien
screw C
3 mm set screw
D

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 5 • ADJUSTMENTS AND TESTING

Buffer Module Sensor, Side (DM 7500SAJSA Plus)

Function

The adjustment of the buffer module side sensor ensures that the
media is fed correctly, and not offset, through the buffer module.

Technical data

Tools and materials required

No special tools are required, only standard equipment (section 1).

Caution! c. Only authorized service personnel may override the interlock

system.

c. Turn off power • connecting or disconnecting cables.

Before
• Before carrying out service operations.

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 mrnn

Buffer Module Sensor, Side (DM 1soosAJSA Plus)

How to adjust

• Open the front cover B (see covers and panels in section 4), by
pressing the two catches underneath the cover and lifting up at the
bottom.
2 • With access through the hole in the right hand side plate of the drum
(fig. 2), screw the adjustment screw A of the side sensor fully in.
3 • Load media into the input cassette and fit the cassette.
4 • Override the interlock system (section 1) and turn power on.
5 • Enter the DotMate imagesetter service program (section 3), and
select C, (Cassette and media menu) in the Main menu.
6 • Select L, (Load).
7 • Disconnect the connector from the output module (fig. 1).
8 • Select F, (Form feed).
Note: a single sheet of media now runs through the drum.
9 • Reconnect the connector to the output module.
10 • Select U, (User menu) and enter the AST password to enter the Auth-
orized Service Technician menu.
11 • Select F, (Manual feed and cut menu).
12 • Select C, (Cut) in order to cut the media.
13 • Disconnect the output module connector.
14 • Select F (Forward feed) until the media feeds through the two out
put rollers in the buffer module and protrudes about 5 mm.
15 • Select G, (General tool menu) in the Main menu and then P, (Periph-
eral status).
16 • Uncrew the adjustment screw A until the the message Media buffer
side is active (TRUE) appears on the screen.
17 • Screw in the adjustment screw A and unscrew again until the same
message appears.
Note: when screw A is screwed in, the end part of the message will
change to FALSE before reverting to TRUE when the adjustment is
correct.
18 • Repeat step 16 two or three times in order to stabilize the setting.
19 • Lock the threads of adjustment screw A with, for example, nail var
nish.
20 • Switch power off and remove the interlock defeater.
21 • Close the front cover B.

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 5 • ADJUSTMENTS AND TESTING

Buffer Module Sensor, Side (DM 7500SAJSA Plus)

Adjustment
screw A

Buffer module seen from

the right hand-side, back

-----.. Access hole for

adjustment
screw A

Drum seen from the right-

hand side, front

Edition 2 • July 1997

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1,r .a.'U4..,.:;,
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mmn 5 • ADJUSTMENTS AND TESTING

Front Conveyor Sensor, Side

(DM 7500P/P Plus or DM 7500SA/SA Plus with an on-line option)

Function

The adjustment of the front conveyor side sensor ensures that the
media is fed correctly, and not offset, through the conveyor.

Technical data

Tools and materials required

No special tools are required, only standard equipment (section 1).

Caution! c.. Only authorized service personnel may override the interlock
system.

C.. Turn off power • Before connecting or disconnecting cables.

• Before carrying out service operations.

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 mrnn

Front Conveyor Sensor, Side

(DM 7500P/P Plus or DM 7500SA/SA Plus with an on-line option)

How to adjust

• Open the front cover B (see covers and panels in section 4), by
pressing the two catches underneath the cover and lifting up at the
bottom.
2 • With access through the hole in the right hand side plate of the drum
(fig. 2), screw the adjustment screw A of the side sensor fully in.
3 • Load media into the input cassette and fit the cassette.
4 • Override the interlock system (section 1) and tum power on.
5 • Enter the DotMate imagesetter service program (section 3), and
select C, (Cassette and media menu) in the Main menu.
6 • Select L, (Load).
7 • Disconnect the connector from the front conveyor (fig. 1).
8 • Select F, (Form feed).
Note: a single sheet of media now runs through the drum.
9 • Reconnect the connector to the output module.
10 • Select U, (User menu) and enter the AST password to enter the Auth-
orized Service Technician menu.
11 • Select F, (Manual feed and cut menu).
12 • Select C, (Cut) in order to cut the media.
13 • Disconnect the output module connector.
14 • Select F (Forward feed) until the media feeds through the two out
put rollers in the front conveyor and protrudes about 5 mm.
15 • Select G, (General tool menu) in the Main menu and then P, (Periph-
eral status).
16 • Uncrew the adjustment screw A until the the message Media buffer
side is active (TRUE) appears on the screen.
17 • Screw in the adjustment screw A and unscrew again until the same
message appears.
Note: when screw A is screwed in, the end part of the message will
change to FALSE before reverting to TRUE when the adjustment is
correct.
18 • Repeat step 16 two or three times in order to stabilize the setting.
19 • Lock the threads of adjustment screw A with, for example, nail var
nish.
20 • Switch power off and remove the interlock defeater.
21 • Close the front cover B.

5•10b Service Manual • DotMate 7500/7500 Plus Edition 2 • July 1997

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 5 • ADJUSTMENTS AND TESTING

Front Conveyor Sensor, Side

(DM 7500P/P Plus or DM 7500SA/SA Plus with an on-line option)

Adjustment
screw A
-

Front conveyor seen from

the right hand-side, back

Access hole for

adjustment
screw A

Drum seen from the right-

hand side, front

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mmn 5 • ADJUSTMENTS AND TESTING

Air flow alarm level

Function

The air flow alarm operates when the flow of air falls below the accep
table level. Without this warning device, a blower failure will most likely
result in chemistry fumes entering the imagesetter.

Technical data

Pl reading: lVDC

Tools and materials required

DC Voltmeter

Caution! c. Only authorized service personnel may override the interlock

system.

c. Turn off power • connecting or disconnecting cables.

Before
• Before carrying out service operations.

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Air flow alarm level

How to adjust

Note: the DotMate has to be run for at least 3 minutes before this
adjustment is carried out.

• Lift up the processor cover I (see covers and panels in section 4).
2 • Remove the black PVC anticondensation cover over the chemistry
tanks.
3 • Remove the black plastic plug A on the fan top cover in order to
gain access to the potentiometer (Pl) on the airflow detector board.
4 • Remove the black plastic plug B and connect a DC voltmeter to pin
23 (Hi lead) and pin 24 (Lo lead) on the cable connector to the air
flow detector board.
5 • Fit the interlock defeater (section 1) and turn on power.
Note: the DotMate has to be run for at least 3 minutes before adjust
ment is carried out.
6 • Adjust Pl until areadingof1 V, +/ 0.1 Vis obtained.
Note: check that all three LED's on the airflow detector board are off
(by looking through the access hole).
7 • Remove the cover for the charcoal air filter and remove the filter.
8 • Check that the voltage increases to at least+ 0.1 V and that all three
LED's illuminate when the voltage passes O V.
9 • Refit the charcoal air filter and cover and check that the three LED's
go off.
10 • Turn off power and remove the voltmeter.
11 • Refit the plastic plugs A and B onto the fan top cover.
12 • Refit the black PVC anticondensation cover.
13 • Lower the processor cover I.

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 5 • ADJUSTMENTS AND TESTING

Air flow alarm level

Pin 23 Pin 24

Cable connector to the

air flow detector board

Anti-condensation
cover

Plastic plug B

Plastic plug A
<.
Both plastic plugs
are underneath the
anti-condensation
cover

/
Charcoal air filter cover

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mrnn 5 • ADJUSTMENTS AND TESTING

Punch Parallelism (Optional Bacher Punch)

Function

The punch(es) mechanically punch the registration holes in the media.

The punch should be parallel to the direction of exposure. If the paral
lelism of the punches is incorrect, the punch module flange has to be
adjusted.

Technical data

Tools and materials required

Film registration strip

Shims for punch adjustment
Torque screwdriver for punch mounting bolts

Caution! � Only authorized service personnel may override the interlock

system.

c.. Turn off power • Before connecting or disconnecting cables.

• Before carrying out service operations.

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 SCANVIEW

Punch Parallelism (Optional Bacher Punch)

How to adjust

1 • Turn on power and start up RipMate.

2 • Output the file "Lines.ps" twice with punch activated in Configure
device in Page Setup. (This postscript job contains a full drum job
with a 1 x 1 cm grid),
3 • Place film 1 emulsion side up and film 2 emulsion side down on
top on a film registration strip.
4 • Check the horizontal lines of film 1 and 2 at the bottom left hand
corner below the punch # 1 register hole, (fig. 2). If there is a dif
ference between the lines, measure this difference. (This shows
that the punches are not parallel with the exposure area).
Note: difference to be no greater than 40µ.
5 • Open the righthand side door C (see covers and panels in section
4).
6 • If, for example, the line on film 2 is higher than the line on film I,
pull out the three extraction hose fittings, remove the close tol
erance attachment bolt# 4 (fig. 1) and loosen #'s 1, 2 and 3.
Note: if the line on film 2 is below the line on film l, then remove
bolt# land loosen bolt #'s 2, 3 and 4.
7 • From the measurement obtained in step 4, select the relevant
shim(s) and fit them around bolt #4 position, (so that they
are between the punch flange and the drum).
8 • Fit bolt# 4, tighten bolt #'s I, 2 and 3 and torque load them to
250 Nern.
9 • Refit the three extraction hose fittings into the punch flange.
10 • Close the righthand side door C.
11 • Repeat steps 2 11 until the punches are parallel with the exposure
area to within a total of 40 µ, (fig. 2).
12 • Carry out the Punch Centering adjustment in the next instruction.

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 5 • ADJUSTMENTS AND TESTING

Punch Parallelism (Optional Bacher Punch)

Bolt# 2

Outer punch
(#1)
Bolt# 3

Extraction
hose fitting

Middle punch
(#2)

Punch flange
Outer punch
(#3) Fig. 1

Punch 3 Punch 2 Punch 1 (on film 2)

Measurement to
be taken in line
with the register
hole

-----. Film 1

_y
Max. -- Film 2 line
40 µ Fig. 2
Film 1 line

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 5 • ADJUSTMENTS AND TESTING

Punch Centering (Optional Bacher Punch)

Function

This instruction is carried out after the punch parallelism adjustment in

the previous instruction
If the centering of the punches is incorrect, the index offset angle has
to be adjusted.

Technical data

Tools and materials required

Film registration strip

Caution! ,... Only authorized service personnel may override the interlock
system.

C_ . Turn off power • Before connecting or disconnecting cables.

• Before carrying out service operations.

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 mrnEW

Punch Centering (Optional Bacher Punch)

How to adjust

• Ensure that film 1 and film 2 from step 7 in the previous instruct
ion are still mounted on the mounting rail with film 1 emulsion
side up and film 2 emulsion side down on top.
2 • Inspect the difference between the center vertical lines of film 1
and 2 as shown in the illustration.
3 • If there is a difference between the lines, measure this difference.
(This shows that the index angle is incorrect).
Note: difference to be no greater than 100µ.
4 • Enter the imagesetter service program (section 5).
5 • Calculate the index offset angle by using the following formula:

Change in index angle ( 0

) =Dist.between lines fmm) x 57.3
Drum diameter

Note: the drum diameter is obtained from the Adjust menu in

the service program
6 • If the line on film 1 is to the left, the index angle should be increas-
ed, if the line is to the right, the index angle should be decreased.
7 • Select A (Adjust) and then I (Index angle).
8 • Change the index value and save.
9 • Output the file "Lines.ps" twice again and repeat steps 1 to 9 until
the difference is no greater than 100 µ.

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 5 • ADJUSTMENTS AND TESTING

Punch Centering (Optional Bacher Punch)

Punch 3 Punch 2 Punch 1 (on film 2)

Measurement to
be taken in line
with the center
register hole

Max.
100 µ

Fig. 2
Film 1 line Film 2 line

Edition 2 • July 1997 Service Manual • DotMate 7500/7500 Plus 5•13c

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 .(
.. '
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 6

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 SCAOIEW
6 • CLEANING AND MAINTENANCE

Contents

Schedules '. 6•3

lmagesetter
Vacuum clean the takeup cassette compartment 6•4
Lubricate the spindle 6•4
Clean the spinner mirror 6•4
Replace the fibre filter elements and carbon filter 6•5
Processor
Flush pumps with water . (operator operation) .. 6•6
Replace developer and fixer filters .. ( operator operation) .. 6•8
Silver recovery unit, clean......... (operator operation) .. 6•9
Lubrication of main drive shaft 6•10
Tension drive belt. 6•10
Hose fittings 6•12
Temperature and replenishment calibrations 6•12
Replace the electrodes of the Silver Recovery Unit 6•12
Replace the charcoal filter 6•12
Optional GQ-unit
Change the water : . (operator operation) .. 6•14
Replace water filter (1 micron) . (operator operation) .. 6•14
Inspect water tank rubber gasket. 6•15
Inspect circulation pump 6•16
Inspect the water filter housing 6•17
Inspect all water hoses 6•18
Replace the silver filter cartridge 6•19
Replace water tank gasket 6•20
Replace the UV light tubes 6•20
Replace circulation pump 6•21

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 6 • CLEANING AND MAINTENANCE

Schedules

Frequency Operation Page Reference

lmagesetter
Every week Vacuum takeup cassette compartment (operator)
Every 3 months Lubricate the spindle Clean the
Every 46 months spinner mirror Replace the fibre
Every 6 months filter elements Replace the
Every year carbon filter

Processor
Every chemical change Flush pumps with water (operator)
Every 2 months Replace developer and fixer filters (operator)
Every 46 months
Lubrication of main drive shaft
Every 46 months
Tension drive belt
Every 46 months
Inspect hose fittings
Every 46 months
Temperature and replenishment calib.
Every 1550 hours Replace the charcoal filter
Optional GQ-unit
Every 50 m2 film Change the water (operator)
Every 5 water changes Replace water filter (1 mic.) (operator)
Every 1500 hrs. Inspect water tank rubber gasket
Every 1500 hrs.
Inspect circulation pump
Every 1500 hrs.
Inspect the water filter housing
Every 1500 hrs. Inspect all water hoses
Every 1550 hrs. Replace the silver cartridge
Every 3000 hrs. Replace water tank rubber gasket
Every 3100 hrs. Replace the UV light tubes
Every 2 years Replace circulation pump

(* Time intervals are expressed as operating hours)

Cautions! � Turn off power • Before connecting or disconnecting cables.

• Before carrying out maintenance operations.

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 mrnn 6 • CLEANING AND MAINTENANCE

lmagesetter

Vacuum clean the take-up cassette compartment (Operator operation)

Operation

• Remove the takeup cassette and thoroughly vacuum clean the cassette
compartment.

•
Lubricate the spindle

Tools and material required:

3 g. tube, ScanView spindle lubricating grease

Lintfree cloth.
No special tools are required.

Operation:

1 • If access is not already available to the spindle, open the right and left
hand side doors I and J (see access panels and covers).
2 • Move the carriage to the righthand position by manually rotating the
flywheel.
3 • Remove any old grease using the lintfree cloth.
4 • Using the spindle lubricating grease, sparingly lubricate the spindle
along as much of its length as possible.
5 • Repeat step 3, but with the carriage moved to the lefthand position.
6 • If no further maintenance or replacement operations are required, close
the right and lefthand side doors I and J.

Clean the spinner mirror

Tools and material required:

Lint free cloth and chemical pure acetone.

No special tools are required.

Operation:

1 • If access is not already available to the spinner mirror, open the right
hand side door J (see access panels and covers).
2 • Move the car to the righthand position by manually rotating the flywheel.
3 • Apply the chemical pure acetone to a lint free cloth.

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6 • CLEANING AND MAINTENANCE

lmagesetter

4 • Clean the mirror with a single downward stroke as shown ahd

repeat until the mirror is clean.
Note: Do not rub in circles.
Do not rub back and forth.
Do not rub hard .

• 5 • If no further maintenance or replacement operations are required,

close the righthand side doors J.

Replace the fibre filter elements and carbon filter

Tools and material required:

PN 960 45 004 50 Carbon filter
No special tools are required.
Operation:
1 • Remove the foot panel E (acess panels and covers).
2 • Remove the two thumb screws A securing the filter box.
3 • Lift the box slightly up at the front and remove the filter box.
Note: the rear of the filter box is retained by two lugs fitting into
two slots on the fan box. They are released when the filter box is
lifted up at the front.
4 • Remove the front and rear fibre filter elements.
5 • Remove the charcoal filter element.
Note: it may be necessary to carefully use a screwdriver, or other
suitable tool, to remove the carbon filter.

Thumb screws Filter box

A Rear fibre filter
/
/

Charcoal filter

Front fibre filter

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 mrnn 6 • CLEANING AND MAINTENANCE

Processor

6 • Fit a new charcoal filter element into the filter box.

7 • Fit the filter box lugs into their respective slots on the fan casing,
and, while holding the box up at the front, place the new front and
rear fibre filter elements on the top the fan casing so that they
align correctly with the filter box.
8 • Lower the filter box and fit the two thumb screws A.
9 • If no further replacement operations are required, refit the foot
panel E by hooking the four lugs on the panel over the brackets on
the imagesetter and lower into place.

Flush pumps with water (operator operation)

Tools and material required:

Special wrench (provided) for removing tank overflow pipes.

Soft sponge or brush for roller and guide cleaning

Operation:

1 • Lift up the processor cover I and remove the righthand side panel
J by simply lifting up and away (see covers and panels).
2 •Liftoff the black PVC anticondensation cover on the top of the
chemistry tanks.
3 •Turnoff the processor and drain all three tanks into the waste con
tainers by unscrewing and removing the overflow pipes with the
special wrench provided in the serevice kit. Remember also to
empty the glass filter bowls.
Note: ensure that the waste containers have enough capacity to t
hold the contents of the tanks.

Special wrench

Overflow pipes

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 SCANYIU
6 • CLEANING AND MAINTENANCE

Processor

4 • Unlock the clips securing the developer, fixer and wash racks, llft the
racks out of the tanks and place them in the transport trays provided .

.=::::::::::: Rack clips

5 • Clean all the rollers and guides in the racks using lukewarm water
and a soft sponge or brush.
6 • Empty the supply and waste containers and fill the supply contain
ers with lukewarm water.
7 • Place the suction hoses for the developer and fixer in their respect
ive containers and the overflow hoses in the empty waste container.
8 • Check that the 0rings are on the threaded portion of the overflow
pipes and then refit the pipes in all three tanks, (do not overtighten
them).
Note: the red pipe is for the developer tank, the blue pipe for the
fixer tank and the transparent pipe for the wash tank.

0-ring

<, Overflow pipe

9 • Turn the processor on. The RIP monitor will report Liquid level
error, Temperature error and Interlock error because the processor
tanks are empty. (These warnings can be ignored).
10 • Select Refill function to fill all three tanks with water.
Note: refer to the DotMate 7500P/P Plus operators manual. (Initial
preparation • DotMate 7500P/P Plus : Filling the processor).

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 SCANVIEW
6 • CLEANING AND MAINTENANCE

Processor

11 • Run the proceesor for approximately 10 minutes in order to allow •

the water to circulate through the system.
12 • Drain all three tanks (and glass filter bowls) by removing the over
flow pipes and clean them with a brush.
13 • Refit each rack into their respective tank and secure them with the
two clips.
14 • Check that the 0 rings are on the threaded portion of the overflow pipes
and then refit the pipes in all three tanks, (do not overtighten them).
Note: the red pipe is for the developer tank, the blue pipe for the
fixer tank and the transparent pipe for the wash tank.
15 • Perform a chemical fillup by refering to the DotMate 7500P/7500P Plus
operators manual. (Initial preparation • DotMate 7500P/7500P Plus:
Filling the processor).

Replace developer and fixer filters (Operator operation)

Tools and material required:

PN 960 45 013 80 Filter element (20 micron)

Gloves and safety glasses
Cspanner for filter bowl
Operation:
1 • Remove the righthand side panel J (see covers and panels) by
simply lifting up and away.
2 • Identify which filter is to be changed from the figure; fixer filter (blue
hoses) and developer filter (red hoses).
3 • Unscrew the filter bowl using the Cspanner provided and remove the
filter element.
4 • Rinse the filter bowl in lukewarm water.

Developer filter

Fixer filter

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6 • CLEANING AND MAINTENANCE

Processor

5 • Fit a new filter element and refit the filter bowl.

I
6 • Ifno further replacement operations are required, refit the righthand
side panel J.

Silver recovery unit, clean (Operator operation)

Note: an advisory message will be displayed in the processor service menu status
for the operator, concerning the cleaning of the silver recovery unit. When this
message appears, carry out the following:

1 • Remove the connector from the top of the unit, unscrew the top and
remove the recovery cylinder.
2 • Using hard plastic or wood, scrape the silver deposits from the cylinder.
Note: the layer of silver should be approximately 2 mm thick If this layer
is thinner, it indicates that the fixer replenishment rates are incorrect.
3 • Refit the cylinder and reconnect the connector.

Connector

Silver recovery
unit

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 mrnn 6 • CLEANING AND MAINTENANCE

Processor

Lubrication of main drive shaft

Tools and material required:

PN 960 45 017 40 Grease

Operation:
1 • Lift up the processor cover I (see covers and panels).
2 • Clean the old lubricant from the worm gears on the shaft and the
gear wheels on the developer, fixer and wash tanks and the dryer
unit.
3 • Apply a thin coat of grease to the 5 worm gears on the shaft.
4 • Lower up the processor cover I.

� · Dryer unit gears (x2)

(The three remaining
gear wheels are located
on each rack)

Drive shaft

Tension drive belt

Tools and material required:

No special tools are required, only standard equipment (section 1).

Operation:

• Raise the processor cover I and remove the processor back panel H
and righthand side panel J (see covers and panels).

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 SCANVIEW
6 • CLEANING AND MAINTENANCE

Processor

2 • Remove the small access panel covering the drive motor (two
screws).
3 • Loosen the three motor attachment bolts securing the motor to its
attachment bracket, adjust the motor so that drive belt tension has
a free play (laterally) of approximately 23 cm. Tighten the three
bolts.

Top view of the

motor with the small
panel removed

Motor attachment
bolts (x3)

Small panel

4 • Refit the small access panel using the two screws.

5 • Ifno further replacement operations are required, refit the right
hand side panel J, processor back panel H and lower the processor
cover I.

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 mrnn 6 • CLEANING AND MAINTENANCE

Processor

Hose fittings

Tools and material required:

Silicon if necessary.
No special tools are required, only standard equipment (section 1).

Operation:

1 • Remove the righthand side panel J (see covers and panels).

2 • Check all the developer (red), fixer (blue) and water (transparent)
hose fittings for security and leaks.
3 • If a leak is apparent, remove the relevant internal access panel(s)
and hose(s) by unscrewing the hose clip.
4 • Remove the old silicon and clean the internal bore of the hose and
the fitting.
5 • Apply a coat of silicon to the fitting, refit the hose(s), tighten the
hose clip and refit the access panel(s).
6 • Refit the right hand side panel J.

Temperature and replenishment calibrations

Carry out these calibrations in accordance with the service program

(section 3).

Replace the electrodes of the Silver Recovery Unit

Refer to section 4 (part replacement).

Replace the charcoal filter

Tools and material required:

PN 960 45 011 60 filter element

No special tools are required.

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 6 • CLEANING AND MAINTENANCE

Processor

Operation:

1 • Raise the processor cover I (see covers and panels).

2 • Remove the filter cover (see the following diagram) and remove the
filter by withdrawing it towards the rear of the processor.
3 • Fit a new filter and refit the filter cover.
4 • Lower the processor cover I.

Air filter cover

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 SCANVIEIT
6 • CLEANING AND MAINTENANCE

Optional GQ Unit

Note: an advisory message will be displayed in DotMonitor for the oper

tor, concerning the following preventative maintenance operations on
the optional GQ unit. This message advises that a service engineer
needs to be ordered to replace the relevant parts:

Replace the carbon filter, (processor)

advised at 1400 hours for replacement at 1500
Replace the silver cartridge
advised at 1400 hours for replacement at 1500
Replace the UV light tubes
advised at 2800 hours for replacement at 3000

Change the water (Operator operation)

Refer to the DotMate Easy Maintenance Guide.

Replace 1 micron water replenishment filter

Tools and material required:

PN 960 45 014 30 Filter element (1 micron)

Cspanner for filter bowl

Operation:

1 • Remove the lefthand side panel K (access panels and covers).

2 • Lift the UV unit up.

UV unit

Water hose connector

GQ-unit

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6 • CLEANING AND MAINTENANCE

Optional GQ Unit

3 • Disconnect the water hose snapon connector from. the water

inlet valve on the processor. ,
4 • Disconnect the power cord on the side of the water wagon and
move the water wagon away from the processor.
5 • Unscrew the filter bowl using the Cspanner provided and remove
the filter element

Water filter
element
(1 micron)

Power cord socket

6 • Rinse the filter bowl in luke warm water.

7 • Fit a new filter element and refit the filter bowl.
8 • Position the water wagon in the processor and connect the power
cord.
9 • Reconnect the water hose snapon connector.
10 • Lower the UV unit to the horizontal position, ensuring that the
rubber gasket seats correctly on the water wagon.
11 • If no further replacement operations are required, refit the left
hand side panel K.

Inspect water tank rubber gasket

Tools and material required:

Rubber gasket (if needed to be replaced) PN 960 45 016 70

Operation:

1 • Remove the lefthand side panel K (access panels and covers).

2 • Lift the UV unit to a horizontal position.
3 • Disconnect the water hose snapon connector from the water inlet
valve on the processor.

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Optional GQ Unit

4 • Disconnect the power cord on the side of the water wagon and move
the water wagon away from the processor.
5 • Inspect the rubber gasket for deformity or splits and replace as necessary.

UV unit

Water hose
connector

Rubber gasket

6 • Position the water wagon in the processor and connect the power
cord.
7 • Reconnect the water hose snapon connector.
8 • Lower the UV unit to the horizontal position ensuring that the
rubber gasket seats correctly on the water wagon.
9 • If no further replacement operations are required, refit the lefthand
side panel K.

Inspect water tank circulation pump

Tools and material required:

No special tools are required, only standard equipment (section 1).

PN 960 45 014 00 Circulation pump (if needed to be replaced)

Operation:

• Remove the lefthand side panel K (access panels and covers).

2 • Lift the UV light unit up.
3 • Disconnect the water hose snapon connector from the water
inlet valve on the processor.
4 • Disconnect the power cord on the side of the water wagon
and move the water wagon away from the processor.

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6 • CLEANING AND MAINTENANCE

Optional GQ Unit

5 • Remove the four bolts (two on each side) securing the access panel
covering the circulation pump and lift the panel away. '
6 • Inspect the pump for security and leakage and the cable for dam
age. Replace as necessary in accordance with section 4.

IT
Power cord socket

_..- Circulation pump

7 • Refit the access panel using the four bolts.

8 • Position the water wagon in the processor and connect the power
cord.
9 • Reconnect the water hose snapon connector.
10 • Lower the UV unit to the horizontal position ensuring that the
rubber gasket seats correctly on the water wagon.
11 • Ifno further replacement operations are required, refit the left
hand side panel K.

Inspect the water filter housing

Tools and material required:

PN 960 45 013 70 Filter housing (if needed to be replaced)

No special tools are required.

Operation:

1 • Remove the lefthand side panel K (access panels and covers).

2 • Lift the UV unit up.
3 • Disconnect the water hose snapon connector from the water inlet
valve on the processor.

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Optional GQ Unit

4 • Disconnect the power cord on the side of the water wagon and move.
the water wagon away from the processor.
5 • Inspect the filter housing for damage or leaks and replace in accord
ance with section 4 if necessary.
6 • Position the water wagon in the processor and connect the power cord.
7 • Reconnect the water hose snapon connector.

Water filter ,
housing

8 • Lower the UV unit to the horizontal position ensuring that the rubber
gasket seats correctly on the water wagon.
9 • Ifno further replacement operations are required, refit the lefthand
side panel K.

Inspect all water hoses

Operation:

• Remove the lefthand side panel K (access panels and covers).

2 • Lift the UV light unit up.
3 • Disconnect the water hose snapon connector from the water inlet
valve on the processor.
4 • Disconnect the power cord on the side of the water wagon and move
the water wagon away from the processor.
5 • Remove the four bolts (two on each side) securing the access panel
covering the circulation pump and lift the panel away.
6 • Inspect all hoses on the GQ unit for security and damage. If a hose needs
to be replaced, contact ScanViews support department for advice.
1 • Refit the tank cover ensuring that the pipe on the cover feeds into the
hole in the filter cartridge.
8 • Position the water wagon in the processor and connect the power cord.

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6 • CLEANING AND MAINTENANCE

Optional GQ Unit

9 • Reconnect the water hose snapon connector.

10 • Lower the UV unit to the horizontal position ensuring that the rubber
gasket seats correctly on the water wagon.
11 • Ifno further replacement operations are required, refit the lefthand
side panel K.

Replace the silver filter cartridge

Tools and material required:

PN 960 45 014 80 Silver filter cartridge
Operation:

1 • Remove the lefthand side panel K (access panels and covers).

2 • Lift the UV light up.
3 • Disconnect the water hose snapon connector from the water
inlet valve on the processor.
4 • Disconnect the power cord on the side of the water wagon and
move the water wagon away from the processor.
5 • Remove the top cover of the water tank.
6 • Move the silver cartridge damper lock away from the wall of the
tank and remove the damper.
7 • Remove the filter cartridge from the tank.

Top cover (with

Damper
buffer)
lock

Damper

Silver filter
cartridge

8 • Fit a new filter cartridge and refit the damper and damper lock.
9 • Refit the tank cover ensuring that the pipe on the cover feeds into the
hole in the filter cartridge.

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 scumw 6 • CLEANING AND MAINTENANCE

Optional GQ Unit

10 • Position the water wagon in the processor and connect the power cord.
11 • Reconnect the water hose snapon connector.
12 • Lower the UV unit to the horizontal position ensuring that the rubber
gasket seats correctly on the water wagon.
13 • Ifno further replacement operations are required, refit the lefthand
side panel K.

•
Replace the UV reactor/water tank rubber gasket

See Inspect water tank rubber gasket in this section.

Replace the UV light tubes and starters

Tools and material required:

PN 960 45 014 90 light tube

No special tools are required, only standard equipment (section 1).

Operation:

•
1 • Remove the lefthand side panel K (access panels and covers).
2 • Lift the UV unit up.
3 • Remove the two cross point screws on the side of the UV unit and pull
the top half of the UV unit out.

� UVunit

= =

Crosspoint screws

I ,....,,..., � - -
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6 • CLEANING AND MAINTENANCE

Optional GQ Unit

4 • Unscrew the outer ring at both ends of the light tube, pull the inner
plastic ring away from the tube retaining brackets, rotate the tube
and remove it from the fitting.
5 • Fit a new UV tube and rotate it into the locked position.
6 • Slide the inner plastic ring into the tube fitting and lock into pos
ition by screwing the outer ring onto the tube fitting.
7 • Replace the UV light starter by rotating and pulling away from the

•
tube fitting.
8 • Refit the UV light assembly and secure in place with the two cross
point screws.
9 • Lower the UV unit to the horizontal position so that it engages With
the water wagon.
10 • If no further replacement operations are required, refit the lefthand
side panel K.

Replace the water tank circulation pump

Refer to section 4 (part replacement) .

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 7 • DIAGRAMS AND LAYOUTS

Contents

Component placement diagrams:

Imagesetter, front view 7•3
Imagesetter, rear view 7•4
Imagesetter, side view right 7•5
Processor, top view 7•6
Processor, front view 7•7
Processor, rear view 7•8
Processor, side view right 7•9
Processor, side view left 7•10
Optional GQunit, side view left 7•11
Processor developer rack 7•12
Processor developer rack, part numbers 7•13
Processor fixer rack 7•14
Processor fixer rack, part numbers 7•15
Processor wash rack 7•16
Processor wash rack, part numbers 7•17
Processor dryer rack 7•18
Processor dryer rack, part numbers 7•19
Pages reserved for future use 7•20 to 7•23
Control board 7•24
Driver board 7•25
Backplane 7•26
Data flow 7•27
Pages reserved for future use 7•28 to 7•32
Chemistry system:
Developer. 7•33
Fixer 7•34
Wash system:
Without optional GQunit. 7•35
With optional GQunit. 7•36
Pages reserved for future use 7•37 to 7•40

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 SCHYIEII
7 • DIAGRAMS AND LAYOUTS

Contents

DIP switch and jumper settings:

Interface board 7•41
Silver Saver board 7•42
CPU board 7•43
Circuit diagrams, Imagesetter
Imagesetter, base 7•44
Imagesetter, carriage/guide 7•45
Imagesetter, conveyor front/rear 7•46
Imagesetter, drum input/ output 7•47
Imagesetter, punch/vacuum 7•48
Imagesetter, power 7•49

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mmn
7 • DIAGRAMS AND LAYOUTS

lmagesetter Component Placement - Front View

c D

-.
A G

v
u
K
A
M
T K
N
R Q 0

A Interlock switches 960 40 001 60

B Step motor (input module) 960 55 003 00
c Optics protection board 960 55 000 90
D Optics unit
E Sensor, drum out (output module) 960 40 00150
F Sensor, drum in (input module)
960 55 003 30
G Sensor, cassette (input module)
960 40 00140
H Input cassette DC motor 960 55 002 80
I Microswitch, knife right (output module)
960 40 00190
J Temperature stabilizer board
Step motor, right & left (front conveyor/buffer module) 960 55 00110
K
960 40 002 00
L Main air filter
Sensor, buffer top (front conveyor/buffer module) 960 55 00150
M
N Microswitch, takeup cassette (front conveyor) 960 40 00150
0 Electronics cooling fan 960 55 003 50
p Backplane 960 40 002 20
Q Driver board 960 55 000 80
R Control board 960 55 00160
s 24V power supply 960 55 002 20
T 5V, +/-12V power supply 960 55 001 70
u Step motor, conveyor (front conveyor) 960 45 000 70
v Microswitch, knife left (output module) 960 55 003 00
w Step motor, knife (output module) 960 40 00190
x Step motor, rollers (output module) 960 40 002 00
960 40 002 00

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 mrnn
7 • DIAGRAMS AND LAYOUTS

lmagesetter Component Placement - Rear View

A c D G

. r ::
,�:. ·.·.·.·.·.·.·.·.·.·.·!:·�.·>··.·.·.·.
Rear conveyor

11/ H
G

0
/

N M L K

'
A Input cassette DC motor 960 55 002
B Sensor, in (rear conveyor) 80
960 40
c Optics unit 00150
D Sensor, out (rear conveyor) 960 40
E Optics protection board 00150
960 55 000
F DC motor (rear conveyor) 90 55
960 002
G Interlock switches 90 40
960
H 5\1, +I 12V power supply 960 45
00160 000
I 24V power supply 70
960 55 001
J Backplane 70 55
960 000
K Line filter, 6A 80 55
960
L Capacitor 2µF 00190
960 55 002
M Optional punch battery 960
00 46 000
N Main air filter 60 55
960
0 Optional punch filter motor 00150
960 46 000
p Optional punches, outer 10 55
960
Q Optional punch, middle 00120
960 55
00130

Service Manual • DotMate 7500/7500 Plus Edition 2 • July 1997

'
manual DotMate 7500.indd 508 06/06/2016 01:20:17 p.m.
 scumw
7 • DIAGRAMS AND LAYOUTS

lmagesetter Component Placement - Side View (Right)

I
A
c

u
v

�
/
�

'
G
�
T
H

K
0 N M L

A Input module 960 55 000 10

B Optional punch, outer 960 55 00120
c Optics unit

'
D Sensor out (rear conveyor) 960 40 00150
E DC motor (rear conveyor) 960 55 002 90
F Optional punch, middle 960 55 00130
G Rear conveyor 960 55 000 50
H Sensor in (rear conveyor) 960 40 00150
I Front conveyor 960 55 000 40
J Step motor conveyor (front conveyor) 960 55 003 50
K Optional punch, filter motor 960 46 000 10
L DC motor, media guide module 960 55 002 90
M Temperature stabilizer board 960 55 00110
N Interlock switch 960 40 00160
0 Microswitch, knife right (output module) 960 40 00190
p Main air filter 960 55 001 50
Q Microswitch, takeup cassette (front conveyor/buffer module) 960 55 003 50
R Step motor, right (front conveyor/buffer module) 960 40 002 00
s Buffer module 960 55 000 30
T Sensor, buffer side (front conveyor/buffer module) 960 55 003 40
u Output module 960 55 000 20
v Input cassette DC motor 960 55 002 80
w Optics protection board 960 55 000 90

Edition 2 • July 1997 Service Manual • DotMate 7500/7500 Plus 7•5

manual DotMate 7500.indd 509 06/06/2016 01:20:17 p.m.
 SCHflEI 7 • DIAGRAMS AND LAYOUTS

Processor Component Placement - Top View

c D G

0 K

w l}c

............------'IL.N... 0
---...... M

v
u 0
N
T R Q
A Charcoal filter 960 45 011 60
B Blower heating element 960 45 01140
c Blower I dryer assembly 960 45 01130
D Dryer temperature sensor 960 45 010 80
E Replenishment pump(s)
960 45 013 90
F Water inlet valve
960 45 01410
G Circulation pump(s)
960 45 014 00
H Drive motor
I Silver recovery unit 960 45 011 00
J Motor encoder 960 45 010 90
K Filter housing, fixer 960 45 011 10
L Circulation flow valve 960 45 013 70
M Filter housing, developer
N Worm gear(s) 960 45 013 70
0 Gear shaft 960 45 016 51
p Heating element, developer 960 45 010 40
Q Heating element, fixer 960 45 010 50
R Overflow pipe, water 960 45 010 50
s Overflow pipe, fixer 960 45 011 70
T Overflow pipe, developer 960 45 01180
u Airflow detector board 960 45 01190
v Airflow board 960 45 012 00
w Processor fan 960 45 012 20
x Drive belt 960 45 012 10
960 45 010 70

Service Manual • DotMate 7500/7500 Plus Edition 2 • July 1997

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mmn 7 • DIAGRAMS AND LAYOUTS

Processor Component Placement - Front View

C D G
A
H
\

u T R p 0 N M
s Q

A Interlock switch 960 40

B Charcoal filter 960 45
00160
c Line noise filter, 20A 01160
960 45 013
D Electronics box 00
E Overflow pipe(s)
F Dryer rack 960 55 020
G Heating element(s) 40
960 45 010
H Filter housing(s) 50
960 45 013
I Silver recovery unit 70
960 45 010
J Circulation pump, developer 90 45 014
960
K Circulation pump, fixer 00
960 45 014
L Replenishment pump, developer 00 45 013
960
M Circulation pump, fixer 90
960 45 013
N Water inlet valve 90 45
960
0 Supply and waste containers 01410
p Autotransformer 960 45 012
Q Low voltage transformer 960
80 45 012
R Silver saver board 70
960 45 012
s CPU board 50
960 45 012
T Interface board 30
960 45 012
u Solid state relay(s) 40
960 45 013
v Water wagon 20
960 45 019
w UV unit 80
960 55 035
10

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 - mrnn
7 • DIAGRAMS AND

LAYOUTS

Processor Component Placement - Rear View

C D
A

��1�G

0 N M L K

A Filter housing(s) 960 45 013 70

B Dryer rack 960 55 020 40
c Overflow pipe(s)
D Electronics box
E Charcoal filter 960 45 011 60
F Interlock switch 960 40 00160
G UV unit
H Power cord socket (water wagon)
I Water filter (water wagon) 960 45 014 30
J Silver filter cartridge 960 45 014 80
K FuseT 15A 960 45 013 30
FuseT lOA 960 45 013 40
Fuse F 4A 960 45 013 50
Fuse F 3A 960 45 013 60
L Replenishment pump, fixer 960 45 013 90
M Water inlet valve 960 45 01410
N Replenishment pump, developer 960 45 013 90
0 Circulation pump, developer 960 45 014 00
p Circulation pump, fixer 960 45 014 00
Q Heating element(s) 960 45 010 50
R Silver recovery unit 960 45 010 90
 7•8 Service Manual • DotMate 7500/7500 Plus Edition 2 • July 1997

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manual DotMate 7500.indd 512 06/06/2016 01:20:18 p.m.

 mmn 7 • DIAGRAMS AND LAYOUTS

Processor Component Placement - Side View (Right)

/ D

A Filter housing, developer 960 45 013 70

B Filter housing, developer 960 45 013 70
c Dryer rack 960 55 020 40
D Silver recovery unit
960 45 010 90
E Circulation pump, fixer
960 45 013 90
F Circulation pump, developer
Water inlet valve 960 45 013 90
G
960 45 014 10

Edition 2 • July 1997 Service Manual • DotMate 7500/7500 Plus

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 mrnn
7 • DIAGRAMS AND LAYOUTS

Processor Component Placement - Side View (Left)

c
K

- - =:-----� D

A Dryer rack 960 55 020 40

B UV unit 960 55 035 10
c Line noise filter, 20A 960 45 013 00
D Solid state relay(s) 960 45 013 20
E Silver saver board 960 45 012 50
F Interface board 960 45 012 40
G CPU board 960 45 012 30
H Fuse lOA (heat, dry) 960 45 013 40
I Fuse 4A (heat, fix.) 960 45 013 50
J Fuse 4A (heat, dev.) 960 45 013 50
K Fuse lA (blower)
960 45 019 00
L Fuse lA (power supply prim.)
960 45 019 00
M Fuse 3A (power supply sec.)
960 45 013 60
N Water wagon water connection:
Quick coupling, female
960 45 018 55
Quick coupling, male
960 45 018 56

rl
Service Manual • DotMate 7500/7500 Plus Edition 2 • July 1997
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 7 • DIAGRAMS AND LAYOUTS

'
swmw

Optional GQ-Unit - Left Hand Side View

A
/

G c

A Water buffer
B Antisplash device 960 45 019 30
c Silver cartridge 960 45 014 80
D Circulation pump 960 45 014 00
E Transformer 960 45 014 60
F Fuses (250 mA and 800 mA) 960 45 015 16/70
G Dual voltage board 960 45 014 50
H Bypass switch (for emptying water wagon) 960 45 014 40
I Antisplash device lock
J Mains socket
K Filter housing (1 micron filter) 960 45 013 70

' Edition 2 • July 1997

Service Manual • DotMate 7500/7500 Plus

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 7 • DIAGRAMS AND LAYOUTS

Processor Developer Rack, Component Placement

T A

---D

------- E
---- F
-- G
-- H

M
K

Service Manual • DotMate 7500/7500 Plus Edition 2 • July 1997

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�
-
scurnw 7 • DIAGRAMS AND LAYOUTS

Processor Developer Rack, Part Numbers

A 960 55 02190 Axle (1) Q 960 55 020 90 Rubber roller

A 960 45 020 36 Gear (1) Q 960 45 020 38 Spring
A 960 45 020 37 Worm gear (1) Q 960 45 020 49 Bearing
A 960 45 020 50 Bearing (2) Q 960 45 020 58 Spring holder
A' 960 45 020 52 Lock washer (1) R 960 55 020 70 Rubber roller
A 960 45 020 59 Hose, red (1) R 960 45 020 28 Gear
A 960 45 020 83 Circlip (1) R 960 45 020 38 Spring
A 960 45 020 91 Slotted pin (2) R 960 45 020 49 Bearing
B 960 55 02180 Rack axle (4) R 960 45 020 58 Spring holder
B 960 45 020 70 Screw (8) s 960 45 020 21 Guide bracke
B 960 45 020 82 Star washer (8) s 960 45 020 56 Bush
c 960 55 020 90 Rubber roller (1) s 960 45 020 66 Screw
c 960 45 020 28 Gear (1) s 960 45 020 74 Nut
c 960 45 020 38 Spring (1) T 960 45 020 35 Middle gear
c 960 45 020 49 Bearing (2) T 960 45 020 66 Screw
c 960 45 020 58 Spring holder (2) T 960 45 020 74 Nut
D 960 55 02140 Guide, output (1) T 960 45 020 87 Bearing bush
D 960 45 020 39 Spring (1)
E 960 55 020 60 Poly. roller (1)
E 960 45 020 32 Gear (1)
E 960 45 020 38 Spring (1)
E 960 45 020 49 Bearing (2)
E 960 45 020 58 Spring holder (2)
F 960 55 020 60 Poly. roller (1)
F 960 45 020 28 Gear (1)
F 960 45 020 49 Bearing (2)
F 960 45 020 58 Spring holder (2)
G 960 45 020 62 Heat shrink (1)
H 960 45 020 90 Rivet (1)
I 960 45 020 30 Bottom guide (1)
I 960 45 020 39 Spring (1)
J 960 45 020 40 Rack side (2)
K 960 55 020 90 Rubber roller (1)
K 960 45 020 32 Gear (1)
K 960 45 020 38 Spring (1)
K 960 45 020 49 Bearing (2)
K 960 45 020 58 Spring holder (2)
L 960 45 020 89 Rivet (1)
M 960 45 020 61 Heat shrink (1)
N 960 55 02120 Bottom guide (1)
N 960 45 020 39 Spring (1)
0 960 45 020 90 Gear (1)
0 960 45 020 71 Screw (1)
0 960 45 020 74 Nut (1)
0 960 45 020 79 Washer (1)
0 960 45 020 87 Bearing bush (1)
p 960 45 020 39 Spring (1)
p Wire guide (1)

Edition 2 • July 1997 Service Manual • DotMate 7500/7500 Plus 7•13

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 mrnn
7 • DIAGRAMS AND LAYOUTS

Processor Fixer Rack, Component Placement

c A

_-(

_o

R G

Q �
H
G
p
G

c K

N
M G

Service Manual • DotMate 7500/7500 Plus Edition 2 • July 1997

manual DotMate 7500.indd 518 06/06/2016 01:20:21 p.m.
scumw 7 • DIAGRAMS AND LAYOUTS

Processor Fixer Rack, Part Numbers

A 960 55 02190 Axle (1) p 960 45 020 79 Washer (1)

A 960 45 020 36 Gear (1) p 960 45 020 87 Bearing bush (1)
A 960 45 020 37 Worm gear (1) Q 960 55 021 60 Guide, low (1)
A 960 45 020 50 Bearing (2) Q 960 45 020 78 Split pin (1)
A 960 45 020 52 Lock washer (1) R 960 55 021 70 Guide, high (1)
A 960 45 020 60 Hose, blue (1) R 960 45 020 78 Split pin (1)
A 960 45 020 83 Circlip (1) s 960 55 020 90 Rubber roller (1)
A 960 45 020 91 Slotted pin (2) s 960 45 020 32 Gear (1)
B 960 45 020 34 Middle gear (1) s 960 45 020 38 Spring (1)
B 960 45 020 71 Screw (1) s 960 45 020 49 Bearing (2)
B 960 45 020 87 Bearing bush (1) s 960 45 020 58 Spring holder (2)
B 960 45 020 88 Nut (1) T 960 55 020 90 Rubber roller (1)
c 960 55 02180 Rack axle (4) T 960 45 020 28 Gear (1)
c 960 45 020 70 Screw (8) T 960 45 020 38 Spring (1)
c 960 45 020 82 Star washer (8) T 960 45 020 49 Bearing (2)
D 960 55 020 90 Rubber roller (1) T 960 45 020 58 Spring holder (2)
D 960 45 020 28 Gear (1) u 960 55 02110 Cr. over guide (1)
D 960 45 020 38 Spring (1) v 960 45 020 24 Holder (1)
D 960 45 020 49 Bearing (2) w 960 55 020 50 Satellite roller (1)
D 960 45 020 58 Spring holder (2) x 960 45 020 46 Bracket f. guide (1)
E 960 55 02100 Rubber roller (1) x 960 45 020 56 Bush f. bracket (1)
E 960 45 020 38 Spring (1) x 960 45 020 66 Screw (1)
E 960 45 020 49 Bearing (2) x 960 45 020 74 Locknut (1)
E 960 45 020 58 Spring holder (2)
F 960 55 02140 Output guide (1)
F 960 45 020 39 Spring (1)
G 960 55 020 60 Poly. roller (1)
G 960 45 020 32 Gear (1)
G 960 45 020 38 Spring (1)
G 960 45 020 49 Bearing (2)
G 960 45 020 58 Spring holder (2)
H 960 55 020 60 Poly. roller (1)
H 960 45 020 28 Gear (1)
H 960 45 020 38 Spring (1)
H 960 45 020 49 Bearing (2)
H 960 45 020 58 Spring holder (2)
I 960 45 020 62 Heat shrink (1)
J 960 45 020 90 Rivet (1)
K 960 55 02130 Bottom guide (1)
K 960 45 020 39 Spring (1)
L 960 45 020 45 Rack side (2)
M 960 45 020 89 Rivet (1)
N 960 45 020 61 Heat shrink (1)
0 960 55 02120 Bottom guide (1)
0 960 45 020 39 Spring (1)
p 960 45 020 31 Gear (1)
p 960 45 020 71 Screw (1)
p 960 45 020 74 Nut (1)

Edition 2 • July 1997 Service Manual • DotMate 7500/7500 Plus 7•15

.., ,.,. /
manual DotMate 7500.indd 519 06/06/2016 01:20:21 p.m.
 scumw
7 • DIAGRAMS AND LAYOUTS

Processor Wash Rack, Component Placement

c A
v

u
I

�(

R G
H
Q

G
G

H
p

�(

c K

N
M G

t
Service Manual • DotMate 7500/7500 Plus Edition 2 • July 1997
manual DotMate 7500.indd 520 06/06/2016 01:20:22 p.m.
scurnw
7 • DIAGRAMS AND LAYOUTS

Processor Wash Rack, Part Numbers

A 960 55 02190 Axle (1) p 960 45 020 87 Bearing bush (1)

A 960 45 020 36 Gear (1) Q 960 55 02160 Guide, low (1)
A 960 45 020 37 Worm gear (1) Q 960 45 020 78 Split pin (1)
A 960 45 020 50 Bearing (2) R 960 55 021 70 Guide, high (1)
A 960 45 020 52 Lock washer (1) R 960 45 020 78 Split pin (1)
A 960 45 020 83 Circlip (1) s 960 55 020 90 Rubber roller (1)
A 960 45 020 91 Slotted pin (2) s 960 45 020 32 Gear (1)
B 960 45 020 34 Middle gear (1) s 960 45 020 38 Spring (1)
B 960 45 020 69 Screw (1) s 960 45 020 49 Bearing (2)
B 960 45 020 74 Nut (1) s 960 45 020 58 Spring holder (2)
B 960 45 020 87 Bearing bush (1) T 960 55 020 90 Rubber roller (1)
c 960 55 02180 Rack axle (4) T 960 45 020 28 Gear (1)
c 960 45 020 70 Screw (8) T 960 45 020 38 Spring (1)
c 960 45 020 82 Star washer (8) T 960 45 020 49 Bearing (2)
D 960 55 020 80 Rubber roller (1) T 960 45 020 58 Spring holder (2)
D 960 45 020 28 Gear (1) u 960 55 02150 Guide, rewash (1)
D 960 45 020 38 Spring (1) u 960 45 020 39 Spring (1)
D 960 45 020 49 Bearing (2) v 960 45 020 22 Bracket f. guide (1)
D 960 45 020 58 Spring holder (2) v 960 45 020 56 Bush f. bracket (1)
E 960 55 020 90 Rubber roller (1) v 960 45 020 66 Screw (1)
E 960 45 020 38 Spring (1) v 960 45 020 74 Locknut (1)
E 960 45 020 49 Bearing (2)
E 960 45 020 58 Spring holder (2)
F 960 55 02140 Output guide (1)
F 960 45 020 39 Spring (1)
G 960 55 020 60 Poly. roller (1)
G 960 45 020 32 Gear (1)
G 960 45 020 38 Spring (1)
G 960 45 020 49 Bearing (2)
G 960 45 020 58 Spring holder (2)
H 960 55 020 60 Poly. roller (1)
H 960 45 020 28 Gear (1)
H 960 45 020 38 Spring (1)
H 960 45 020 49 Bearing (2)
H 960 45 020 58 Spring holder (2)
I 960 45 020 62 Heat shrink (1)
J 960 45 020 90 Rivet (1)
K 960 55 02130 Bottom guide (1)
K 960 45 020 39 Spring (1)
L 960 45 020 45 Rack side (2)
M 960 45 020 89 Rivet (1)
N 960 45 020 61 Heat shrink (1)
0 960 55 02120 Bottom guide (1)
0 960 45 020 39 Spring (1)
p 960 45 020 31 Gear (1)
p 960 45 020 71 Screw (1)
p 960 45 020 74 Nut (1)
p 960 45 020 79 Washer (1)

Edition 2 • July 1997 Service Manual • DotMate 7500/7500 Plus 7•17

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 mrnn
7 • DIAGRAMS AND LAYOUTS

Processor Dryer Rack, Component Placement

A
c

� A
0

F
(x 15)
M

I
I
K

A
H G

Service Manual • DotMate 7500/7500 Plus Edition 2 • July 1997

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 SCAN VIEW 7 • DIAGRAMS AND LAYOUTS
I
Processor Dryer Rack, Part Numbers

A 960 45 020 70 Screw (8) M 960 55 030 60 Rubber roller,

A 960 55 02180 Axle (4) heavy
A 960 45 020 81 Star washer (8) N 960 55 030 90 Roller
B 960 55 030 40 Top guide (1) N 960 45 020 49 Gear
� 960 45 020 57 Bush (2) N 960 45 020 58 Spring holder
B 960 45 020 68 Screw (2) 0 960 55 030 10 Lower guide
B 960 55 020 73 Nut (2) 0 960 45 020 57 Bush
c 960 45 020 63 Temp. sensor (1) 0 960 45 020 68 Screw
c 960 45 020 67 Screw (1) 0 960 45 020 73 Nut
c 960 45 020 73 Nut (1) p 960 55 030 20 Guide
D 960 45 020 64 Cable tie wrap (1) p 960 45 020 72 Screw
E 960 55 03110 Guide (3) p 960 45 020 80 Star washer
E 960 45 020 78 Split pin (3) Q 960 55 030 30 A/static brush
F 960 55 030 70 Poly. roller (15) Q 960 45 020 65 Screw
F 960 45 020 33 Gear (15) R 960 45 020 44 Rack side, left
F 960 55 020 49 Bearing (30) s 960 55 020 42 Rack side, righ
F 960 45 020 54 Distance piece (15)
F 960 45 020 58 Spring holder (15)
G 960 55 030 80 Drive roller (1)
G 960 45 020 29 Worm gear (1)
G 960 45 020 33 Gear (1)
G 960 55 020 49 Bearing (2)
G 960 45 020 54 Distance piece (1)
G 960 45 020 91 Slotted pin (1)
H 960 55 030 50 Rubber roller (1)
H 960 45 020 33 Gear (1)
H 960 45 020 49 Bearing (2)
H 960 45 020 54 Distance piece (1)
I 960 55 031 00 Drive roller (1)
I 960 45 020 27 Gear (1)
I 960 45 020 29 Worm gear (1)
I 960 45 020 91 Slotted pin (1)
J 960 45 020 30 Middle gear (1)
J 960 45 020 69 Screw (1)
J 960 45 020 73 Nut (1)
J 960 45 020 74 Locknut (1)
J 960 45 020 79 Washer (1)
J 960 45 020 87 Bearing bush (1)
K 960 55 030 50 Rubber roller,
light (1)
K 960 45 020 32 Gear (1)
K 960 45 020 49 Bearing (2)
K 960 45 020 58 Spring holder (2)
L 960 45 020 38 Spring (2)
M 960 45 020 32 Gear (2)
M 960 45 020 49 Bearing (4)
M 960 45 020 58 Spring holder (4)

Edition 2 • July 1997 Service Manual • DotMate 7500/7500 Plus

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 mrnn 7 • DIAGRAMS AND LAYOUTS

Control Board Print View

Service Manual • DotMate 7500/7500 Plus Edition 2 • July 1997

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 SCAN VIEW
7 • DIAGRAMS AND LAYOUTS

Driver Board Print View

Edition 2 • July 1997 Service Manual • DotMate 7500/7500 Plus

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 SCANVIEW 7 • DIAGRAMS AND LAYOUTS

Backplane Print View

·I
-w �
$ • � �
$

..,.

.
Iii]
Oii

""'

..
1 1 1

.1

!!Ill

&
..
am

.""

"" CJ

D
[II)
Ill)
(ii)

""':

7 • 26 Service Manual • DotMate 7500/7500 Plus Edition 2 • July 1997

manual DotMate 7500.indd 526 06/06/2016 01:20:24 p.m.
 mrnn 7 • DIAGRAMS AND LAYOUTS

Data Flow

RIP PC

8 bit

Control board

Shift
reg

Data elk

TIL
Driver board

1 bit
Spinner driver Car driver

Bitmap data Clock

Index

Edition 2 • July 1997 Service Manual • DotMate 7500/7500 Plus

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_.,,,.,

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 7 • DIAGRAMS AND LAYOUTS

Developer System {Red Hoses)

..
. ..... A

Used chemistry

New chemistry
D
c

A Nonreturn valve
B Replenishment pump, developer
C Circulation flow valve, developer
D Filter, developer (20 micron)
E Circulation pump, developer
F Overflow pipe, developer (red)

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 mrnn 7 • DIAGRAMS AND LAYOUTS

Fixer System (Blue Hoses}

Used chemistry

New chemistry

D C

A Nonreturn valve, fixer

B Replenishment pump, fixer
C Circulation pump, fixer
D Silver recovery unit
E Filter, fixer (20 micron)
F Overflow pipe, fixer (blue)

7•34 Service Manual • DotMate 7500/7500 Plus Edition 2 • July 1997

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mmn 7 • DIAGRAMS AND LAYOUTS

Wash System, without Optional GQ-Unit

Water
I inlet

Drain

A Water inlet valve

B Overflow pipe, water (transparent)

Edition 2 • July 1997 Service Manual • DotMate 7500/7500 Plus

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 SCANflEll
1 • DIAGRAMS AND LAYOUTS

Wash System, with Optional GQ-Unit

...
D

A Water inlet valve

B Filter, (1 micron) inside the water wagon
C Recirculation pump inside the water wagon
D Overflow pipe, water (transparent)

7•36 Service Manual • DotMate 7500/7500 Plus Edition 2 • July 1997

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 7 • DIAGRAMS AND LAYOUTS

DIP Switch and Jumper Settings, Interface Board

'
sw1

=-
2
3
4=
�
M27
5=
J1
6 -==i

ffl 8=
7= �
M28
off on

Interface board SW 1
1 : lmagesetter installed ON =yes
2 : GQ installed ON =yes
3 : Silver saver unit installed ON =yes
4: Not used
5: Not used
6: Not used
7: Not used
8: EEPROM OFF = normal mode
ON = reset at power on ( resets to factory values )

M27 Plug for imagesetter communication

M28 Plug for DotMate service program

Jl Jumper in position 2 3 ensures RS 232 level on both M27 and M28

Edition 2 • July 1997 Service Manual • DotMate 7500/7500 Plus 7•41

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 7 • DIAGRAMS AND LAYOUTS

DIP Switch and Jumper Settings, Silver Saver Board

sw1

6 c::::::ii
5 c::::::ii
�
4 c::::::ii

23 c:=111
1 c:::Ji
on o . J2
[I
J1

[CJ]

Note: the switches are numbered from the bottom and up

Silver saver board SW 1

1 : GQ installation ON = on line (connected to the water tap and
drain)
OFF = off line (no water or drain connected) ON
2 : GQ water exchange time = 90 minutes (works only if switch 3 is on) OFF =
45 minutes (works only if switch 3 is on) ON =
3 : GQ water exchange mode auto I 50 sq. meter (only if switch 1 is on) (Note:
During water change, the processor must not be
used)
OFF= manual
4: Not used
5: Not used
6: Not used
7: Factory use only OFF = normal mode
ON = factory use
8: EEPROM OFF = normal mode
ON = reset at power on (resets to factory values)

Service Manual • DotMate 7500/7500 Plus Edition 2 • July 1997

�--r.
manual DotMate 7500.indd 534 06/06/2016 01:20:27 p.m.
 7 • DIAGRAMS AND LAYOUTS

Jumper Settings, CPU board

I I
I
I

1 2 3
J1 •HJ
J2 •H

�
J3 •H
J4 •H
J5
JS H•
J7 •H

Jl Pas. 23
J2 Pas. 23
J3 Pas. 23
J4 Pas. 23
JS Pas. 12
J6 Pas. 12
J7 Pas. 23

POS. 12 POS. 23

Jl 1Mb/2Mb Eprom 256Kb/512Kb Eprom*

J2 2MbEprom 256Kb/512Kb/1Mb Eprom*
J3 256.KbRAM 64.KbRAM*
J4 Osc. wd. disable Osc. wd. enable*
JS Power saving enable* Start wd. timer
J6 Volt. sensor available P83 IS normal input"
J7 256.Kb Eprom 512Kb/1Mb/2Mb Eprom*

Edition 2 • July 1997 Service Manual • DotMate 7500/7500 Plus

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 8

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 II

•
manual DotMate 7500.indd 550 06/06/2016 01:20:33 p.m.
 8 • TROUBLE SHOOTING

• Contents

lmagesetter
Communications problems 8•3
Exposure problems 8•3
Paper jams 8•3
Image positioning problems 8•4

Processor (DotMate 7500P/7500P Plus)

General 8•5

• Edition 2 • July 1997 Service Manual • DotMate 7500n500 Plus

manual DotMate 7500.indd 551 06/06/2016 01:20:33 p.m.

manual DotMate 7500.indd 552 06/06/2016 01:20:33 p.m.
mrnn 8 • TROUBLE SHOOTING

lmagesetter

Problem Possible Cause Solution·

Communication errors

No communication with 1. Bad connection on SCSI � Check SCSI cable and con
the DotMate from the Rip. cable and connectors. nectars.
� Use SCSI interrogator on
Rip PC.

No communication thro 1. Bad connections on mon � Check SCSI cable and con
ugh the imagesetter mon itor cables and connectors. nectars.

.
itor program. Reboot Windows program
and restart terminal

The service program 1. Baud rate incorrect. (

Set communication rate
starts but is unreadable. to 9600 baud.

Exposure problems

Density of the exposed media 1. Filter motor possibly out of � Check filter motor adjust
is too high, even adjustment. ment (section 5).

though the exposure level

is low.

Paper jams
Load error 1. No media in the cassette.
2. Insufficient amount of
(

� . Load media.
Adjust media in cassette.

Paper jam: drum out

sensor
- 1. Incorrectly loaded or ten
sioned media.
(

.. Manually pull the

mediainto the cassette.
back

media protruding from

the cassettte.
2. Media may not have been
cut correctly.
(
With the takeup
removed, cut thecassette
media
manually.
 Edition 2 • July 1997 Service Manual • DotMate 7500/7500 Plus

manual DotMate 7500.indd 553 06/06/2016 01:20:34 p.m.

 •
8 • TROUBLE SHOOTING
SCAHI ii

lmagesetter

Problem Possible cause Solution

Image positioning problems
 left hand side. the media.
.. C
been defined correctly in

•
regard to width in the

... edit media of the RipMate

page set up .
Perform a zero off set,
across scanline, Y offset ad

...
justment (section 5) .

Bottom part of image is 1. Zero offset, scanline P

clipped, with the clipped direction, adjustment line direction, index offset

.
part appearing on the foll incorrect. (section 5)
owing film.

Refer to the RipMate system

..
monitor for where the clip
ping is invalid.

Scanline error, or across 1. Exposure settings in ( Check the exposure perfor

.. •
scanline error. correct. mance of the test files
(section 5).

Adjustment error. 1. Tensioning system out (

Adjust tensioning system

...
of adjustment. (section 5) .

This adjustment to be car

.
Scanline error, deviation 1. Carriage out of alignment
over 2x75 µ. ried out by a ScanView tech
nician.

Across scanline error 1. Carriage out of alignment (

deviation over 2x75µ. ried out by a ScanView

technician .

...
..
Check the security of the
Density and/or screening 1. False light.
deviation error. DotMate covers and
panels
to ensure that light is not
entering the unit.
Adjust focus (section 5).
Screening deviation error. 1. Focus settings incorrect. (

Service Manual • DotMate 7500/7500 Plus Edition 2 • July 1997

manual DotMate 7500.indd 554 06/06/2016 01:20:34 p.m.

 8 • TROUBLE SHOOTING

Processor (DotMate 7500P/7500P Plus)

Problem

The processor does not

Possible Cause
1. Selected developer temp. . Solution
Wait until the correct devel

..
operate even though main has not been reached. oper temperature has been
power is on. reached.
2. No circulation. The heated
Check that the

•
chemistry does not operate the pumps are running .

.
temp. sensor (the processor
will assume that the temp. has for kinks .
not been reached).

..
Check for air in the system .
3. Low liquid level in one or Refill the tank(s) as necess

heck image setter to proc

all of the tanks. ary .

Processor operates con

tinuosly.
Low liquid level warning.
1. Input signal from image
setter unstable.
1. Replenishment containers .... C
essor communication .

2. Solution level low in the

are empty.
. Fill the replenishment tanks.

Refill the tank(s) as necess

tanks. ary.
3. Air in the system. Turn the processor on and

..
off several times in order to
purge the system.

...
(
4. Replenishment control set Reset the replenishment

•
5. Replenishment hoses kinked. ( traighten or replace the

.
too low. control, (refer to RipManager.
S
hoses .
Slow circulation in one 1. Air in the system(s) Turn the processor on and
or all of the systems. off several times in order to

...
purge the systems.

..
Temperature of developer 1. Temperature settings too ( Reset the temperature set
or fixer too high. high. tings (refer to the service

.
2. Slow circulation because
 program section 3) .
Turn the processor on and
Inadequate drying of the 1. Dryer temperature setting

of air in the system. off several times in order to

...
purge the systems .
media. too low. setting, (refer to RipManager)
2. Dryer heat too low. (
Replace the dryer assembly.
(Refer to section 4)

Edition 2 • July 1997 Service Manual • DotMate 7500/7500 Plus

manual DotMate 7500.indd 555 06/06/2016 01:20:35 p.m.

 8 • TROUBLE SHOOTING

Processor (DotMate 7500P/7500P Plus)

Problem
Marks from rollers or guides
Pessible Cause
1. Dirt on the rollers or guides ..... Run cleanup sheets .

..
on the media. in the racks. Remove
Change and clean the
the chemistry. (Refer
(
to the operators manual) .

...
Media does not transport 1. Rack roller springs have lost Replace the springs.
their tension.

The processor stops 1. Media jam in the racks. (

Clear the jam .
operating. 2. Excessive friction in the Remove and clean the racks
racks. and check for free rotation.

.
3. Excessive friction in the Replace the drive motor.

Lower temperature settings

drive shaft or motor. (Refer to section 4) .

Overdeveloped media. 1. Incorrectly mixed developer. Remix the developer.
Chemistry temperature too

. Check exposure level. (Rip

2.
high.
3. Over exposure.

4. Development time too long.

.. (refer to the processor service
program (section 3) .

Mate page setup)

Reduce development time.
(RipManager, media manag

.
ment) .

Underdeveloped media. 1. Incorrectly mixed developer. Remix the developer .

2. Chemistry temperature too Increase temperature settings
low. (refer to the processor service

..
program (section 3).

Increase development time.

3. Under exposure. (
Check exposure level. (Rip
4. Development time too short. Mate page setup)
 5. Developer level in the tank (RipManager, media manag
ment) .
Check the replenishment
too low. container and/ or increase

..
the developer replenishment
setting.
(RipManager, media manag
ment).
6. Developer contaminated ( Thoroughly clean the devel
with fixer. aper system and replace the
developer. (Refer to operators
manual).

Service Manual • DotMate 7500/7500 Plus Edition 2 • July 1997

manual DotMate 7500.indd 556 06/06/2016 01:20:35 p.m.

 scum,
8 • TROUBLE SHOOTING
I
Processor (DotMate 7500P/7500P Plus)

Film not fixed. 1. Contaminated fixer. ... Thoroughly clean the fixer

2. Fixer level in the tank too ...

... system and replace the fixer
(refer to operators manual) .
Increase fixer replenishment
low. setting (refer to RipManager) .
3. Fixer temperature too low. Increase the temperature
setting, (refer to the proces

4. Incorrectly mixed fixer.

5. Development time too short.
... sor service program section
3) .
Remix the fixer.
Increase development time

...
(refer Rip Manager).

Film sticks in the dryer. 1. Fixer level too low. ( Check the replenishment
container and/or increase the

...
fixer replenishment setting
(refer to RipManager).
2. Contaminated fixer. (
Thoroughly clean the fixer

..
system and replace the fixer
(refer to operators manual) .
3. Incorrectly mixed fixer. Remix the fixer.
4. Fixer temperature too low. (
Increase the temperature

...
setting (refer to the service
program section 3).
5. Insufficient washing of the (
Check the level in the wash

emove the dryer rack

media. tank and/or check that the

inlet valve is open .
R
(section 4) and clean the
rollers.
 Edition 2 • July 1997 Service Manual • DotMate 7500/7500 Plus

manual DotMate 7500.indd 557 06/06/2016 01:20:35 p.m.

manual DotMate 7500.indd 558 06/06/2016 01:20:36 p.m.
 9

manual DotMate 7500.indd 559 06/06/2016 01:20:36 p.m.

 -

manual DotMate 7500.indd 560 06/06/2016 01:20:37 p.m.

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