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DIGITAL FILM IMAGER

UP-DF500

SERVICE MANUAL
Volume 1 2nd Edition
Serial No. 818001 and Higher
! WARNING
This manual is intended for qualified service personnel only.
To reduce the risk of electric shock, fire or injury, do not perform any servicing other than that
contained in the operating instructions unless you are qualified to do so. Refer all servicing to
qualified service personnel.

! WARNUNG
Die Anleitung ist nur für qualifiziertes Fachpersonal bestimmt.
Alle Wartungsarbeiten dürfen nur von qualifiziertem Fachpersonal ausgeführt werden. Um die
Gefahr eines elektrischen Schlages, Feuergefahr und Verletzungen zu vermeiden, sind bei
Wartungsarbeiten strikt die Angaben in der Anleitung zu befolgen. Andere als die angegeben
Wartungsarbeiten dürfen nur von Personen ausgeführt werden, die eine spezielle Befähigung
dazu besitzen.

! AVERTISSEMENT
Ce manual est destiné uniquement aux personnes compétentes en charge de l’entretien. Afin
de réduire les risques de décharge électrique, d’incendie ou de blessure n’effectuer que les
réparations indiquées dans le mode d’emploi à moins d’être qualifié pour en effectuer d’autres.
Pour toute réparation faire appel à une personne compétente uniquement.

When using a modular jack cable:


For safety, do not connect to the connector for peripheral
device wiring that might have excessive voltage.

UP-DF500
ADVARSEL!

Lithiumbatteri-Eksplosionsfare ved fejlagtig


håndtering.
Udskiftning må kun ske med batteri
af samme fabrikat og type.
Levér det brugte batteri tilbage til leverandøren.

CAUTION
ADVARSEL
Danger of explosion if battery is incorrectly replaced.
Lithiumbatteri - Eksplosjonsfare.
Replace only with the same or equivalent type
Ved utskifting benyttes kun batteri som
recommended by the manufacturer.
anbefalt av apparatfabrikanten.
Dispose of used batteries according to the
Brukt batteri returneres
manufacturer’s instructions.
apparatleverandøren.

Vorsicht!
VARNING
Explosionsgefahr bei unsachgemäßem Austausch
Explosionsfara vid felaktigt batteribyte.
der Batterie.
Använd samma batterityp eller en likvärdig typ
som rekommenderas av apparattillverkaren.
Ersatz nur durch denselben oder einen vom
Kassera använt batteri enligt gällande
Hersteller empfohlenen ähnlichen Typ. Entsorgung
föreskrifter.
gebrauchter Batterien nach Angaben des
Herstellers.

VAROITUS
ATTENTION
Paristo voi räjähtää jos se on virheellisesti
asennettu.
Il y a danger d’explosion s’il y a remplacement
Vaihda paristo ainoastaan laitevalmistajan
incorrect de la batterie.
suosittelemaan tyyppiin.
Hävitä käytetty paristo valmistajan ohjeiden
Remplacer uniquement avec une batterie du même
mukaisesti.
type ou d’un type équivalent recommandé par le
constructeur.
Mettre au rebut les batteries usagées conformément
aux instructions du fabricant.

UP-DF500 1 (P)
Table of Contents

Manual Structure 2-7. Maintenance Check ...................................................... 2-15


2-7-1. Preparation .......................................................... 2-15
Purpose of this manual ................................................................. 3 2-7-2. Appearance Check ............................................... 2-16
Related manuals ........................................................................... 3 2-7-3. Check of Current Status ...................................... 2-16
Trademarks ................................................................................... 3 2-7-4. Periodic Replacement Parts and Cleaning .......... 2-16
2-7-5. Version Upgrade and Virus Patch ....................... 2-17
2-7-6. Confirmation ....................................................... 2-17
1. Installation 2-8. Unleaded Solder ............................................................ 2-17

1-1. Operating Environment .................................................. 1-1


1-2. Outside Dimension Diagram .......................................... 1-2 3. Replacing the Main Parts
1-3. Installation Space ............................................................ 1-3
1-4. Caster Assembly Installation Procedure ......................... 1-3 3-1. Replacing the Board ....................................................... 3-1
3-1-1. MA-155 Board ...................................................... 3-1
1-5. Setting Procedure ............................................................ 1-4
3-1-2. DR-618 Board ....................................................... 3-3
1-6. Film Loading Procedure ................................................. 1-5
3-1-3. KEY-59 Board/LE-336 Board/SW-1341 Board ... 3-4
1-7. Check List ....................................................................... 1-5
3-1-4. CN-2932 Board ..................................................... 3-4
3-2. MD Assembly ................................................................. 3-5
3-3. PH1 Assembly ................................................................ 3-6
2. Service Overview
3-4. PH2 Assembly ................................................................ 3-7

2-1. Board Location ............................................................... 2-1 3-5. PH3 (S) Assembly .......................................................... 3-8

2-2. Main Parts Location ........................................................ 2-3 3-6. Head Block Assembly .................................................... 3-9

2-3. Sensor/Actuator Location and Function ......................... 2-5 3-7. Thermal Head Assembly .............................................. 3-10

2-4. Removing/Installing the Cabinet .................................... 2-7 3-8. Transfer Cleaning Roller .............................................. 3-12
2-4-1. Front Sash Assembly ............................................. 2-7 3-9. Capstan B/Platen ........................................................... 3-13
2-4-2. MD Cover (BD) .................................................... 2-7 3-10. Rear Chassis Assembly ................................................. 3-15
2-4-3. Front Panel (L) Assembly ..................................... 2-8 3-11. Base Chassis (2T) Assembly ........................................ 3-16
2-4-4. Front Panel (R) Assembly ..................................... 2-8 3-12. Pinch Press Lever Assembly ........................................ 3-17
2-4-5. MD Front Panel Assembly/MD Upper Cover ....... 2-9 3-13. Switching Regulator ..................................................... 3-17
2-4-6. Side Panel (L) ...................................................... 2-10 3-14. DICOM BOARD .......................................................... 3-18
2-4-7. Side Panel (R) ...................................................... 2-10
3-15. Paper Feed Chassis Assembly ...................................... 3-19
2-4-8. Outer Frame L Cover .......................................... 2-10
3-16. Paper Feed Roller Assembly ........................................ 3-21
2-4-9. Top Cover (D) ..................................................... 2-11
3-17. Separation Roller Assembly ......................................... 3-22
2-4-10. Rear Cover (TD)/PH2 Flap ................................. 2-11
2-4-11. Rear Cover (BS) .................................................. 2-12 3-18. Installing the Alternate Unit ......................................... 3-22

2-5. Optional Fixtures .......................................................... 2-12


2-5-1. Reference Sheet ................................................... 2-12
4. Procedures after Replacement
2-6. Periodic Inspection ....................................................... 2-12
2-6-1. Cleaning of Main Unit ......................................... 2-12
4-1. Adjustment after Replacing the Thermal Head .............. 4-1
2-6-2. Tray Cleaning ...................................................... 2-13
4-1-1. Adjusting the Density ............................................ 4-1
2-6-3. Fan Filter ............................................................. 2-13
4-1-2. Adjusting the Head Position .................................. 4-2
2-6-4. Dust Cleaning Roller ........................................... 2-14
2-6-5. Replacing the Periodic Replacement Parts .......... 2-14

UP-DF500 1
4-2. Procedures after Replacing the Board ............................ 4-3 6. Service Mode
4-2-1. MA-155 Board ...................................................... 4-3
4-2-2. DR-618 Board ....................................................... 4-4 6-1. Activating the Service Mode .......................................... 6-1
4-2-3. CT-248 Board ........................................................ 4-4 6-2. Menu Configuration of Service Mode ............................ 6-2
4-2-4. SE-880 Board, SE-881 Board ............................... 4-6 6-2-1. Information ............................................................ 6-3
4-2-5. DICOM BOARD ................................................... 4-7 6-2-2. Print Quality .......................................................... 6-4
4-3. Printing Position Adjustment Procedures ....................... 4-8 6-2-3. Calibration ............................................................. 6-5
4-4. Operation List during Replacement of 6-2-4. Gamma Sel ............................................................ 6-7
Main Assembly Parts ...................................................... 4-9 6-2-5. Print Operation ...................................................... 6-7
6-2-6. System Settings ..................................................... 6-8
6-2-7. Test Print ............................................................. 6-11
5. Circuit Operation Description 6-2-8. Manual Mecha ..................................................... 6-12
6-2-9. Error Info ............................................................. 6-13
5-1. MA-155 Board ................................................................ 5-1 6-2-10. Adjust .................................................................. 6-14
5-1-1. Outline ................................................................... 5-1 6-2-11. Self Check ........................................................... 6-15
5-1-2. Configuration ........................................................ 5-1 6-2-12. Media (Tag) Menu .............................................. 6-16
5-1-3. CPU, PLD, and Peripheral Circuits ....................... 5-1 6-3. Firmware Version Upgrade Procedures ........................ 6-17
5-1-4. USB 2.0 Interface Block ....................................... 5-2 6-3-1. Required Equipment ............................................ 6-17
5-1-5. SDRAM Control Block ......................................... 5-2 6-3-2. Upgrade Procedures ............................................ 6-17
5-1-6. PQC Block (Picture Quality Correction), 6-3-3. Version Check ..................................................... 6-17
Thermal Head Control Block and 6-4. DICOM Version Upgrade Procedures .......................... 6-18
+5 V Driver in IDMAC PLD ................................ 5-2 6-4-1. Required Equipment ............................................ 6-18
5-1-7. DC/Stepping Motor Controller Block, 6-4-2. Upgrade Procedures ............................................ 6-18
+5 V Driver and Sensor A/D Input Block ............ 5-3 6-4-3. Version Check ..................................................... 6-18
5-1-8. Memory Stick and USB 1.1 Interface Block 6-5. FilmStation Support Software ...................................... 6-19
(Service Interface) ................................................. 5-3 6-5-1. Installing the FilmStation Support Software ....... 6-19
5-1-9. Key Switch, LED, and LCD Interface Block ........ 5-3 6-5-2. Operating Procedures for FilmStation Support
5-1-10. UART Block ......................................................... 5-3 Software .............................................................. 6-19
5-1-11. Sensor and Switch Control .................................... 5-4 6-6. DICOM Anti-Virus Patch Procedure ............................ 6-20
5-2. DR-618 Board ................................................................. 5-6
5-2-1. Outline ................................................................... 5-6
5-2-2. Configuration ........................................................ 5-6 7. Troubleshooting
5-3. CT-248 Board ............................................................... 5-11
5-3-1. Outline ................................................................. 5-11 7-1. Error Display .................................................................. 7-1
5-3-2. Configuration ...................................................... 5-11 7-1-1. Error Display ......................................................... 7-1
5-3-3. CPU and Peripheral Circuits ............................... 5-11 7-1-2. Error Message List ................................................ 7-1
5-4. DICOM BOARD .......................................................... 5-12 7-1-3. Error History ......................................................... 7-8
5-4-1. Interface ............................................................... 5-12 7-2. Mechanical Troubleshooting ........................................ 7-11
5-4-2. Functions ............................................................. 5-12 7-3. Electrical Troubleshooting ............................................ 7-16
7-3-1. Electrical Troubleshooting .................................. 7-16
7-3-2. Operation Defects of Motors and Sensors ........... 7-17

2 UP-DF500
Manual Structure

Purpose of this manual


This manual is the Service Manual Volume 1 of the Digital Film Imager UP-DF500.
This manual contains the installation, service overview, replacing the main parts,
procedures after replacement, circuit operation description, service mode, trouble-
shooting.

Related manuals
In addition to this Service Manual Volume 1, the following manual is provided.

. Service Manual Vol.2


Contains the spare parts, block diagrams, schematic diagrams and board layouts.

. Operating Instructions
This manual describes the information required for the actual management and
operation of this unit.

. “Semiconductor Pin Assignments” CD-ROM (Available on request)


This “Semiconductor Pin Assignments” CD-ROM allows you to search for
semiconductors used in Broadcast and Professional equipment.
Part number: 9-968-546-06

Trademarks
Trademarks and registered trademarks used in this manual are as follows.

. Windows is a registered trademark of Microsoft Corporation in the United States


and other countries.
. Memory Stick is trademark of Sony Corporation.

Other system names, product names, and company names appearing in this manual
are trademarks or registered trademarks of their respective holders.

UP-DF500 3
Section 1
Installation

n 1-1. Operating Environment


. Keep the packing material because it is used for the
transportation in servicing. . Electric voltage:
When transporting this unit, remove the paper eject tray 100 V AC to 240 V AC, 50/60 Hz
and caster from this unit. . Electric current consumption:
. When installing this unit, check the following setting 4.4 A to 1.8 A
items. . Operation temperature:
IP ADDRESS: Network setting 10 dC to 30 dC
SUBNETMASK: Network setting . Storage/transportation temperature:
DEFAULT GATEWAY: Network setting 20 dC to 60 dC
UP-DF500 installation location and space: . Storage/transportation humidity:
Location and power supply, 20% to 80%
network cable . Maximum outside dimension (Width/height/depth):
UP-DF500 carry-in route: Approx. 600 x 250 x 686 mm
Check of elevator, door, step, (Largest protrusion is not included.)
etc. . Mass:
Size of film used Approx. 55kg
Attendance of Modality
service personnel, or advance
setting

UP-DF500 1-1
1-2. Outside Dimension Diagram

600

250

686
622

289

(When a caster is installed.)

Unit: mm

1-2 UP-DF500
1-3. Installation Space 1-4. Caster Assembly Installation
Procedure
This unit can be installed in either horizontal or vertical
direction. (Refer to Section 1-4.) This unit can be installed in vertical direction by attaching
When installing, be sure to make space for the unit as the supplied caster assembly.
shown in the illustration below.
m
. When attaching the caster assembly, be sure to work by
two persons.
. Be sure to keep the four screws and four shoulder

265
washers removed from the side panel (L).
210

. When attaching the caster assembly, make sure that there


70 is no gap between the side panel (L) and front panel (L).
. When installing this unit in vertical direction, it is
recommended to place it with the left side facing down-
ward.
. In the case of placing the unit in vertical direction with
the right side facing downward, change the installation
direction from the service menu.(Refer to Section 6-2-6.)
This unit is differently controlled depending on the
direction it is installed; horizontal direction, vertical
direction with right side down or left side down. The
Avoid installing this unit in the following places to prevent sensor can detect the difference between vertical and
it from being damaged by foreign material, condensation, horizontal direction. But it cannot detect the difference
etc. between right and left when the unit is installed in
. Near the air exit of air conditioner vertical direction. Therefore, the setting is performed
. Near the open window or door manually. The setting state of this unit can be checked
. Near the busy passageway by LCD. Check it in the lower display area of LCD when
. Places easily getting spattered with liquid turning off the power.
. Places being subjected by direct sunlight ([]: Blank)
In the case of left side setting:
[][][][][]PLEASE[]WAIT
In the case of right side setting:
[][][][]PLEASE[]WAIT[]
. When attaching the caster assembly, be sure to use the
supplied stopper sheet. (Refer to the instruction manual
for the usage.)

UP-DF500 1-3
1. Remove the four screws (RK4 x 8) and four shoulder 1-5. Setting Procedure
washers from the side panel (L).
Each setting is as follows.

1. Power On
Check that the system starts after turning on the power,
then enter the service mode. (Refer to Section 6-1.)
When performing the setting copy using Memory Stick,
execute upload. (Refer to Section 3-18.)

2. Network setting
Perform the network setting such as an IP address via PC
or by system setting. For more details, refer to the Operat-
Shoulder washers ing Instructions.

3. Film loading
RK4 x 8
1. Load the film in the tray.
2. Check that the number of remaining sheets are dis-
Side panel (L) played on the LCD panel.

n
2. Attach the caster assembly using the four screws (B4 If TAG MISMATCH is displayed, the specifications of
x 16). UP-DF500 do not conform to those of the film. Contact
you local Sony’s sales/service office.

Side panel (L)


Space 4. Calibration
Perform calibration and check that LCD becomes standby
state.
n
If the CAL automatic correction cannot be performed,
CALIBRATION INVALID is displayed.

The film can be used without calibration because it is


adjusted to specified density.
B4 x 16 Perform calibration in the following cases. In addition to
the manual calibration, it is possible to set the unit so that
the first sheet can be automatically calibrated when new
B4 x 16 film is loaded.For more details, refer to the Operating
Instructions.
Front panel (L) . Accurate density control is required.
. The unit is used under the environment where tempera-
ture or humidity changes greatly.
Perform calibration as required when the print density does
not seem to meet the gamma setting.

1-4 UP-DF500
5. Printing from Modality 1-6. Film Loading Procedure
After checking the setting of UP-DF500 of Modality,
perform the printing from Modality. n
Check the items below. . Handle the film wrapped by the aluminum moisture-
. Dmax and Dmin setting proof bag with both hands. The contamination on the
. AE title name film surface such as fingerprint and sweat may cause
. ConfigInfo setting degradation of the printed image quality. Be careful not
. 320DPI/resize setting to touch the print surface.
. When handling the paper feed tray, firmly hold the side
6. Gamma setting of the tray and tray cover.
When the gamma data is available in advance, setting is For details, refer to the instruction manual supplied with
performed by FSSS. If the gamma is specified by Default, this unit.
change the setting of the main unit.

7. Gamma check and approval 1-7. Check List


Print out the image specified by the hospital and obtain the
approval of density setting by a responsible person. The check items are described in the check list. Use it for
n installation and maintenance. (Refer to the next page.)
If there is any request by the hospital, adjust the gamma
curve using FSSS. The selection of gamma can be per-
formed by the default setting, AE title setting from DI-
COM BOARD or Config setting. In the service mode, the
selected gamma is indicated as G=x in the lower area of
the printed output. So it can be checked. Be sure to per-
form calibration before printing the image for obtaining the
approval of gamma.

8. Check other setting


As for FRAME TYPE, the image frame can be enlarged.
The density in the edge of film is not uniform, therefore
the image quality of the area outside of the specified size
(HOOK) of film is not assured. In the case of changing the
setting, explain users about this. The factory setting is as
follows.

. DITHER: ON
. MIRROR: OFF
. L/R MARK: OFF
. FRAME TYPE: HOOK
. CAPTION: ON (No data)
. FILM EMPTY BUZZER: OFF
. VERTICAL SETTING: L
. AUTO CAL setting (user menu): OFF

UP-DF500 1-5
Check list No. 1 Installation information list (S/N: )
List_Ver_500A1

UP-DF500 DICOM setup information User settings


TCP/IP IP Address
Sub-net Mask
Default Gateway
Primary Printer AE Title
E-Mail settings Mail Server IP address
User ID
From:
Send To:
Errors/events Motor/Sensor error
to monitor
Film Jamming
More than 50000…

UP-DF500 gamma setting information


Name SHARPNESS 95% 5% Memo
1 SONY1 OFF ( ) 25 ( ) 75 ( )
2 OFF ( ) 25 ( ) 75 ( )
3 OFF ( ) 25 ( ) 75 ( )
4 OFF ( ) 25 ( ) 75 ( )
5 OFF ( ) 25 ( ) 75 ( )
6 OFF ( ) 25 ( ) 75 ( )
7 OFF ( ) 25 ( ) 75 ( )
8 OFF ( ) 25 ( ) 75 ( )
9 OFF ( ) 25 ( ) 75 ( )
10 OFF ( ) 25 ( ) 75 ( )
11 OFF ( ) 25 ( ) 75 ( )
12 OFF ( ) 25 ( ) 75 ( )
13 OFF ( ) 25 ( ) 75 ( )
14 OFF ( ) 25 ( ) 75 ( )
15 OFF ( ) 25 ( ) 75 ( )
16 OFF ( ) 25 ( ) 75 ( )
17 OFF ( ) 25 ( ) 75 ( )
18 OFF ( ) 25 ( ) 75 ( )
19 OFF ( ) 25 ( ) 75 ( )
20 OFF ( ) 25 ( ) 75 ( )

Memo: If any GAMMA dat File is set, write it.


File name Date
Save
Load
Memo: Check MAX DENSITY setting of UP-DF500.
UP-DF500 MAX DENSITY (SYSTEM SETTINGS) 320 ( )

Connected Modality information

Maker/type
Category CR DR CT MR Others ( ) Comp. Unknown
1 Magnification Type CUBIC NONE (320dpi, 79 µ) Others ( )
Max. Density 320 300 Unknown Others ( )
DICOM set
Min. Density 22 Unknown Others ( )
Gamma specification NONE:UP-DF500 default AE Title ( ) Config. Info. ( )

Maker/type
Category CR DR CT MR Others ( ) Comp. Unknown
2 Magnification Type CUBIC NONE (320dpi, 79 µ) Others ( )
Max. Density 320 300 Unknown Others ( )
DICOM set
Min. Density 22 Unknown Others ( )
Gamma specification NONE:UP-DF500 default AE Title ( ) Config. Info. ( )

Maker/type
Category CR DR CT MR Others ( ) Comp. Unknown
3 Magnification Type CUBIC NONE (320dpi, 79 µ) Others ( )
Max. Density 320 300 Unknown Others ( )
DICOM set
Min. Density 22 Unknown Others ( )
Gamma specification NONE:UP-DF500 default AE Title ( ) Config. Info. ( )

Maker/type
Category CR DR CT MR Others ( ) Comp. Unknown
4 Magnification Type CUBIC NONE (320dpi, 79 µ) Others ( )
Max. Density 320 300 Unknown Others ( )
DICOM set
Min. Density 22 Unknown Others ( )
Gamma specification NONE:UP-DF500 default AE Title ( ) Config. Info. ( )

1-6 UP-DF500
Check list No. 2 UP-DF500 setting value (Set S/N: )
List_Ver_500A2B
Initial
setting Check Check Check Check
Inspection
Written date / / / / / / / / / /
Menu Item Initial setting MS

CALIBRATION AUTO CALIBRATION OFF O

GAMMA SEL DEFAULT SONY1 O

DITHER ON O
MIRROR OFF O
L/R Mark OFF O
FRAME TYPE HOOK O
CAPTION U: ON /D: ON O
SYSTEM SETTINGS HEAD OFFSET ADJ ON
EDGE MODE ON O
MAX DENSITY 320 O
FILM EMPTY BUZZ. OFF O
VERTICAL SETTING L O
OUTPUT TRAY ON

IP ADDRESS 192.168.1.100 O
TOTAL PRINTS 0
TOTAL HEAD PRINTS 0
MA Ver (Shipment Ver)
DR Ver (Shipment Ver)
CT Ver (Shipment Ver)
INFORMATION
ICTAG VER (Shipment Ver)
DICOM Ver (Shipment Ver)
IDMAC Ver (Shipment Ver)
HEAD Ave. (Individual data)
HEAD NAME (Individual data)

VOLTAGE_ADJ (Adjustment value)


PITCH ADJ (Adjustment value)
X POS ADJ (Adjustment value)
ADJUST
Y POS ADJ (Adjustment value)
LUT[0] GRAD ADJ 0
LCD CONTRAST 0

Setting information
(Gamma file name Save/Load) (To be determined)
GAMMA File (File update date check) / /
20 (check/fine adjust) O
Fine name (Shipment Ver)
PATCH File
(File update date check) / /
CAPTION UP (To be determined) O
DOWN (To be determined) O
Inspection. check item
Appearance . installation check
Densitometer calibration
Maintenance check Consumable parts replacement
Cleaning
DICOM Virus Patch Ver.
After CAL Before CAL/after CAL Before CAL/after CAL Before CAL/after CAL Before CAL/after CAL
Density: 0% / / / /
(Density: %) (User specified density) / / / /
Density measurement (Density: %) (User specified density) / / / /
(Density: %) (User specified density) / / / /
Density: 100% / / / /
Internal densitometer calibration Difference of density compared to reference sheet ± ± ± ± ±
Check of execution
CALIBRATION Film lot memo used
CAL PRINT CHECK
Visual check
TEST (STEP) PRINT
Skew/print position
Clinical image Check request

↑ The information items to be saved in Memory Stick are marked


with a circle (O).

UP-DF500 1-7
Section 2
Service Overview

2-1. Board Location

DR-618 board MA-155 board

CN-2932 board
CN-2938 board

SW-1340 board

IF-1042 (500)
board
CT-248 board
LE-336 board

SW-1341 board
DICOM BOARD
KEY-59 board

SE-680 board SU-77 board


SE-802 board SE-681 board
SE-694 board

SW-1096 board

SE-679 board

SU-76 board

CN-2327 board

CN-2326 board SE-868 board

UP-DF500 2-1
SE-881 board (PH3)
SE-892 board (PH3) SE-880 board (PH3)

SW-1342 board (PH2) SU-121 board (PH2)


SU-121 board (PH3)
SE-874 board (PH2)
PH2 assembly SE-898 board (PH3)

CN-2940 board (PH3)

CN-2934 board (PH2) PH3 (S) assembly

SE-892 board (PH3)


SE-896 board (PH3)
SE-891 board (PH3)

SE-894 board SE-899 board


SE-895 board CN-2941 board
SE-888 board SE-876 board

PH1 assembly SE-872 board

SW-1345 board SE-877 board

CN-2939 board

SE-875 board
SE-878 board
Paper feed chassis
SU-123 board
assembly
CN-2935 board
SU-122 board AN-31 board

2-2 UP-DF500
2-2. Main Parts Location

n
For the function of each motor, refer to “Circuit Operation Description” (Section 5) and “Troubleshoot-
ing” (Section 7).

Switching regulator
DC fan (For inside)

Capstan up/down motor

Thermal head

Head up/down motor

Fan motors (For head)

Encoder assembly Platen drive motor

UP-DF500 2-3
Intermediate feed roller motor (PH2)

Paper eject selection flap motor (PH3)


Stepping motor for driving (PH3)
PH2 assembly

PH3 (S) assembly


Side registration
stepping motor (PH2)

PH1 assembly

Stepping motor

Electromagnetic clutch
Paper feed chassis
assembly
Lift up motor

Tray out motor

2-4 UP-DF500
2-3. Sensor/Actuator Location and Function

n
For the function of each sensor, refer to “Circuit Operation Description” (Section 5) and “Troubleshoot-
ing” (Section 7).

Paper lead edge and


Capstan up/down sensor trail edge path sensor
Jamming path sensor

Head up/down sensor

Full stack sensor 1

Full stack sensor 0

Eject turn path Photoreception sensor (PH3)


sensor (PH3) LED sensor (PH3)
Intermediate drive
PH2 assembly path sensor (PH2)
Flap POS
sensor (PH3)

Eject path sensor (PH3) PH3 (S) assembly

Density path sensor (PH3)

UP-DF500 2-5
Pick position sensor PH1 assembly
End turn path sensor
Film tray in sensor
Pick end path sensor Paper eject tray sensor

NO film sensor Film tray out sensor

Lift up home sensor


Paper feed chassis
Lift up motor FG sensor assembly

2-6 UP-DF500
2-4. Removing/Installing the Cabinet 2-4-2. MD Cover (BD)

2-4-1. Front Sash Assembly 1. Remove the front sash assembly.


(Refer to Section 2-4-1.)
1. Remove the four screws (B4 x 8), then remove the 2. Remove the three hooks [A], then remove the MD
front sash assembly. cover (BD) in the direction of the arrow.
2. Remove the two screws (PSW3 x 6), then remove the
front angle (L) from the front sash assembly.
3. Remove the two screws (PSW3 x 6), then remove the
front angle (R) from the front sash assembly.

Front angle (R)


B4 x 8

PSW
3x6

B4 x 8 PSW
3x6
PSW
3x6 Hooks [A]
MD cover (BD)

Front angle (L) Front sash assembly


3. Attach the MD cover (BD) in the reverse order of steps
PSW 1 and 2.
3x6

4. Attach the front sash assembly in the reverse order of


steps 1 to 3.

UP-DF500 2-7
2-4-3. Front Panel (L) Assembly 2-4-4. Front Panel (R) Assembly

1. Remove the front sash assembly. 1. Remove the front sash assembly.
(Refer to Section 2-4-1.) (Refer to Section 2-4-1.)
2. Remove the screw, then remove the cover (USB). 2. Remove the front panel (R) assembly.
3. Remove the front panel (L) assembly.

Cover (USB)

Front panel (R) assembly

PTTWH
M3 x 8
3. Attach the front panel (R) assembly in the reverse
Front panel (L) assembly
order of steps 1 and 2.

4. Attach the front panel (L) assembly in the reverse


order of steps 1 to 3.

2-8 UP-DF500
2-4-5. MD Front Panel Assembly/MD Upper 4. Remove the three fan filters.
Cover

1. Release the lock of the eject lever, then open the MD


MD front panel
assembly. assembly
2. Loosen the two screws (BVTT3 x 6).
3. Remove the two shoulder screws, then remove the MD
front panel assembly.

MD assembly

Fan filters

5. Remove the two screws, then remove the MD upper


cover.

MD upper cover
PTTWH
M3 x 8
Eject lever

BVTT3 x 6

MD front panel 6. Attach the MD front panel assembly/MD upper cover


Shoulder assembly
screws in the reverse order of steps 1 to 5.

UP-DF500 2-9
2-4-6. Side Panel (L) 2-4-8. Outer Frame L Cover

1. Remove the four screws and four shoulder washers, 1. Remove the side panel (L). (Refer to Section 2-4-6.)
then remove the side panel (L) in the direction of the 2. Remove the six screws (PTTWH M3 x 8) and eight
arrow. screws (BVTT3 x 6), then remove the shield plate
(MD-L) and outer frame L cover.
Side panel (L)
PTTWH
BVTT 3x8
Shoulder
3x6
washers

RK4 x 8

Shoulder washers
PTTWH
3x8
RK4 x 8

BVTT
2. Attach the side panel (L) in the reverse order. 3x6
Outer frame L cover BVTT
3x6 Shield plate (MD-L)

2-4-7. Side Panel (R)


3. Attach the outer frame L cover in the reverse order of
1. Remove the four screws and four shoulder washers, steps 1 and 2.
then remove the side panel (R) in the direction of the
arrow.

Shoulder washers
Side panel (R)
RK4 x 8

Shoulder washers
RK4 x 8

2. Attach the side panel (R) in the reverse order.

2-10 UP-DF500
2-4-9. Top Cover (D) 2-4-10. Rear Cover (TD)/PH2 Flap

1. Open the top guide assembly, then remove the four 1. Remove the side panel (L). (Refer to Section 2-4-6.)
shoulder screws. 2. Remove the side panel (R). (Refer to Section 2-4-7.)
2. Remove the screw (BVTT3 x 6), then remove the 3. Remove the rear cover (TD) and PH2 flap.
GND bracket (T).
PH2 flap
Rear cover (TD)
GND bracket (T)

BVTT Top guide assembly


3x6

Shoulder
screws

4. Attach the rear cover (TD) and PH2 flap in the reverse
3. Remove the two shoulder screws, then remove the top order of steps 1 to 3.
cover (D).
Shoulder screw
Top cover (D)

4. Attach the top cover (D) in the reverse order of steps 1


to 3.
UP-DF500 2-11
2-4-11. Rear Cover (BS) 2-5. Optional Fixtures

1. Remove the side panel (L). (Refer to Section 2-4-6.) 2-5-1. Reference Sheet
2. Remove the side panel (R). (Refer to Section 2-4-7.)
3. Remove the two shoulder screws, then remove the rear Reference sheet
cover (BS). Sony part number: A-8279-926-C

Shoulder screws
2-6. Periodic Inspection

Perform the periodic inspection every 5000 sheets of


printing or every 4 months. When performing inspection
and maintenance, place this unit in the horizontal direction
except for special cases.
Cleaning is performed for the following places.
. Film transport path
. Transport roller, belt
Rear cover (BS) . Densitometer
. Capstan roller
. Thermal head
. Platen
. Cleaning roller

4. Attach the rear cover (BS) in the reverse order of steps 2-6-1. Cleaning of Main Unit
1 to 3.
Required items

. Kimwipe (synthetic paper without fluff)


. Alcohol for disinfection (medical use) with a purity
greater than 90% or cleaning pad supplied as accessory
(Do not use fuel alcohol because it has harmful effects
on the thermal head rubber roller.)

Preparation

1. Open the front cover, top cover, inner cover 1, inner


cover 2 and rear cover.
2. Remove the transfer cleaning roller.
(Refer to Section 3-8.)

Cleaning

n
Be sure to perform the cleaning of the thermal head first.
In order to prevent the damage to the thermal head, do not
use the wiping cloth and pad used for cleaning other parts.

2-12 UP-DF500
Thermal head Others
Clean the heating element of the thermal head using the Wipe the guide, wall, belt (visible from outside), etc. in
wiping cloth or cleaning pad dampened with alcohol. It PH1, PH2 and PH3.
will be stained with reddish brown contamination, but this
is not abnormal state. Procedure after cleaning
m
. Do not touch the thermal head with your fingers directly. 1. Return the transfer cleaning roller to the original
Otherwise, it may cause an electrostatic discharge position, then attach the bearing lock securely.
failure. 2. Close the front cover, top cover, inner cover 1, inner
. Be sure to touch the metal portion of this unit with your cover 2 and rear cover.
hand for grounding to prevent the build up of static
electricity on the thermal head.
2-6-2. Tray Cleaning
Cleaning roller
The dust on the transfer cleaning roller (gray) moves to the n
paper cleaning roller. (Replace the paper cleaning roller.) When handling the film loaded in the tray, be careful not to
In the case that the roller becomes too dirty, wash the roller touch the printing surface of the film.
in the water and dry naturally.
1. Remove the tray from this unit.
Calibration sensor window 2. Take out the film.
Fold a clean wiping cloth so that it becomes about 1 mm in n
thickness. Insert the cloth into the calibration sensor and Be extremely careful that the dust does not adhere to
clean the sensor window by moving it back and forth the film.
several times. 3. Remove the tray cover.
n 4. Clean inside, outside and backside of the tray.
In the usual periodic inspection, the calibration of calibra-
tion sensor is not required. n
In this unit, the separation roller is attached to the main
Capstan roller unit. The cleaning is not required in the usual periodic
Clean the capstan roller using the wiping cloth or cleaning maintenance. However, in case that the occurrence of
pad dampened with alcohol. multi-feed problem during paper feed is reported, the
cleaning or replacement is required.
Platen roller
Clean the platen roller using the wiping cloth or cleaning
pad dampened with alcohol. 2-6-3. Fan Filter
m
. When cleaning the roller, be careful not to dent or 1. Remove the fan filter. (Refer to Section 2-4-5.)
scratch the platen. 2. Clean the filter by vacuum cleaner (scrubbing with
. Applying pressure to the platen may cause the nonuni- fingers, using gum tape, wash with water, etc.).
formity of density. When cleaning the platen, use the 3. Attach the fan filter. (No difference between the sides.)
cleaning pad so that it contacts with the platen lightly.
The platen rotates about one-forth turn when the front
cover is closed once and the mechanical block starts
initialization. Clean all around the platen by repeating
the cleaning and initialization.
The platen is eliminated from the cleaning items per-
formed by users in the operating instructions because it
is easily damaged.

UP-DF500 2-13
2-6-4. Dust Cleaning Roller

n
For the replacing procedure of the dust cleaning roller,
refer to Section 3-7.
The users are recommended to replace the dust cleaning
roller every 500 sheets. When the dust cleaning roller is
contaminated, replace it.

2-6-5. Replacing the Periodic Replacement


Parts

The parts needing the periodic replacement are as follows.

Name Recommended Refer to Remarks


number of
printed sheets
to be replaced

Thermal head 50,000 Section 3-7 *1


Separation 25,000 Section 3-17
roller assembly
Transfer 10,000 Section 3-8
cleaning roller
Replacement of 100,000 Section 3
each engine
*1: Refer to “4-1. Adjustment after Replacing the Thermal Head” for the
adjustment after replacement.

2-14 UP-DF500
2-7. Maintenance Check (3) Consumable parts required for maintenance
. Replacing every 500 sheets:
2-7-1. Preparation Cleaning roller
(Supplied with the unit or accessory UPA-500.)
Prepare the materials and parts as required for each . Replacing every 10,000 sheets:
maintenance. Transfer cleaning roller (3-748-168-02)
. Replacing every 25,000 sheets:
. In the maintenance check, basically only the cleaning is Separation roller assembly
the required work. (A-8286-345-C and later are used.)
. The firmware version upgrade is not required for the UP- . Replacing every 50,000 sheets:
DF500 that is already installed unless otherwise speci- Thermal head assembly
fied by the technical news. (A-8246-560-E and later are used.)
. As for the need of DICOM BOARD virus patch, deter- (4) Materials and parts required for readjustment of the
mine it after consulting with the network administrator in gamma curve. (Only when readjustment is required)
the hospital. . PC, FSSS, USB cable
. The items marked with asterisk (*) are the special check * Handy densitometer
procedure for the hospital in which the density control is (5) Materials and parts required for firmware version
performed by numeric value. upgrade
. PC, FSSS + USB cable (DF500 firmware), cross cable
1. Check the technical news information. (DICOM firmware)
2. Information of the estimated total count of printed . Version upgrade file
sheet number of the user. (6) Material and parts required for virus patch
3. Required materials and parts . USB memory
. PC
(1) Materials and parts required for cleaning . Virus patch file
. Cleaning sheet (UPA-500 cleaning kit, or synthetic paper
without fluff (marketed item))
. Alcohol for disinfection (medical use) with a purity
greater than 90%, or alcohol sheet for disinfection.
(Do not use fuel alcohol because it has harmful effects
on the thermal head and rubber parts.)
. Tape (UL tape, scotch tape, gum tape, etc.)
(2) Materials and parts required for density control
* Reference sheet (For density adjustment: A-8279-926-C)
(Suffix “C” and later are used for UP-DF500.)
* Handy densitometer (KonicaMinolta PAD-100 or
GretagMacbeth icFilm is recommended.)
About the densitometer for UP-DF500;
The correct density of the UPT-517BL film used in UP-
DF500 cannot be measured by X-Rite301 due to the
difference of spectroscopic characterization. In the service,
it is recommended to use the above handy densitometer.
In the practical use, UP-DF500 has the internal densitome-
ter. By performing the calibration, it is possible to control
the print density that is enough to make a diagnosis.
Therefore, it is not required to use the external densitome-
ter separately.
n
In the case that the hospital controls the density by using
X-Rite301, the filter for UPT-517BL is available.

UP-DF500 2-15
2-7-2. Appearance Check

Item Action

Check the appearance of unit, power cable, Ethernet cable.


. There should be no noticeable dent, scratch, etc. . If the operation or image quality is affected,
. There should be no damage to cables. Routing should be repair it.
appropriate. . Replace the cable. Or, route the cables
appropriately.
. Check the dust, etc. near the power plug and AC inlet. . Perform cleaning to prevent the electric leakage.
Check the installation location, orientation and environment. . If there is any change of location, other devices or
air conditioning, install the unit in an appropriate
method.

2-7-3. Check of Current Status

m
. For the check list, refer to Section 1-7. It is helpful to use the DUMP LIST of the test printing by which
the main settings can be printed at a time.
* Perform the calibration of densitometer by using the reference sheet. Check that the setting value is
± 0.06 with respect to the reference value. (Refer to Section 4-2-3.)

Items Action

Check the setting value, density, image quality and (Write in list 2.)
installation.
. Write the setting value, etc. in the list. . Check the reason if there is any change in setting from the
* Calibration of internal densitometer previous setting
* Measure the density and write the result in the list. . Readjust the densitometer if the value is ± 0.07 or more.
. If the result does not meet the specified value, adjust the
gamma in FSSS. (If there is any chart specified by the
hospital, print it out.)
. Print out STEP. . Readjust the registration of printing position after cleaning.
Refer to “Side registration and printing position
adjustment” in the training documentation.
Refer to “4-3. Printing Position Adjustment Procedures”.

2-7-4. Periodic Replacement Parts and Cleaning

Items Action

Perform the replacement and cleaning according . Replace the consumable parts according to Section 2-6-5.
to the service manual. . Perform the cleaning according to Section 2-6-1 and later.

2-16 UP-DF500
2-7-5. Version Upgrade and Virus Patch

n
The version upgrade of DICOM BOARD is performed to improve the connectivity with the new Modali-
ty. It is recommended to use this as it is unless the version upgrade is specified by technical news, etc.

Item Action

Firmware version upgrade and virus patch Only when it is required (Refer to technical news and
. Upgrade the version of MA, DR, CT, TAG consult with the administrator in the hospital.)
and DICOM using FSSS.
. Implement the anti-virus patch for DICOM BOARD.

2-7-6. Confirmation

n
Before performing the calibration, ask users about the calibration status of use for confirmation. If the
unit has been operated without calibration for long period of time, the print density gradually changes,
which may give impression that the density is changed after the calibration is performed (after mainte-
nance check). In such a state, perform the calibration after explaining the function of calibration to the
user.

Item Action

Perform FULL RANGE → CAL PRINT CHECK. . Write the lot of film. (Lot No. of packing box or Media Tag
. Write the result and used film in the check list. DATE of menu)
Perform TEST PRINT>STEP. . Readjust if the printing position is not correct.
. Perform visual check → Check the list.
Print out via user’s DICOM.
. Check if the printing is normal. → Check the list.

2-8. Unleaded Solder

Boards requiring use of unleaded solder are printed with a lead free mark (LF) indicating the solder
contains no lead.
(Caution: Some printed circuit boards may not come printed with the lead free mark due to their particular
size.)

: LEAD FREE MARK

m
. Be sure to use the unleaded solder for the printed circuit board printed with the lead free mark.
. The unleaded solder melts at a temperature about 40 dC higher than the ordinary solder, therefore, it is
recommended to use the soldering iron having a temperature regulator.
. The ordinary soldering iron can be used but the iron tip has to be applied to the solder joint for a
slightly longer time. The printed pattern (copper foil) may peel away if the heated tip is applied for too
long, so be careful.

UP-DF500 2-17
Section 3
Replacing the Main Parts

n
Board/connector Cable Board/connector
Use a screwdriver of 150 mm or more in length when
replacing main parts. MA-155/CN1004 Flexible flat cable Thermal head/CN1
MA-155/CN1005 Flexible flat cable Thermal head/CN2
MA-155/CN1006 Flexible flat cable Thermal head/CN3
3-1. Replacing the Board MA-155/CN1008 Flexible flat cable CN-2938/CN6902
MA-155/CN1011 Flexible flat cable CN-2932/CN7101
3-1-1. MA-155 Board
MA-155/CN1013 Flexible flat cable LE-336/CN6501
MA-155/CN1014 Flexible flat cable KEY-59/CN6403
n
MA-155/CN1001 Harness Switching regulator/
When replacing the MA-155 board, it is required to
CN203
retrieve the specific data from the board (defective board)
MA-155/CN1015 Harness CT-248/CN5001
to be replaced and write the setting value in EEPROM of
MA-155/CN1017 Harness Room fan
the new MA-155 board. For details, refer to “4-2-1. MA-
155 Board”. MA-155/CN1003 Harness DICOM BOARD/J22
MA-155/CN1019 Harness DICOM BOARD/J8
1. Remove the front panel (L) and (R) assemblies.
(Refer Sections 2-4-3 and 2-4-4.) CN1005
2. Remove the side panel (L). (Refer to Section 2-4-6.) CN1006 CN1004
3. Remove the outer frame L cover.
(Refer to Section 2-4-8.)
4. Remove DICOM BOARD. (Refer to Section 3-14.)
CN1003
5. Disconnect the cable and harness from the MA-155
board. CN1009 CN1016
(For tool)
CN1002
(*1)

CN1001
CN1013
CN1008

CN1014
CN1010
CN1012
CN1019 (*1)

CN1015 CN1011 CN1017


*1: For PLD version upgrade

UP-DF500 3-1
6. Disconnect the harness from the DR-618 board. 7. Remove the four screws, then remove the DR-618
board and MA-155 board.
Board/connector Cable Board/connector

DR-618/CN100 Harness CN-2938/CN6908


DR-618/CN3 Harness CN-2938/CN6903
DR-618/CN2 Harness CT-248/CN1
DR-618/CN602 Harness CT-248/CN2
DR-618/CN601 Harness CN-2935/CN5101 BVTT
DR-618/CN605 Harness CN-2326/CN3102 3x6

DR-618/CN607 Harness SE-802/CN3701


DR-618/CN608 Harness CN-2934/CN5601
DR-618/CN609 Harness SE-874/CN7501
SU-121/CN3221
DR-618/CN611 Harness CN-2938/CN6910
DR-618/CN1 Harness Switching regulator/CN202
DR-618/CN606 Harness DICOM BOARD/J19
BVTT
3x6

DR-618 board
CN100 CN609 CN605 MA-155 board
CN608 BVTT
3x6

CN611
CN607

CN2

CN1

CN3

CN602

CN606

CN601

3-2 UP-DF500
8. Remove the four screws (BVTT3 x 6), two screws 3-1-2. DR-618 Board
(PSW3 x 6) and connector (CN1007), then remove the
MA-155 board. 1. Remove the front panel (L) and (R) assemblies.
(Refer Sections 2-4-3 and 2-4-4.)
2. Remove the side panel (L). (Refer to Section 2-4-6.)
3. Remove the outer frame L cover.
(Refer to Section 2-4-8.)
4. Remove DICOM BOARD. (Refer to Section 3-14.)
5. Remove the MA-155 board. (Refer to Section 3-1-1.)
6. Remove the four screws, then remove the DR-618
board.
MA-155 board
CN1007 DR-618 board

DR-618 board

BVTT
3x6

PSW BVTT
3x6 3x6
Rivet

DR-MA fixing plate


BVTT
3x6

BVTT Rivet
9. Install the MA-155 board in the reverse order of steps 3x6
1 to 8.
n
When attaching the connector (CN1007) on the MA-
155 board, be sure to securely attach it to the DR-618
board.

7. Install the DR-618 board in the reverse order of steps 1


to 6.
n
When attaching the connector (CN1007) on the MA-
155 board, be sure to securely attach it to the DR-618
board.

UP-DF500 3-3
3-1-3. KEY-59 Board/LE-336 Board/SW-1341 3-1-4. CN-2932 Board
Board
1. Remove the front sash assembly.
1. Remove the front sash assembly. (Refer to Section 2-4-1.)
(Refer to Section 2-4-1.) 2. Remove the front panel (L) assembly.
2. Remove the front panel (L) assembly. (Refer to Section 2-4-3.)
(Refer to Section 2-4-3.) 3. Remove the side panel (L). (Refer to Section 2-4-6.)
3. Remove the side panel (L). (Refer to Section 2-4-6.) 4. Remove the MD assembly. (Refer to Section 3-2.)
4. Disconnect the flexible flat cable from the connector 5. Remove the two screws, then remove the CN-2932
(CN6403) and disconnect the two harness from the board.
connectors (CN6401 and CN6402) on the KEY-59 6. Disconnect the flexible flat cable from the connector
board. (CN7101) and disconnect the harness from the connec-
5. Remove the two screws, then remove the KEY-59 tor (CN7104) on the CN-2932 board.
board.
Flexible flat cable CN-2932 board
6. Remove the screw, then remove the humidity sensor
board. CN7101
BVTT
7. Disconnect the harness from the connector (CN1) on 3x6
the humidity sensor board. Harness
8. Remove the two screws and disconnect the flexible flat
cable from the connector (CN6501) on the LE-336 CN7104
board, then remove the LE-336 board.
9. Remove the screw and disconnect the harness from the
connector (CN4021) on the SW-1341 board, then
remove the SW-1341 board.

Flexible
flat cable
LE-336 board

CN6501
BVTT
3x6

SW-1341 board

BVTT
3x6 7. Install the CN-2932 board in the reverse order of steps
CN4021
BVTT
1 to 6.
Harness Harnesses
3x6

CN1
Humidity sensor board
CN6402
Flexible flat cable

CN6401
KEY-59 board
BVTT
CN6403 3x6

10. Install the SW-1341 board, LE-336 board and KEY-59


board in the reverse order of steps 1 to 9.

3-4 UP-DF500
3-2. MD Assembly Board/connector Cable Connected to

MA-155/CN1004 Flexible flat cable Thermal head/CN1


m
MA-155/CN1005 Flexible flat cable Thermal head/CN2
. When removing the MD assembly, be sure to work by
MA-155/CN1006 Flexible flat cable Thermal head/CN3
two persons.
. When removing the MD assembly, be careful that the CN-2938/CN6904 Flexible flat cable CN-2326/CN3101

cable is not caught in the chassis.


Switching regulator Harness Thermal head/CN4
. After removing the MD assembly, place it on a flat
/CN201
place.
DR-618/CN605 Harness CN-2326/CN3102
. When attaching the MD assembly, be careful not to
CN-2938/CN6913 Harness SW-1096/CN4041
pinch the cable.

1. Remove the front sash assembly.


CN-2938 board CN6913
(Refer to Section 2-4-1.)
2. Remove the front panel (L) assembly.
(Refer to Section 2-4-3.)
3. Remove the front panel (R) assembly.
(Refer to Section 2-4-4.)
4. Remove the side panel (L). (Refer to Section 2-4-6.) CN6904
5. Remove the side panel (R). (Refer to Section 2-4-7.)
6. Remove the outer frame L cover. Switching
regulator
(Refer to Section 2-4-8.)
7. Remove the DICOM BOARD. CN201
(Refer to Section 3-14.)
8. Disconnect the cable and harness from each board.

Harness

CN1006 CN1004

CN605

CN607
CN1005

DR-618 board MA-155 board

UP-DF500 3-5
9. Open the top guide assembly. 3-3. PH1 Assembly
10. Remove the two screws, then remove the MD flap
assembly. m
11. Release the eject lever lock, then open the MD assem- . When removing the PH1 assembly, be careful that the
bly. cable is not caught in the chassis.
12. Remove the six screws, then remove the MD assem- . When attaching the PH1 assembly, be careful not to
bly. pinch the cable.

1. Remove the side panel (L). (Refer to Section 2-4-6.)


MD flap assembly
2. Remove the side panel (R). (Refer to Section 2-4-7.)
BVTT
BVTT 3x6 3. Remove the rear cover (TD) and PH2 flap.
3x6 (Refer to Section 2-4-10.)
MD assembly 4. Remove the outer frame L cover.
BVTT
3x6 (Refer to Section 2-4-8.)
5. Remove the connector from the CN-2938 board and
BVTT remove the harness from the wire retainer.
3x6

Board/connector Cable Connected to


MD assembly
CN-2938/CN6901 Harness CN-2939/CN4101
Top guide assembly CN-2938/CN6915 Harness SW-1345/CN4061

Eject lever Wire retainer


CN-2938 board

CN-2938 board CN6915

13. Attach the MD assembly in the reverse order of steps 1


to 12.
m
. After attaching the MD assembly, check that the
eject lever on the cabinet is correctly inserted into the Wire retainer CN6901
eject lever of the MD assembly.
. When replacing the MD assembly, remove parts
such as the ferrite core and shield sheet from the MD
assembly before replaced, then attach them to a new
MD assembly.

3-6 UP-DF500
6. Remove the six screws and two hooks, then remove 3-4. PH2 Assembly
the PH1 assembly in the direction of the arrow.
m
. When removing the PH2 assembly, be careful that the
cable is not caught in the chassis.
Hook
. When attaching the PH2 assembly, be careful not to
BVTT pinch the cable.
3x6
Hook BVTT
3x6
1. Remove the side panel (L). (Refer to Section 2-4-6.)
2. Remove the side panel (R). (Refer to Section 2-4-7.)
BVTT
3x6 3. Remove the outer frame L cover.
BVTT (Refer to Section 2-4-8.)
3x6
4. Disconnect the harness from each board.

Board/connector Cable Connected to

CN-2938/CN6914 Harness SW-1342/CN4031


DR-618/CN608 Harness CN-2934/CN5601
PH1 assembly DR-618/CN609 Harness SE-874/CN7501
SU-121/CN3221

PH1 assembly CN-2938 board CN6914

DR-618 board CN609


7. Attach the PH1 assembly in the reverse order of steps
CN608
1 to 6.

UP-DF500 3-7
5. Remove the two screws, then remove the panel bracket 3-5. PH3 (S) Assembly
(L).
6. Remove the two screws, then remove the panel bracket m
(R). . When removing the PH3 (S) assembly, be careful that
7. Remove the four screws, then remove the PH2 assem- the cable is not caught in the chassis.
bly. . When attaching the PH3 (S) assembly, be careful not to
pinch the cable.
Panel bracket (R)
PH2 assembly 1. Remove the side panel (L). (Refer to Section 2-4-6.)
BVTT
3x6 2. Remove the side panel (R). (Refer to Section 2-4-7.)
Panel bracket (L)
3. Remove the outer frame L cover.
BVTT
3x6 (Refer to Section 2-4-8.)
BVTT 4. Remove the PH1 assembly. (Refer to Section 3-3.)
3x6 5. Remove the PH2 assembly. (Refer to Section 3-4.)
BVTT 6. Disconnect the harness from each board.
3x6
Board/connector Cable Connected to

CN-2938/CN6909 Harness CN-2940/CN7001


CN-2938/CN6906 Harness CN-2940/CN7002
CT-248/CN7 Harness SE-881/CN5901
CT-248/CN3 Harness SE-880/CN3301

CN-2938 board

CN6909

CN6906

8. Attach the PH2 assembly in the reverse order of steps


1 to 7.

CT-248 board CN7

CN3

3-8 UP-DF500
7. Remove the four screws, then remove the PH3 (S) 3-6. Head Block Assembly
assembly in the direction of the arrow.
m
PH3 (S) assembly . When attaching the one-way hinge, attach it while
rotating in the direction of the arrow (it does not rotate
BVTT
BVTT 3x6 counterclockwise).
3x6
. When attaching the head block assembly, be careful that
the head chassis is not placed over the dust cleaning
roller lever B. Place the dust cleaning roller B so that it
is positioned inside of the head chassis.
. When attaching the head block assembly, be careful not
to pinch the cable.

1. Remove the MD assembly. (Refer to Section 3-2.)


2. Disconnect the harness from the connector (CN3108)
on the CN-2326 board, then remove it from the three
clampers.
3. Remove the two reuse bands from the rear beam
assembly.

Reuse bands

8. Attach the PH3 (S) assembly in the reverse order of


steps 1 to 7. Rear beam assembly

Clampers

Harness
CN3108
CN-2326 board

UP-DF500 3-9
4. Open the head block assembly, then remove the snap 3-7. Thermal Head Assembly
ring (W3.2) and paper eject dumper idler gear.
5. Remove the screw (BVTT3 x 6), then remove the m
harness. . Before removing the thermal head assembly, eliminate
6. Remove the two screws (BVTT3 x 8), then remove the static electricity.
the one-way hinge. . When removing the transfer cleaning roller, be careful
7. Remove the bearing 8 in the direction of the arrow. not to drop the bearing and roller.
8. Remove the bearing 10/14 from the head fulcrum . When removing the thermal head, be careful not to drop
shaft. the thermal head.
9. Remove the head block assembly in the direction of . When attaching the thermal head assembly, be sure to
the arrow. securely insert the head fulcrum arm into the groove of
10. Remove the gear lever, parallel pin and wave washer the head fulcrum shaft.
from the head fulcrum shaft. . When attaching the harness (GND), be sure to securely
attach it being careful of the orientation.
Wave washer . After replacing the thermal head, perform the required
Head block assembly procedure. For details, refer to “4-1. Adjustment after
Gear lever
Replacing the Thermal Head”.

1. Release the lock of the eject lever, then open the head
Harness block assembly.
(GND) 2. Remove the dust cleaning roller in the direction of the arrow.
Parallel Paper eject
pin dumper idler
gear
BVTT
3x6
W3.2
Bearing 8
Head fulcrum
shaft

Bearing 10/14

One-way
hinge Eject lever

Head block
assembly

BVTT
3x8

Installation Head
chassis

Dust cleaning
roller lever B

11. Attach the head block assembly in the reverse order of


steps 1 to 10.
Dust cleaning roller

3-10 UP-DF500
3. Remove the four shoulder screws, then remove the 5. Remove the screw, then remove the harness (GND).
head cover assembly A. 6. Remove the thermal head assembly from the two
4. Remove the three shoulder screws, then remove the hooks of the head up lever in the direction of the
head cover assembly B. arrow, then place it on the platen roller carefully.

Head cover assembly A Head up lever

Attaching
harness (GND)

Harness

Shoulder
screws
Hook

Hook Hook

BVTT
Head cover assembly B 3x6

Shoulder
screws

Platen roller
Harness
(GND) Thermal head assembly

UP-DF500 3-11
7. Remove the two screws, then remove the head fulcrum 3-8. Transfer Cleaning Roller
arm.
8. Disconnect the three flexible flat cables and the m
harness from the thermal head assembly. . When removing/installing the transfer cleaning roller, be
careful not to drop the bearing and roller.
Head fulcrum arm Harness . When attaching the bearing lock 2 assembly/bearing
lock assembly, be careful not to attach them in the wrong
PSW orientation.
3 x 12

1. Open the head block assembly.


(Refer to step 1 of Section 3-7.)
2. Release the bearing lock assembly and bearing lock 2
Flexible assembly in the direction of the arrow, then remove the
flat cables Thermal head
assembly
transfer cleaning roller.
3. Remove the bearing lock assembly, bearing lock 2
assembly, two bearings and two rollers from the
transfer cleaning roller.

Bearing

Transfer cleaning roller Bearing lock


2 assembly
Roller

Bearing lock
assembly

Bearing

Roller

9. Attach the thermal head assembly in the reverse order


of steps 1 to 8.

Pinch press link Transfer


cleaning roller

Bearing lock assembly

4. Attach the transfer cleaning roller in the reverse order


of steps 1 to 3.

3-12 UP-DF500
3-9. Capstan B/Platen 6. Remove the two snap rings (W2.3), then remove the
two tension rollers.
m 7. Remove the timing belt 207 and pulley assembly.
. When replacing the transfer cleaning roller, platen and 8. Remove the snap ring (E3.0), then remove the timing
capstan B, be careful not to damage the roller. belt 207, pulley 71 and platen pulley 132.
. When removing/installing the transfer cleaning roller, be
careful not to drop the bearing and roller.
. When attaching the bearing lock 2 assembly/ bearing
lock assembly, be careful not to attach them in the wrong
orientation.

1. Remove the MD assembly. (Refer to Section 3-2.) Platen pulley 132


2. Remove the helical extension spring, then remove the
three screws (BVTT3 x 6), polywasher, bearing 5/8 in Timing belt 207
order. Tension roller
3. Remove the two screws (PSW3 x 6), then remove the
platen bracket assembly.
4. Disconnect the harness from the encoder assembly. E3.0
W2.3
5. Loosen the setscrew, then remove the encoder assem-
bly and timing belt. Pulley 71

W2.3 Timing belt 207


Pulley assembly Tension
roller

Harness
9. Remove the snap ring (W2.3), then remove the tension
Encoder Timing belt roller.
assembly
10. Remove the two snap rings (E3.0), then remove the
Platen bracket
timing belt 220, pulley cap 29 and turn pulley 121.
assembly
Pulley cap 29
BVTT E3.0
3x6
W2.3
PSW Tension
3x6 roller

Setscrew
E3.0
BVTT
Polywasher 3x6

Helical
extension spring Timing
Bearing 5/8 belt 220

Turn pulley 121

UP-DF500 3-13
11. Release the lock arm, then open the head block 14. Remove the transfer cleaning roller.
assembly. (Refer to Section 3-8.)
12. Remove the two screws, then remove the guide C. 15. Remove the two screws, two capstan bearing holders
13. Disconnect the harness from the connector on the SU- and roller 6/8, then remove the capstan B.
77 board. 16. Remove the two ball bearings from the capstan B.

Ball bearing
Capstan
Head block assembly Capstan B bearing
holder
Ball bearing
BVTT
Roller 6/8 3x6

BVTT
3x6
Lock arm
Capstan bearing holder

17. Remove the two screws, two platen bearing holders


(P), platen bearing holder and platen earth plate, then
Guide C remove the platen.
18. Remove the four ball bearings and two wave washers
BVTT from the platen.
3x6

Wave washer

Platen
Platen bearing
holder (P)
Wave washer
BVTT
3x6
SU-77 board Harness

Platen
earth plate
BVTT
3x6 Ball bearings
Ball bearings

Platen bearing
holder Platen bearing
holder (P)

19. Attach the capstan B and platen in the reverse order of


steps 1 to 18.

3-14 UP-DF500
3-10. Rear Chassis Assembly 7. Disconnect the harness form the connector on the SW-
1096 board.
1. Remove the MD assembly. (Refer to Section 3-2.) 8. Disconnect the harness from the connector (CN3109)
2. Remove the head block assembly. on the CN-2326 board.
(Refer to Section 3-6.) 9. Remove the two screws, then remove the rear beam
3. Remove the two screws, then remove the guide C. assembly.
4. Disconnect the harness from the connector on the SU- 10. Remove the six screws, then remove the rear chassis
77 board. assembly.
5. Remove the two helical extension springs from the
rear chassis.
Rear beam assembly
6. Remove the two helical extension springs.

Harness BVTT
3x6
BVTT
Guide C 3x6
SU-77 board

BVTT
3x6 BVTT
3x6
SW-1096 board

Harness

Rear chassis
assembly

BVTT
Harness 3x6
Helical CN3109
extension spring
CN-2326 board
Rear chassis

Helical
extension spring
11. Attach the rear chassis assembly in the reverse order of
steps 1 to 10.

UP-DF500 3-15
3-11. Base Chassis (2T) Assembly 7. Disconnect the three harnesses from the connectors
(CN3104, CN3105 and CN3107) on the CN-2326
1. Remove the MD assembly. (Refer to Section 3-2.) board.
2. Remove the head block assembly. 8. Remove the harness from the five harness clampers.
(Refer to Section 3-6.) 9. Remove the six screws, then remove the base chassis
3. Remove the snap ring (W2.3), then remove the tension (2T) assembly in the direction of the arrow.
roller.
4. Remove the timing belt 220.
5. Remove the two snap rings (E3.0), then remove the
turn pulley 121 and pulley cap 29. Base chassis (2T) assembly
6. Remove the torque limiter and parallel pin (2 x 8).
CN3104
Pulley cap 29 Harness

E3.0
Parallel pin
2x8 W2.3

Tension
roller CN-2326 board
CN3105

E3.0 CN3107

Harnesses
Timing belt 220 BVTT
3x6

Turn pulley 121


BVTT
3x6
Torque limiter
BVTT
Harness 3x6
clampers
BVTT
3x6 Harness
clampers

10. Attach the base chassis (2T) assembly in the reverse


order of steps 1 to 9.

3-16 UP-DF500
3-12. Pinch Press Lever Assembly 3-13. Switching Regulator

1. Remove the MD assembly. (Refer to Section 3-2.) n


2. Remove the head block assembly. After replacing the CT-248 board, perform the required
(Refer to Section 3-6.) procedure. For details, refer to “4-2-3. CT-248 Board”.
3. Remove the rear chassis assembly.
(Refer to Section 3-10.) 1. Remove the side panel (L). (Refer to Section 2-4-6.)
4. Remove the capstan B/platen. (Refer to Section 3-9.) 2. Remove the outer frame L cover.
5. Remove the two snap rings (W2.3), then remove the (Refer to Section 2-4-8.)
two dust cleaning roller levers B. 3. Remove the DICOM BOARD.
6. Remove the screw (PSW3 x 6), snap ring (W2.3) and (Refer to Section 3-14.)
bearing, then remove the pinch press lever assembly. 4. Remove the two screws, two hooks and three harness-
es, then remove the power block assembly.

Power block assembly


Pinch press
lever assembly
BVTT
3x6

Dust cleaning Side plate R


roller levers B PSW
3x6
Harnesses

W 2.3 TO
Thermal head
Side plate L TO
W2.3 DR-618 board
TO
MA-155 board

Harness

W2.3
Hooks
Bearing

7. Attach the pinch press lever assembly in the reverse


order of steps 1 to 6.

UP-DF500 3-17
5. Remove the four screws (BVTT3 x 6), then remove 3-14. DICOM BOARD
the CN-2938 board.
6. Remove the four screws (PSW3 x 6), then remove the n
CN-2938 frame. After replacing the DICOM BOARD, perform the required
7. Remove the four screws (BVTT3 x 6), then remove procedure. For details, refer to “4-2-5. DICOM BOARD”.
the CT-248 board.
8. Remove the four screws (PSW3 x 6), then remove the 1. Remove the side panel (L). (Refer to Section 2-4-6.)
two board frames. 2. Remove the outer frame L cover.
9. Remove the two screws (PSW3 x 6) and the harness, (Refer to Section 2-4-8.)
then remove the AC frame assembly. 3. Disconnect the three cables (A, B, and C) from
10. Remove the switching regulator. connector on the DICOM BOARD.
4. Remove the two screws, then remove the DICOM
AC frame assembly BOARD in the direction of the arrow.
BVTT
3x6 CN-2938 board Cable B
PSW Cable A
3x6 DICOM BOARD

PSW
3x6 CN-2938 frame

Cable C

Harnesses
Harness
PSW
3x6

BVTT
3x6

Switching regulator

CT-248 board Board frames

BVTT
3x6 BVTT
3x6

11. Attach the switching regulator in the reverse order of


steps 1 to 10.

5. Install the DICOM BOARD in the reverse order of


steps 1 to 4.

3-18 UP-DF500
3-15. Paper Feed Chassis Assembly

n
When removing the paper feed chassis assembly, be sure
to work by two persons.

1. Remove the cabinet. (Refer to Section 2-4.)


2. Remove the DICOM BOARD.
(Refer to Section 3-14.)
3. Disconnect the harness from the board.

Board/connector Cable Connected to

CT-248/CN5003 Harness AN-31/CN4402


DR-618/CN601 Harness CN-2935/CN5101

CT-248 board DR-618 board

CN5003

CN601

4. Remove the paper feed roller assembly.


(Refer to Section 3-16.)

UP-DF500 3-19
5. Place this unit with the power block assembly facing downward.
6. Remove the four screws (PTTWH M3 x 8), then remove the bottom plate.
7. Remove the four screws (BVTT3 x 6), then remove the two foot assemblies.
8. Remove the four screws (PSW M4 x 12), then remove the two foot assemblies.
9. Remove the eight screws, then remove the paper feed chassis assembly.
(1) Shift the paper feed chassis assembly slightly to the DC motor side.
(2) Rotate the DC motor in the direction of arrow 2 with its side as a fulcrum.
n
Be careful not to damage the sensor cable by the edge of the chassis.
(3) Remove the paper feed chassis assembly while shifting it in the direction of arrow 3.

Foot assemblies

BVTT
Paper feed chassis
3x6
assembly

BVTT
DC motor 3x6

1
2
Bottom plate

Power block
assembly
PSW
BVTT
M4 x 12
3x6
Foot assemblies

PTTWH
M3 x 8

10. Attach the paper feed chassis assembly in the reverse order of steps 1 to 9.

3-20 UP-DF500
3-16. Paper Feed Roller Assembly

1. Remove the side panel (R). (Refer to Section 2-4-7.)


2. Remove the two screws, then remove the FR plate.
3. Disconnect the harness from the board.

Board/connector Cable Connected to

CN-2941/CN6001 Harness CN-2938/CN6907

4. Remove the screw, then remove the paper feed roller assembly in the direction of the arrow.

BVTT
3x6 FR plate
BVTT
3x6
Paper feed roller assembly

Harness

CN6001
CN-2941 board

Paper feed chassis assembly

5. Attach the paper feed roller assembly in the reverse order of steps 1 to 4.

UP-DF500 3-21
3-17. Separation Roller Assembly 1. Remove the screw and servicing cover (USB) from the
unit to be repaired, then take out Memory Stick.
1. Remove the paper feed roller assembly. 2. Remove the screw and servicing cover (USB) from the
(Refer to Section 3-16.) alternate, then take out Memory Stick.
2. Remove the two screws, then remove the separation
roller assembly in the direction of the arrow. Memory Stick

Separation roller
assembly Paper feed
roller assembly

PTTWH
M3 x 8

Cover (USB)

BVTT
3x6 Unit to be repaired/alternate unit

3. Attach the separation roller assembly in the reverse 3. Turn on the power of the alternate unit. (Do not turn
order of steps 1 and 2. off the power before the procedure is completed.)
4. Enter the service mode (refer to Section 6-1.). Select
SYSTEM SETTINGS → MEMORY STICK →
3-18. Installing the Alternate Unit LOAD SETTING, then press [EXEC] key. The
reading process starts when [YES] is selected accord-
n ing to the indication on LCD.
When installing the alternate unit for the repair, it is 5. Although “PLEASE POWER OFF” is displayed after
possible to copy the user setting to the alternate unit using about 1 minute, do not turn off the power at that time.
Memory Stick. (Refer to Section 6-2-6.) Be sure to turn OFF the power after taking out
Memory Stick.
n 6. Check the IP address, and check that the setting value
The setting value of UP-DF500 is backed up in Memory is copied.
Stick for service every time the power is turned off using 7. Insert Memory Stick into the unit to be repaired and
the On-Standby switch on the front. Therefore, it is alternate unit, then attach the servicing cover (USB).
possible to copy the setting value even if the power of UP-
DF500 to be repaired cannot be turned on. As described above, the user setting such as network
setting, gamma curve, caption, etc. can be copied by using
the setting copy function of Memory Stick.
The details of items to be copied are represented with mark
O in the MS column of “Check list No.2” in Section 1-7.

3-22 UP-DF500
Section 4
Procedures after Replacement

4-1. Adjustment after Replacing the Thermal Head

m
After replacing the thermal head, perform the following adjustments.
. Adjusting the density (Section 4-1-1)
. Adjusting the head position (Section 4-1-2)
. Adjusting the printing position (Section 4-3)
. Resetting the head print count (Section 6-2-1)

4-1-1. Adjusting the Density

Required equipment
. Personal computer (equipped with USB interface, compatible with Windows 2000 or Windows XP)
. USB cable
. FilmStation Support Software

Writing the non-uniformity correction data


1. Remove the front cover L, then connect the personal computer (hereafter referred to as PC) with the
UP-DF500 using the USB cable.
2. Insert the floppy disk (FilmStation Support Software) into the PC.
3. Start the FilmStation Support Software, then transfer the correction data from the floppy disk sup-
plied with the thermal head to the UP-DF500.
n
For the operating procedure for the FilmStation Support Software, refer to Section 6-5.

Density adjustment procedures


n
When adjusting the thermal head density, use the film stored in the sealed moisture-proof bag (silver bag
in which the film is packaged).

1. Start the service mode. (Refer to Section 6-1.)


2. Check that “READY” is displayed on the LCD, then press the [MENU] key.
3. Select ADJUST[>] using the [(] and [)] keys, then press the [*] key.
4. When V-ADJ PRINT is displayed, press the [EXEC] key.
Printing is started and the density is automatically adjusted. Then, the head voltage after being
adjusted and adjusting values are displayed on the LCD.
5. Press the [MENU] key to exit from the service mode.

In case that NG is displayed


. When dust or scratch is observed on the printing surface:
→ Perform the cleaning of thermal head and roller.
. When contact of thermal head is not good:
→ Adjust the contact of thermal head.
. Others
→ Readjust the calibrator and adjust the density again.
n
For adjusting procedures, refer to “2. Adjusting the density measuring point”, “3. Density check by
using reference sheet” and “4. Density measurement” in “4-2-3. CT-248 Board”.
UP-DF500 4-1
4-1-2. Adjusting the Head Position Adjustment Procedures
The head position of the head assembly for servicing (A-
Head Adjusting Cam 8346-560-) is adjusted at the factory shipment. Perform the
The thermal head position can be adjusted by rotating the following procedures with the head position as it is.
adjusting cam of the head assembly.
The adjusting cam can be moved as follows with reference 1. Print “BLACK” of the test print.
to the zero position. (A small round projection can be seen (Refer to Section 6-2-7.)
at the zero position.) 2. Check the print.
. Three clicks in a counterclockwise direction. (The cam is . Wrinkle shall not occur in the “BLACK” printing
rotated 45 degrees per click.) portion on the chart.
. Three clicks in a clockwise direction. (The cam is rotated In case that the wrinkle occurred, rotate the adjusting
45 degrees per click.) cam in the plus direction.
. Matt (lusterless) shall not occur in the “BLACK”
When the adjusting cam is moved in a counterclockwise printing portion on the chart.
direction, the head assembly moves upward (plus) and In case that the matt occurred, rotate the adjusting
when the adjusting cam is moved in a clockwise direction, cam in the plus direction, or in case that the faint
the head assembly moves downward (minus) printing occurred, rotate the adjusting cam in the
minus direction.
m 3. After performing step 2, print “DARK GRAY H-
. Although the adjusting cam can be rotated 360 degrees, TEMP”.
the fourth click is not used for adjustment. (It takes approximately 10 minutes to finish printing
. The adjusting cams are attached on the left and right because the head temperature needs to be raised.)
sides of the head assembly. These adjusting cams are 4. Check the print.
identical, therefore they rotate in the same direction (plus . Faint printing shall not occur in “GRAY”.
or minus). . Wrinkles and non-uniformity of density in the
slanting direction shall not occur around the print
Stepped portion of the cam used as a reference starting point.
when the cam is adjusted to the zero position.

Counterclockwise The optimum head position is where the adjusting cam


is set in the lowest position (minus position) within the
adjusting range in which no wrinkle or matt occurs in
the “BLACK” printing portion. Therefore, when no
wrinkle or matt occurs after printing with the head
Clockwise assembly for servicing attached, rotate the adjusting
Protruding mark to indicate the
cam in the minus direction once and check that the
Head adjusting cam zero position of cam wrinkle or matt occurs. After this, rotate the adjusting
cam in the plus direction until no wrinkle or matt
occurs.

5. Affix the H check label to the head assembly for


servicing supplied. (In order to prevent the user from
rotating the adjusting cam)

n
To check the adjusting position of the adjusting cam, rotate
both cams by three clicks in the minus direction and print
“BLACK” chart of the test print.

Head assembly

4-2 UP-DF500
4-2. Procedures after Replacing the Non-uniformity correction data
Board Each thermal head has its own specific non-uniformity
correction data that is stored in the floppy disk supplied
When replacing the MA-155 board, DR-618 board, CT- with the UP-DF500. (After replacing the thermal head, use
248 board, density sensor board (SE-880 board and SE- the data of the new thermal head.) The non-uniformity
881 board) and DICOM BOARD, procedures such as correction data is backed up in the files named HEAD.csv
upgrading of firmware version and setting of internal data and OFFSET.csv in Memory Stick. After replacing the
are required. MA-155 board, rewrite the data into the EEPROM using
the FilmStation Support Software.

4-2-1. MA-155 Board Setting data such as gamma data


In the UP-DF500, setting data such as gamma data is
Before replacing the MA-155 board, write down each written in the Memory Stick when the power is turned off.
value of VOLTAGE ADJ, PITCH ADJ (four values Use the UP-DF500 with the writable Memory Stick
corresponding to the media size), X POS ADJ, Y POS inserted.
ADJ on the LCD referring to the service mode (6-2-10. After replacing the MA-155 board, rewrite the user setting
Adjust). data into the EEPROM referring to the “LOAD SET-
TINGS” menu in the service mode. In case that the power
Procedures after replacing the MA-155 board of the UP-DF500 is accidentally turned off during this
. Write the latest firmware into the flash ROM (IC1702). procedure, the data in the memory stick is overwritten.
. Extract the specific data of the UP-DF500 from the MA- Therefore back up the data to the PC and write protect the
155 board to be replaced and write the setting values into memory stick in advance.
the EEPROM (IC1703) of the new MA-155 board.
Printing position adjusting parameter
1. Upgrading the firmware version The printing position adjusting parameter can be referred
Write the latest firmware version into the flash ROM and changed in the service mode (6-2-10. Adjust). Reset to
(IC1702) of the MA-155 board referring to “6-3. Firmware the value of PITCH ADJ, X POS ADJ, Y POS ADJ before
Version Upgrade Procedures”. replacement of the board. (Refer to the parameter on the
n LCD before replacing the MA-155 board.)
The firmware data of the DR-618 board is also stored in the
MA-155 board. When upgrading the firmware version, be Reference density
sure to upgrade the DR-618 board firmware version besides Density adjusting parameter
the MA-155 board firmware version. (Refer to Section 6-3.) The density adjusting parameter can be referred and changed
Although “DR TROUBLE” may be displayed before in the service mode (6-2-10. Adjust). Reset to the value of
completion of the DR-618 board firmware version upgrade, ±NN of VOLTAGE ADJ HV = **.*V+DA[±NN] before
continue the upgrade of the DR-618 board firmware version replacement of the board. (Refer to the parameter on the
as it is. After completion of upgrade, initialize the EEPROM LCD before replacing the MA-155 board.)
referring to Section 6-2-10.

2. Rewriting the specific data


It is required to rewrite the specific data (gamma data, non-
uniformity correction data, printing position adjusting
parameter, density adjusting parameter, etc.) of the UP-
DF500 written in the EEPROM (IC1703) of the MA-155
board into the EEPROM after replacement.

UP-DF500 4-3
4-2-2. DR-618 Board

The firmware data of the CPU (IC200) on the DR-618 board is stored in the MA-155 board. Therefore,
when replacing only the DR-618 board, you do not have to upgrade the firmware version. As described in
Section 4-2-1, when replacing the MA-155 board, upgrading of the DR-618 board firmware version is
required.

4-2-3. CT-248 Board

Procedures after replacing the CT-248 board


. Write the latest firmware into the CPU (IC1) flash memory.
. Adjust the density measuring point and measure the density.

1. Upgrading the firmware version


Write the latest firmware version of the CT or TAG into the flash memory of CPU (IC1) referring to “6-
3. Firmware Version Upgrade Procedures”.

2. Adjusting the density measuring point


Adjust the density measuring point.
In order to correct the LED and photodiode characteristics, adjust the gain with no film condition. Place
the reference sheet in the sensor area and adjust the offset to correct the high density point.

Preparation
Prepare a reference sheet and write down the largest value (hereafter referred to as reference density)
among the density values written in the reference sheet.

Reference density

4-4 UP-DF500
Procedures 6. Push the reference sheet against the plate on the right
1. Start the service mode. (Refer to Section 6-1.) side and set it to the SE-880 assembly.
2. Proceed to the CALIBRATION item, then select the
GAIN ADJ item.
3. Press the [EXEC] key. After “REMOVE REF Reference sheet
SHEET” is displayed, press the [EXEC] key again.
4. After approximately 10 seconds, “OFFSET ADJUST”
is displayed. Then, set the “REF=” value to the
reference density by pressing the [&] and [*] keys.
Press the [EXEC] key.
5. After “SET REF SHEET” is displayed, open the top
cover and inner cover.

Top guide assembly


Inner unit assembly

7. Close the inner cover and top cover, then press the
[EXEC] key. After approximately 15 seconds,
“REMOVE REF SHEET” is displayed.
8. Open the top cover and inner cover, then remove the
reference sheet.
9. Close the inner cover and top cover, then press the
[EXEC] key.
10. After “GAIN-OFFSET ADJ<OK>” is displayed, press
the [EXEC] key.
n
When “SELF CHECK CH-1<NG>” is displayed,
check the SE-880 assembly, connection of connector,
etc. and perform adjustment from step 1 again.

UP-DF500 4-5
3. Density check by using reference sheet
Measure the density of the reference sheet to check if the density measurement can be performed
correctly.

Procedures
1. Start the service mode. (Refer to Section 6-1.)
2. Proceed to the CALIBRATION item, then select the SPOT MEASURE item.
3. Press the [*] key and measure the density.
4. Open the top cover and inner cover, then set the reference sheet. (Refer to “2. Adjusting the density
measuring point”.)
5. Close the inner cover and top cover.
6. Check the difference between the density value displayed on the LCD and the value indicated on the
reference sheet.
Spec: About within ± 0.05
7. Open the top cover and inner cover, then remove the reference sheet.
8. Close the inner cover and top cover.

4. Density measurement
Print the pattern for calibration and measure the density with respect to the printing data. The calibration
functions based on this measurement value.

Procedures
1. Start the service mode. (Refer to Section 6-1.)
2. Proceed to the CALIBRATION item, then select the FULL RANGE CAL item.
3. Press the [EXEC] key to print the pattern for calibration.
When the unit returns to READY state after printing, the density measurement is completed.
n
If “CALIBRATION INVALID” is displayed on the LCD, it indicates that the density measurement
was not correctly performed. Therefore, perform the density measurement again. When non-
uniformity such as white spot or vertical streak is observed on the printed sheet, clean the thermal
head and other rollers, and try to print again.

4-2-4. SE-880 Board, SE-881 Board

Procedures after replacing the SE-880 Board and SE-881 Board


. Various adjustments
. Calibration pattern print, etc.

Perform the following referring to “4-2-3. CT-248 Board”.


. “2. Adjusting the density measuring point”
. “3. Density check by using reference sheet”
. “4. Density measurement”

4-6 UP-DF500
4-2-5. DICOM BOARD

Before replacing the DICOM BOARD, write down the network address setting, mail setting and DICOM
setting referring to the setup manual of the UP-DF500.

Procedures after replacing the DICOM BOARD


. Write the latest software into the built-in CF card.
. Perform the setting of network

1. Upgrading the software version


Write the latest version of the DICOM software into the DICOM BOARD referring to “6-4. DICOM
Version Upgrade Procedures”.

2. Setting the network


When replacing the DICOM BOARD, it is required to set the network address setting, mail setting and
DICOM setting again because they are stored in the DICOM BOARD. For setting procedures, refer to the
setup manual of the UP-DF500.

UP-DF500 4-7
4-3. Printing Position Adjustment 5. Loosen the screw A to rotate the side registration
Procedures adjusting cam or fine adjust the clearance between the
side registration adjusting cam and registration plate to
After replacing the MD block, PH2 block and thermal head loosen the screw B and screw A. Repeat this procedure
and MA-155 board, adjust the printing position using the so that the difference between the left margin and right
PH2 side registration adjusting cam and adjusting menu (6- margin is within 0.5 mm.
2-10. Adjust). Place the UP-DF500 in the horizontal
direction for adjustment. Loosen the screws to adjust the clearance between the side
Select HOOK (factory setting) in FRAME TYPE. registration adjusting cam and PH2 side plate.

1. Loosen the screw B, then set the side registration


adjusting cam position to “0” (mark). Registration
plate

Set the side registration adjusting cam so that the mark


Screw A
on the cam is vertical to the PH2 side plate.

Side registration adjusting


Screw B
cam

Side registration
adjusting cam

Screw B

Print side

Lead edge portion

Lead edge margin Lead edge margin


Side registration adjusting plate on the left side on the right side

Difference between the left margin and


right margin shall be within 0.5 mm.
2. Start the service mode. (Refer to Section 6-1.)
3. Set the X POS ADJ value to “0”.
(Refer to Section 6-2-10.)
n
The Y POS ADJ value and PITCH ADJ value are not
changed at this point.
4. Adjust Y POS and PITCH.
Print the MEDIUM GRAY test pattern.
(Refer to Section 6-2-8.)

4-8 UP-DF500
6. Check that the following items are within specifica- 4-4. Operation List during Replacement
tions. of Main Assembly Parts
Lead edge margin: 2.0 ± 0.5mm
Trail edge margin: 2.0 ± 1.0mm This section describes the operation during replacement of
Solid on the right side: 9.3 ± 1.0mm main assembly parts. Refer to the tables on the next pages
and later.
Solid on the right side
Symbols in each table are as follows:
Trail edge *1: An adjustment value is rewritten when Memory Stick
margin is loaded.
*2: Enter the adjustment values peculiar to each unit
manually.

Print side O: Operation is required during replacement.


T: Value adjusted by a user as required
: Item requiring operation before disassembly
_: Item not requiring operation

Lead edge Lead edge portion


margin

7. Perform the following adjustment for the item that the


specification in step 6 is not met.
Lead edge margin: Y POS ADJ adjustment
(Refer to Section 6-2-10.)
Trail edge margin: PITCH ADJ adjustment
(Refer to Section 6-2-10.)
Solid on the right side: X POS ADJ adjustment
(Refer to Section 6-2-10.)
n
When the value X does not become 9.3 ± 1.0mm after
X POS ADJ adjustment, return to step 5 and perform
the adjustment again.

UP-DF500 4-9
DR-618 board MA-155 board CT-248 board DICOM board
*1
Preparation Backup of Memory Stick to PC _ _ _
*2
Writing down of “Adjust” value _ _ _
(Section 4-2-1)
*1
Writing down of network setting _ _
value (Setup Manual)
Upgrading Upgrading of MA firmware (Section 6-3) _ O _ _
Upgrading of DR firmware (Section 6-3) _ O _ _
Upgrading of CT firmware (Section 6-3) _ _ O _
Upgrading of tag firmware (Section 6-3) _ _ O _
Upgrading of DICOM (Section 6-4) _ _ _ O
Adjustment of Adjustment of densitometer _ _ O _
densitometer measurement part (densitometer)
(Section 4-2-3, 2)
Confirmation of density using _ _ O _
reference sheet (Section 4-2-3, 3)
Density measurement _ _ O _
(Section 4-2-3, 4)
Change of Network setting value (Setup Manual) _ O *1 _ O
customer setting
Change and Initialization of EEPROM _ O _ _
adjustment of (Section 6-2-10)
data peculiar
Writing of non-uniformity correction data _ O _ _
to unit
(Supplied FD) (Section 6-5-2)
Head position adjustment _ _ _ _
(Section 4-1-2)
Density adjustment: V-Adj _ O *2 _ _
(Section 4-1-1)
Print position adjustment: Side _ O *2 _ _
registration (Section 4-3)
Print position adjustment: X, Y, and pitch _ O *2 _ _
(Section 4-3)
Change for Tag: Change in setting of A, B, C ... _ O _ _
special tag
Change of Loading of Memory Stick information _ O *1 _ _
customer setting (Section 6-2-6)
. Automatic densiy adjustment _ T*1 _ _
(AUTO CALIBRATION)
. Setting information _ T*1 _ _
(SYSTEM SETTINGS) all items
. Selection of Gamma (GAMMA SEL) _ T*1 _ _
*1
. Print image adjustment _ T _ _
(PRINT QUALITY) (Gamma data)
Tools used Reference sheet _ _ O _
FSSS version 6.0 or higher _ O O _
PC (Memory Stick slot + USB cable) _ O O _
PC (Ether-cross cable) _ _ _ O
Head correction data _ O _ _
Tag: A/B/C rewrite tool _ O _ _
(Packaged together with products and
MS-backed up)

4-10 UP-DF500
Switching PH1 PH2 PH3 SE-880/SE-881
regulator board

Preparation Backup of Memory Stick to PC _ _ _ _ _


Writing down of “Adjust” value _ _ _ _ _
(Section 4-2-1)
Writing down of network setting value _ _ _ _ _
(Setup Manual)
Upgrading Upgrading of MA firmware (Section 6-3) _ _ _ _ _
Upgrading of DR firmware (Section 6-3) _ _ _ _ _
Upgrading of CT firmware (Section 6-3) _ _ _ _ _
Upgrading of tag firmware (Section 6-3) _ _ _ _ _
Upgrading of DICOM (Section 6-4) _ _ _ _ _
Adjustment of Adjustment of densitometer _ _ _ O O
densitometer measurement part (densitometer)
(Section 4-2-3, 2)
Confirmation of density using _ _ _ O O
reference sheet (Section 4-2-3, 3)
Density measurement _ _ _ O O
(Section 4-2-3, 4) (Setup Manual)
Change of Network setting value _ _ _ _ _
customer setting
Change and Initialization of EEPROM (Section 6-2-10) _ _ _ _ _
adjustment of
Writing of non-uniformity correction data _ _ _ _ _
data peculiar
to unit (Supplied FD) (Section 6-5-2)
Head position adjustment (Section 4-1-2) _ _ _ _ _
Density adjustment: V-Adj _ _ _ _ _
(Section 4-1-1)
Print position adjustment: Side registration _ _ O _ _
(Section 4-3)
Print position adjustment: X, Y, and pitch _ _ _ _ _
(Section 4-3)
Change for special Tag: Change in setting of A, B, C ... _ _ _ _ _
tag
Change of Loading of Memory Stick information _ _ _ _ _
customer setting (Section 6-2-6)
. Automatic density adjustment _ _ _ _ _ _
(AUTO CALIBRATION)
. Setting information _ _ _ _ _ _
(SYSTEM SETTINGS) all items
. Selection of Gamma (GAMMA SEL) _ _ _ _ _ _
. Print image adjustment _ _ _ _ _ _
(PRINT QUALITY) (Gamma data)
Tools used Reference sheet _ _ _ O O
FSSS version 6.0 or higher _ _ _ _ O
PC (Memory Stick slot + USB cable) _ _ _ _ O
PC (Ether-cross cable) _ _ _ _ _
Head correction data _ _ _ _ _
(Packaged together with products and
MS-backed up)
Tag: A/B/C rewrite tool _ _ _ _ _

UP-DF500 4-11
Mechanical Load Load Load Service
deck chassis roller tray head
(including head)

Preparation Backup of Memory Stick to PC _ _ _ _ _


Writing down of “Adjust” value (Section 4-2-1) _ _ _ _ _
Writing down of network setting value _ _ _ _ _
(Setup Manual)
Upgrading Upgrading of MA firmware (Section 6-3) _ _ _ _ _
Upgrading of DR firmware (Section 6-3) _ _ _ _ _
Upgrading of CT firmware (Section 6-3) _ _ _ _ _
Upgrading of tag firmware (Section 6-3) _ _ _ _ _
Upgrading of DICOM (Section 6-4) _ _ _ _ _
Adjustment of Adjustment of densitometer measurement _ _ _ _ _
densitometer part (densitometer) (Section 4-2-3, 2)
Confirmation of density using _ _ _ _ _
reference sheet (Section 4-2-3, 3)
Density measurement _ _ _ _ _
(Section 4-2-3, 4)
Change of Network setting value (Setup Manual) _ _ _ _ _
customer setting
Change and Initialization of EEPROM (Section 6-2-10) _ _ _ _ _
adjustment of
Writing of non-uniformity correction data O _ _ _ O
data peculiar
to unit (Supplied FD) (Section 6-5-2)
Head position adjustment (Section 4-1-2) _ _ _ _ O
Density adjustment: V-Adj O _ _ _ O
(Section 4-1-1)
Print position adjustment: Side registration O _ _ _ O
(Section 4-3)
Print position adjustment: X, Y, and pitch O _ _ _ O
(Section 4-3)
Change for special Tag: Change in setting of A, B, C ... _ _ _ _ _
tag
Change of Loading of Memory Stick information _ _ _ _ _
customer setting (Section 6-2-6)
. Automatic density adjustment T _ _ _ T
(AUTO CALIBRATION)
. Setting information T _ _ _ T
(SYSTEM SETTINGS) all items
. Selection of Gamma (GAMMA SEL) T _ _ _ T
. Print image adjustment T _ _ _ T
(PRINT QUALITY) (Gamma data)
Tools used Reference sheet _ _ _ _ _
FSSS version 6.0 or higher O _ _ _ O
PC (Memory Stick slot + USB cable) O _ _ _ O
PC (Ether-cross cable) O _ _ _ O
Head correction data _ _ _ _ _
(Packaged together with products and
MS-backed up)
Tag: A/B/C rewrite tool _ _ _ _ _

4-12 UP-DF500
Section 5
Circuit Operation Description

This unit is mainly controlled by the boards below. 5-1-3. CPU, PLD, and Peripheral Circuits
. MA-155 board: System control and mechanical control
. DR-618 board: Motor driving and sensor recognition CPU
. CT-248 board: Density data acquisition and IC tag data CPU (IC1403) supplies a clock of 48 MHz, generated
acquisition using a clock oscillator (X1401), from the outside by SH3
. DICOM board: DICOM interface (HD6417709AF133) and uses an internal operation clock
for the setting of 48 MHz x 2 = 96 MHz. Flash ROM
This section describes the operation of these boards. (IC1702) of 32 M bits and work SDRAM (IC1701) of 64
M bits are connected to the outside as program memory.
CPU is started at the rising edge of a reset signal that is
5-1. MA-155 Board generated using a system reset circuit (IC2401) and passed
through system control PLD (IC2402). After each initial-
5-1-1. Outline ization is performed, CPU is put into the command wait
state. CPU operates according to the command input from
To transfer high-capacity image data at high speed, this a key switch or USB 2.0 interface (IC1801). The firmware
unit separates an image data bus from a CPU bus by a of CPU is stored in flash ROM (IC1702) and can be
DMA controller (IDMAC PLD, IC1004) for which PLD is updated from USB 1.1 interface (IC1003) for upgrading.
used and improves the data transfer rate. Each heat Refer to “6-3. Firmware Version Upgrade Procedure” for
correction is also performed in real time by the hardware the upgrading of firmware. CPU on the MA-155 board is
of PLD. The MA-155 board performs image data process- connected with CPU on the DR-618 and CT-248 boards
ing (read, spool, PQC (picture quality correction), and (calibration control CPU) using a serial communication
thermal head control) and controls the whole mechanism. line. CPU on the MA-155 board is also connected with
To take measures for radiation, this time, 48 MHz and 32 CPU on the CT-248 board (IC tag control CPU) and
MHz clocks are spectrum-diffused by CY25100ZXCF. DICOM board through UART IC using a serial communi-
cation line.
Communication protocols are as described below.
5-1-2. Configuration
Protocol for communication with DR-618 board
The configuration of the MA-155 board is as described . Sync system: Asynchronous
below. . Rate: 19,200 bps
. Data length: 8 bits
. CPU, PLD, and peripheral circuits (IC1003, IC1004, . Stop bit length: 1 bit
IC1301 to IC1303, IC1403, IC1701 to IC1703, IC2401, . Parity: Even
IC2402, and X1401) . Transmission order: LSB first
. USB 2.0 interface block (IC1801 and IC1004)
. SDRAM control block (IC1004, and IC1901 to IC1904) Protocol for communication with CT-248 board
. PQC (picture quality correction), thermal head control (calibration control CPU)
block, and +5 V driver (IC1004, IC2001, IC2003 to . Sync system: Asynchronous
IC2010, Q2001, D2001, R2001, R2002, R2081 to . Rate: 38,400 bps
R2088, and C2020) . Data length: 8 bits
. DC/stepping motor controller block, +5 V driver, and . Stop bit length: 1 bit
sensor A/D input block (IC1003, and IC2102 to IC2108) . Parity: Even
. Memory Stick and USB 1.1 interface block (IC1003) . Transmission order: LSB first
. Key switch, LED, and LCD interface block (C1003,
IC2403 to IC2405, and Q2401)
. UART block (IC2603 and IC2604)

UP-DF500 5-1
Protocol for communication with CT-248 board 5-1-5. SDRAM Control Block
(IC tag control CPU)
. Synch system: Asynchronous SDRAM of an SDRAM control block (IC1901 to IC1904)
. Rate: 38,400 bps is used to store image data. IDMAC PLD (IC1004) is used
. Data length: 8 bits for the DMA data write from a USB 2.0 interface
. Stop bit length: 1 bit (IC1801), the DMA data read into the PQC (picture quality
. Parity: Even correction) block in IDMAC PLD, the DMA write of
. Transmission order: LSB first fixed-value data, and the data access from CPU.

Protocol for communication with DICOM board


. Sync system: Asynchronous 5-1-6. PQC Block (Picture Quality Correction),
. Rate: 9600 bps Thermal Head Control Block and +5 V
. Data length: 8 bits Driver in IDMAC PLD
. Stop bit length: 1 bit
. Parity: None The data read into a PQC block for each line during DMA
. Transmission order: LSB first data read from SDRAM performs each correction using the
line memory in the PQC block. The corrected data is
PLD (IDMAC) written in the double buffer of a thermal head control
IDMAC PLD (IC1004) is SRAM-type PLD that is block. The image data read from the other buffer is
XC2V3000. It requires configuration when the power is compared with gradation data for each port and sent to the
turned on. Configuration data is stored in configuration thermal head as a PWM-modulated output signal. A driver
ROM (IC1301 to IC1303). Configuration operation is circuit in the thermal head requires 0.8 x VCC = 4 V as
started at the rising edge of a reset signal output from CPU VIH (min), so a signal level is converted using a 5 V TTL
(IC1403). A “high” level signal is output to input buffer (IC2003 to IC2008). The thermal head may
nIDMAC_DONE (CL1313) when configuration operation be burned when an nSTB terminal continuously remains
is terminated normally. “low” due to some failure. Therefore, a protection circuit
is incorporated that forcibly outputs a “high” level signal
Peripheral circuits by the time constant of CR when the nSTB terminal
CXD9165AGG-P (IC1003), IDMAC PLD (IC1004), and remains “low” for a fixed time. To prevent the thermal
UART IC (IC2604) as well as flash ROM (IC1702) and head from being continuous preheated due to some failure,
SDRAM (IC1701) are connected to a CPU bus, and a protection circuit that sets V_CONT as 0 V and applies
EEPROM (IC1703) is connected to the I/O port of CPU. no head voltage is also incorporated when the head
The functions of CXD9165AGG-P, IDMAC PLD, and temperature is out of the setting range. The protection
UART IC are described for each block. Data specific to a circuit for an nSTB terminal consists of Q2001, R2001 to
model is stored in EEPROM. Therefore, data must be R2003, D2001, C2020, and IC2001. The protection circuit
transferred during replacement of the MA-155 board. for a head temperature consists of IC2009, IC2010, and
(Refer to Section 4-2-1.) R2081 to R2088.

5-1-4. USB 2.0 Interface Block

NET2270 (IC1801) made by NETCHIP is used as a USB


2.0 interface controller. The timing arbitration during CPU
access and the control signal generation during DMA are
performed using IDMAC PLD (IC1004). The maximum
transfer rate during DMA transfer is approximately 17.5
MB/s.
A function that requests interrupt to CPU using a watchdog
timer when setting time DMA is interrupted is added to
take measures for a failure occurring during DMA transfer.

5-2 UP-DF500
5-1-7. DC/Stepping Motor Controller Block, 5-1-9. Key Switch, LED, and LCD Interface
+5 V Driver and Sensor A/D Input Block
Block
[MENU], [EXEC], [(], [)], [*], and [&] keys perform
The output signal of a DC/stepping motor controller block key scan through combined use of KEY_OUT[0-1] and
of CXD9165AGG-P (IC1003) is output from an open KEY_IN[0-3]. (The ON/OFF operation of each key switch
collector. Therefore, each output signal is pulled up using does not correspond to signal lines at a ratio of 1 to 1
a resistor of 1 kZ. These output pins are fixed to a “low” because of the key scan that constitutes a matrix by
level when the power is turned on. However, a “high” KEY_OUT[0-1] and KEY_IN[0-3].) Each key switch is
level signal is designed to be output using an inverter connected to the chattering function-equipped input port of
(IC2102 to IC2105) because a current flows through a CXD9165AGG-P (IC1003). The chattering function is
plunger. thus realized by hardware. Since LCD is a 5 V interface, a
A general motor driver is a 5 V input, so a signal level is signal level is converted using a 3 V_to_5 V bidirectional
converted using a 5 V TTL input buffer (IC2106 to level converter (IC2403) and 5 V TTL input buffer
IC2108). The AD input range of CXD9165AGG-P is 0 to (IC2404). The control signal of LCD is generated using
2.5 V. A sensor AD input block is thus pulled up to a the general-purpose I/O port output signal of
power supply of +2.5 V. The pull-up resistance of the CXD9165AGG-P by software.
sensor A/D input block is standardized to 47 kZ for except
FG input. An FG input signal was not in time in response
time when it is pulled up in 47 kZ. Therefore, only the FG 5-1-10. UART Block
input signal is pulled up in 10 kZ. An AD conversion
output signal is automatically binary-processed in A two-channel UART circuit (IC2604) is added because a
CXD9165AGG-P. It can be used for the dispersion in a serial port is insufficient in only CPU (IC1403). The UART
sensor by changing the setting value of a threshold level of circuit is connected to a CPU bus. In one of the two chan-
“L → H” and “H → L”. nels, it communicates with IC tag control CPU on the CT-
248 board. IC tag control CPU reads the IC tag information,
installed in a film protection sheet, from an antenna board.
5-1-8. Memory Stick and USB 1.1 Interface An IC tag is used to manage the remaining quantity of a film
Block (Service Interface) and discriminate the type of a film. Communication with an
IC tag is not done continuously, but it is done only in a
CXD9165AGG-P (IC1003) incorporates Memory Stick specific case. The other channel of the UART circuit is used
and USB 1.1 interface control functions. It performs to set the IP address of a DICOM board. To communicate
control operation using these functions. with the DICOM board through RS-232C, a signal level is
converted using an RS-232C driver (IC2603).

UP-DF500 5-3
5-1-11. Sensor and Switch Control

The control lines of sensors and switches that the MA-155 board controls are described in the sensor and
switch control table shown below. HEAD_CAM_HOME_SENS, HEAD_CAM_POSI_SENS,
CAP_CAM_HOME_SENS, and CAP_CAM_POSI_SENS signal lines are paired with a motor that the DR-
618 board handles. Refer to the circuit operation description of the DR-618 board (in Section 5-2) for the
motor operation and the sensors not described in the table below.

MA-155 board and sensor motor list

Signal name Description Connector Pin No. Connected to Remarks

HEAD_CAM_HOME_SENS Set “low” when the thermal head CN1008 Pin 8 SE-679 board Analog input of 0 to 2.5 V
is in the home position.
Set “high” when the thermal
head is not in the home position.
HEAD_CAM_POSI_SENS Set “low” every time the thermal head is CN1008 Pin 7 SE-679 board Analog input of 0 to 2.5 V
moved to the prescribed position.
Set “high” for except described above.
CAP_CAM_HOME_SENS Set “low” when the capstan is in the CN1008 Pin 6 SE-680 board Analog input of 0 to 2.5 V
home position. Set “high” when it is
not in the home position.
CAP_CAM_POSI_SENS Set “low” every time the capstan is CN1008 Pin 5 SE-680 board Analog input of 0 to 2.5 V
moved to the prescribed position.
Set “high” for except described above.
PRINT_ST_POSI_SENS Set “high” when a film reaches the print CN1008 Pin 4 SE-681 board Analog input of 0 to 2.5 V
start position. Usually, set “low”.
END_TURN_PATH_SENS Set “high” when a film reaches the exit CN1008 Pin 14 SE-894 board Analog input of 0 to 2.5 V
of PH1. Usually, set “low”.
PICK_END_PATH_SENS_0 Set “high” when the film reaches the CN1008 Pin 15 SE-888 board Analog input of 0 to 2.5 V
entrance of PH1. Usually, set “low”.
FEED_END_PATH_SENS Set “high” when a film reaches the CN1008 Pin 12 SE-681 board Analog input of 0 to 2.5 V
entrance of MD. Usually, set “low”.
JAMMING_PATH_SENS Set “high” when a film reaches the exit CN1008 Pin 3 SE-694 board Analog input of 0 to 2.5 V
of MD. Usually, set “low”.
DENSITY_PATH_SENS Set “high” when a film reaches just CN1008 Pin 13 SE-891 board Analog input of 0 to 2.5 V
before a densitometer.
Usually, set “low”.
EJECT_PATH_SENS Set “high” when a film reaches the exit CN1008 Pin 11 SE-892 board Analog input of 0 to 2.5 V
of PH3. Usually, set “low”.
PICK_POSI_SENS_0 Set “high” when the lift plate rises to the CN1008 Pin 19 SE-899 board Analog input of 0 to 2.5 V
paper feed position.
Set “low” for except described above.
LIFT_UP_FG_SENS_0 The distance between the “FG” home CN1007 Pin 6 SE-878 board Analog input of 0 to 2.5 V
position and paper feed position is
counted for detecting the very little
movement quantity of the lift plate.
DRIVE_PATH_SENS Set “high” when a film reaches the CN1007 Pin 15 SE-874 board Digital input of 3.3 V
intermediate carrier roller in the center
of PH2. Usually, set “low”.

5-4 UP-DF500
Signal name Description Connector Pin No. Connected to Remarks

FLAP_POSI0_SENS Paper eject flap state is indicated by CN1008 Pin 21 SE-898 board Analog input of 0 to 2.5 V
FLAP_POSI1_SENS the combined use of two sensors. CN1008 Pin 20 SE-898 board Analog input of 0 to 2.5 V
Indicates the flap state.

POSI0 POSI1
L L Prohibits the paper eject in this state.
H L Prohibits the paper eject in this state.
L H Select the eject port for 14 x 17.
H H Prohibits the paper eject in this state.

OUTSIDE_TH A detection voltage is low when the CN1014 Pin 2 KEY-59 board Analog input of 0 to 3.3 V
outside air temperature is high.
It is high when the outside air
temperature is low.
INSIDE_TH A detection voltage is low when the CN1008 Pin 18 CN-2326 board Analog input of 0 to 3.3 V
temperature inside this unit is high.
It is high when the temperature is low.
PLATEN_TH A detection voltage is low when the CN1008 Pin 17 Platen Analog input of 0 to 3.3 V
platen temperature is high. It is high
when the platen temperature is low.
HEAD_TH A detection voltage is low when the CN1004 Pin 21 Thermal head Analog input of 0 to 3.3 V
thermal head temperature is high.
It is high when the temperature is low.
HUMIDITY_SENS A detection voltage is low when humidity CN1014 Pin 3 Humidity sensor Analog input of 0 to 3.3 V
is low. It is high when humidity is high.
TRAY_OUT_SW_0 A film tray is ejected when the tray eject CN1011 Pin 17 SW-1340 board Digital input of 3.3 V
switch (0) is pressed and when a “low”
level is detected. A “high” level is
detected when the switch is not pressed.
REMOTE_POWER The power is turned on with the power CN1014 Pin 12 SW-1341 board Open collection output of
connected to GND using a power switch digital transistor
or digital transistor. It is turned off with
the power opened to GND.
POWER_SW Set “low” when the power switch is CN1014 Pin 17 SW-1341 board Digital input of 3.3 V
pressed toward the inner part. Set
“high” when it is returned this side.
V_CONT The head power is turned off when the CN1007 Pin 12 Power supply Analog output of 0 to 3.3 V
head voltage control is 0 V. The head
voltage is 33 ± 4 V when the DA output
power is 1 to 3 V.
LCD_CONTRAST LCD is turned off when the LCD CN1013 Pin 22 LE-336 board Analog output of 0 to 3.3 V
contrast control is 0 V. The LCD display
becomes dark as an output voltage
becomes higher.

UP-DF500 5-5
5-2. DR-618 Board . Power supply to CT-248 board and relay of communica-
tion line
5-2-1. Outline . REMOTE signal
. V_CONT signal
The DR-618 board controls motors or sensors and inter-
locking power in cooperation with the MA-155 board. Mechanical control CPU (IC200)
The mechanical control CPU (IC200) functions as the sub-
CPU of IC1403 (on the MA-155 board), controls a platen
5-2-2. Configuration drive motor, PH1 carrier motor, PH3 carrier motor, offset
motor, head fan, room fan, sensor light source voltage
The DR-618 board consists of a drive circuit of each (SW5 V), platen FG sensor voltage (FG5 V), and motor
motor, a sensor detection circuit, and a sensor LED control voltage (SW24 V), and reads a sensor value. IC200 and
circuit. IC1403 are connected by serial communication and using
The configuration of the DR-618 board is as described six hot lines. IC1403 sends the operating instructions of a
below. motor or fan to IC200. IC200 returns a sensor read value
to IC1403.
. Mechanical control CPU (IC200)
. Head fan control Head fan control
. Room fan control The head fan is used to cool a head. It operates when the
. Pickup clutch control head temperature is more than 40 dC or during print. The
. Platen drive motor control (1-to-2 phase excitation) head fan operates when the signal at pin 82 of mechanical
. PH1 carrier motor control (Two-phase excitation) control CPU (IC200) controls a drive transistor (Q6).
. PH3 carrier motor control (1-to-2 phase excitation)
IC200, pin 82 State
. Offset motor control (Two-phase excitation)
. Lift-up motor control L ON
. Tray-out motor control H OFF
. Flap motor control
. Head-up/down motor control Room fan control
. Capstan-up/down motor control The room fan is used to cool MA-155, DR-618, and
. Drive motor control DICOM boards. It operates when the internal temperature
. Sensor light source voltage (SW5 V) control of this unit is more than 5 dC. The room fan operates when
. Platen FG sensor voltage (FG5 V) control the signal at pin 81 of mechanical control CPU (IC200)
. Motor voltage (SW24 V) control controls a drive transistor (Q7).
. Interlock control
IC200, pin 81 State
. No-film sensor 0 monitoring
. Full stack sensor 0 monitoring L ON

. Full stack sensor 1 monitoring H OFF


. Tray-in sensor 0 monitoring
. Lift home sensor 0 monitoring Pickup clutch control
. Tray-out sensor 0 monitoring The pickup clutch is turned on when the motive power of a
. H/V sensor monitoring PH1 carrier motor is transmitted to take out the film from a
. Eject turn path sensor monitoring feed tray. It operates when a drive transistor (Q8) is
. Offset home sensor monitoring controlled by the signal from the MA-155 board.
. Eject tray sensor monitoring
IC1, pin 6 State
. Platen FG sensor monitoring
H ON
. Lift-up motor FG sensor 0 monitoring
. Intermediate drive path sensor monitoring L OFF

. Power supply to DICOM BOARD

5-6 UP-DF500
Platen drive motor control (1-to-2 phase excitation) Offset motor control (Two-phase excitation)
The platen drive motor is used as a film drive motor during The offset motor is used as the drive motor of a film offset
print. The signal from the MA-155 board or the signal mechanism. Rotation and speed are controlled when the
from pins 22 to 25 of mechanical control CPU (IC200) is signals at pins 8 to 11 of mechanical control CPU (IC200)
selected by IC103. Selection by IC103 is determined using control a stepping motor drive circuit (IC104).
the signal from pin 29 of IC200. Rotation and speed are The signal at pin 87 of IC200 controls the voltages at the
controlled by controlling a stepping motor drive circuit motor current setting terminals (pins 3 and 14) of IC104.
(IC100) using the selected signal.
IC200 State
The signal at pin 44 of IC200 controls the voltages at the
motor current setting terminals (pins 3 and 14) of IC100. Pin 8 INA H H L L
Pin 9 INB L H H L
IC100 State
Pin 10 nINA L L H H
Pin 6 INA H H H L L L L L
Pin 11 nINB H L L H
Pin 17 INB L L H H H L L L
Pin 5 nINA L L L L H H H L Lift-up motor control
Pin 16 nINB H L L L L L H H The lift-up motor drives the lift-up plate of a feed tray. It
operates when a DC motor drive circuit (IC403) is con-
PH1 carrier motor control (Two-phase excitation) trolled by the signal from the MA-155 board. The lift-up
The PH1 carrier motor is used as a film carrier motor motor controls PWM (Pulse-Width Modulation).
during paper feed. Rotation and speed are controlled when
IC400, IC400, Operation
the signals at pins 96 to 99 of mechanical control CPU pin 2 pin 4
(IC200) control a stepping motor drive circuit (IC101).
UP H(PWM) L Raises a lift-up plate.
The signal at pin 44 of IC200 controls the voltages at the
DOWN L H(PWM) Lowers a lift-up plate.
motor current setting terminals (pins 3 and 14) of IC101.
OFF L L Non-operation
IC200 State

Pin 96 INA H H L L n
Pin 97 INB L H H L A lift-up home sensor recognizes when a lift goes down
Pin 98 nINA L L H H (DOWN). A no-film sensor recognizes when a lift goes up
(UP).
Pin 99 nINB H L L H

Tray-out motor control


PH3 carrier motor control (1-to-2 excitation)
The tray-out motor is used to eject a feed tray. It operates
The PH3 carrier motor is used as film carrier motor during
when a DC motor drive circuit (IC406) is controlled by the
paper eject. Rotation and speed are controlled when the
signal from the MA-155 board.
signals at pins 100, 1, 2, and 3 of mechanical control CPU
(IC200) control a stepping motor drive circuit (IC102). IC401, IC401, Operation
The signal at pin 43 of IC200 controls the voltages at the pin 2 pin 4
motor current setting terminals (pins 3 and 14) of IC102. OUT H L Ejects a feed tray (upper).

IC200 State OFF L L Non-operation

Pin 100 INA H H H L L L L L


Flap motor control
Pin 1 INB L L H H H L L L
The flap motor drives a flap cam. It operates when a DC
Pin 2 nINA L L L L H H H L motor drive circuit (IC407) is controlled by the signal from
Pin 3 nINB H L L L L L H H the MA-155 board.

IC401, IC401, Operation


pin 6 pin 8

ON H L Drives a flap cam.


OFF L L Non-operation

UP-DF500 5-7
Head-up/down motor control Drive motor control
The head-up/down motor drives a head-up/down cam. It The drive motor intermediately carries a film and moves a
operates when a DC motor drive circuit (IC408) is con- drive roller. It operates when a DC motor drive circuit
trolled by the signal from the MA-155 board. (IC404) is controlled by the signal from the MA-155
board.
IC401, IC401, Operation
pin 10 pin 12 IC400, IC400, Operation
UP H L Raises a head. pin 6 pin 8

DOWN L H Lowers a head. ON L H Carries a film intermediately.

OFF L L Non-operation DOWN H L Lowers a drive roller.


OFF L L Non-operation
The up/down position is controlled by a head home sensor
and head position sensor. There are two positions to be Sensor light source voltage (SW5 V) control
used. (Sensor I/O is mounted on the MA-155 board.) This circuit is used to supply the power of the light emit-
ting block (LED) in a photointerrupter. A sensor (not
Home Positions 1 and 2
including a platen FG sensor) does not operate in the state
Head home sensor L H where SW5 V is not supplied. It operates when the signal
Head position sensor L L at pin 36 of mechanical control CPU (IC200) controls a
transistor (Q12).
There are slits in each cam position (including the home
IC200, pin 36 State
position) of a thermal head. Therefore, a head position
sensor is set “high” during position movement and set H OFF
“low” when it reaches the section of a slit prescribing the L Supply of 5 V
position. At that time, the head position sensor recognizes
that it was set to the prescribed position. Platen FG sensor voltage (FG5 V) control
This circuit is used to supply the power of a platen FG
Capstan-up/down motor control sensor that detects the rotation speed of a platen axis. The
The capstan-up/down motor drives a capstan-up/down platen FG sensor does not operate in the state where FG5
cam. It operates when a DC motor drive circuit (IC409) is V is not supplied. It operates when the signal at pin 37 of
controlled by the signal from the MA-155 board. mechanical control CPU (IC200) controls a transistor
(Q14).
IC402, IC402, Operation
pin 2 pin 4 IC200, pin 37 State
ON H L Drives a capstan-up/down cam. H OFF
OFF L L Non-operation L Supply of 5 V

The up/down position is controlled by a capstan home


sensor and capstan position sensor. There are three
positions to be used. (However, position 2 is unused.
Sensor I/O is mounted on the MA-155 board.)

Home Positions 1, 2, and 3

Capstan home sensor L H


Capstan position sensor L L

Like a head position sensor, the capstan position sensor is


set “high” during position movement.

5-8 UP-DF500
Motor voltage (SW24 V) control Full stack sensor 0 monitoring
This circuit operates when the signal at pin 88 of mechani- This sensor detects the film stack quantity in a feed tray. It
cal control CPU (IC200) controls FET (Q16). IC200 turns reads the quantity by the A/D block of mechanical control
on Q16 according to the command from IC1403 on the CPU (IC200).
MA-155 board. Q16 must be turned on when a motor and
IC200, pin 49 State
clutch operate. Even when Q16 is off, a voltage of 24 V
usually exists in SW24 V because a current flows through H Full stack
positive characteristic thermistor THP11. However, when L Others
an abnormal current flows because of the short-circuited
circuit, THP11 performs self-heating, the temperature Tray-in sensor 0 monitoring
rises, and the resistance value increases. Therefore, a This sensor detects that a feed tray has been mounted. It
voltage of SW24 V decreases. SW24 V is voltage-divided reads the completion of mounting by the A/D block of
using R63 and R64 and input to the A/D block at pin 51 of mechanical control CPU (IC200).
IC200. When a voltage of SW24 V is less than 18 V,
IC200, pin 45 State
IC200 ignores the command even if it receives a command
for turning on Q18 from IC1403 on the MA-155 board. H Mounting completion of feed tray
L Others
IC200, pin 88 FET (Q16)

H ON Lift home sensor 0 monitoring


L OFF This sensor detects the home position of a lift-up lever for
a feed tray. It reads the home position by the A/D block of
Interlock control mechanical control CPU (IC200).
SW24 V and SW12 V are turned off when a front cover,
IC200, pin 48 State
rear cover, or top cover is opened. A motor and clutch
cannot operate in this case. The reason is that no current H Home position of lift-up lever

flows through the coil of a relay (RY1) when one of the L Others
covers is opened with the switches of each cover connected
in series. This is a function that prevents the trouble Tray-out sensor 0 monitoring
occurring when a motor malfunctions with the cover This sensor detects that a feed tray (upper) has been
opened. However, a room fan is designed so that it cannot ejected. It reads the completion of eject operation by the
be touched directly. The room fan thus operates even with A/D block of mechanical control CPU (IC200).
the cover opened.
IC200, pin 50 State

L Eject completion of feed tray (upper)


No-film sensor 0 monitoring
This sensor detects the existence of a film in a feed tray. It H Others

reads a film by the A/D block of mechanical control CPU


(IC200). H/V sensor monitoring
This sensor detects whether a printer is ranged vertically or
IC200, pin 46 State horizontally when it is used. It reads how to arrange a
H Film loaded printer by the A/D block of mechanical control CPU
L No film (IC200).

IC200, pin 52 State

H Horizontal
L Vertical

UP-DF500 5-9
Eject turn path sensor monitoring Lift-up motor FG sensor 0 monitoring
This sensor detects the existence of a film before (near) an This sensor finely adjusts the lift plate position of a feed
eject turn. It reads the existence of a film by the general- tray. A signal is sent to the MA-155 board through
purpose port of mechanical control CPU (IC200). CN700. (Refer to Section 5-1.)

IC200, pin 15 State


Intermediate drive path sensor monitoring
H Film loaded This sensor detects the existence of a film near a drive
L No film roller. A signal is sent to the MA-155 board through
CN700. (Refer to Section 5-1.)
Offset home sensor monitoring
This sensor detects the home position of a film offset Power supply to DICOM BOARD
mechanism. It reads the home position by the general- Power (5 V) is supplied to the DICOM BOARD.
purpose port of mechanical control CPU (IC200).
Power supply to the CT-248 board and relay of
IC200, pin 20 State
communication line
H Home position of offset mechanism The DR-618 board supplies 3.3 V and 5 V to the CT-248
L Others board through CN2. IC1 on the CT-248 board and IC1403
on the MA-155 board are connected by serial communica-
Eject tray sensor monitoring tion and using four hot lines. These signals are relayed
This sensor detects that an eject tray has been mounted. It using CN602.
reads the completion of mounting by the general-purpose
port of mechanical control CPU (IC200). REMOTE signal
The REMOTE signal from the SW-1341 board on the front
IC200, pin 21 State
panel is sent to the power supply through MA-155 and
H Mounting completion of eject tray
DR-618 boards. The power is turned on when this signal
L Others is low.

Platen FG sensor monitoring V_CONT signal


This sensor detects the rotation speed of a platen. It reads This signal is used for adjustment of a head voltage. The
the rotation speed by the interrupt input of mechanical signal from the MA-155 board is received using a voltage
control CPU (IC200). follower (IC207) and sent to the power supply. A FET
IC200, pin 92 State
(Q203) switches prevents an illegal V_CONT signal from
being input to the power supply when the power is turned
H and L set repeatedly During platen rotation
on.
H or L set fixedly Platen stop

5-10 UP-DF500
5-3. CT-248 Board Peripheral circuit
The peripheral circuit of CPU consists of SRAM (IC5) and
5-3-1. Outline multiple ICs controlled using an I2C bus. SRAM functions
as each arithmetic buffer during density measurement. IC
To ensure a stable print density, this unit has a calibration that is controlled by an I2C bus is as follows:
function that measures the transmitted density of a print
result and feeds the result back to the print energy. The . IC3EEPROM
CT-248 board is used to measure the density. . Temperature detection sensor IC4
The CT-248 board also controls the read/write operation of . D/A converter IC11 for light-emitting amount control
an IC tag. . Digital potentiometer IC12 for controlling the gain and
offset of photosensing voltage

5-3-2. Configuration Light-emitting amount control block


. D3301 on SE-880 board: LED for measuring the density
The CT-248 board consists of the following. of print film
. CPU and peripheral circuit For LED control, CPU first controls a D/A converter
. Light-emitting amount control block (IC11). The voltage output from the D/A converter is sent
. Photosensing voltage input block to an operational amplifier (IC103), and the current
. Gain and offset adjustment block proportional to an input voltage value is output. This
. Three-channel A/D input block using amplification value output current is sent through a connector (CN3) to D3301
. IC tag control block (on the SE-880 board) so as to control the light-emitting
amount.

5-3-3. CPU and Peripheral Circuits Photosensing voltage input block


A photodiode detects the quantity of light penetrated
CPU through a film.
CPU (IC1) is H8S/2238 that has an internal flash memory . D5901 on SE-881 board: Photodiode for measuring the
of 256K bytes. It starts at the rising edge of the reset density of a print film
signal from a reset circuit (IC7) and put into the state The current of each photodiode that flowed under recep-
waiting for the command from the MA-155 board. The tion of transmitted light is converted into a voltage value
CT-248 board operates by controlling the command from using an operational amplifier (IC5901 on the SE-881
the MA-155 board. The control line for communication board) and input from a connector (CN7) to the CT-248
with the MA-155 board is connected from connector CN2 board.
to CPU through the DR-618 board.
A communication protocol is as described below. Gain and offset adjustment block
. Sync system: Asynchronous Even if dispersion exists in the characteristics of LED or a
. Rate: 38,400 bps photodiode, the same voltage must be input to CPU when
. Data length: 8 bits the transmission amount is the same. Therefore, the
. Stop bit length: 1 bit amplification value of a photosensing voltage is adjusted to
. Parity: Even correct the dispersion when there is no film. (Gain adjust-
. Transmission order: LSB first ment)
Firmware is downloaded from the MA-155 board to the To correct high density, the offset value of a photosensing
flash memory of CPU by this communication when voltage is adjusted when a reference sheet is penetrated.
upgrading the firmware of the CT-248 board. Refer to “6- (Offset adjustment) This adjustment is performed by
3. Firmware Version Upgrade Procedures” for the upgrad- changing a resistance value using the digital potentiometer
ing of firmware. controlled by an I2C bus. The voltage value input to a
connector (CN7) is first offset-adjusted using an operational
amplifier (IC8 (2/5)). The voltage value is then gain-
adjusted using an operational amplifier (IC8 (3/5)).

UP-DF500 5-11
Three-channel A/D input block using 5-4. DICOM BOARD
amplification value
The voltage value for which each adjustment was per- 5-4-1. Interface
formed is input to the 10-bit A/D converter of CPU. When
the voltage value is directly detected, however, high- The DICOM BOARD is provided with the interface
precision density cannot be detected because an input connectors below.
voltage is very little in a high-density film. Therefore, this
block is divided into three channels. These channels are . Power (2-mm pitch and 4-pin connector: J19)
amplified in a different way, and the obtained value is 5 VDC (Supplied through the DR-618 board.)
input to CPU. Each channel is amplified to 1, 10, and 100 . PS/2 keyboard (Mini DIN 6-pin)
times using operational amplifiers (IC8 (1/5) and IC8 (4/ This is a terminal for debugging. Do not use this
5)). terminal.
(Example) . Printer (USB A)
. CPU detects an A/D input value of 2.0 V amplified to 1 This is used for connection to a printer engine.
time when the film density is low and when an input A connector and signal are the same as for USB because
value is 2.0V. parts for USB are used in common. However, this is
. CPU detects an A/D input value of 1.00 V amplified to used exclusively for a printer engine.
100 times when the film density is high and when an . Network (RJ-45)
input value is 0.01 V. This is used for connection to a DICOM network. This
As described above, high-precision density can be detected network is compatible with 10/100Base-T.
by detecting the A/D values in different channels accord- . USB memory (USB A)
ing to the density of a film. This is connected to a service-dedicated connector for
virus batch.
IC tag control . Other connectors
Communication with the IC tag controllers on the AN-31 These connectors are not used for maintenance service.
board is done to control the data read and write into an IC (Used for manufacturing.)
tag.
CPU (IC5005) starts the boot mode by setting boot opera-
tion “low” and reset operation “high”, “low”, and then 5-4-2. Functions
“high”. This enables the upgrading of firmware by FSSS.
Refer to “6-3. Firmware Version Upgrade Procedure” for The functions of a DICOM BOARD are as described
the upgrading of firmware. below.

. Reception of the print request from a DICOM network


. Spool processing of the received print request
. Creation of a print image based on print request (Howev-
er, the ambient blank space is created on the print engine
side.)
. Mail origination during occurrence of an error in a print
engine
. Communication with a Web browser

Communication protocol with IC tag controller


. Sync system: Asynchronous
. Rate: 38,400 bps
. Data length: 8 bits
. Stop bit length: 1 bit
. Parity: Even
. Transmission order: LSB first

5-12 UP-DF500
Section 6
Service Mode

6-1. Activating the Service Mode

The two ways to activate the service mode are described below.
. Turn on the power while simultaneously pressing the [&] and [*] keys.
. Press each key in the order of [*], [(], [&], [*], [)], and [&] in the READY state of the normal
mode. (Press each key sequentially so that you draw an S character.)
n
Activate the service mode after the mechanical initialization is completed.

FILM STATION :S
READY state of service mode
READY [120]

“:S” is displayed in the upper-right position at the top of the LCD when the service mode is activated.
To exit the service mode, press the [EXEC] key continuously on the READY screen of the service mode
three times. The service mode is then shifted to the normal mode without turning off the power.

FILM STATION
READY state of normal mode
READY [120]

UP-DF500 6-1
6-2. Menu Configuration of Service Mode

n
[→], [←], [↑], and [↓] described in the flowchart of this section indicate the arrow keys ( [*], [&], [(],
[)]) on the front panel.

FILM STATION :S
READY state of service mode
READY [120]

[↑] [MENU]
Section INFORMATION IP address display, head print counter and
6-2-1 [>] version display
[↑] [↓]
Section PRINT QUALITY
6-2-2 Sharpness adjustment
[>] 5% and 95% density adjustment
[↑] [↓]
Section CALIBRATION Densitometer
6-2-3 [>]
[↑] [↓]
Section
GAMMA SEL Gamma table selection
6-2-4
[>]
[↑] [↓]
Section
PRINT OPERATION Reprint operation and
6-2-5
[>] setting of reprinted sheet count
[↑] [↓]
Section
SYSTEM SETTING Various settings
6-2-6
[>]
[↑] [↓]
Section
TEST PRINT
6-2-7 Test print activation using internal pattern
[>]
[↑] [↓]
Section
MANUAL MECHA Manual operation of each motor and clutch
6-2-8
[>] Sensor level check
[↑] [↓]
Section
ERROR INFO Error history display and
6-2-9
[>] error history clear
[↑] [↓]
Section
ADJUST Head voltage adjustment, print position adjustment, and
6-2-10
[>] mechanical operation adjustment
[↑] [↓]
Section
SELF CHECK
6-2-11 Self-check activation and result confirmation
[>]
[↑] [↓]
Section
MEDIA (TAG) MENU
6-2-12 Media information confirmation
[>]
[↓]

6-2 UP-DF500
6-2-1. Information

This menu is used to confirm the number of printed sheets and the version of software.

INFORMATION
[>]
[→]
[↑]
Displays the IP address.
IP ADDRESS
***.***.***.***
n
An IP address is only displayed here. It can be changed in
“SYSTEM SETTINGS” → “NETWORK SETTING”.
[↑] [↓]

TOTAL PRINTS Displays the print sheet counter of this unit.


***

[↑] [↓]

TOTAL HEAD PRINT Displays the print sheet counter of a thermal head.
*** Press the [&] and [*] keys simultaneously during thermal head replacement.
(counter reset)
[↑] [↓]

MA VER Displays the version of the firmware installed on the MA-155 board.
V*.** ****.**.**

[↑] [↓]

DR VER
V*.** ****.**.** Displays the version of the firmware installed on the DR-618 board.

[↑] [↓]

CT VER
Displays the version of the firmware installed on the CT-248 board.
V*.**

[↑] [↓]

IC TAG VER
Displays the version of the IC TAG1 on the CT-248 board.
V*.**

[↑] [↓]

DICOM VER
**.** Displays the version of DICOM Board

[↑] [↓]

IDMAC VER
Displays the version of IC1004 (PLD, “IDMAC”) on the MA-155 board.
V**.* **.**.**

[↑] [↓]

HEAD AVERAGE
***** Displays the average resistance value of the installed print head.

[↑] [↓]

HEAD NAME
************* Displays the serial number of the installed print head.

[↓]

UP-DF500 6-3
6-2-2. Print Quality

This menu is used to perform sharpness adjustment.

Select the gamma to be adjusted among the twenty


PRINT QUALITY SELECT GAMMA gamma.
[>] [→] SONY 1/[EXEC]
[EXEC]

SHARPNESS OFF Sharpness adjustment (Initial value: OFF)


* Adjust (increase or decrease) the sharpness using
a [&] or [*] key.
[↑] [↓]
Select a tray using a [&] or [*] key and print a selection
PATTERN PRINT pattern of 95% and 5% in density using an [EXEC] key.
[EXEC]

[↑] [↓]
This is the result of patterns (01 to 49) printed in
SELECT POINT 95% “PATTERN PRINT”. Using a [&] or [*] key, select the
[25] number in which the relation between 100% and 95% in
density is good. (Initial value: 25)
[↑] [↓]
This is the result of patterns (51 to 99) printed in
SELECT POINT 5% “PATTERN PRINT”. Using a [&] or [*] key, select the
[75] number in which the relation between 0% and 5% in
density is good. (Initial value: 75)
[↑] [↓]
Determine the setting using an [EXEC] key.
SAVE GAMMA The setting is not changed when you select a [MENU]
[EXEC] key without determining the setting.

6-4 UP-DF500
6-2-3. Calibration

This menu is used to execute and confirm calibration, calibrate a density sensor, and confirm the density.

CALIBRATION
[>]
[→]
[↑]
FULL RANGE CAL
Execute calibration using an [EXEC] key.
[EXEC]

[↑] [↓]

AUTO CALIBRATION Calibration is automatically executed when a new film is mounted during
[on/OFF] setting to ON. (Initial value: OFF)

[↑] [↓]

CAL RESET Clear the correction value to the specified size as non-correction using an
[EXEC] [EXEC] key.

[↑] [↓]

SPOT MEASURE [→]


[>]

[↑] [↓] DENSITY The measurement and display of density are repeated
*.** until you press the [MENU] key.
GAIN ADJ Execute calibration of a density sensor.
[EXEC]

[↑] [↓]

CAL PRINT CHECK Select a tray using a [&] or [*] key, print a pattern using an [EXEC] key, and confirm calibration.
[EXEC]

[↑] [↓]

CAL UNDO Discard the correction value of the lastly executed calibration and return it to the value obtained
[EXEC] before calibration is executed.

[↓]

UP-DF500 6-5
1. Calibration/Gain Adj
This is a menu used for calibrating a calibration density sensor.

GAIN ADJ
[EXEC]

[EXEC]
REMOVE REF CH-0 Confirm that a reference sheet is not mounted and press the [EXEC] key.
[EXEC]

[EXEC]

GAIN ADJUST Please wait a moment.


PLEASE WAIT

OFFSET ADJUST Enter the density value described in a reference sheet using a [&] or [*] key and press the [EXEC] key.
REF=*.** [EXEC]

[EXEC]

SET REF SHEET Mount a reference sheet and press the [EXEC] key.
OK? [EXEC]

[EXEC]

OFFSET ADJUST Please wait a moment.


PLEASE WAIT

REMOVE REF SHEET Remove the reference sheet and press the [EXEC] key.
OK? [EXEC]

[EXEC]
CAL CHECK Please wait a moment.
PLEASE WAIT

CAL OPT ADJUST Please wait a moment.


PLEASE WAIT

GAIN OFFSET ADJ Confirm OK and press the [EXEC] key.


,OK. PUSH [EXEC]

[EXEC]

6-6 UP-DF500
6-2-4. Gamma Sel

This menu is used to select and adjust gamma.

GAMMA SEL [→]


[>]

Select the gamma using [&] and [*] keys.


DEFAULT
Gamma has priority if it is specified from modality during print. (Initial value: SONY: 1)
/***** */

6-2-5. Print Operation

This menu is used to perform a reprint and set the number of reprinted sheets.

PRINT OPERATION
[>]
[→]
[↑]
Reprints the lastly printed image.
REPRINT
(Handle with care when reprinting a medical image.)
[EXEC]

[↑] [↓]

PRINT QTY
Sets the number of printed sheets output in “REPRINT”.
1 to 125 [***]

[↓]

UP-DF500 6-7
6-2-6. System Settings

This menu can be used to set the operation of a printer.


m
. Usually, use the initial setting.
. Check the user’s setting using the check list No.2 in Section 1-8.

SYSTEM SETTINGS
[>]
Move the cursor using [&] and [*] keys and increase and decrease the numeric value using [(] and [)] keys.
[↓] The change is determined when you press the [EXEC] key in [SAVE SETTINGS].
[→]
NETWORK SETTINGS
To page 6-10
[>]

[↑] [↓]

DITHER Select dither processing. (Initial value: ON)


[ON/off] Select the display of upper-case letters using [&] and [*] keys.
[↑] [↓]

MIRROR Select the designation of mirror (mirror image reversal) print. (Initial value: OFF)
[on/OFF] Select the display of upper-case letters using [&] and [*] keys.
[↑] [↓]

L/R MARK Select the insertion of an L/R mark print screen. (Initial value: OFF)
[on/OFF] Select the display of upper-case letters using [&] and [*] keys.
[↑] [↓]

STRICT SIZE Initial value: OFF


[on/OFF]
[↑] [↓]

FRAME TYPE Specify the size of a print area. *1:


[HOOK/c2/c1/wd] (Initial value: HOOK) The initial value is ON. However, it is not set until the contents of FSSS are
set. The initial value may not be set depending on the frame type used.
[↑] [↓] [↑]
[→] Select whether to insert the fixed caption at the top of print.
CAPTION CAPTION UPPER (Initial value: ON)*1
[>] [ON/off]

[↑] [↓] [↑] [↓]


Select whether to insert the fixed caption at the bottom of print.
CAPTION LOWER (Initial value: ON)*1
To page 6-9
[ON/off]
[↓]

Return the setting to the initial state

List of FRAME TYPE and print area


FRAME TYPE at the shipment: HOOK, CAP2: same size as UP-DF550, WIDE: print size is wider than film width

14 x 17 inch Black frame Upper Lower


Film width (4448 dots) range →

WIDE 4512 5320 0 _60


CAP1 4384 5306 0 _74
CAP2 4360 5232 _74 _74
HOOK 4224 5060 _74 _246

6-8 UP-DF500
From page 6-8

DEFAULT SETTING
[EXEC]

[↑] [↓]
Initial value: ON
HEAD OFFSET ADJ
[ON/off]

[↑] [↓]
[→] Read the setting from Memory Stick.
MEMORY STICK LOAD SETTING
[>] [ON/off]

[↑] [↓]
Initial value: ON
EDGE MODE
[ON/off]

[↑] [↓]
Initial value: OFF
LINEAR 20
[on/OFF]

[↑] [↓]
Initial value: 320
MAX DENSITY
[320]

[↑] [↓]
Set whether to generate a buzzer when SET FILM and REMOVE PRINTS are reached.
FILM EMPTY BUZZ.
(Initial value: OFF)
[on/OFF]

[↑] [↓]
Set whether to put this unit on its left side or right side.
VERTICAL SETTING (Initial value: R)
[L/r] SIDE UP

[↑] [↓]
Set whether to use an eject tray. (Initial value: ON)
OUTPUT TRAY ON: Not printed when an eject tray is not mounted.
[ON/off] OFF: Printed even when an eject tray is not mounted.

UP-DF500 6-9
Select preset number
and press [EXEC] key
to accept it.
[→] [→] [→]
LOAD PRESET PRESET 1 IP ADDRESS
From page 6-8
[>] [EXEC]
[←] ***.***.***.***
[↑] [↓]
[→] [→] [→]
CHANGE SETTING IP ADDRESS SUBNETMASK
Go to A
[>] ***.***.***.*** ***.***.***.***
[←] [←]
[↑] [↓]
[→] [→] [→]
EDIT PRESET PRESET 1 PRESET NAME
Go to B
[>] [>] PRESET 1
[←] [←]
Select preset number.

Change AE title.
[→] [→] [→]
DEFAULT GATEWAY AE TITLE SAVE SETTINGS
A
*.*.*.* SONY [EXEC]
[←] [←] [←]

[→] [→] [→] [→]


IP ADDRESS SUBNETMASK DEFAULT GATEWAY
B Go to C
***.***.***.*** ***.***.***.*** *.*.*.*
[←] [←] [←] [←]

[→] [→]
AE TITLE SAVE SETTINGS
C
[←] SONY [←] [EXEC]

6-10 UP-DF500
6-2-7. Test Print

This menu can be used to print an internal test pattern.


The six types of test patterns below are provided.
. STEP pattern
. RAMP pattern
. 75% gray print
. 50% gray print
. 25% gray print
. Black print

TEST PRINT
[>] Start the test print of an internal pattern.
[→]
[↑]
STEP
STEP pattern print
[EXEC]

[↑] [↓]

RAMP RAMP pattern print


[EXEC]

[↑] [↓]

LIGHT GRAY
75% gray print
[EXEC]

[↑] [↓]

MEDIUM GRAY
50% gray print
[EXEC]

[↑] [↓]

DARK GRAY
[EXEC] 25% gray print

[↑] [↓]

DARK GRAY H-TEMP


[EXEC] 25% gray print (For thermal head position adjustment check)

[↑] [↓]

BLACK
Black print
[EXEC]

[↑] [↓]
Print various settings or version numbers.
DUMP LIST
[EXEC]

UP-DF500 6-11
6-2-8. Manual Mecha

This menu is used to directly operate and confirm motors and sensors and verify the operation.

MANUAL MECHA
[>]
[→]
[↑]
Using an [EXEC] key, make print without applying any current to a thermal head.
MOVING TEST
[EXEC]

[↑] [↓]

MOTOR TEST Select a motor and clutch using [(] and [)] keys and forcibly operate the motor and
[>] clutch selected using [&], [*], and [EXEC] keys.
(Refer to the table below.)
[→]
[↑] [↓]

PH1 LIFTUP MOTOR


L:UP R:DW E:MOV

Display the state of the sensor selected using [(] and [)] keys.
SENSOR MONITOR (Refer to the table below.)
[>]
[→]

PICK END PASS 0


LOW

n
L:[←] R: [→] E: [EXEC]
For more details of the sensor, refer to Section 7-1-2.
PH1 LIFTUP MOTOR UP DOWN Initialization
PH1 MAIN MOTOR ON _ OFF
PH1 PICK CLUTCH ON OFF _
OFFSET MOTOR HOME PRESS Size change
PH2 DRIVE MOTOR DOWN UP Carrying
MD HEAD MOTOR Print 1 Print 2 UP
MD CAPS MOTOR POS1 POS3 HOME
MD MAIN MOTOR High speed Low speed Stop
PH3 MAIN MOTOR High speed Low speed Stop
PH3 FLAP MOTOR 14x17 11x14 8x12/10x12
PH1 TRAY MOTOR IN OUT _
BUZZER ON OFF _
HEAD FAN ON OFF _
ROOM FAN ON OFF _

6-12 UP-DF500
6-2-9. Error Info

This menu is used to store the previous jamming information and display the history.

ERROR INFO
[>]
[→]
[↑]
ERR-0: NO. NNNNNN
QQ-QQ S=HHHHHHHH Can confirm the previous ten unit information items
using [&], [*] keys when abnormality occurs.

ERR-*: ERR-0: indicates the latest error, and ERR-9: indicates


the error preceding by ten.
NNNNNN: Indicates the counter value of a total print sheet count
when this error occurs.
QQ-QQ: Indicates the unit sequence code number when this error
occurs.
S=********: Indicates the sensor level information when this error occurs.
For more details of an error, refer to “7-1. Error Display”.

[↑] [↓]

ERROR RESET
Clears all of the previous ten error histories.
[EXEC]

[↓]

UP-DF500 6-13
6-2-10. Adjust

This menu is used for various adjustments (refer to the description below).

ADJUST Press the [*] key to enter the fine-adjustment mode of a head print-time voltage, a print start
[>] position, and mechanical drive timing.
[→]
[↑]
Perform after replacement of a thermal head. A dedicated internal pattern begins to be printed
V-ADJ PRINT when you press the [EXEC] key. The head voltage is automatically determined, and the result is
*****Z [EXEC] displayed in “VOLTAGE ADJ”.

[↑] [↓]

VOLTAGE ADJ n
HV=**.*V+DA[+NN] Usually, do not change this.

[↑] [↓]
Specify a pitch.
PITCH ADJ
[***]

[↑] [↓]

X POS ADJ
[***]

[↑] [↓]

Y POS ADJ
[***]

[↑] [↓]

EEP INIT RESET


[EXEC]

[↑] [↓]

LIFT UP POWER n
ON DUTY = [ 85]% Usually, do not change this.

[↑] [↓]

LUT [0] GRAD ADJ n


- [ 0]% Usually, do not change this.

[↑] [↓]

LCD CONTRAST
[EXEC]

6-14 UP-DF500
6-2-11. Self Check

This menu is used to discriminate a defective point during self-diagnosis.

SELF CHECK
[>] Close all covers before execution. (*1)
[→]
[↑]
Press the [EXEC] key to activate a self-check function.
SYSTEM CHECK n
[EXEC] Put a film in the tray and execute it with the tray set in this unit. (*2)

[↓] [EXEC]

OPEPANEL CHECK Check the LCD, LED and buzzer on the front panel of this unit after LCD blinks.
PUSH [****] SW Press the relevant switch according to the display.

**********
PLEASE WAIT Check of sensors and motors (*3)

SDRAM/* CHECK
Read/write check of image memory SDRAM
PLEASE WAIT

DICOM CHECK
PLEASE WAIT Status check of DICOM BOARD

CAL CHECK
Self check of densitometer
PLEASE WAIT

If the result is NG, confirm the state of the relevant sensor, motor, and unit in
SELF CHECK “MANUAL MECHA MENU” or take measures referring to the troubleshooting
<OK> PUSH[EXEC] (Section 7). After that, execute “SELF CHECK” again. (*3)
[↑]

CAL CHECK
Press the [EXEC] key to activate the self-check function of a densitometer.
[EXEC]

[↓] [EXEC]

CAL CHECK
During self check.
PLEASE WAIT

CAL CHECK CH-0&1 If the result is NG, check the SE-708 assembly and connector connection
<OK> PUSH[EXEC] and execute “CAL CHECK” again.

(*1): When even one of the covers is opened before execution, self-diagnosis cannot be performed because power is not
supplied to the motor system by interlocking.
(*2): Diagnosis can be performed with the tray not put in this unit. However, the diagnosis of the block related to the tray
operation is omitted in this case. Be sure to put a film in the tray and execute it with the tray set in this unit.
(*3): Refer to the error message for the location of the sensor and motor displayed on the LCD. (Refer to Section 7-1.)
Refer to “Section 7 Troubleshooting” for the location diagnosed as “NG”.

UP-DF500 6-15
6-2-12. Media (Tag) Menu

This menu can be used to confirm the film information stored in IC_TAG.

MEDIA (TAG) MENU


[>]
[→]

MEDIA INFORMATION
[>]
[→]
[↑]
MODEL NAME
**********

[↑] [↓]

VERSION
**********

[↑] [↓]

MAX PRINTS
******

[↑] [↓]

FILM DATE
****.**.**

[↑] [↓]

FILM LOT No.


***************

[↑] [↓]

TAG DATA DATE*


**.**.**

[↑] [↓]

OEM
****

[↑] [↓]

OEM INFOMATION
******

[↑] [↓]

FILM MAKER
******

6-16 UP-DF500
6-3. Firmware Version Upgrade Procedures

This Section describes the upgrade procedures for the MA-155 board, DR-618 board and CT-248 board.

6-3-1. Required Equipment

. Upgrade file of each firmware (file :***.vup, vup indicates extension)


For obtaining the latest firmware version upgrade file, contact your local Sony Sales Office/Service
Center.
. FilmStation Support Software
. Personal computer (hereafter reffered to as PC)
(equipped with USB interface, compatible with Windows 2000 or Windows XP)
. USB cable
. Phillips screwdriver

6-3-2. Upgrade Procedures

1. Take out the film tray from this unit.


2. Remove the screw on the upper-right side (left side of tray slot) of the power button, then open the
front cover (USB). Check the USB connector.
3. Connect the UP-DF500 with the personal computer (hereafter referred to as PC) using the USB cable.
4. Turn on the power of the UP-DF500 and PC.
n
If the installation of driver is requested during power on, install the driver referring to “6-5.
FilmStation Support Software”.
5. Start the FilmStation Support Software and select the “Firmware” tab.
6. Select the upgrade file.
The unit automatically determines which board to be upgraded and the version upgrade starts.
n
During upgrade, be careful not to turn off the power before the message of step 8 is displayed.
7. When “<OK> PUSH [EXEC]” is displayed on the LCD, press the [EXEC] key.
8. When “PLEASE POWER OFF” is displayed on the LCD, turn off the power of the UP-DF500.
9. Remove the USB cable, then close the cover (USB).

6-3-3. Version Check

1. Start the service mode. (Refer to Section 6-1.)


2. Proceed to the INFORMATION item. (Refer to Section 6-2-1.)
3. Display the firmware version of each board using the [(] and [)] keys.
After checking the version, the firmware version upgrade is completed.

UP-DF500 6-17
6-4. DICOM Version Upgrade Procedures

This Section describes the DICOM BOARD software version upgrade procedures.

6-4-1. Required Equipment

. UP-DF500 DICOM BOARD upgrade file (file :***.zip)


For obtaining the latest DICOM Board version upgrade file, contact your local Sony Sales Office/
Service Center.
. PC (equipped with network interface, compatible with Windows 2000 or Windows XP)
. Network cross cable

6-4-2. Upgrade Procedures

1. Start the service mode. (Refer to Section 6-1.)


2. Write down the IP address in “IP ADDRESS” of “INFORMATION” in the menu.
(Refer to Section 6-2-1.)
3. Set the IP address of the same segment as step 2 to the PC.
4. Connect this unit with the PC using the cross cable.
5. Copy the DICOM BOARD upgrade file to the PC.
6. Uncompress the upgrade file (compressed) copied on the PC and execute UpdatePrinter in the folder
extracted.
7. Type the IP address written in step 2 in the IP Address of the Printer box and click the
[Update|Printer|Software] button.
When “READY” is displayed on the panel, the upgrade is completed.
n
The upgrade procedures take approximately 5 minutes. Be careful not to turn off the power during the
upgrade procedures.

6-4-3. Version Check

The DICOM BOARD software version can be checked on the front panel of the UP-DF500.

1. Start the service mode. (Refer to Section 6-1.)


2. Proceed to the “INFORMATION” item. (Refer to Section 6-2-1.)
3. Display the DICOM BOARD software version using the [(] and [)] keys.
After checking the version, the upgrade is completed.

6-18 UP-DF500
6-5. FilmStation Support Software Firmware Version Upgrade Procedures
1. Press the Firmware tab.
This Section describes the operating procedure for the 2. Press the [Ref.] button and select the upgrade file.
FilmStation Support Software. Press the [Transfer] button.
The firmware version upgrade starts.
n
6-5-1. Installing the FilmStation Support During upgrade, be careful not to turn off the power
Software before the message of step 4 is displayed.
3. When “<OK>PUSH [EXEC]” is displayed on the
1. Copy the FilmStation Support Software folder to any LCD, press the [EXEC] key.
folder of the PC. 4. When “PLEASE POWER OFF” is displayed on the
2. Take out the film tray from this unit. LCD, turn off the power of this unit.
3. Remove the screw on the right side (left side of tray For upgrading other boards after this, turn on the
slot) of the power button, then open the cover (USB). power of this unit again and repeat the procedures
4. Connect the UP-DF500 with the PC using the USB from step 2.
cable.
5. Turn on the power of this unit and PC. Non-uniformity Correction Data Transfer
If the installation of driver is requested during power 1. Press the “HeadProfile” tab.
on, install the FilmStation Support Software in the 2. Transfer the data.
following procedures. Be careful not to overwrite the data by transferring the
. If you are asked to select either “Installing the data in the wrong direction. Transfer the data referring
software automatically” or “Installing the software to the following.
from the list or specific place”, select the latter one. m
. If you are asked to select either “Searching the . When transferring the data to this unit, use the left
optimum driver in the next place” or “Selecting the side of the screen.
driver to install without searching”, select the latter . When transferring the data from this unit, use the
one. right side of the screen.
Select the FilmStation as driver. If the PC does not . Transfer the data having the same file name as the
have FilmStation, select updrv. inf under the folder head serial using “Head Profile”.
of step 1 in “Using disk”. . Transfer the data having the file name of SxxxBB
using “Head Coefficient”.
3. Press the [Ref.] button and select the file to be
6-5-2. Operating Procedures for FilmStation transferred.
Support Software 4. Press the [Transfer] button (the icon displayed in the
lower portion of the screen).
Preparation Transfer of the non-uniformity correction data starts.
1. Take out the film tray from this unit.
2. Remove the screw on the right side (left side of tray FSSS (FilmStation Service Software)
slot) of the power button, then open the front cover L.
3. Connect this unit with the PC using the USB cable. FSSS is used to fine adjust the gamma of this unit.
4. Turn on the power of this unit and PC. FSSS has the following functions.
n
If the installation of driver is requested, install it . Gamma data file is a data file that controls all of the
referring to Section 6-5-1. twenty gamma data files.
5. Start the FilmStation Support Software. . Gamma curve is one of the twenty gamma data files. It
6. Select UP-DF500 (2) and press the [OK] button. consists of the name of eight alphabetic characters,
gamma fine adjustment value, 5% setting value, 95%
setting value and sharpness setting value.

UP-DF500 6-19
The functions that can be used when each tab of FSSS is 6-6. DICOM Anti-Virus Patch Procedure
opened are as follows.
1. Gamma The DICOM BOARD uses Windows XP Embedded as
. Fine adjusts the gamma curve. OS. Therefore, virus patch processing is updated in the
. Fine adjustment is performed using SONY1 or D value way different from the general virus-compatible updating
as reference. of PC.
. Auxiliary line of DICOM setting Dmax=300/280 is
displayed. Preparation
. Density area where no adjustment is required is locked
to improve the adjustment efficiency. . Make USB memory recognize to this unit before actual
. Performs setting of the gamma curve name, 5%, 95% updating.
and sharpness. . Write patch information into the USB memory using PC.
. Imports the image data of the last print of this unit or the . Install the USB memory in this unit for updating.
image data of PC so that the data value (8 bits) of image
can be checked. Required equipment
. Loads and saves the gamma data file for PC.
. Gets and sends the gamma data file for this unit. . Security update patch file for UP-DF500 DICOM
. Selects the gamma curve of UP-DF500 and reprints the BOARD (.zip format)
image of the last print. n
. Specifies the density value of SMPTE to create the Perform the update on the assumption that the updating
gamma curve. up to R15 (patch state of DICOM BOARD is unclear)
. Examines the correlation between the internal densitom- has been completed.
eter of this unit and the densitometer used. . Personal computer
2. HeadProfile (that is provided with an USB interface and in which
. Transfers Head Profile Data/Head Coefficient Data from Windows 2000/XP operates)
PC to this unit. . USB memory
. Backs up Head Profile Data/Head Coefficient Data to (USB memory recommended: Model number USM256,
PC. USM512, USM1G and RUF-C256ML manufactured by
3. Firmware BUFFALO)
. Transfers the firmware update file from PC to this unit.
4. Text Image
. Performs editing/setting of the caption characters and
image.
Logo (image) can be set as well as characters.
5. XferImage
. Imports the image data of the last print of this unit to PC.
Only 12-bit + 8-bit data/128-bit data can be selected.
. Transfers the image data in PC to this unit and print it
out.
6. EditGamma Tbl
. Copies the existing gamma curve.
. Edits the ten gamma data files of the UP-DF500 into the
twenty gamma data files of this unit.

Completion

1. Disconnect the USB cable, then close the cover (USB).

6-20 UP-DF500
Procedure 3. Perform update.
(1) Install the USB memory, in which the update file
1. Make USB memory recognize to this unit. was expanded, in this unit and turn on the power.
This operation must be performed every time the (2) The update starts automatically. Wait until this
combination of this unit and USB memory is changed. unit returns to the READY state.
Depending on the model, some USB memories may n
not be able to be recognized. Therefore, confirm in A DICOM trouble error message may halfway
advance that USB memory can be recognized before appear on the LCD display. However, never turn
maintenance service when using the USB memory not off the power. Wait until this unit is put into the
recommended. READY state. It takes several tens of minutes to
complete the update depending on the type of
(1) Make the USB memory empty in PC. update.
(2) Remove the network cable on the rear of this unit. (3) Remove the USB memory.
(Remove the cable to prevent the virus infection (4) Return the change in network setting, rewritten to
via network during the virus patch.) make the USB memory recognize, to the former
(3) Remove the USB cover of the rear side and install state. (Rewrite example: Return the setting of
the emptied USB memory. 255.255.254.0 to 255.255.255.0 because it was
(4) Change the setting of DICOM. UP-DF500 rewritten.)
recognizes the USB memory. (5) Confirm that the change in the setting of UP-
The change in setting corresponds to the change DF500 was completed and that this unit was
in network setting. Rewrite a net mask in this returned to the READY state and close the service
case. cover.
Rewrite example: 4. Connect the removed network cable, make a test print
Rewrite the setting of 255.255.255.0 into from modality and confirm that the print is made
255.255.254.0. normally.
(5) Terminate the change in the setting of this unit. Write down the patch number (example: R09) in
Confirm that this unit was returned to the READY DICOM Virus Patch Ver. of the maintenance check
state, remove the USB memory, and turn off the list 2. If you do not have the maintenance check list,
power. write it on the backside of the cover for servicing.
2. Write patch information into USB.
(1) Insert the USB memory recognized in step 1 into
PC and check that the folder named DUA is
created.
n
If this folder is not created, the USB you are using
cannot be used.
(2) Delete the created DUA folder.
(3) Expand (uncompress) a Zip format security
update file.
n
At that time, expand the security update file
without creating a sub-folder. When the security
update file is expanded in a sub-folder, this unit
cannot recognize the update file in the next
operation.

UP-DF500 6-21
Section 7
Troubleshooting

7-1. Error Display

7-1-1. Error Display

When abnormality occurs in this unit, the ALARM lamp on the front panel of this unit lights and an error
message is displayed on the LCD.

Viewing the error message


Example of screen
MECHA TROUBLE
****

Upper area: The status of a trouble or the instructions for improving a trouble are displayed.
Lower area: The error message corresponding to the occurrence of a trouble is displayed.

7-1-2. Error Message List

Example of screen
MECHA TROUBLE
****

The message displayed in the upper stage indicates mechanical abnormality. The unit in which abnor-
mality occurred is displayed in the lower area of the LCD.
Refer to “7-2. Mechanical Troubleshooting” or “7-3. Electrical Troubleshooting” when a trouble occurs.

Display in lower area Defective operation point Remarks

TRAY UNIT : U1 Tray delivery mechanism Chassis block


LIFT UNIT : U2 Lifter up/down mechanism Chassis block
PICK UP UNIT : U3 PH1 drive mechanism PH1 block
OFFSET UNIT : U4 Offset mechanism PH2 block
HEAD U/D UNIT : U5 Head up/down mechanism Mechanical deck
CAPS U/D UNIT : U6 Capstan drive mechanism Mechanical deck
FILM OUT UNIT : U8 PH3 drive mechanism PH3 block
FLAP : U9 Shift the paper eject point PH3 block

CT TROUBLE [**] Abnormality of calibration mechanism


CT-248, SE-880, and SE-881 boards

DR TROUBLE Abnormality of CPU on DR-618 board


IC200 on DR-618 board

SDRAM/0 TROUBLE Abnormality of image SDRAM0


IC1901 and IC1902 on MA-155 board

SDRAM/1 TROUBLE Abnormality of image SDRAM1


IC1903 and IC1904 on MA-155 board

UP-DF500 7-1
Display in Name Block Remarks Sony parts No.
lower area

M01 Lift-up motor Chassis SU-123 A-1246-204-A


LIFTUP MOTOR
M03 Paper-feed carry stepping motor PH1 17PM-K401P7V 1-763-748-11
PH1 MAIN MOTOR
M04 Pickup clutch PH1 MIC 5NE-61 1-455-017-11
PH1 PICK CLUTCH
M06 Offset stepping motor PH2 PM35L-048-SNL1 1-787-289-13
OFFSET MOTOR
M07 Paper carry motor PH2 SU-121 A-1246-202-A
PH2 DRIVE MOTO
M08 Head up/down motor MD SU-76 A-8346-193-A
MD HEAD MOTOR
M09 Capstan up/down motor MD SU-77 A-8346-173-B
MD CAPS MOTOR
M10 Platen drive stepping motor MD PK244M-01A-C9 1-763-986-11
MD MAIN MOTOR
M11 Paper eject stepping motor PH3 17PM-K401P7V 1-763-748-11
PH3 MAIN MOTOR
M12 Flap motor PH3 SU-121 A-1246-202-A
PH3 FLAP MOTOR
M13 Tray-out motor Chassis SU-122 A-1246-203-A
TRAY MOTOR
M15 Buzzer Front KEY-59 A-1246-181-A
BUZZER
M16 Head fan MD 2406KL-04W-B59-L04 1-763-172-11
HEAD FAN
M17 Room fan Front 2406KL-04W-B59-L04 1-763-172-11
ROOM FAN
. The name displayed in parentheses of the name column appears on the LCD in a “MANUAL_MECHA” (section 6-2-8) menu.

“:M**” displayed in the lower area is abnormality in a motor solenoid system. Confirm the connection of
a connector and harness to the relevant motor.
The relevant motor can be forcibly operated in the item of MENU → MANUAL MECHA → MOTOR
TEST with the service mode activated. (Refer to Section 6-1.) Abnormality exists in the motor if a motor
does not operate during forced operation. Replace the relevant motor. (Refer to Section 7-3.)

n
Close all covers of this unit during forced operation. The power in a motive power system is not supplied
when even one of the covers is open.

7-2 UP-DF500
Example of screen
MECHA TROUBLE
****

Display in lower Defective operation sensor Block Board Sony parts


area No. (Parts No. A)

S01 Pick end pass sensor PH1 SE-888 A-1246-193-A


PICK END PASS 0
S03 End turn pass sensor PH1 SE-894 A-1246-196-A
END TURN PASS
S04 Drive pass sensor PH2 SE-874 A-1246-186-A
DRIVE PASS
S05 Film end pass sensor MD SE-681 A-8346-205-B
FILM END PASS
S06 Print top pass sensor MD SE-681 A-8346-205-B
PRINT TOP PASS
S07 MD jamming pass sensor MD SE-694 A-8346-171-B
MD-JAM PASS
S08 Density pass sensor PH3 SE-891 A-1246-194-A
DENSITY PASS
S09 Eject turn pass sensor PH3 SE-892 A-1246-195-A
EJECT TURN PASS
S10 Exit pass sensor PH3 SE-892 A-1246-195-A
EXIT PASS
S12 Full stack sensor 0 MD SE-868 A-1246-184-A
FULL STACK 0
S13 Full stack sensor 1 MD SE-868 A-1246-184-A
FULL STACK 1
S15 Film tray in sensor Chassis SE-876 A-1246-188-A
FILM TRAY IN 0
S17 Film tray out sensor Chassis SE-877 A-1246-189-A
FILM TRAY OUT 0
S19 Lift-up home sensor Chassis SE-875 A-1246-187-A
LIFT UP HOME 0
S21 Lift-up motor FG sensor Chassis SE-878 A-1246-190-A
LIFT UP FG 0
S23 Pick position sensor Supply Chassis SE-899 A-1246-201-A
PICK POSITION 0
S25 No film sensor Supply Chassis SE-895 A-1246-197-A
NO FILM 0
S27 Offset home sensor PH2 CN-2934 A-1246-170-A
OFFSET HOME
S28 Head up/down home sensor MD SE-679 A-8346-216-A
HEAD HOME
S29 Head up/down cam POS sensor MD SE-679 A-8346-216-A
HEAD POS
S30 Capstan cam home sensor MD SE-680 A-8346-174-B
CAPS HOME
S31 Capstan cam POS sensor MD SE-680 A-8346-174-B
CAPS POS

UP-DF500 7-3
Display in lower Defective operation sensor Block Board Sony parts
area

S32 Flap cam POS0 sensor PH3 SE-898 A-1246-200-A


FLAP POS 0
S33 Flap cam POS1 sensor PH3 SE-898 A-1246-200-A
FLAP POS 1
S34 Eject tray sensor Chassis SE-872 A-1246-185-A
EJECT TRAY
S38 H/V setting sensor Chassis CN-2935 A-1246-171-A
H/V SETTING
S39 Interlock switch MD SW-1096 A-8346-169-B
INTER LOCK
PH1 SW-1345 A-1246-215-A
PH2 SW-1342 A-1246-214-A
S40 Tray-out switch Front SW-1340 A-1246-212-A
TRAY SW 0
S43 Head thermistor Head CN1006/MA-155 A-1246-183-A
HEAD TEMP
S44 Outside temperature thermistor Front TH6401/KEY-59 A-1246-181-A
OUTSIDE TEMP
S45 Platen thermistor MD CN3106/CN-2326 A-8346-170-B
PLATEN TEMP
S46 Inside temperature thermistor MD TH3101/CN-2326 A-8346-170-B
INSIDE TEMP
S47 Moisture sensor Front CN6401/KEY-59 A-1246-181-A
MOISTURE
. S14, S35, S36, S37, and S42 displayed in the lower stage are missing numbers. They do not function and are not displayed.
. The name displayed in parentheses of the defective operation sensor column appears on the LCD when the Sensor Monitor function in a “MANUAL_MECHA”
(section 6-2-9) menu is used.

“:S*” displayed in the lower area is abnormality in a sensor. Confirm the connection of a connector and harness to the
relevant sensor.
The level of the relevant sensor can be confirmed in the item of MENU → MANUAL MECHA → SENSOR MONITOR
with the service mode activated. Abnormality exists in the sensor if the level does not change when a sensor is operated
manually. Replace the relevant board.
The message displayed in the upper stage indicates the residence and jamming of a film. The location in which a trouble

REMOVE FILM
****

occurs is displayed in the lower area of the LCD.

Display in lower area Jamming position Sensor

TRAY 1 A film is jammed near the feed tray. S01


REAR A film is jammed near the rear cover. S03
TOP A film is jammed near the top cover. S04, S05, S06
FRONT A film is jammed near the front cover. S05, S06, S07
TOP & INNER 1 A film is jammed between the PH2 and PH3. S07
TOP & INNER 2 A film is jammed near the PH3. S07, S08, S09, S10
OUTPUT TRAY A film is jammed near the eject tray. S11

7-4 UP-DF500
CLOSE COVER

The front cover, rear cover, or top cover is opened.


Close the opened cover.
Check PH1, PH2 and mechanical deck interlock switch.

REMOVE PRINTS

A film is full at the eject port of a film tray.


Remove the film.

CT TROUBLE [xx]

This message is displayed when the power is turned on. Abnormality exists in this unit.
1

CALIBRATION INVALID (Display in user mode)

CALIBRATION [xx] (Display when service mode is activated.)


-NG- INVALID

n
If the CALIBRATION INVALID error is displayed frequently, check in the service mode.

1
Measurement was performed for density correction, but a normal measurement value is not obtained.
Print for density correction again.
n
Do not use the film being left opened for long time.

However, clean the thermal head or rollers when white spot or vertically striped unevenness occurs as a
result of print.

2
Abnormality exists in the calibration block. An error number is displayed in [ ].
n
However, an error may be displayed when the power is turned on after replacing the SE-880 board and
SE-881 board. Perform adjustment according to Section 4, “Procedures after Replacement”.

UP-DF500 7-5
Clean the calibration sensor window according to Section 2-6-1.

Error No. Contents of error Remedy

00 No response is returned from the CT-248 board. Confirm the CT-248 board operation and connector connection.
0E A step pattern of print cannot be correctly detected If there is no problem in the result of print, confirm the installation
during density measurement. and operation of the CT-248 board, SE-880 assembly, SE-881
assembly.
Refer to “7-2. Mechanical Troubleshooting” when the density is
abnormal.
Clean the thermal head or rollers when white spot or vertically
striped unevenness occurs as a result of print.
10 No gain adjustment could be performed. Confirm that a reference sheet was removed from the sensor
during gain adjustment.
Confirm the installation and operation of the CT-248 board, SE-
880 assembly, SE-881 assembly.
13 The light quantity of LED cannot be corrected. Confirm the dirt and installation of the SE-880 assembly and
SE-881 assembly.
16 Data cannot be read from EEPROM. Check IC3 on the CT-248 board and the block around an I2C bus.
17 Data cannot be written in EEPROM. Check IC3 on the CT-248 board and the block around an I2C bus.
18 A step pattern of print cannot be correctly detected If there is no problem in the result of print, confirm the installation
during density measurement. and operation of the CT-248 board, SE-880 assembly, SE-881
assembly.
Refer to “7-2. Mechanical Troubleshooting” when the density is
abnormal.
Clean the thermal head or rollers when white spot or vertically
striped unevenness occurs as a result of print.
61 Abnormality in CH-0 of densitometer Confirm the installation and operation of the CT-248 board, SE-
880 assembly, SE-881 assembly.
62 Abnormality in CH-0 of densitometer Confirm the installation and operation of the CT-248 board, SE-
880 assembly, SE-881 assembly.
63 Abnormality in input voltage amplifier in CH-0 of Confirm the operation around IC8 on the CT-248 board.
densitometer
64 Abnormality in input voltage amplifier in CH-0 of Confirm the operation around IC8 on the CT-248 board.
densitometer
FE Gain and offset adjustments are not completed. Perform adjustment according to “2. Adjusting the density
measuring point in section 4-2-3”.
FF A normal measurement value is not obtained during . Execute density measurement and calibration again.
density measurement and calibration. However, clean the thermal head and rollers when white spot
and vertically striped unevenness occur as a result of print.
. Perform “4-1-1. Adjusting the Density” for the troubles occurred
after replacing the thermal head. When the thermal head is not
replaced, set the head voltage to +3 or _3.

SET TRAY

A film tray is not set.


Put the tray, in which a film was set, in this unit.

SET FILM

The film in a tray is not confirmed.


Refer to “Film is left, but SET FILM is displayed” in “7-2. Mechanical Troubleshooting” when this message is displayed in
spite of the fact that a film is put in the tray.

7-6 UP-DF500
CHECK TRAY

The film is not correctly loaded in the tray.


Check the sensor.
Pull out the feed tray. Select MANUAL MECHA → SENSOR MONITOR and display NO FILM 0/1.
Move the lever up and down with your hand, and check that the display changes in Hi and Low. The Hi
and Low information with the film fed is not accurate because its timing is different from that of the
control to perform the film detection.

Check the lift drive.


Remove the cover from the load tray and insert it into the unit. If the lift plate is raised to the position
where the pick up roller is raised, the lift drive is normal.

Note on loading the film


Load the film in the right orientation.

SET OUTPUT TRAY

The eject tray is not attached. Attach the eject tray correctly.

TAG MISMATCH

. Although this unit operates normally, the IC tag information does not conform to it.
. For details of the setting of IC tag and this unit, contact your local Sony Sales Office/Service Center.

TAG INVALID

This message is displayed when IC-TAG attached to the protection case of a film cannot communicate
with this unit or when this unit receives abnormal data.
. Notice that the set film may not be a formal film.
. The film may be added.
. The IC tag may be removed or damaged.

UP-DF500 7-7
7-1-3. Error History

ERR-?: No.NNNNNNN
QQ-QQ S=********

The previous ten error histories can be confirmed in “MENU/ERROR INFO [>]” of the service mode.
n
Refer to Section 6-2-9 for the operation.

ERR-?: “?” indicates the history number.


0: Latest error
No.NNNNNNN: Counter value of total printed sheet count during occurrence of error
QQ-QQ: Sequence number of this unit during occurrence of error
********
S= : Sensor level information during occurrence of error

QQ-QQ Sequence of unit Operation state of the unit

08-10 Setting of offset mechanism to home position Preparation


08-20 Head temperature control
08-30 Capstan open
08-40 MD STM READY wait
10-10 Lift-up Paper feed start
10-20 Clutch on
10-30 PH1 STM activation
10-40 PICK_END ON wait
10-50 Clutch OFF
10-60 Lifter down
10-70 END-TURN ON wait
18-10 Retraction of intermediate carrier roller During paper feeding
18-20 DRIVE ON wait
18-30 MD STM ON
18-40 END_TURN OFF wait
18-50 PH1 STM stop
18-60 MD STM OFF
18-70 Printed sheet count
18-80 Lifter down completion wait
20-10 Intermediate carrying to halfway Preparation for offset
20-20 Retraction of intermediate carrier roller
20-30 Capstan close
20-40 MD STM activation
20-50 REED ON wait
28-10 MD STM OFF by excessive feeding Offset
28-20 Short- time reverse rotation of PH1 STM
28-30 Lifter film check
28-40 Capstan open
28-50 Offset press
28-60 MD STM ON (Continued)

7-8 UP-DF500
QQ-QQ Sequence of unit Operation state of the unit

30-10 Capstan close Preparation for offset


30-20 Retraction of intermediate carrier roller
30-30 (Film cleaning)
30-40 PRINT_TOP ON wait
30-50 MD STM stop
30-60 Downstream READY wait
30-70 Print parameter setting
38-10 Head voltage ON Print
38-20 Head bounding
38-30 Setting to offset wait position
38-40 Capstan open
38-50 Head fan ON
38-60 MD STM activation
38-70 Print completion wait
38-80 JAM ON confirmation
40-10 Head open Eject
40-20 MD/PH2 STM short-time drive
40-30 Head voltage OFF
40-40 Intermediate roller
40-50 PH2 STM ON
40-60 MD STM ON
48-10 Density measurement start Density measurement
48-20 Paper eject flap operation
48-30 JAM OFF wait
48-40 MD STM OFF
48-50 Capstan HOME
50-10 (Dealing with jamming) Film eject
50-20 EJECT ON wait
50-30 EJECT OFF wait
50-40 PH2 STM OFF
50-50 Retraction of intermediate roller
50-60 Acquisition of density measurement data

UP-DF500 7-9
S=********: Sensor level information
Indicates the detection level of each sensor in hexadecimal.
- Logic -
Corresponding sensors *1, *2 ‘1’ ‘0’ READY mode 0 0 0 7 9 E 0 2

S01: PICK END PASS 0 Yes No 0 0 ↑ ↑ ↑ ↑ ↑ ↑ ↑


S02:
S03: END TURN PASS Yes No 0
S04: DRIVE PASS Yes No 0
S05: FILM END PASS Yes No 0 0 ↑ ↑ ↑ ↑ ↑ ↑
S06: PRINT TOP PASS Yes No 0
S07: MD-JAM PASS Yes No 0
S08: DENSITY PASS Yes No 0
S09: EJECT TURN PASS Yes No 0 0 ↑ ↑ ↑ ↑ ↑
S10: EXIT PASS Yes No 0
S11:
S12: FULL STACK 0 Yes No 0
S13: FULL STACK 1 Yes No 1 7 ↑ ↑ ↑ ↑
S15: FILM TRAY IN 0 *1 *1 1
S16:
S17: FILM TRAY OUT 0 *1 *1 1
S18: 9 ↑ ↑ ↑
S19: LIFT UP HOME 0 Detected Not detected 0
S20:
S23: PICK POSITION 0 Detected Not detected 1
S24: E ↑ ↑
S25: NO FILM 0 Film loaded No film 1
S26:
S27: OFFSET HOME Detected Not detected _
S28: HEAD HOME Not detected Detected 0 0 ↑
S29: HEAD POS Not detected Detected 0
S30: CAPS HOME Not detected Detected 0
S31: CAPS POS Not detected Detected 0
S32: FLAP POS 0 *2 *2 _ 2
S33: FLAP POS 1 *2 *2 _
S34: EJECT TRAY Yes No 1
S35: H/V SETTING Set horizontally Set vertically _
*1: The combination of FILM TRAY IN 0 sensor and FILM TRAY OUT 0 sensor is as follows.
FILM TRAY IN 0 FILM TRAY OUT 0
0 0 Tray is removed.
0 1 Tray is not firmly attached.
1 0 Abnormal
1 1 Tray is attached.

*2: The combination of FLAP POS 0 and FLAP POS 1 is as follows.


FLAP POS 0 FLAP POS 1
0 0 Unused position
0 1 Paper ejecting position of 14 x 17
1 0 Unused position
1 1 Unused position
7-10 UP-DF500
7-2. Mechanical Troubleshooting

For the judgment of a defective point, the defective point is restricted with reference to “7-3. Electrical
Troubleshooting” after confirming “7-1-2. Error Message List” and “7-1-3. Error History”.
This section describes the measures to be taken for a mechanical trouble little related to the electrical
block (a motor or sensor). For the defective operation of a motor and sensor, refer to “7-3. Electrical
Troubleshooting”.
n
When the front, top, and rear doors are opened, an interlock switch functions and a printer does not
operate. Confirming the operation with the door opened improves the operation efficiency when
analyzing a trouble. To satisfy the safety standard, a strapping switch cannot be installed in an interlock
switch circuit. However, interlocking can be released by strapping the cable connected to connector CN-
6903 on the CN-2325 relay board.

Print sequence
Preparation → Paper feed start → During paper feeding → Offset → Positioning → Print → Eject →
Density measurement → Eject monitoring → Press

Operation flowchart for locating defective point


1. Confirm the error message (Section 7-1-2) or jamming history (Section 7-1-3) appearing on the LCD.
2. Take measures as described below according to the point to be anticipated as the cause of an error.
. Drive system: Drive the motor or solenoid in which a trouble is anticipated in “MOTOR TEST” of
“6-2-8. Manual Mecha”. Check the drive source, drive circuit, and sensor when the
motor or solenoid is not driven.
. Sensor: Confirm “SENSOR MONITOR” of “6-2-8. Manual Mecha”. The possible cause of
a trouble is restricted using a sensor, circuit, or harness when there is a problem.

Measures to be taken for mechanical trouble little related to electrical block (motor or
sensor)

Trouble Possible cause/Remedy

A flaw is put on the print surface (film surface). Check the life of the thermal head. (Refer to Section 6-2-1.)
Replace the thermal head when the number of printed sheets
exceeds 50,000.
1. Sharp flaw existing in the whole width of the Stains on the thermal head or the thermal head when
longitudinal direction (Reproducibility is high the life span is not reached (the number of printed sheets
when the print density little changes.) does not exceed 50,000).
Clean the thermal head.
1. Clean the thermal head using a supplied cleaning pad.
Check visually that no flaw exists in the IC cover (made of
stainless steel) of the thermal head.
2. If a trouble is not improved in step 1, clean the thermal
head with ethyl alcohol of more than 99%. (Use clean
cloth or paper in this case.)
n
Notice that the adherence of grease or other stains
damages the thermal head.
3. If a trouble is not improved in step 2, wrap the thermal
head heating unit using a wrapping sheet (about five
times). Use a wrapping sheet of Sony parts No. 3-813-
981-02 head wrapping sheet UPA-500 (supplied or
optional) as the wrapping sheet.
After wrapping, clean the thermal head with alcohol as in
step 2. If no effect is obtained, replace the thermal head.

UP-DF500 7-11
Trouble Possible cause/Remedy

2. Sharp flaw exists in the whole width of the The thermal head may be often damaged.
longitudinal direction (Reproducibility is high Wrap the thermal head heating unit using a wrapping sheet
when the print density inclines toward white (about five times).
or black.) Use a wrapping sheet of Sony parts No. 3-813-981-02 head
wrapping sheet UPA-500 (supplied or optional) as the
wrapping sheet.
After wrapping, clean the thermal head with alcohol. If no
effect is obtained, replace the thermal head.
3. Short flaw in the longitudinal direction Flaw due to the dust in a carry path
(Reproducibility is low.) Open each cover (front, top and rear covers) and clean PH1,
PH2, and the mechanical block.
Absorb dust using a cleaner or wipe with alcohol. Additionally,
clean the tray. Confirm the operation environment (whether it
is excessively dusty). Request the user to move the
installation place if there is a problem.
4. Small flaw, of within 5 cm in width, in the Stains on paper feed roller and separation roller
longitudinal direction and in the center Wipe the three rollers of the feed roller assembly with alcohol.
Replace the separation roller assembly when the rollers are
very dirty.
5. Oblique flaw Flaw occurring during film insertion
This flaw occurs with the film belt broken or during incorrect
film insertion.
A film was ejected from or inserted into the tray to clear
jamming while it is being used.
A printer was moved with the film inserted.
Clean the tray or confirm that a film is properly inserted during
normal operation.
6. Oblique flaw Flaw in the eject tray
Since many printed films exist in the eject tray, they were
rubbed with one another.
Flaw on the underside Confirm that the full stack sensor is normal.
Confirm that the eject tray is installed properly.
1. Short flaw in the longitudinal direction. Flaw due to the dust in a carry path
(Reproducibility is low.) Open each cover (front, top and rear covers) and clean PH1,
PH2, PH3, and the mechanical block.
Absorb dust using a cleaner or wipe with alcohol. Additionally,
clean the tray. Confirm the operation environment (whether it
is excessively dusty). Request the user to move the
installation place if there is a problem.
2. Oblique flaw Flaw occurring during film insertion
This flaw occurs with the film belt broken or during incorrect
film insertion.
A film was ejected from or inserted into the tray to clear
jamming while it is being used or a printer was moved with the
film inserted.
Clean the tray or confirm that a film is properly inserted during
normal operation.
3. Oblique flaw Flaw in the eject tray
Since many printed films exist in the eject tray, they were
rubbed with one another.
Confirm that the full stack sensor is normal.

7-12 UP-DF500
Trouble Possible cause/Remedy

Image deletion on the print surface (White spot, etc.) White spot of ø0.5 mm in diameter occurs because of the
characteristics of a film.
1. Small spot (Insufficient maintenance) Replace the transfer cleaning roller (paper) or clean the
transfer cleaning roller. (Refer to Section 2-6.) Replace it
when the life span of the transfer cleaning roller is reached.
2. Small spot (Stains inside this unit) Flaw due to the dust in a carry path
Open each cover (front, top and rear covers) and clean PH1,
PH2, PH3, and the mechanical block.
Absorb dust using a cleaner or wipe with alcohol. Additionally,
clean the tray. Confirm the operation environment (whether it
is excessively dusty). Request the user to move the
installation place if there is a problem.
3. Small spot (Confirmation of fan filter) Confirm that the fan filter is inserted properly.
4. Small spot (Stains in tray) A tray is pulled out from this unit and put in the excessively
dusty place of the floor during film setting or dust is put in a
printer if the bundle of a film is placed on a desk when it is
taken out from the package.
Absorb dust using a cleaner or wipe with alcohol. Additionally,
clean the tray. Confirm the operation environment (whether it
is excessively dusty). Request the user to move the
installation place if there is a problem. Pull out the tray and
clean the inside of a printer. Additionally, confirm that a film is
properly inserted during normal operation.
5. Belt-shaped image deletion (Large dust) Belt-shaped image deletion suddenly occurs due to the
performance of a thermal printer.
If image deletion frequently occurs, perform steps 1 to 3
above and then confirm whether the operation environment is
excessively dusty. Request the user to move the installation
place if there is a problem.
6. Slightly large spot Stains or struck marks on platen roller. Replace the platen
roller.
Print unevenness Misty unevenness (that is not periodic) is the characteristics of
this unit and a film.
1. Periodical unevenness in the carry direction Visually check the gear, pulley, and belt between the stepping
(Whole width) motor of the mechanical deck and the platen roller. For the
adherence of dust or the occurrence of a flaw, clean or
replace the relevant gear, pulley, and belt clutch.
Visually check the capstan roller. Replace the capstan roller if
coating is abnormal.
Drive the MD CAPS motor manually. (Refer to
Section 6-2-8.) Replace the platen drive motor if abnormality
is found.
2. Periodical unevenness in the carry direction The unevenness occurring at intervals of about 82 mm is
(Spot) caused by the platen roller. Check the platen roller visually.
Clean it if dust adheres to the platen roller. Replace it if a flaw
exists in the platen roller.

UP-DF500 7-13
Trouble Possible cause/Remedy

Density is abnormal. Abnormal density occurs when the maximum density is not
3.2 during setting of gamma or DENSITY_ADJ by the user.
1. Dispersion in media Sensitivity slightly varies depending on the manufacturing lot
and storage state.
For density correction, the print density is corrected
automatically. (CALIBRATION) (Refer to the Operation
Manual of this unit.)
2. Confirmation of set value Confirm the density setting of a printer.
SELECT POINT 95%: Initial value 25
SELECT POINT 5%: Initial value75
GAMMA: Initial value SONY1
3. Thermal head voltage Abnormality is found in the thermal head voltage adjustment.
Readjust according to the density adjustment after thermal
head replacement. (Refer to Section 4-1.)
4. Defective calibration mechanism Perform the processing during CT-248 board replacement.
(Refer to Section 4-2-3.)
5. Thermal head life Check the number of printed sheets in the thermal head.
(Refer to Section 6-2-1.)
Replace the thermal head when the number of printed sheets
exceeds 50,000.
6 Confirmation of densitometer Use a densitometer recommended by Sony.
7 Confirmation and setting of DICOM Confirm the maximum density value of modality for use.
Make the matching with a γ curve.
An image becomes jagged or grows faint. Adjust SHARPNESS in a “PRINT QUALITY” menu of the
service mode. (Initial value OFF)
Select the expansion on the resize of a DICOM image
properly. Confirm the image processing on the modality side.
A film is left, but SET FILM is displayed. Check the sensor.
Pull out the load tray. Select MANUAL MECHA → SENSOR
MONITOR and display NO FILM 0/1. Move the lever up and
down with your hand, and check that the display changes in Hi
and Low. The Hi and Low information with the film loaded is
not accurate because its timing is different from that of the
control to perform the film detection.
When jamming occurs sometimes When a motor or sensor is not defective
For tray X Clean or replace the roller (especially, separation roller) of the
load roller assembly. Remove the cover of the load tray and
confirm the shutter of the cover and the (two) rear rollers.
Replace the tray cover (rear) assembly (A-8286-335-XX)
when abnormality is found.
Top/front Confirm that the pitch is adjusted properly.
Confirm that the transfer cleaning roller and bearing roller are
installed properly.
For OUTPUT TRAY Confirm that the partition plate of the eject tray coincides with
the size of the film used.

7-14 UP-DF500
Trouble Possible cause/Remedy

“REMOVE PRINTS” is often displayed and printing . When the error is not cleared after the film is removed.
stops. Select MANUAL MECHA → SENSOR MONITOR and check
the PASS sensors from S01 to S11.
. When the trouble occurs continuously.
The stopping control is abnormal. Check the error contents
(XX-XX) in ERROR INFO, and then check XX-XX of the unit
sequence. Check the sensors (before and after) and drive
function.
. Trouble occurs frequently.
Check the abnormality in the film as well as in the main unit.
When the unit is installed in a place where the temperature
and humidity change rapidly, the film may be stuck or curled
causing the paper feed failure and multi-feed.
Measures: Change of the installation place should be
considered.
. Multi-feed occurs frequently.
First, check the film condition. Then, remove the load roller
assembly and clean the roller if it is stained. If the separa
tion roller is worn out (25,000 sheet or more), replace it.
. In the case of XXXXTRAY, REAR
Check that the shutter of the load tray operates normally
besides the check of the drive and sensor systems.
. In the case that XXXX is OUTPUT TRAY
Check if the eject tray is correctly inserted in place.
HEAD IN COOLING is often displayed. HEAD IN COOLING is hardly displayed at an outside
temperature of 20 dC. Clean the fan filter and confirm the fan
motor operation. Move the fan motor to the proper place
when it is set to the baldy-ventilated place.
HEAD IN HEATING does not disappear. In a cold place, it may take a few minutes until the thermal
head reaches the prescribed temperature.

UP-DF500 7-15
7-3. Electrical Troubleshooting

7-3-1. Electrical Troubleshooting

Contents Remedy

“PLEASE POWER OFF>POWER ON AGAIN” is 1. Confirm each harness of DICOM board. Replace the
displayed soon after the power is turned on again. relevant harness if abnormality is found.
2. Replace DICOM Board.
3. Replace the MA-155 board. (Refer to Section 3-1-1.)
READY display appears, but an image is not 1. Confirm the DICOM-ETH harness if an error occurs on the
printed even if it is sent. transmission side. Replace it if abnormality is found.
2. Confirm the DICOM-USB harness if no error occurs on the
transmission side. Replace it if abnormality is found.
3. Replace DICOM Board.
An error occurs in calibration. 1. Confirm that the SE-880 and SE-881 boards are mounted
properly. Modify them if abnormality is found.
2. Replace the SE-880 and SE-881 boards.
3. Confirm that no abnormality is found in the harness of the
sensor above. Replace it if abnormality is found.
4. Replace the CT-248 board. (Refer to Section 3-14.)
The power is not turned on. 1. Confirm the operation of the seesaw switch on the rear
panel.
2. Confirm that pin 7 of CN202 in a switching regulator is low
when the power switch on the front panel is turned on. If
pin 7 is not low, a REMOTE signal line is disconnected or
the power switch on the front panel is defective.
3. Replace the switching regulator. (Refer to Section 3-14.)
The power is turned off during operation. 1. Confirm that the power cable of a thermal head is
connected properly. (CN4 on the thermal head side and
CN201 on the switching regulator side)
2. Replace the switching regulator.
3. Deeply press the power switch if the LED lamp of the
power switch on the front panel blinks and if the power is
turned off.
No image is printed in a film. (A non-marked image 1. Confirm that the power cable of a thermal head is
film is ejected.) connected properly. (CN4 on the thermal head side and
CN201 on the power supply unit side)
2. Confirm that the thermal head harness is connected
properly.
3. Replace the thermal head. (Refer to section 3-8.)
Only the left half of a print result is abnormal. 1. Confirm that the harness from the thermal head is properly
connected to CN1005 on the MA-155 board.
2. Confirm that the head harness is properly connected to
connector CN2 of the thermal head.
Only the right half of a print result is abnormal. 1. Confirm that the head harness is properly connected to
CN1006 on the MA-155 board.
2. Confirm that the head harness is properly connected to
connector CN3 of the thermal head.
No image is displayed on LCD. 1. Confirm that the harness is properly connected to the LE-
336 board.
Cannot be accessed using a WWW browser in 1. Confirm the DICOM-ETH harness. Replace it if
spite of the “READY” state. abnormality is found.
2. Replace DICOM Board.
3. Check the network setting such as IP address.
Setting cannot be changed from a WWW browser. 1. Replace DICOM Board.
(Returned to the former state.)

7-16 UP-DF500
7-3-2. Operation Defects of Motors and Sensors

This section describes each trouble on the operation defects of motors and sensors. For the mechanical
trouble little related to motors and sensors, refer to “7-2. Mechanical Troubleshooting”.

The “trouble around **” described in this section indicates the possibility of parts damage in parts **,
signal line bridge, and disconnection.

1. MA-155 board

Head home/position sensor cannot be detected.

Confirmation item Cause

Is a signal input to CN1008, pin 7 YES: The block around CN1008 on the MA-155 board or the MA-155 board
of head home sensor and is defective.
CN1008, pin 8 of a head NO: Harness disconnection, oblique insertion, or sensor (SE-679 board)
position sensor? trouble

Capstan home/position sensor cannot be detected.

Confirmation item Cause

Is a signal input to CN1008, pin 6 YES: The block around CN1008 or the MA-155 board is defective.
of a capstan home sensor and NO: Harness disconnection, oblique insertion, or sensor (SE-680 board)
CN1008, pin 5 of a capstan trouble
position sensor?

Print start pass sensor cannot be detected.

Confirmation item Cause

Is a signal input to pin 4 of CN1008 YES: The block around CN1008 or the MA-155 board is defective.
on the MA-155 board? NO: Harness disconnection, oblique insertion, or sensor (SE-681 board)
trouble

End turn pass sensor cannot be detected.

Confirmation item Cause

Is a signal input to pin 14 of CN1008 YES: The block around CN1008 or the MA-155 board is defective.
on the MA-155 board? NO: Harness disconnection, oblique insertion, or sensor (SE-894 board)
trouble

Pick end pass sensor (0) cannot be detected.

Confirmation item Cause

Is a signal input to pin 15 of CN1008 YES: The block around CN1008 or the MA-155 board is defective.
on the MA-155 board? NO: Harness disconnection, oblique insertion, or sensor (SE-888 board)
trouble

UP-DF500 7-17
Paper feed end pass sensor cannot be detected.

Confirmation item Cause

Is a signal input to pin 12 of CN1008 YES: The block around CN1008 or the MA-155 board is defective.
on the MA-155 board? NO: Harness disconnection, oblique insertion, or sensor (SE-681 board)
trouble

MD jamming pass sensor cannot be detected.

Confirmation item Cause

Is a signal input to pin 3 of CN1008 YES: The block around CN1008 or the MA-155 board is defective.
on the MA-155 board? NO: Harness disconnection, oblique insertion, or sensor (SE-694 board)
trouble

Density pass sensor cannot be detected.

Confirmation item Cause

Is a signal input to pin 13 of CN1008 YES: The block around CN1008 or the MA-155 board is defective.
on the MA-155 board? NO: Harness disconnection, oblique insertion, or sensor (SE-891 board)
trouble

Eject pass sensor cannot be detected.

Confirmation item Cause

Is a signal input to pin 11 of CN1008 YES: The block around CN1008 or the MA-155 board is defective.
on the MA-155 board? NO: Harness disconnection, oblique insertion, or sensor (SE-892 board)
trouble

Pick position sensor (0) cannot be detected.

Confirmation item Cause

Is a signal input to pin 19 of CN1008 YES: The block around CN1008 or the MA-155 board is defective.
on the MA-155 board? NO: Harness disconnection, oblique insertion, or sensor (SE-899 board)
trouble

Lift-up motor FG sensor (0) cannot be detected.

Confirmation item Cause

Is a signal input to pin 6 of CN1007 YES: The block around CN1007 or the MA-155 board is defective.
on the MA-155 board? NO: DR-618 board trouble, or sensor (SE-878 board) trouble

Middle drive pass sensor (1) cannot be detected.

Confirmation item Cause

Is a signal input to pin 15 of CN1007 YES: The block around CN1007 or the MA-155 board is defective.
on the MA-155 board? NO: DR-618 board trouble, or sensor (SE-898 board) trouble

7-18 UP-DF500
Flap position 0/1 sensor cannot be detected.

Confirmation item Cause

Is a signal input to pin 21 of CN1008 YES: The block around CN1007 or the MA-155 board is defective.
on the flap position 0 sensor and NO: Harness disconnection, oblique insertion, or sensor (SE-898 board)
pin 20 of CN1008 on the flap trouble
position 0 sensor?

m
. The lift-up motor FG sensor 0, lift-up motor FG sensor 1 and middle drive pass sensor are connected
from CN1007 on the MA-155 board through the DR-618 board. For these sensors, refer to “The lift-up
motor FG sensor 0 cannot be detected.”, “The lift-up motor FG sensor 1 cannot be detected.” and “The
middle drive pass sensor cannot be detected.” in “2. DR-618 board”.
. The detection failure of these sensors also occurs when the connection of connectors CN1007 (MA-155
board) and CN700 (DR-618 board) that connect the MA-155 and DR-618 boards are defective.

Abnormality of outside temperature thermistor

Confirmation item Cause

Is a signal input to pin 2 of CN1014 YES: The block around CN1014 or the MA-155 board is defective.
on the MA-155 board? NO: Harness disconnection, oblique insertion, or thermistor (KEY-59
board) trouble

Abnormality of inside temperature thermistor

Confirmation item Cause

Is a signal input to pin 18 of CN1008 YES: The block around CN1008 or the MA-155 board is defective.
on the MA-155 board? NO: Harness disconnection, oblique insertion, or thermistor (CN-2326
board) trouble

Abnormality of platen thermistor

Confirmation item Cause

Is a signal input to pin 17 of CN1008 YES: The block around CN1008 or the MA-155 board is defective.
on the MA-155 board? NO: Harness disconnection, oblique insertion, or platen thermistor trouble

Abnormality of head thermistor

Confirmation item Cause

Is a signal input to pin 21 of CN1004 YES: The block around CN1004 or the MA-155 board is defective.
on the MA-155 board? NO: Harness disconnection, oblique insertion, or head thermistor trouble

Abnormality of humidity sensor

Confirmation item Cause

Is a signal input to pin 3 of CN1014 YES: The block around CN1014 or the MA-155 board is defective.
on the MA-155 board? NO: Harness disconnection, oblique insertion, or humidity sensor trouble

Tray eject switch (0) does not function.

Confirmation item Cause

Is a signal input to pin 7 of CN1011 YES: The block around CN1011 or the MA-155 board is defective.
on the MA-155 board? NO: Harness disconnection, oblique insertion, or switch (SW-1340 board)
trouble

UP-DF500 7-19
When the power cannot be turned on and off (REMOTE and POWER_SW signals)

Confirmation item Cause

When the power cannot be turned on:


. Is pin 12 of CN1014 on the NO: Connection defect of the harnesses connecting the SW-1341, KEY-
MA-155 board set low when the 59, and MA-155 boards, oblique insertion, disconnection, or power
power switch on the front panel switch trouble
is set to ON?
. Is pin 28 of CN700 on the DR-618 NO: MA-155 board trouble or connection defect of connectors CN1007
board set low? (MA-155 board) and CN700 (DR-618 board) connecting the MA-155
and DR-618 boards
. Is pin 7 of CN202 in the power YES: Power failure
block set low? NO: Connection defect of the harnesses connecting the DR-618 board
and power block, disconnection, or DR-618 board trouble
When the power cannot be turned off:
. Is pin 7 of CN202 in the power YES: Power failure
block set high when the power
switch on the front panel is
set to OFF?
. Is pin 28 of CN700 on the DR-618 YES: Shorted-circuit GND of the harnesses connecting the DR-618 board
board set high? and power block or DR-618 board trouble
. Is pin 12 of CN1014 on the NO: Shorted-circuit GND of the harnesses connecting the SW-1341,
MA-155 board set high? KEY-59, and MA-155 boards or power switch trouble
. Is pin 17 of CN1014 on the YES: MA-155 board trouble
MA-155 board set high? NO: Shorted-circuit GND of the harnesses connecting the SW-1341,
KEY-59, and MA-155 boards or power switch trouble

Refer to the troubleshooting viewed from the DR-618 board described in “2. DR-618 board”.

No head voltage is input. (V_CONT signal)


A V_CONT signal is sent from pin 207 of IC1403 on the MA-155 board to pin 3 of CN202 in the power
block through pin 12 of CN1007, pin 12 of CN700 on the DR-618 board, and pin 3 of CN1. In this path,
disconnection, shorted-circuit GND, or power failure is considered as a possible cause.
Also, refer to “When the head voltage is not input (V_CONT signal)” of “2. DR-618 board” for details
of this item.

2. DR-618 board

The motor, fan, and clutch do not operate.


A motor, fan, and clutch do not operate because the power of a motor block is not supplied with the
cover opened (not including a room fan). Interlock may have been released when they do not operate.

Confirmation item Cause

Are the front, top, and rear covers NO: Close the relevant cover (to activate interlock).
closed?
Is power of 12 V and 24 V supplied NO: Harness disconnection or power failure
from the power block?
Are SW24V and SW12V output YES: Interlock harness disconnection or switch trouble (CN6903, CN6913,
when pins 1 and 3 of CN3 on the CN6914, and CN6915 harnesses on the CN-2325 board and
CN6805,
DR-618 board are strapped? and CN6806 on the CN-2937 board)
NO: RY1’s peripheral circuit trouble or F2 and F4 is broken.

7-20 UP-DF500
Multiple sensors do not operate.
A sensor light source voltage (SW5 V) may not be output when multiple sensors do not operate. The
sensor read value at that time is set high at all times.

Confirmation item Cause

Is pin 13 of IC1 on the DR-618 NO: IC200’s peripheral circuit trouble


board set low?
Is pin 12 of IC1 on the DR-618 NO: IC1 trouble
board set high?
Is a voltage at TP7 on the DR-618 NO: Q11 and Q12’s peripheral circuit trouble
board about 5 V?

IC200 on the DR-618 board cannot communicate with IC1403 on the MA-155 board.

Confirmation item Cause

Are the voltages at TP3 and TP4 on NO: Harness disconnection or F3 and F5 are broken.
the DR-618 board 5 V and 3.3 V
respectively?
Does IC200 on the DR-618 board NO: IC200’s peripheral circuit trouble
operate?
Do 3 V to 5 V converter IC201 and YES: The block around CN700 or the block around IC1403 on the MA-155
5 V to 3 V converter IC202 on the board is defective.
DR-618 board operate? NO: IC201 and IC202 trouble

The head fan does not operate.

Confirmation item Cause

Do three head fans not operate? NO: Trouble of stopped fan


Is pin 1 of IC1 on the DR-618 board NO: IC200’s peripheral circuit trouble
set low?
Is pin 2 of IC1 on the DR-618 board NO: IC1 trouble
set high?
Is pin 3 of D3 on the DR-618 board NO: F4 is broken or Q1 and Q6’s peripheral circuit trouble
about 12 V?
Is the harness connected? YES: Harness disconnection or fan trouble
NO: Connect the harness.

The room fan does not operate.

Confirmation item Cause

Is pin 3 of IC1 on the DR-618 board NO: IC200’s peripheral circuit trouble
set low?
Is pin 4 of IC1 on the DR-618 board NO: IC1 trouble
set high?
Is pin 3 of D4 on the DR-618 board YES: The block around CN700 or the block around CN1017 on the MA-155
about 12 V? board is defective or the fan is defective.
NO: F4 is broken or Q2 and Q7’s peripheral circuit trouble

UP-DF500 7-21
The pickup clutch (upper) does not operate.

Confirmation item Cause

Is pin 5 of IC1 on the DR-618 board NO: The block around CN700 or the block around IC1003 on the MA-155
set low? board is defective.
Is pin 6 of IC1 on the DR-618 board NO: IC1 trouble
set high?
Is pin 3 of D5 on the DR-618 board NO: Q3 and Q8’s peripheral circuit trouble
about 24 V?
Is the harness connected? YES: Harness disconnection or clutch trouble
NO: Connect the harness.

The platen drive motor does not operate.

Confirmation item Cause

Is a control signal input to pins 6, NO: The block around CN700 or the block around IC1003 on the MA-155
17, 5, and 16 of IC100 on the board is defective.
DR-618 board?
Is a signal output from pins 8, 18, 1, NO: IC100’s peripheral circuit trouble
and 11 of IC100 on the DR-618 board?
Is the harness connected? YES: Harness disconnection or motor trouble
NO: Connect the harness.

The PH1 feed motor does not operate.

Confirmation item Cause

Is a control signal input to pins 6, NO: IC200’s peripheral circuit trouble


17, 5, and 16 of IC101 on the
DR-618 board?
Is a signal output from pins 8, 18, NO: IC101’s peripheral circuit trouble
1, and 11 of IC101 on the DR-618
board?
Is the harness connected? YES: Harness disconnection or motor trouble
NO: Connect the harness.

The PH3 feed motor does not operate.

Confirmation item Cause

Is a control signal input to pins 6, NO: IC200’s peripheral circuit trouble


17, 5, and 16 of IC102 on the
DR-618 board?
Is a signal output from pins 8, 18, 1, NO: IC102’s peripheral circuit trouble
and 11 of IC102 on the DR-618 board?
Is the harness connected? YES: Harness disconnection or motor trouble
NO: Connect the harness.

The offset motor does not operate.

Confirmation item Cause

Is a control signal input to pins 6, 17, 5 NO: IC200’s peripheral circuit trouble
and 16 of IC104 on the DR-618 board?
Is a signal output from pins 8, 18, 1 NO: IC104’s peripheral circuit trouble
and 11 of IC104 on the DR-618 board?
Is the harness connected? YES: Harness disconnection or motor trouble
NO: Connect the harness.

7-22 UP-DF500
The lift-up motor does not operate.

Confirmation item Cause

Is a control signal input to pins 1 NO: The block around CN700 or the block around IC1003 on the MA-155
and 3 of IC400 on the DR-618 board? board is defective.
Is a signal output from pins 2 and 4 NO: IC400 trouble
of IC400 on the DR-618 board?
Is a signal output from pins 1 and 2 NO: IC403’s peripheral circuit trouble
of CN601 on the DR-618 board?
Is the harness connected? YES: Harness disconnection or motor trouble
NO: Connect the harness.

The tray-out motor does not operate.

Confirmation item Cause

Is a control signal input to pins 1 NO: The block around CN700 or the block around IC1003 on the MA-155
and 3 of IC401 on the DR-618 board? board is defective.
Is a signal output from pins 2 and 4 NO: IC401 trouble
of IC401 on the DR-618 board?
Is a signal output from pins 3 and 4 NO: IC406’s peripheral circuit trouble
of CN601 on the DR-618 board?
Is the harness connected? YES: Harness disconnection or motor trouble
NO: Connect the harness.

The flap motor does not operate.

Confirmation item Cause

Is a control signal input to pins 5 NO: The block around CN700 or the block around IC1003 on the MA-155
and 9 of IC401 on the DR-618 board? board is defective.
Is a signal output from pins 6 and 8 NO: IC401 trouble
of IC401 on the DR-618 board?
Is a signal output from pins 13 and 14 NO: IC407’s peripheral circuit trouble
of CN611 on the DR-618 board?
Is the harness connected? YES: Harness disconnection or motor trouble
NO: Connect the harness.

The head up/down motor does not operate.

Confirmation item Cause

Is a control signal input to pins 11 NO: The block around CN700 or the block around IC1003 on the MA-155
and 13 of IC401 on the DR-618 board? board is defective.
Is a signal output from pins 10 and NO: IC401 trouble
12 of IC401 on the DR-618 board?
Is a signal output from pins 7 and 8 NO: IC408’s peripheral circuit trouble or F400 is broken.
of CN605 on the DR-618 board?
Is the harness connected? YES: Harness disconnection or motor trouble
NO: Connect the harness.

UP-DF500 7-23
The capstan up/down motor does not operate.

Confirmation item Cause

Is a control signal input to pins 1 NO: The block around CN700 or the block around IC1003 on the MA-155
and 3 of IC402 on the DR-618 board? board is defective.
Is a signal output from pins 2 and 4 NO: IC402 trouble
of IC402 on the DR-618 board?
Is a signal output from pins 9 and NO: IC409’s peripheral circuit trouble
10 of CN605 on the DR-618 board?
Is the harness connected? YES: Harness disconnection or motor trouble
NO: Connect the harness.

The drive motor does not operate.

Confirmation item Cause

Is a control signal input to pins 5 NO: The block around CN700 or the block around IC1003 on the MA-155
and 9 of IC400 on the DR-618 board? board is defective.
Is a signal output from pins 6 and 8 NO: IC400 trouble
of IC400 on the DR-618 board?
Is a signal output from pins 4 and NO: IC404’s peripheral circuit trouble
5 of CN609 on the DR-618 board?
Is the harness connected? YES: Harness disconnection or motor trouble
NO: Connect the harness.

The NO film sensor 0 cannot be detected.

Confirmation item Cause

Is a signal input to pin 1 of CN611 NO: Harness disconnection or sensor trouble


on the DR-618 board?
Is a signal input to pin 46 of IC200 YES: IC200 trouble or defective communication with IC1403 on the MA-155
on the DR-618 board? board
NO: IC200’s peripheral circuit trouble

The full stack sensor 0 cannot be detected.

Confirmation item Cause

Is a signal input to pin 3 of CN611 NO: Harness disconnection or sensor trouble


on the DR-618 board?
Is a signal input to pin 49 of IC200 YES: IC200 trouble or defective communication with IC1403 on the MA-155
on the DR-618 board? board
NO: IC200’s peripheral circuit trouble

The full stack sensor 1 cannot be detected.

Confirmation item Cause

Is a signal input to pin 4 of CN611 NO: Harness disconnection or sensor trouble


on the DR-618 board?
Is a signal input to pin 18 of IC200 YES: IC200 trouble or defective communication with IC1403 on the MA-155
on the DR-618 board? board
NO: IC200’s peripheral circuit trouble

7-24 UP-DF500
The tray-in sensor 0 cannot be detected.

Confirmation item Cause

Is a signal input to pin 7 of CN601 NO: Harness disconnection or sensor trouble


on the DR-618 board?
Is a signal input to pin 45 of IC200 YES: IC200 trouble or defective communication with IC1403 on the MA-155
on the DR-618 board? board
NO: IC200’s peripheral circuit trouble

The lift home sensor 0 cannot be detected.

Confirmation item Cause

Is a signal input to pin 8 of CN601 NO: Harness disconnection or sensor trouble


on the DR-618 board?
Is a signal input to pin 48 of IC200 YES: IC200 trouble or defective communication with IC1403 on the MA-155
on the DR-618 board? board
NO: IC200’s peripheral circuit trouble

The tray-out sensor 0 cannot be detected.

Confirmation item Cause

Is a signal input to pin 9 of CN601 NO: Harness disconnection or sensor trouble


on the DR-618 board?
Is a signal input to pin 50 of IC200 YES: IC200 trouble or defective communication with IC1403 on the MA-155
on the DR-618 board? board
NO: IC200’s peripheral circuit trouble

The H/V sensor cannot be detected.

Confirmation item Cause

Is a signal input to pin 10 of CN601 NO: Harness disconnection or sensor trouble


on the DR-618 board?
Is a signal input to pin 52 of IC200 YES: IC200 trouble or defective communication with IC1403 on the MA-155
on the DR-618 board? board
NO: IC200’s peripheral circuit trouble

The paper eject turn pass sensor cannot be detected.

Confirmation item Cause

Is a signal input to pin 6 of CN611 NO: Harness disconnection or sensor trouble


on the DR-618 board?
Is a signal input to pin 15 of IC200 YES: IC200 trouble or defective communication with IC1403 on the MA-155
on the DR-618 board? board
NO: IC200’s peripheral circuit trouble

The offset home sensor cannot be detected.

Confirmation item Cause

Is a signal input to pin 8 of CN608 NO: Harness disconnection or sensor trouble


on the DR-618 board?
Is a signal input to pin 20 of IC200 YES: IC200 trouble or defective communication with IC1403 on the MA-155
on the DR-618 board? board
NO: IC200’s peripheral circuit trouble

UP-DF500 7-25
The paper eject tray sensor cannot be detected.

Confirmation item Cause

Is a signal input to pin 6 of CN601 NO: Harness disconnection or sensor trouble


on the DR-618 board?
Is a signal input to pin 21 of IC200 YES: IC200 trouble or defective communication with IC1403 on the MA-155
on the DR-618 board? board
NO: IC200’s peripheral circuit trouble

The platen FG sensor cannot be detected.

Confirmation item Cause

Is a voltage at pin 1 of CN607 NO: Q13 and Q14’s peripheral circuit trouble
on the DR-618 board about 5 V?
Is a signal input to pin 2 of IC607 YES: C200’s peripheral circuit trouble
on the DR-618 board? NO: Harness disconnection or sensor trouble

The lift-up motor FG sensor 0 cannot be detected.

Confirmation item Cause

Is a signal input to pin 11 of CN601 YES: The block around CN700 or the block around IC1003 on the MA-155
on the DR-618 board? board is defective.
NO: Harness disconnection or sensor trouble

The middle drive pass sensor cannot be detected.

Confirmation item Cause

Is a signal input to pin 2 of CN609 YES: The block around CN700 or the block around IC1003 on the MA-155
on the DR-618 board? board is defective.
NO: Harness disconnection or sensor trouble

DICOM is not activated.

Confirmation item Cause

Is 5 V supplied from CN606 F600 is broken.


on the DR-618 board?
Is a cable connected? YES: DICOM trouble or harnss disconnection
NO: Connect the cable.

CPU (IC1) on the CT-248 board is not activated.

Confirmation item Cause

Is the harness between the DR-618 NO: Connect the harness.


boards connected properly?
Are 3.3 V and 5 V supplied from NO: Trouble in 3.3 V and 5 V systems
CN2 on the DR-618 board?
Is a communication signal input to YES: The block around CN700 or the block around IC1403 on the MA-155
CN602 on the DR-618 board? board is defective.
NO: Harness disconnection or defective block around IC1 on the CT-248
board

7-26 UP-DF500
When the power is not turned on (REMOTE signal)

Confirmation item Cause

Are a power cable and power NO: Connect the relevant power cable and power harness.
harness connected?
Is a REMOTE signal low? YES: Power or harness trouble
NO: The block around CN700 or the SW-1341 board is defective.
Disconnection on the MA-155 board

When the head voltage is not input (V_CONT signal)

Confirmation item Cause

Is a head power harness connected? NO: Connect the head power harness.
Can a V_CONT signal input to pin 3 NO: The block around CN700 or the block around IC1403 on the MA-155
of IC207 on the DR-618 board be board is defective.
adjusted?
Can a V_CONT signal of pin 3 of CN1 YES: Power or harness trouble
on the DR-618 board be adjusted? NO: IC207 and Q203’s peripheral circuit trouble

UP-DF500 7-27
SAFETY CHECK-OUT

After correcting the original service problem,


perform the following safety checks before
releasing the set to the customer :

Check the metal trim, “metallized” knobs, screws,


and all other exposed metal parts for AC
leakage. Check leakage as described below.

LEAKAGE TEST

The AC leakage from any exposed metal part to


earth ground and from all exposed metal parts to
any exposed metal part having a return to
chassis, must not exceed 0.5 mA. Leakage
current can be measured by any one of three
methods.

1. A commercial leakage tester, such as the


Simpson 229 or RCA WT-540A. Follow the
manufacturers’ instructions to use these
instruments.
2. A battery-operated AC milliammeter. The
Data Precision 245 digital multimeter is
suitable for this job.
3. Measuring the voltage drop across a resistor
by means of a VOM or battery-operated AC
voltmeter. The “limit” indication is 0.5 V, so
analog meters must have an accurate low-
voltage scale. The Simpson 250 and Sanwa
SH-63Trd are examples of a passive VOM
that is suitable. (See Fig. A)

To Exposed Metal
Parts on Set

10 kZ

AC
1.0 kZ 0.015 µF voltmeter
(0.5V)

Earth Ground

Fig A. Using an AC voltmeter to check AC leakage.

UP-DF500
Sony Corporation
UP-DF500 (SY) E B2B Solution Business Group Printer Business Div. 2008. 4 22
9-889-041-01 Published by Sony Techno Create Corporation ©2008