SATELLITE SCANNER DROP TABLE INSTALLATION

Instructions on installing the Satellite Scanner column onto the Drop Table Stand unit.

The ZBE Satellite Scanner comes in three basic versions: the standard Bench-mount and Wall-mount versions, and the drop-table-equipped Floor-standing version. This section covers the installation of the basic Satellite Scanner column assembly (common to all versions of the machine) onto the Drop-table unit. The resulting Floor-standing enlarger will be capable of full-autofocus operation over it’s entire range of print sizes, up to about 40 x 60 inches (101 x 152 cm).

The following parts should have been supplied as a kit for this installation:

Items indicated with an (*) are not included if the Drop Table / Satellite Column Plate are already installed on the Drop Table.

The installation is performed in three major steps: the mounting of the column, the installation of the encoder module, and the final electrical and mechanical connections. The following pages describe this procedure.

INSTALLING THE SATELLITE SCANNER ONTO THE DROP TABLE UNIT

Install the Column Mounting Plate. In order for the Satellite to be mounted onto the Drop Table unit, the Column Mounting Plate must be installed onto the top of the Drop Table unit. In some cases, this is done before the unit is shipped. If it has not been installed, secure the plate to the top of the Drop Table unit as shown, using the 5/16 x 1.5" Bolts and Nuts provided. Use the brass spacers under the nuts if needed.

Before Securing any bolts, examine the plate to determine which side is the top. One side should be marked in some way. If there are no markings, refer to the figure at the right, above. Note that the group of holes that are off-center should be positioned to the left-hand side when viewing the plate while standing at the front of the table.

Install all of the bolts loosely at first, then tighten once all are in place.

Mount the Satellite Scanner column assembly onto the Drop Table unit. Due to the weight of the Satellite column assembly, it is recommended that it be placed upon the drop table itself for the purpose of lifting. A piece of 3/4- to 1-inch thick wood or plywood will be required to protect the table’s surface.

If the Satellite has not already been lifted upright, see the instructions in the Satellite Operations Manual on setting up the machine. Be sure that the column is fully assembled when performing this procedure.

Lower the Drop Table as far as it will go. Lock it into place in the bottom-most lock position. To move the table, it is necessary to turn the lock handle, located just under the front edge of the table.

Place a piece of 3/4 or 1-inch thick wood onto the table. This will protect the surface of the table and ease in lifting the column up to the mounting plate.

Lift the column onto the piece of wood, standing it upright. Position the column base towards the rear of the table surface. This will make it easier to get the column onto the mounting plate once the table is lifted.

While a helper steadies the column in its upright position, lift the table all the way to the top, and lock it in the top-most position. This will require at least three people in all. The table should be lifted from either side, rather than the front, to avoid damage. Once the table is at the top, make sure it is securely locked, to avoid an accident.

It will now be relatively easy to move the column base from the word, onto the mounting plate. Position it at the front, center of the plate, with the front edge of the column about one quarter inch in from the front edge of the mounting plate.

Lower the table a bit, to gain access to the bolt holes in the mounting plate under the base of the column.

Insert a 1/4-28 x 1.5" Hex-head bolt (supplied) up through one of the holes. Jockey the column around until the threads engage. Once one bolt is threaded, install the other three. Tighten the bolts only when all four are in place.

The Satellite Scanner should now be securely attached to the drop table unit. The next step will be to install the encoder module.

Mount the Drop Table Encoder Unit. The Encoder unit is installed behind the column, using four screws to attach it to the main mounting plate. It’s measurement cable is then connected to the moving table itself, so the computer can monitor the table’s position.

Note the plate that is attached to the encoder module. The four holes in the module’s plate line up with four threaded holes in the main mounting plate, just behind the column. Also note that the encoder module’s measurement cable end has a loop terminal on it. The terminal attached to the moving part of the table. A screw may be placed in the terminal when the module was shipped. This screw is for ease of installation only, and will later be discarded. The drawing below, left shows the parts of the encoder module:

Place the Encoder Module on the main mounting plate as shown, above, at right. The measurement cable end will feed through the 1/2" hole in the main plate. The screw in the terminal will allow the cable to be pulled from the other side of the plate after the module is secured.

Screw the Module into place using the four 10-32 x 1/4" phillips screws provided. Make sure that there are no obstructions between the module and the surface to which it is mounted. Tighten all four screws.

Attach the Encoder measurement cable to the movable table. The measurement cable with the ring-terminal end will now be attached to the frame of the drop table.

Identify the encoder measurement Cable Attachment Plate. A diagram of this plate is shown below, in the proper orientation it will be installed, as viewed standing in front of the drop table unit.

Looking over the top of the table, between the bellows and the column, locate the two screws that hold the bellows to the moving frame that supports the table. (Lock the table in position about 12 to 16 inches below the main mounting plate for the best view.) Remove each of these screws and replace it with the 8-32 x 1/2" phillips-head screws provided. These slightly longer screws will allow the plate shown above to be secured at the two notches.

Once the new screws are in place, install the Cable Attachment Plate under the two screws, with the notches pointing towards the table (away from the column). Standing in front of the table, and looking over it, the plate should be in the same orientation as shown above. Fully seat the plate into it’s notches, and tighten the screws. Be sure that the bellows are still firmly attached.

Very carefully pull the measurement cable down from the Encoder Module (through the hole in the main mounting plate), using the screw inserted in the ring terminal as a handle. Extend the cable far enough to position the ring terminal at the hole in the Attachment plate. Secure the ring terminal using the small 4-40 x 1/4 inch flat-head screw provided.

NOTE: The Measurement Cable of the Encoder Module is very fragile. Be very careful not to kink or bend the cable while working. If pliers are used to hold the cable, cover the jaws with masking tape. When gripping the cable, do not turn the pliers so as to bend or kink the cable. A bent cable will cause inaccurate operation of the autofocus system. Do not let the cable "snap" back into the Encoder Module: it may break, making the module unusable.

Once the cable end is attached, examine the cable itself, from the hole in the main plate down to where it is attached to the table’s frame. It should be parallel to the tensor spring next to it. If it is slightly askew, adjust the position of the ring terminal to bring it straight. If it is very angled, check that the Cable Attachment Plate is installed correctly.

Check the operation of the encoder’s cable by moving the table up and down. The cable should travel smoothly and remain taught at all times.

Attach top of bellows to underside of column mounting plate. The bellows that covers the front of the Drop Table column are designed to mask the reflective tensator springs to prevent image interference. The bellows has steel plates at both the top and bottom. The bottom plate was secured underneath the Cable Attachment plate when the Encoder module was installed. The top Plate will now be secured to the underside of the column mounting plate.

There are two methods by which this is done. The first simply uses Velcro® hook-and-loop fastener to hold the upper end of the bellows in place. The second (on some older machines) utilizes two screws and spacers to secure this plate. In this case, please refer to the description below:

Locate the two small holes in the top bellows plate (shown below). Working with only one side to start, place one of the 6-32 x 3/4" screws (10-32 on some models) up through one of the holes, so that it projects up through the hole, as shown. While holding the screw in place, put a spacer over the projecting part of the screw.

Insert the screw, while holding it in place, along with the spacer, into the threaded hole in the underside of the column mounting plate. When installed, the spacer should separate the bellows top plate from the column mounting plate. This allows clearance for the heads of the column’s mounting bolts. Repeat for the second screw. It will be necessary to move the bellows around a bit to get behind them for turning these screws. When finished, be sure that the plate is straight.

Check that the bellows are lying in an orderly manner, and that they move accordingly as the table is moved up and down.

Hookup the electrical cable from the Encoder Module. The electrical hookup is simple. The cable from the newly-installed encoder module plugs into the small

(D-9) connector located on the rear of the Satellite Scanner’s Negative stage. This is the connector immediately next to the connector for the keypad/expansion junction box. See below:

Plug in the connector and secure it using the two small lock screws at either end.

Tell the Satellite computer that the Drop Table is installed. This is done in the Sentinel’s Preferences menu as follows.

From the regular operating screen, press the MENU key. Then press [5] or use the Arrow Keys to get to the "SATELLITE PREFERENCES MENU" item. Press ENTER.

In the Preferences Menu, press [9] or use the Arrow Keys to get to the "SET SECURITY LOCK" item and then press ENTER.

The screen will read "SECURITY LOCK ON" on the top line. Press any of the number keys once so that it reads "SECURITY LOCK OFF." Press ENTER. This will disable the security lock, and then return operation to the normal operating screen.

Once again, get into the Preferences Menu, as described above. In the Preferences Menu, press [8] or use the Arrow Keys to get to the "ENABLE DROP TABLE" item. Press ENTER.

The screen will read "DROP TABLE NOT ACTIVE" on the top line. Press any number key once to change it to "DROP TABLE ACTIVE." Press ENTER.

The autofocus system is now capable of reading the position of the drop table. Since the Drop Table Encoder is matched to the other encoders in the Sentinel, there is no further setup necessary for autofocus operation.

Since the Drop Table at it’s uppermost position is not quite at the same position as the standard bench-top baseboard (if the enlarger is being converted from a bench top model) the lens setups will need to be reprogrammed.

Operation of the Drop Table is fully integrated into the daily usage of the machine, simply move the table to the desired position. The computer will even indicate which direction, and how far, the table should be moved when a change in printsize requires it!

Level the Table and it’s stand. Leveling of the Drop Table is done first at it’s base, then at the table itself.

The Drop Table Unit has four square-headed bolts at its feet for the purpose of stabilizing the machine’s stance on the floor. Adjust these bolts to attain a stance that is free of movement, and such that the Drop Table unit’s column is reasonably plumb.

The table itself features five stud-and-bolt assemblies for the purposes of leveling. It is recommended that the center one be disabled temporarily until the table is level. This is done by loosening the nuts above the table support frame, and backing them off, in an upward direction away from the frame, to give the table room to move as it is leveled. The is true for the bottom nut.

Leveling the table should be done one axis at a time, using a standard carpenter’s bubble level to determine correct position. Start with left-to-right leveling. Loosen and "disable" the two front mounting post assemblies, just as the center one was in the last step. This will enable the left-to-right leveling to be adjusted using only the two rear posts.

Place the carpenter’s level horizontally at the rear of the table, between where the two rearmost studs are. Adjust the nuts above and below the table frame to attain a level reading in the bubble of the level. When finished, secure the two posts’ settings.

For front-to-rear leveling, the level should be placed in the center of the table, in a front-to-back orientation.

Lift the front of the table at the center of the front edge. This movement will show up on the bubble of the level. Move the top nuts on the front two posts so they support the table in a level manner. The left-front and right-front post top nuts should rest on the frame at the same time as the table is lowered from holding it at the front edge midpoint. Further adjustments should be made in the same amounts for both left and right front posts. This will insure that the left-to-right leveling is not thrown off.

Once the front-to-rear leveling is attained, tighten the remaining nuts to secure the positions at all four corners.

The center post may now be engaged by bringing the top nut down to rest on the frame, then tightening the bottom nut to secure its position.

The installation of the Satellite Scanner Drop Table is now complete.

STEP 2. INSTALLING THE LENSES

The Satellite utilizes a three-lens turret to ease the selection of different lenses while scanning. The lenses mount in the lens turret disk, located within the bellows, under a light-trap cover. The procedure for installing a lens follows.

IMPORTANT: Make sure that the main power is turned off for this procedure.

1. Gently move the bellows apart by pushing the lens stage down or the film stage up. NOTE: When manually pushing either of the stages, do so slowly and gently. Pushing faster or harder may damage the motor drive system.
   
2. Lift the bellows from the lens stage, carefully separating the Velcro material.
   
3. Loosen the light-trap cover by removing the four screws at the corners. With the screws removed, the cover lifts up, then forward. NOTE: When working within the bellows, be careful not to kink the thin steel cable running vertically inside the bellows area. It is integral to the proper operation of the autofocus system.
   
4. With the cover removed, the lens turret disk is now visible. The disk has three lens holes in it: two are designed for use with lenses of small focal length (50mm-135mm) with 39mm mounting threads, and one is for larger lenses (150mm). To install lenses, first remove the light trap disk which is attached to the lens turret by means of the three rotation handles. Unscrew the handles by grasping and turning the upper part which does not rotate. Once all three handles are removed the light trap disk will lift off. Be careful not to bend the levers of the two micro-switches at the rear of the turret area.
   
5. Secure smaller lenses in the appropriate holes using matching retainer rings for the threads on the lens. Install the lens up from the bottom, and its retainer ring from the top side of the turret disk. When nearly tight, rotate the lens body as needed so the aperture display is visible at the front of the machine when that lens is in the turret's front click-position. Be sure that each lens it tight and secure in its mount.
   
6. A threaded ring is provided for a larger lens in the third hole. That lens threads directly into this hole from the bottom.
   
7. Once all lenses to be used are installed, replace the light-trap cover and secure it with the four corner screws. Reattach the bellows to complete the lens installation process.

STEP 3. LEVELING THE SCANNER

Leveling the Satellite is accomplished through the use of four thumbscrews located at the rear plate attaching each stage to the column. There are four screws to adjust the pitch and roll of each stage.

There are many different methods that can be used to level a machine like the Satellite. Several companies have developed systems that are used in many color labs to align their enlargers. Please contact ZBE or your local photo equipment dealer for more information about these systems.

Whatever method is used, both the lens and film stages on the Satellite are adjustable in two axes. The figure below shows which screws affect which direction of alignment.

For adjustments on the film stage, it may be helpful to lift up on its front to aid the turning of the screws. When all adjustments are done, be sure that all screws are tightened to assure that the settings will not move.

STEP 4. HOOKING UP THE CABLE

The electrical hookup is as shown:

• The main power cord simply plugs into the AF Computer Box.
• The main interface cable (beige cable) goes from the connector on the bottom of the Camera Stage to the "SENTINEL" connector on the Junction Box.
• The keypad plugs into the "KEYPAD" connector on the Junction Box.
• The Rack-over Footswitch plugs into any of the "ACCESSORIES" connectors on the Junction Box.

Once all these connections are made, the machine is ready for first power-up. The power will come on as soon as the main power cord is plugged in. After an opening message, there will be a delay of about 10-20 seconds, after which the keypad will read, "PRESS ANY KEY TO BEGIN REFERENCING." Check that the baseboard area is clear, then press any button on the keypad. The machine will go through a series of movements, after which normal operation and setup can begin.

POWERING UP AND FIRST-TIME ELECTRICAL TESTS

When the Satellite is first assembled, there are a few tests which should be performed to ensure that all systems are functioning properly. These tests are listed below, in the order they should be performed.

1: POWER ON

The Satellites AC power is wired directly into the autofocus computer box. An external power distribution strip may be used to allow one switch to control the Satellite and any equipment used in conjunction with it, like copy lights, a Starlite Colorhead, or other light sources. It is recommended that any computer used with your camera scan-back be plugged in separately and controlled from it’s own power switch.

After power is applied to the machine, the first thing that should happen is a beep from the keypad. The display will read "ZBE Inc."

At this time, press and hold the key on the keypad. This will cause the scanner to skip its initial referencing procedure temporarily while the following tests are performed. (Skipping the reference process is only recommended at this time; in normal use, the Satellite must reference in order for the autofocus setup to work properly.)

2: TEST MOTORS

This test, as are all the tests in this section is accessed through the Satellite's menu system. To get to the Motors Test press the key. Select "SATELLITE DIAGNOSTICS" from this main menu using or under the numeric keypad, and press . The Diagnostics menu will now be displayed.

From this menu , select "TEST MOTORS" (again using the arrow keys) and press . The display will now read "NEG: STOP LENS: STOP". This is the Motors test screen. Use the arrow keys ( and ) under the number keys to jog the negative stage, and the arrow keys in the lower right corner of the keypad to jog the lens stage. When the arrow keys are pressed the appropriate stage should move in the direction of the arrow. This display for that stage should also indicate the direction of movement: "UP" or "DOWN". Both displays should read "STOP" when no keys are being held down.

WARNING: It is important to note that the limit switches are disabled in this test, so care must be taken not to overrun the top and bottom limit switches, nor to separate the bellows excessively. Damage to the Scanner may result.

Before ending this test, position the bellows so they are separated by about 6 inches or so. This will aid in some of the following tests.

Press to exit this test.

3: TEST ENCODERS

Access this test from the Satellite Diagnostics menu in the same manner as the motors test was called up in step 2, above. Select "Test Encoders" from the diagnostics menu and press .

IMPORTANT: If you have a floor-standing machine, you will need to "ENABLE DROP TABLE" from the Satellite Preferences menu. Press then select "SATELLITE PREFERENCES" and press . From the Preferences menu, select item "8: ENABLE DROP TABLE" and press .

The display will now read "COL: nnnnn" on the top line, and "BEL: nnnnn" on the bottom line. (The "nnnnn" indicates a random number displayed on the keypad.)

Gently pull straight up on the measuring cable that is lying along the front of the column from the negative stage up to the top of column. Do not pull this cable more than 12 inches, or kink it while holding it. As the cable is pulled straight up, both numbers on the display should decrease in value. As the cable is returned to its original position, the numbers should count back up to their original values, within a couple of counts. NOTE: When releasing the cable, NEVER let it snap into position.

Next detach the bellows at the bottom. You will see the bellows measuring cable inside at the front left and rear right corners. Very carefully pull the cable straight down (or as close to straight down as possible) at the front left section of the cable, do not pull down more than 8 inches. When doing this, note the Lens Encoder number: it should decrease as the cable is pulled, and return to its original value when the cable is released.

If both numbers perform as described above, proceed to the next step.

When finished with this test, press .

4: TEST LIMIT SWITCHES

Access through the Satellite diagnostics as with the previous tests. The display for this test is a readout of the status of all three limit switches on the Satellite. The limit switches are used by the computer to tell if any moving part of the scanner is in danger of overrunning its range.

Test the "Bellows" switch by reaching up behind the bellows, under the negative stage, there is a small lever located roughly at the centerline of the bellows. Push this lever upward. When the switch clicks, the display for the "BEL:" switch will go from off to on as long as the plunger is held in.

The other limit switches will actually be tested later, during the initial Referencing procedure. This test will make sure that the limit switch connections are generally functional.

Exit this test by pressing .

5: TEST REFERENCE PULSES

The positional encoders in the Satellite use reference pulses to determine its initial position. Test the reference pulses, using the "TEST REFERENCE PULSES" in the diagnostics menu . The display should read: "COL: ---" on the top line, and "BEL: ---" on the bottom line.

As in the encoders test, pull each cable slowly. In this test, when a cable is pulled, a beep will occur approximately every 4 inches of travel. At each beep, a number should appear next to the appropriate encoder's display. The cable along the front of the column is the "COL" encoder, while the cable inside the bellows is the "BEL" encoder.

When both encoders are made to beep and give a number display,
press to exit this test.

This completes the initial testing of the Satellite. The main power should now be turned off, then back on. This will put the Satellite into its normal daily power up procedure.

The display will read "PRESS ANY KEY TO BEGIN REFERENCING." At this time make sure there is nothing on the baseboard which will obstruct the stages as they move to the bottom of the column. Check for cords lying right next to the column. When all is clear, press a key. The stages will move together, then both will move to the bottom of the column. The negative stage will then rise slowly until a reference pulse is read from each encoder. When this occurs, the keypad will display its main screen display.

The Satellite is now fully installed and operational, ready for the lenses and other items to be set up and calibrated.

OPTICAL ALIGNMENT OF FILM STAGE RACKOVER SYSTEM

This procedure will guide you through the alignment of the Satellite’s digital camera image plane and the reticule used for composing the image. This is a one-time-only process. Since this procedure requires the removal of the case enclosing the rack-over stage and other mechanical adjustments, the following tools will be needed:

• A small (#1 head) Philips Screwdriver
• A 1/8" Allen (Hex) driver.
• A medium-sized blade-tip screwdriver.

1. Remove the rack-over enclosure. You will need to remove the 8 small screws around its base.
   
2. With the enclosure removed, you will see something similar to what is pictured at right. Use the blade-tip to remove the single white screw at the front edge of the viewing reticule. The two similar screws at the rear of the reticule do not need to be removed.

3. Carefully remove the viewing reticule from its position under the viewing mirror by lifting up at the front edge, and pulling towards you. Be extremely careful not to scratch the mirror. It is a front-surface type, and scratches very easily.
   

4. Place the reticule into the camera back holder. There is a machined surface that the reticule will rest on. In this position, the reticule is at the same height as the installed CCD array of the digital camera.
   
5. Use the Rack-over Footswitch to move to the "taking" position. The Taking position is when the rack-over stage is positioned to the left, with the camera holder located over the lens. Warning: keep clear of the exposed rack-over stage when in motion.
   
6. Place some form of subject matter on the baseboard. The Focusing Target supplied with the Satellite is ideal. The article you use here is not important, but it should have enough detail to easily see whether or not the machine is in focus. Focus the machine using the keypad, as follows:
   
   A: Rotate the lens turret to the shortest lens.
   
   B: Press until the keypad reads "MANUAL" in the upper right corner.
   
   C: Use the right-hand arrow keys on the keypad (the set located under and . ) to move the Satellite to as large a size as possible where you can still view the reticule in the camera holder. These arrows move both the camera stage and the lens stage together and are always used for sizing the image. Press along with either arrow to get faster movement.
   
   D: Use the other arrow keys (under the number pad area) to focus the image. These keys move only the camera stage, and are used for focusing whenever you are in "Manual" mode. You can tap these keys to achieve very fine movements. After tapping a key, wait for a few seconds for the Satellite to settle into position.
   
   E: Double check to make sure that the focus is perfect.
   

7. Examine the image in the reticule very closely, and note whether all corners of the image area are in focus. If they are not, you should level the Satellite chassis by means of the thumbwheels located on the runner plate of each stage. These thumbwheels are used to adjust the tilt and droop of each stage. There is not any single method of determining perfect level, but several systems are available for leveling photographic enlargers, which will work well for the Satellite. You can also do it visually by trial and error.
   
8. Once this image is perfect in all areas, the next step is to level the image in the viewing area. For this, you will need to re-install the reticule into the viewing position under the mirror. This is basically the reverse of the procedure of removing the reticule. Be careful of the corners of the reticule when lying it flat into the recess. If, for some reason, you need to remove the mirror, this can be done by pulling down on the front ends of the two mirror retainer clips and pulling the mirror out. Do not remove the mirror entirely unless absolutely necessary. Re-install and tighten the white screw removed in step 3.

9. Activate the Rack-over Footswitch to bring the rack-over stage into "viewing" position. This is the position where the viewing reticule and mirror are positioned over the lens. An image should be in view in the reticule. From this point on, do not move the machine at all using the keypad. Working on the stages will not cause problems, since the computer is constantly maintaining their positions.
   
10. You will probably notice that the image is slightly out of focus, or not in focus in the corners. You can adjust the position of the reticule stage using the three hex-drive screws that hold the mirror frame down. The front two screws, in relation to each other, adjust the left-to-right tilt of the reticule. The rear screw, in relation to the other two, adjusts the front-to-rear tilt. All three screws together adjust the overall height of the reticule.

11. When satisfied that the reticule image is perfect, re-install the rack-over enclosure. This procedure is now complete, and should not have to be done again.