Panasonic CRS1 Service Manual

CRS1

ORDER NO. MD0509368C0

Mechanism Unit

CONTENTS

Page Page

1 Mechanism Overview 3

2 Mechanism Drive Unit

2.1. Tray Open/Close and Multi-Discs Change operations

2.2. Disc Selection operation

2.3. Play/Stop operation

3 Mechanism Operation Description

3.1. General Feature

3.2. Hardware composition

3.3. Mechanism Operation

3.4. Switches Chattering Check

3.5. Motor Movement Control

3.6. Plunger Timing Chart

3.7. Initialization of Mechanism Unit.

3.8. Mechanism "HOME" position

3.9. Mechanism "Play Driving" position

3.10. Trays Operation

3.11. Drive tray between STOCK and PLAY position

3.12. Selection of Tray by Moving UD base Up/down

3.13. Fail Safe

3.14. Manual Trigger Tray Close

3.15. Changer Error Code

4 Self diagnosis and special mode setting

4.1. Special Mode Table 32

4.2. Error code Table

5 Troubleshooting Explorer

5.1. Preparation of service jig

5.2. Checking of Changer Unit

5.3. Setting the trays in "STOCK" position

6 Flow Chart

6.1. Disassembly Flow Chart

6.2. Assembly Flow Chart

6.3. Disassembly Flow

7 Assembling and Disassemb ling Procedure.

7.1. Disassembling Procedures

7.2. Assembling Procedure

8 CRS1 (Changer Unit) Ageing / Reliability

8.1. Equipments

9 Notes of Schematic Diagram

10 Schematic Diagram

10.1. CD Loading Circuit

11 Printed Circuit Board

11.1. CD Loading P.C.B.

12 Exploded Views

12.1. CD Loading Mechanism

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13 Replacement Parts List 100

13.1. CD Loading Mechanism Parts List

101

13.2. Electrical Parts List

102

1 Mechanism Overview

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2 Mechanism Drive Unit

2.1. Tray Open/Close and Multi-Discs Change operations

2.1.1. Description of tray open/close and multi-discs change operations

1. The motor turns in the clockwise direction and the rotation is transmitted via the belt, the pulley gear also turns clockwise.

2. The relay gear 1 turns counterclockwise.

3. The relay gear 2 turns clockwise.

4. The relay gear 3 turns counterclockwise.

5. The switching gear at down position turns clockwise (up/down position functioned by the plunger lever).

6. The main drive gear turns counterclockwise.

7. The cam gear turns clockwise, which is engaged with the trigger gear and slide plate, are driven, causes the tray lock lever unlock.

8. The tray relay gear turns counterclockwise, which is engaged with the OC assy, is driven.

9. The movement of the OC assy releases the disc trays.

(The operation of the disc trays closed is the opposite of that for opening of disc trays.)

2.2. Disc Selection operation

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2.2.1. Description of disc selection operation

Note: Check that the cam gear is in “HOME” position.

1. The motor turns in the clockwise direction and the rotation is transmitted via the belt, the pulley gear also turns clockwise.

2. The relay gear 1 turns counterclockwise.

3. The relay gear 2 turns clockwise.

4. The relay gear 3 turns counterclockwise..

5. The switching gear move up turns clockwise (up/down position functioned by the plunger lever).

6. The long gear turns counterclockwise.

7. The function gear moved up turns clockwise.

8. The UD gear 1 turns counterclockwise.

9. The UD gear 2 turns clockwise engaged with the UD rack R drives the UD connection lever turns clockwise, UD rack L, is driven to move the traverse deck assembly up.

(The operation of the traverse deck assembly down is the opposite of that for the traverse deck assembly up.)

2.3. Play/Stop operation

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2.3.1. Description of play/stop operation

Note: Check that the Lock Lever 1 is unlock.

1. The motor turns in the clockwise direction and the rotation is transmitted via the belt, the pulley gear also turns clockwise.

2. The relay gear 1 turns counterclockwise.

3. The relay gear 2 turns clockwise.

4. The relay gear 3 turns counterclockwise.

5. The switching gear move up turns clockwise (up/down position functioned by the plunger lever).

6. The long gear turns counterclockwise.

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7. The function gear move down turns clockwise.

8. The play gear 1 turns counterclockwise.

9. The play gear 2 turns clockwise engaged with the tray drive rack and tray catch lever to push in the disc trays.

10. Play lever B engaged with the traverse deck assembly’s play lever A, causes slide plate move towards to the play position.

3 Mechanism Operation Description

3.1. General Feature

· This is a five disc changer mechanism for CD/DVD. The outline figure is shown below.

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· The mechanism has "CHANGE WHILE PLAY" function. It open other trays for disc exchanging while one tray is at PLAY

position performing recording or reproducing.

· The mechanism can quickly change all trays with "CHANGE ALL" function. All trays can be move to OPEN position with one

operation.

· There is no sensor to indicate presence of disc on any tray.

3.2. Hardware composition

· Below is the hardware components of the mechanism

Name Function

Open Switch (OPEN-SW) The switch is used to detect normal tray opening

The switch is used for detect tray being manually push/trigger when full open Home Switch (HOME-SW) Is used to detect cam gear home position Close Sensor (CLOSE-SENSOR) Used for normal single tray closing

Used to detect cam gear rotate to Play Driving position Play Switch (PLAY-SW) Detect TRV clamping complete position Stocking Switch (STOCK-SW) Detect tray completely transfer for play position to stocking positi UD Sensor (UD-SENSOR) Detect TRV vertical movement position Top Switch (TOP-SW) Detect a default position of TRV vertical movement position Driver IC To drive Motor Motor Main driving source for changer Plunger Switching the driving source from motor to:

1. Tray open/close

2. Drive tray to play/stock position and TRV vertical movemen

3.3. Mechanism Operation

· This mechanism has the following state:

1. Driving of a tray to open/close

2. Up/down operation of a traverse performs a state changes of tray.

By using the plunger to lift/release of a switching gear, and the cam gear to lift/release the function gear the motor can be link to several gear trains to perform various operations.

· The functions that can be perform in this mechanism are described as below:

Condition Explanation

Open current playing tray The state to change current playing disc. All tray will be open at once and current tray at PLAY position

Open All The state where all trays being driven to OPEN position. The disc can be taken in or out from tray to tray

Stock The state where the trays are stored in STOCK position Play The state where one of the tray 5 trays is being driven to PLAY position and clamped by traverse unit

will be expose.

by close tray one by one from top to bottom.

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Condition Explanation

Play & Open Tray-* The state where one of the tray is in playing position performing recording or reproducing, other trays can

Change The state when one of the opened tray being driven from OPEN position to STOCK position and other

Close All The state where all open trays will being driven from OPEN position to STOCK position, one by one from

Note: * represent tray number (from 1 ~ 5)

be used (OPEN position) for disc exchanging without stopping the recording or reproducing process.

opened trays remain still at OPEN position.

top to bottom

· Logics of motor control:

Action CW CCW Plunger

Tray Opening H L L Tray Closing L H L Cam move from Home Position to Play Driving Position H L L Cam move from Play Driving Position to Home Position L H L Drive tray to PLAY position H L H Drive tray to STOCK position L H H UD base moving upward H L H UD base moving downward L H H

Notes :

CW/CCW : Motor direction control (CW : clockwise, CCW : Anti-clockwise) Plunger : Solenoid Control (H : ON = Activation)

· Cam gear in the mechanism use for opening/closing of trays and lifting a function gear to link to gear train that drive UD base

moving up/down. When cam gear is being driven to play driving position, the function gear will be bring down to link the gear train that drive tray to and from STOCK position and PLAY position. Below are the relation between mechanism function and cam gear movement and position

Motor Direction Plunger Unit Cam gear movement/position Function

CW Release Home SW → rotate CW Trays Open CCW Release Rotate CCW → Home SW Trays Close CW Release Home SW → close sensor 1st L-H signal Cam gear move from Home Position to Play

CCW Release Close sensor 1st (H → L) signal → Home SW Cam gear move from Play Driving Position to

CW Up Cam Stop at Home Position UD base moving from bottom to top CCW Up Cam Stop at Home Position UD base moving from top to bottom CW Up Cam Stop at Play Driving Position Tray move from STOCK to PLAY position CCW Up Cam Stop at Play Driving Position Tray move from PLAY position to STOCK

Driving Posi

Home Position

Position

· Cam gear rotation direction, switch and state changes is show in figure below:

· The movement of UD base (vertical up/down) and driving of tray(s) between STOCK position and PLAY position is only enable

when plunger ON (lift up the switching gear to link driving source to the both gear train). Only one gear train can be driven at one time, the selection of either gear train is depending on cam gear position. Below are figure showing the operation of motor driving direction and its function carry out.

Cam Gear

Motor Home Position (UD Driving Position) Play Driving Position CW UD base move upwards direction 5→1 Stock → Play CCW UD base move downwards direction 1→5 Play → Stock

· For driving UD base up/down the cam gear must be at the home position (UD driving position) and plunger need to be

activated, the switch and state change is as figure below:

· To drive the tray(s) between STOCK/PLAY position, cam gear must be at the play driving position and plunger need to be

activated, the switch and state change is as figure below:

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· The mechanism tray opening and closing is cycle process. It is able to open all trays in STOCK position while one of the tray

is in PLAY position. The closing can be done one by one or close all at once depend on the user instruction. Below show the tray opening and closing flow.

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3.4. Switches Chattering Check

· Each input shall perform chattering check processing.

OPEN-SW 2ms Periodic sampling. It logic-decides by continuation same 5 times. PLAY-SW 2ms Periodic sampling. It logic-decides by continuation same 5 times. STOCK-SW 2ms Periodic sampling. It logic-decides by continuation same 5 times. TOP-SW 2ms Periodic sampling. It logic-decides by continuation same 5 times. HOME-SW 2ms Periodic sampling. It logic-decides by continuation same 5 times. UD-SENSOR 2ms Periodic sampling. It logic-decides by continuation same 5 times. CLOSE-SENSOR 2ms Periodic sampling. It logic-decides by continuation same 5 times.

3.5. Motor Movement Control

Condition Motor

CW CCW

Free L L Rotate CW H L Rotate CCW L H Short Brake H H

3.6. Plunger Timing Chart

· Plunger is use for pulling the lever that a switching gear is sit on the lever. When current supply to the plunger to pulling (kick)

switching gear, it will be lift up to engage to 1 be bring done by gravity force and mechanical coil spring on top of it. Plunger use for connect the driving source from motor to 2 different gear train in the mechanism, the functions of the gear trains are as below:

1. Tray open/close

2. Drive tray to play/stock position and TRV vertical movement

gear train. When current supply to plunger is cut off (release), switching gear will

· The plunger movement is define as below:

Kick = H, Release= L

· Each time during plunger activation time (Kick/Release), the motor shall perform a short time CW and CCW rotation for release

the gear side force and ensure complete gear to gear engagement.

· The basic concept of the motor rotation sequence (CW or CCW) is base on the initial and final motor rotating direction. The

direction should be opposite to the initial and final motor driving direction in order to:

1. To release the gear teeth side force

2. To release mechanism belt tension

3. To ensure switching gear disengage or engage into other gear´s teeth

· Summary of the type of motor short rotation direction is as below:

Motor Direction Initial Short Rotate Direction Final Switching Mode

Plunger Kick CW CCW CW CCW CW A

CCW CW CCW - CW C

Plunger Release CW CCW CW CCW CW E

CCW CW CCW - CW G

CCW CW - CCW B

CW CCW CW CCW D

CCW CW - CCW F

CW CCW CW CCW H

· Below are the timing charts of plunger activation time.

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· As the plunger only activate at 2 position of cam gear. The plunger mode summary as below:

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Switching

Position

Home

Position

Play

Driving

Position

Cam gear rotate CCW to HOME Motor : CCW

UD base move from bottom to top Motor : CW

UD base move from top to bottom Motor : CCW

Cam gear rotate CW from HOME to Play Driving Position. Motor : CW

Drive tray from STOCK position to PLAY position. Motor : CW

Drive tray from PLAY position to STOCK position. Motor : CCW

Initial Motor Direction Switching

Mode

C UD base move from bottom to top

D UD base move from top to bottom

E Cam gear rotate CW from HOME to

G Cam gear rotate CW from HOME to

A Drive tray from STOCK position to

B Drive tray from PLAY position to

F Cam gear rotate CCW from Play

H Cam gear rotate CCW from Play

G Cam gear rotate CW from until trays full

Initial Motor Direction Function

Motor : CW

Motor : CCW

Play Driving Position. Motor : CW

PLAY position. Motor : CW

STOCK position. Motor : CCW

Driving Position to HOME. Motor : CCW

open. Motor : CW

Tray selection from bottom to top

Tray selection from top to bottom

After tray selection, cam gear rotate to Play Driving Position

Load tray to Play

Unload tray from Play to Stock

After load tray to Play, cam gear return to HOME

After unload tray from Play, cam gear return to HOME

Open trays while one tray Play

· Switching mode G is used during initialization to ensure that the switching gear is at the release (down) condition before the

initialization process begins.

3.7. Initialization of Mechanism Unit.

· Mechanism Initialization -- This mechanism is designed to operate & set to a pre-defined position to prevent malfunction when

unavoidable circumstances happen. For examples: user mis-handling during transportaion or abnormal user operations.This is comply to the product shippin g reliability standards.

· Mechani sm is initialized when the mechanism controller is unable to detect the present condition/state of mechanism. For

example, when the microcomputer carries out a cold start. (In complete unit)

· Once the initialization process is completed, the mechanism unit is set to this condition:-

1. Tray 1 is at PLAY position (Top tray)

2. The traverse unit is at clamping condition (PLAY SW-L)

3. All the remaining trays are in STOCK Position (Trays 2 ~ 5 )

4. Plunger lever at release condition

5. Cam gear is at Home position ( HOME SW-L)

6. Motor is free (CW-L, CCW-L)

Note: This is same as shipment condition. (In complete unit)

· Below is the flow chart of the initialization process:-

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3.8. Mechanism "HOME" position

· Mechanism HOME position is a starting position for few functions, such as below:

1. Load tray from STOCK position to PLAY position

2. Unload tray from PLAY position to STOCK position

3. Open trays

4. Driving UD base up/down

· Besides this, it will always return to “HOME” position after performing below functions:

1. After tray completely clamped by Traverse unit

2. Closing All trays

3. Closing tray 5

4. After completely the UD base movement

· There are 2 type of mode to go to HOME position.

Mode 1 is to go to HOME position and motor brake and stay at HOME position, motor need longer brake time for reduce overrun of mechanical parts.

For Mode 2, after mechanism go to HOME position, motor immediately rotate reverse direction to go do loading/unloading processing, shorter brake time necessary to reduce the total mechanism operation time.

The table below is types of "GO HOME" mode and operation that use it.

GO HOME MODE 1 GO HOME MODE 2

1. After loading tray to PLAY position 1. After closing all trays (no tray at PLAY position)

2. After unloading tray to STOCK position

3. After closing all trays (one tray at PLAY position)

· The timing chart for the mechanism to set to “HOME” position is illustrated as below.

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· Below is the flow chart for the mechanism to set to “HOME” position.

3.9. Mechanism "Play Driving" position

· Play driving position is a position driving source linkage to drive the tray(s) between STOCK position and PLAY position (load

and unload of tray). Cam gear will rotate to this position from HOME position, and after the completion of clamping process will back to HOME position. For Go to Play Driving position, cam gear move from HOME position, motor brake after detect 1 change from H→L

time CLOSE sensor signal

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· Below is the flow chart for the mechanism to set PLAY DRIVING position.

3.10. Trays Operation

3.10.1. Tray ‘Open’ Operation

· Changer mechanisms are required to open trays to load a disc. This mechanism feature s an "All Open" or "Change all one by

one" function for quick & easy disc change. There are 3 kinds of "Tray Open" conditions.

1. All trays open

Occurs when OPEN/CLOSE button is pressed, playing tray will be driven to STOCK position and all trays will driven to OPEN position. All trays will remain open until "DISC CHANGE" or "OPEN/CLOSE" is pressed. When "DISC CHANGE" is pressed, the upper most tray will close while "OPEN/CLOSE" is close all trays.

2. Open selected tray while one tray at PLAY position

Occurs when specify tray is selected to be opened while one tray is at PLAY position. This operation never disturbs the playing disc operation and allow user to change desire disc on specific tray.

3. Direct open playing tray

Occurs only when the user selects to open playing tray. Tray at PLAY position will stop recording/reproducing process and being driven to STOCK position. This will follow by driven all trays to OPEN position and trays closing until the previous playing tray expose for disc changing.Example: User press "DISC CHANGE" + "DISC 3". Mechanism opens all the trays, then closes trays 1 & 2 respectively exposing the tray 3.

· The timing chart for both positions is the same, motor rotate CW direction, until OPEN SW changing signal H→ L → H, motor

need to continue run for 45ms.

· Motor free at the end of tray open, this is for enable the tray to be manually pushing by user.

· Below is the timing chart for tray opening.

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· For all type of trays openin g, either 4 trays (open remaining) or 5 trays (all open) will be set to OPEN position.

3.10.2. Tray Closing Operation

· The following action is tray closing. For this mechanism, there are 3 types of trays closing also.

1. All trays close When user press "OPEN/CLOSE" after trays open, all trays (at any condition) will being driven to STOCK position.

2. Auto Tray Close This closing operation is an internal operation in the mechanism. This operation completes the open selected tray function. Mechanism uses this operation to drive trays that cover top surface of desire tray to STOCK position and then expose the selected tray for user to do disc exchanging.

3. Change When user press "CHANGE", one tray will be driven to STOCK position. This operation is for changing disc one by one from top to bottom. The operation each time will only drive the upper most tray to STOCK position, it can be only being interrupt by "OPEN/CLOSE". If the "CHANGE" being pressed during one tray is closing, mechanism will close the second tray immediately after 1

· All trays close can occurs anytime when there is tray at open condition. The all trays close processing is used when mechanism

carry out the function as:

1. Close Tray 5

2. Close Tray 4 while tray 5 is in PLAY position

3. User press OPEN/CLOSE to instruct all trays close.

tray. The number of tray will be closed equal to numbe r time of "CHANGE button " being pressed.

· Mechanism will close all the trays by rotating cam gear at CCW direction until detect HOME position

· Below is the timing chart for tray close (until detect HOME position).

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· Table below explain the function of open selected tray while one tray at PLAY position. This table indicated the possible tray

at playing trays. For opened tray, all trays will be open except the tray at PLAY position. Trays will close to expose the selected tray for user to input or change the disc.

· Timing chart below, shown an example of user select to open tray 4 only.

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· The "Change" operation is to close one tray each time when "CHANGE" is pressed. This is the basic operation of "auto tray

close". The "change" operation will stop after detect a signal change in CLOSE-SENSOR while "auto tray close" count the number of CLOSE-SENSOR signal change and stop at before selected tray start to move to STOCK position.

If there is a case where user select a upper level tray of current tray in PLAY position to be closed, (e.g. current tray at PLAY position is tray 4, user select tray 3 to be open), micro-p counting of CLOSE sensor signal must done until tray 4 position, before motor brake. The reason is to eliminate long waiting time for the next tray closing.

· Below is the timing chart of tray closing (Change Operation):-

· Tray opening and closing is control by cam gear and CLOSE-SENSOR signal. OPEN-SW is only use for full open operation in

order to get more accurate tray stroke. Figure below show the cam gear rotation direction for tray opening and closing, and cam important position.

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· Below is the flow chart for tray open processing.

· The flow charts below shown the types of tray close processing, for tray auto close processing is use if user select a specify

tray to be close automatically after trays full open.

· Tray change close processing use if use select a function and want to change disc one by one from top tray to bottom tray.

· Close all processing is use when user wants to close all trays at once, or want to close tray no.5 or close tray no.4 while tray

no. 5 is at PLAY position.

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· When there is a OPEN/CLOSE button pressed during tray open or tray close operation. Motor will rotate revere direction.

There are 2 type of cases, where 1 trays full open condition. For the 1

is before full open condition (open/close gear assembly still resting) and the 2ndis after

condition, motor will rotate the cam gear to move between HOME direction and tray open

While for the 2ndcase, cam gear inside mechanism will move between specific positions by checking CLOSE-SENSOR signal change.

· The flow chart for both open reverse (when tray opening motor reverse) and close reverse (when tray closing motor reverse)

is as below. The operation use when user press OPEN/CLOSE button during tray is opening or closing.

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3.11. Drive tray between STOCK and PLAY position

· Play position is defined as the position whereas the tray is aligned to be played over the CD/ DVD unit. Only a single tray can

be at this location & note that the traverse mechanism is at its clamped position. Play position can be either disc playing (actively reading disc data) or its not playing (no data reading).

* Shipment or Initialize positions always finish with a tray at this location.

· Loading operation is process to move tray from STOCK position to PLAY position.

· Unloadin g operation is process to move tray from PLAY position to STOCK position.

· If there is a certain operation key pressed at the middle of movement. The reversal operation is necessary. The reversal

operation should carry out after the tray arriving the STOCK position or PLAY position.

· The flow chart and timing chart for load a disc from STOCK position to PLAY position is as below:

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· The flow chart and timing chart for unload a disc from PLAY position to STOCK position is as below:

3.12. Selection of Tray by Moving UD base Up/down

· Tray alignment & selection is achieved by UD (up/down) movement, whereas the Mechanism vertically aligns itself to the

selected tray to be driven to PLAY position or STOCK position. The upper most tray is defined as tray 1 and bottom most tray is defined as tray 5. Counting is achieved by resetting during initialization to the TOP-SW (tray 1) and counting the signal change by UD-SENSOR.

· Below are the timing chart for UD base tray selection Up/down:

· Tray 1 is the reset position for UD base up/down processing. The position should be unique; a TOP-SW is use in this purpose.

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· Below is the flow chart for UD selection processing.

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· For tray 1 selection, flow chart below will be used.

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3.13. Fail Safe

· Fail safe function is for purpose of recovery of tray movement if the mechanism is not able to carry out tray open or close within

a specified time.

Fail safe 1: Tray can not open: Fail safe - move all trays to home position

Fail safe 2: Tray can not close: Fail safe - move to next close sensor transition position

Note : For Fail safe 2 :

1. If done on tray 1 - will fully go to Open position because OC gears are fully engaged

2. If done on either one of the remaining trays (2, 3, 4 & 5) - will only release the gear engagement and leave the tray at free condition, tray can only open manually by user.

After fail safe, any subsequent button pressed on main set, the mechanism must follow "GO HOME" flowchart.

· Fail safe flow chart are shown as below:

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3.14. Manual Trigger Tray Close

· W hen user push open tray at full open position, user may able to activate tray to be all close. This function will be disable if user

happen to press "OPEN/CLOSE" button and fail safe happen before.

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Panasonic CRS1 Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual