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3. suc me M SOLENOID 76 o o J15 E 421 8 d 105876 3 um E ER TRANSMISSION SOLENOID 2 12 gt 5 Fl FEED HOPPER PCR SENSOR SENSOR mi ri o J4 x E Fig 10 2 ACS 4600 Secondary Wiring Diagram 821160 5 ASG MTM 001 031128 11 Special Service Tools Special Tools Camera Adjustment Card p n 6699A111 Key for Safety Switch p n 6699A201 Standard Tools with specific requirements to one or more dimensions Allen Key 0 9 mm for the lock screws of Input Sensor Arm and Input Sensor Shutter Pozidriv no 2 long blade 200 mm for the inside fixing screws of the Camera Backpiece For cleaning of the Scanning Platen and the Aperture Plate for the Punched Card Reader Use a damp soft cloth and a mild detergent for cleaning of the Scanning Platen Note Alcohol solvents or other cleansers must not be used for cleaning of the Scanning Platen For cleaning of the CCD use A soft lint free cloth and ethyl alcohol be careful not to scratch th
4. oonan 04 rrr Oz Os 95 T o C37 R2 28 C29 O R90 R91 R92 R93 P9 O C36 N R 669 ej 033 BRnnnnnnnnnnnnnnnnnnnn 9 U27 BnBRBnBnnnnnnnnnnnnnnnnnnn 026 5 6 46 R29 828 12 1 0 C14 right Fig 3 4 CBG Component Layout
5. nnnm T2 13 TOUT TUTT C44 R78 R T Dooo0001 77 C17 8 020 023 TUUTUTTT TUTTI LITT 100 C59 Ri 1 R79 R82 R101 11101111 Roa 1224 R83 884 C54 77 J4 J6 17 265 264 9641 564 0119 752 C56 R103 68 168 See text for adjustment procedure Fig 3 2 MSC Component Layout 17 81 7 i 2 SOLENOID 3 DRIVER 1i SOLENOID 24V SOLENOID tb 2 DRIVER FEEDER 3 NOT US ED 12 5V PSU CONVERTER SMPS SOLENOID GEAR 12 02 15 gt gt 4 3 4 7 CRLE 9 0 2 6 1 E suce HN 2 0 280 e STEPPER 9 10 12 13 14 LAMPON DAC T pk 2 14 12 1 12V 2 16 BLEEDER 1 5V 12V 2 43 DRIVER ES 12V 2 15 LAMP 1
6. 9 wx Go 11111711 111111 2 129 R42 R39 gt Fig 3 10 PCR Component Layout 30 18 44 44 24 13 4 0 KB DON 3 0 KBDOUT 6 0 PTL PT13 w SENS3 SENS2 lt 5 51 245 ji KBDIN 5 0 5V 2 1 5 KBDON3 2 CARD DATA LOGIC RD_PCD 1 12 1 EDGE DETECTOR KBDON3 16 READER OUTPUTS Fig 3 11 PCR Block Diagram 801160 TO0 INLIN OSV ASG MTM 001 031128 3 9 Check of Operator Panel All test points referred to are shown in Fig 3 12 page 33 All voltages are measured relative to PCB Ground Plane OPB Block Diagram is shown in Fig 3 13 page 34 3 9 1 DC Voltages Ref on Fig DC Voltage J1 pinl4 15 20 21 J1 pinl9 5 1 V 0 1 0 2 3 9 2 Functional Test SCANtest 6 Test 1 Scanner ID Switch Test 2 LED test Test 3 Key test 3 9 3 Markings ACS 4600 OPBBdd where dd board revision number 3 9 4 Sw
7. ome A 077 Bg 000 929 Um J4 xi 5 R4 R2 63 922 om 8 g 00 8 e ce 2 2 5 3V 0 0 2V 5 2V 0 0 2V D1 bottom 5 Fig 3 8 Component Layout 27 5 001 031128 IEEE 1394 1394 CONTROLLER IEEE 1394 40 MHz Eos SUC ADRDATABUS BUS USB 1 1 CONTROLLER USB CONTROL MODULE Fig 3 9 IMC Block Diagram 28 ASG MTM 001 031128 3 8 Check of Punched Card Reader Board PCR All Test Points referred to below are shown in Fig 3 10 page 30 All voltages are measured relative to GND 16 14 PCR Block Diagram is shown in Fig 3 11 page 31 3 8 1 DC Voltages Ref on Fig DC Voltage pin 20 15 3 V 40 0 2 V 3 8 2 Check Phototransistor Outputs The outputs of the phototransistors are connected to J6 pins 1 through 13 see PCR Block Diagram Fig 3 11 page 31 PT1 PT2 PT3 PT13 correspond to J6 pin 1 pin 2 pin 13 where pin 13 is the output of the Edge Detector and pin14 is GND The outputs levels of the phototransistors should be lt 250 mV Lamp ON no card inserted gt 25 Lamp all apert
8. Reject Tray Switch Fixing Screws Fig 3 19 Adjustment of the Reject Tray Sensor 46 ASG MTM 001 031128 4 ACS Optical System The adjustment procedures presented in this chapter cover all adjustments needed for replacing the complete CCD camera It will hardly ever be necessary to replace mechanical parts such as Lens Backpiece etc and in most cases the only adjustments necessary after replacement of the CBG Board are e CCD Centering Section 4 2 4 page 57 CCD Tilt Section 4 2 5 page 58 e Check Scan Width if it is within the limits given in Section 4 2 3 page 54 Focus will also be OK and no further adjustments are required e Run Scanner Maintenance These adjustments can be made without loosening the Backpiece Fixing Screws and without loosening the Focus Lock Screw 4 1 Description of ACS Optical System See Fig 4 1 page 48 The optical system of the Aperture Card Scanner consists of Halogen Lamp Green Glass Filter BG18 heat tempered Scanning Platen with Integrated Condensing Lens for image illumination Shaped Opal Filter for Light Profile Correction Condensing lens for Punched Card Reader Camera Compartment with Lens Lens Mounting Camera Backpiece Camera Board CBG Board The aperture card is kept in position in front of the Camera by the Scanning Platen The distance between the Scanning Platen and the Camera Compartment is fixed Focus and Scan Width
9. TRAY Gear Solenoid Eject Roller f N 5 Safety Switch 5 afety Interlock Switc o CA 7 Upper Right Guide Upper Left Card Guide 821160 TOO NLW OSY 6 Belt Tension 10mm 500g Exit Roller Feeder Solenoid Belt Tightener o Cable Fixture Sheet 1 E 5 32 4 S o 5 Scanning Rollers Fig 8 8 ACS Front End Bottom View Clutch Assembly 801160 TO0 INLIN OSV ASG MTM 001 031128 5 5 Inlet RFI Filter CBG Board SCR Board IMC Board SUC Board MSC Board SO e PCR Board OIB Board below chassis Fig 8 9 ACS Rear End Top View 94 ASG MTM 001 031128 9 SCANtest 6 The purpose of the scanner test program SCANtest 6 is to support troubleshooting and adju
10. Ee 97 9 1 6 Test 6 EG 97 9 1 7 Test 9 Camera Adjustment enn 97 9 1 8 Test 13 Switch Scanner to Test Mode 98 9 1 9 Test 2L SGANQUmp a e Fette 98 10 WIRING DIAGRAMS eeii 99 11 SPECIAL SERVICE TOOLS errore 102 ASG MTM 001 031128 List of Figures FIG 2 1 ACS 4600 BLOCK DIAGRAM tentent 10 FIG 3 1 SMPS TEST POINTS c ccccsscsssccsscessccsscesscesscesscesscesscesssesssesscesscessnesanessnesarevarevasevarevarearevareanevates 15 FIG 3 2 MSC COMPONENT 244222 0 0 20 060 010000000 17 FIG 3 3 MSC BLOCK DIAGRAM o ch e ret n ed dn e es tacet 18 FIG 3 4 CBG COMPONENT 0 0410000 20 FIG 3 5 CBG P OCR DIAGRAM estas A 21 FIG 3 6 SUC COMPONENT LAYOUT x citrus Tto 24 HG 52 SUC IBLOCK 25 FIG 3 8 COMPONENT LAYOUT treten tentent tte 27 FIG 3 9 BLOCK DIAGRAM teet 28 FIG 3 10 PCR COMPONENT 30 FIG 3 11 PCR BL
11. 31 9637 31 9637 22222222222222222222 70 opaque 70 um transparent Scan Width Pattem CCD Tilt Pattem DSP Test Pattem Not used with ACS 4600 Fig 4 8 Details of Adjustment Patterns 850 um 2 2 2 Detail NN lt SSSS SESS 722272 140 opaque S N N 70 um transparent 280 transparent 15 x30 um 82116960 5 ASG MTM 001 031128 5 General Maintenance General Maintenance consists of the following steps e Check the condition of the Teflon Tape on the Scanning Platen replace if necessary e Check if the color in the center of the green glass filter has faded replace if necessary e Check Camera Adjustments e Clean the Scanning Platen and the Aperture Plate for the Punched Card Reader Use a soft damp cloth and a mild detergent for cleaning of the Scanning Platen Note Alcohol solvents or other cleansers must not be used for cleaning of the Scanning Platen e Check the output level of the phototransistors on the PCR Board Section 3 8 page 29 e Run Scanner Maintenance Basic Calibration e Functional Tests SCANtest 6 Test 4 Original Sensor Test Runa batch of aperture cards with Hollerith Code and Use the batch log facility of WIDEimage to record and to check reading of the Hollerith coded information of
12. 77 8 5 CARD SENSORS stud 79 ASG MTM 001 031128 8 6 REJECT BIN SENSORS e 82 87 en 83 8 8 FEEDER SOLENOID 4 ni uineas ie etes E EA ce tidie 83 8 9 GEAR SODENOID 84 8 10 STEPPER MOTOR 55552 ee ROHR eC t c ele PERO 85 8 11 GEAR CARRIAGE cuc Arena cte 86 8 12 DRIVING BELT AND eec sfide Price ce e ea He 88 8 13 SEPARATOR UNIT AND FRICTION PAD 88 8 14 GARD TRAYS veal bid eise ditis 90 8 15 pe 90 9 95 9 1 DESCRIPTION OFSC ANTEST O eset ec eie rci ug ch ates Bete Aw Reith ceed 96 9 1 1 Test 1 Scanner Information 96 012 Test 2 ee ee RE ER eet 96 9 1 3 CV 96 9 1 4 Test 4 Orisinal Sensor Test sse eet esee genie eie ce ete eee diede 96 9 1 5 Test 3
13. de ndi tita 6 1 ZINTRODUGCTION esee eene oo Pe Fees eee oo ra eene an 7 2 GENERAT DESCRIPTION ee ores pe We ERES 8 Dal ACS APERTURE CARD SCANNER 5 8 3 ELECTRICAL CHECK AND 1 seen ssepe seen seen 11 3 1 MARKING CODES FOR CIRCUIT BOARDS AND PROGRAMMED DEVICES eee 11 3 2 DOWNLOADING SCANNER FIRMWARE 11 3 2 1 Erase Restore Parameter Blocks 12 3 3 CHECK AND ADJUSTMENT OF THE SWITCH MODE POWER SUPPLY 13 33d AC 13 3 92 eie es edes tse eese 13 3 303 TII E 13 13 13 3 36 Jumper Settings re Wh bie ren De 13 e ect tette 14 3 4 CHECK AND ADJUSTMENT OF MOTOR DRIVER BOARD MSC 16 3 44 aie acetate ege 16 3 42 Stepper Motor Reference 16 3253 Functional Test uer ree
14. 78 FIG 8 3 INPUT SENSOR ASSEMPBLY 2 e 80 FIG 8 4 OIB BOARD WITH BRACKET edes e aue RUN T PIN RCM d 81 FIG 8 5 STEPPER MOTOR AND GEAR ASSEMBLY 87 FIG 8 6 PRESSURE ARM WITH FRICTION 89 FIG 8 7 ACS FRONT END 92 FIG 8 8 ACS FRONT END 0 11 1100 93 FIG 8 9 ACS REAR END TOP VIEW 94 FIG 10 1 ACS 4600 PRIMARY WIRING DIAGRAM tette tette tette tret 100 FIG 10 2 ACS 4600 SECONDARY WIRING DIAGRAM cette tete 101 ASG MTM 001 031128 1 Introduction The scope of this Maintenance Manual MTM is to provide technical information to support board level troubleshooting and maintenance of the Aperture Card Scanner ACS model GA66D ACS 4600 Chapter 2 contains a general technical description based on block diagrams Chapter 3 describes Electrical Check and Adjustments including jumper and switch settings Chapter 4 contains a general description of the Optical System and the CCD Camera Adjustments Chapter 5 describes General Maintenance Chapter 6 contains a list of Error Codes and gives some hints on troubleshooting Chapter 7 describes Disassembly and Assembly procedures Chapter 8 provides guide for replacement of parts for which the procedure is not obvious Chapter 9
15. Fuses SMPS F4A IEC 127 2 2 UL Rec 5x20 mm 0177A030402 Mechanical Parts Front End Cover ACS4600 6602D102 Pivot Screw for Front End Cover 6602A207 Front End Base Cover ACS4600 6602D702 Scanner Cabinet ACS4600 6602D701 Bottom Plate 6602A206 Pozidriv Screws for Covers M4x5 00025524 Input Hopper and Separator Separator Unit 6608A103 AOG PLS 002 031120 Description Part Number ACS 4100 ACS 4200 Self Adhesive Friction Pad for Separator 6608A224 Input and Exit Card Tray ACS4600 6608D703 Lower Left Card Guide Input 6608A113 Lower Right Card Guide Input 6608A114 Lower Left Card Guide Exit 6608A115 Right Card Guide Exit ACS4600 6608D101 Left Reject Bottom Guide 6611D105 Right Reject Guide 6611D104 Card Reject Tray with Brace 6611D103 Torsion Spring Input Pressure Plate 6608A257 Torsion Spring Output Pressure Plate 6608A258 X ACS 4600 Card Feeding System Feed Roller 6629A112 Separator Roller 6629 111 Scanning Roller 6629A102 Eject Roller Hard Rubber 6629A107 Eject Roller Foam Rubber 6629A101 General Bronze Bearings for Rollers 0004L101 Bronze Bearing for Eject Roller Foam Rubber 6629A258 Top Guide on Separator Roller 6611A218 Spring for 6611A218 6611A225 Scanning Top Guide 1 plastic block 6611A213 Scanning Top Guide 2 plastic block 6611A219 Guide
16. 35 3 10 3 Marking 35 3 10 4 DIP SwichSetling 3 2 d eo 35 3 10 5 Signal LED on SCR Board sse ree 35 3 11 CHECK OF OPTOINTERRUPTER BOARD 38 3 11 1 FUN CHONG Test Miser M lel 38 3 11 2 Mar kilgs SURE 38 3 12 CHECK AND ADJUSTMENT OF CARD 5 5 0 40 Check Adjustment Input Sensor eese 40 3 12 2 Check of Feeder Sensors qe bebe the hen o 42 3 12 3 Check Of Edge Detector tsi e ER tut ne rore Te en ons Pin 42 3 13 CHECK AND ADJUSTMENT OF REJECT BIN 5 5 42 3 13 1 Check and Adjustment of Bin Full Sensor eene 42 3 13 2 Check and Adjustment of Reject Tray Sensor sse 45 4 ACS OPTICAL 47 4 1 DESCRIPTION OF ACS OPTICAL SYSTEM 47 4 2 CCD CAMERA CHECK AND 50 42241 Check of Light Profiles 50 422 Check and Adjustment Focus sss eene rennen nennen 53 4 2 3 Check and Adjustment of Scan 54 4 24 Check and Adjustment of CCD Centering eese eene 57 4 2 5 Check
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18. 3 10 1 DC Voltages Ref on Fig 3 DC Voltage 15 1 V 0 1 0 2 V 3 10 2 Functional Test SCANtest 6 Test 1 Scanner Model Smart Card 3 10 3 Markings ACS 4600 SCRAdd where dd board revision number 3 10 4 Switch Setting SCSI related switch settings SW No 1 2 3 4 and 5 do not apply for ACS 4600 Default DIP Switch Setting Switch No 11 12 3 14 5 l6 7 8 and Test Switches 112 3 la Js 16 7 Boot start up Forced ON Normal OFF Factory testing Self test ON Normal OFF SWI 6 Not used SWT If download fails try to set SW7 to ON For normal operation SW7 must be set to OFF 5 8 Reserved for factory testing and must be to OFF NB switches read at power on only and the scanner must be switched OFF and back ON for a changed switch setting to become effective 3 10 5 Signal LED on the SCR Board The signal LED on the SCR Board turns ON when the Smart Card is inserted It only signals that a Smart Card has been inserted it does not show whether the card 1 valid or not 33 5 001 031128 5 1 0 1 0 2 R2 top GND S1 right pins Switch 1 SCSI ID Switch Switch no 8 8 TEST MODE Fig 3 14 SCR Component Layout 36 5 001 031128 s SCSIID Switch 2 3 475 6 7958 Fig 3 15 SCR Block Diagram 37 ASG MTM 001 031128 3 11 Check of Optointerrupter Board T
19. LAMP ZH DRIVER m m 2 INTERLOCK SWITCH CIRCUIT Fig 3 3 MSC Block Diagram 821160 5 ASG MTM 001 031128 3 5 Check Adjustment of Camera Board CBG All test points referred to are shown in Fig 3 4 page 20 All voltages are measured relative to GND and TPS CBG Block Diagram is shown in Fig 3 5 page 21 3 5 1 DC Voltages Note The test points are not accessible when the CBG Board is mounted on the camera Ref on Fig 3 6_ DC Voltage C45 left 53 0 0 2 From SUC SMPS C124 right 4 85 V 0 1 0 2 V Derived from 5 3V on CBG C14 right 12 0 V 1 0 V From SUC SMPS C32 top 3 3 V0 1 V From SUC SMPS 3 5 2 Adjustments The gain and offset of the CBG Board are adjusted automatically by running Scanner Maintenance 3 5 3 Functional Test SCANtesr 6 Test 9 Camera Adjustment Light Profiles 3 5 4 Markings ACS 4600 CBGAdd where dd board revision number 3 5 5 Jumper Settings No jumpers 3 5 6 Hints 3 3 V 5 3 V and 12 V is supplied from the SMPS via the SUC Board After replacement of CBG Board do e CCD Centering Section 4 2 4 page 57 e CCD Tilt Section 4 2 5 page 58 e Check Scan Width if it is within the limits given in Section 4 2 3 page 54 Focus will also be OK and no further adjustments are required Run Scanner Maintenance 19 ASG MTM 001 031128 3 3V 0 1V C14 top
20. 16 16 34 54 16 346 On 16 3 5 CHECK AND ADJUSTMENT CAMERA BOARD 19 VOUA ES d sa 19 E MO ITZ T MERERETUR 19 3 5 3 FEunclon ldesi ss eii t LL IMS PER ette te e Lee reete 19 EMEN I II M 19 3 523 Jumper Settings siecle D CU Roe era 19 BOO 2 11 wie ID are vta olo dra RID utosds ed tat 19 3 6 CHECK OF CONTROLLER BOARD 22 3 61 DG Vollages ua octo odio ten asses ee duel di e ane 22 3 62 Adjustments eso ti ee hs ea Ge etre te v e hte 22 220590 CEUNCHONAL Test oet MeL Dd Beo 22 36 4 Markinos ao 22 3 6 5 Switch Settings Download Control Switches serene 22 3 6 6 vet deccm 22 3 6 7 Signal LEDs the 5 22 22 37 CHECK OF INTERFACE MODULE 0 00000000000
21. 6 Scan Width Units 3 Black Lines 3 White Space should be shown at the end of the scanline with the fewest Black Lines corresponding to an offset of less than 0 2 mm Tighten the fixing screws 57 ASG MTM 001 031128 Interaction Check Scan Width and CCD Tilt readjust if necessary Note The Media Offsets option of WIDEimage can be used to compensate for offsets of up to 1 27 mm 4 2 5 Check and Adjustment of CCD Tilt Images of the CCD Tilt are shown in Fig 4 6 ACS 4600 CCD Centering and CCD Tilt page 60 The aim of this adjustment is to align the scanline to be perpendicular to the direction in which the card moves during scanning The alignment is based on the number of Black Lines shown on the oscilloscope when scanning the CCD Tilt Pattern of the Camera Adjustment Card The step height of the CCD Tilt Pattern is 30 um giving a total distance from the first step to the last step of the staircase of 15 x 30 1000 0 45 mm Adjustment Procedure Open the Reject Tray and pull out the card stop Start SCANtest 6 Select Test 9 Select Corrected Light Profile Press Execute Insert Camera Adjustment Card Press CCD Tilt Select Detail View CCD Tilt This positioning often displays 16 Black Line the position of the card may be adjusted to get about 8 Black Lines at the left side of the image by pressing the Reverse Stop key Loosen the CBG Board fixing screws just enough to allow the board to
22. 20 GND TP5 4 85 0 1 0 2V C124 right 5 3V 0 0 2V C45 left Ic DIFF AMP Wolfson Scanner Controller Fig 3 5 CBG Block Diagram POWER SUPPLY IMAGE DATA CONTROL SIGNALS ANALOG OUT Ji 821160 I00 IN LLIN DSV ASG MTM 001 031128 3 6 Check of Controller Board SUC All test points referred to below are shown in Fig 3 6 page 24 All voltages are measured relative to test point GND2 SUC Block Diagram is shown in Fig 3 7 page 25 3 6 1 DC Voltages Ref on Fig DC Voltage 12V CAM 12 V 1 0V Supply for Camera Board 5V CAM 5 3 V 0 0 2 V Supply for Camera Board 5 1 V 0 1 0 2 V APEX 50 18V 01V APEX PIL 18 VeE005V 05 3 6 2 Adjustments No adjustments 3 6 3 Functional Test SCANtest 6 Test 1 Scanner Information 3 6 4 Markings ACS 4600 SUCEdd where dd board revision number 3 6 5 Switch Settings Download Control Switches The download program reads the Download Control Switches SW1 and SW2 on the SUC Board to check if the actual firmware and the SUC hardware are compatible The Download Control Switches are factory set and the setting must not be changed 3 6 6 Jumper Settings No jumpers 3 6 7 Signal LEDs on the SUC Board The three signal LEDs on the SUC Board are for debugging purposes only The ON OFF pattern displayed by these LEDs is not intended for troubleshooting 3 6 8 Hints After repl
23. 69 st er TUUTUUUU 8 3 3V 0 1v 5 3V 0 0 2v T 12V i ov 1 8V o0 05v 3 CAM 12 CAM 5 1V 0 1 0 2v 1 8 0 1v GND APEX SUP GND2 Fig 3 6 SUC Component Layout 82116960 5 SC CAMERA DATA ACQUISITION MODULE CONNEC TORS 2 Optical SERIAL PROCESSOR INTERFACE MODULE MODULE 386 EX COLOR SPACE CONVER ENSHFT ADDR DATA BUS PAR BLOCK BOOT POSITION Fig 3 7 SUC Block Diagram SHARPE DOUBLE DMA1 BUFFER DMAO MODULE IMC ADDR DATA BUS SEN SORS KEYBORD SCR AND SCR SENSOR INTERFACE OPB PCR STEPPER RAM MOTOR MSC CONTROL COUNTER MODULE 82116960 5 ASG MTM 001 031128 3 7 Check of Interface Module IMC All test points referred to below are shown in Fig 3 8 page 27 All voltages are measured relative to test points GND_T1 IMC Block Diagram is shown in Fig 3 9 page 28 3 7 1 DC Voltages Ref on Fig DC Voltage D1 bottom anode 5 3 V 0 0 2 V 52 V 0 0 2 V 1 3 3 0 1 3 7 2 Adjustments No adjustments 3 7 3 Functional Test Connect the computer to each separate port in turn and start SCANtest 6 or WIDEimage to check if the scanner is connecting on all ports available 3 7 4 Markings 4600 IMCAdd where dd board revision number 3 7 5 Jumper Settings No jumpers 3 7 6 Hints None 26 ASG MTM 001
24. and IMC Boards Error 08 147 Invalid Scanner ID e Error 08 147 indicates that the DIP Switch pos 4 5 6 7 and 8 on the Operator Panel is set to an undefined scanner type or inconsistency between the detected scanner hardware and the Scanner ID switch setting see Section 3 9 4 page 32 e Error 08 147 may also indicate a bad connection between the SUC Board and the Operator Panel Error 08 149 Invalid Smart Card e The Smart Card is not valid for this scanner type e Error 08 149 may also indicate a bad connection between the SUC Board and the Smart Card Reader Error 08 208 Keyboard check failed e Check cable to Operator Panel Replace Operator Panel Error 30 240 Light Profile Correction Failed Error 30 is displayed if more than 200 consecutive pixels or a total of 1500 pixels cannot be adjusted up to the required White Signal Level e Use SCANtest 6 Test 9 to check the Light Profiles see Section 4 2 1 page 50 If the Light Profile is distorted the cause may be Some object inside the scanner shades the Scan Area Lamp does not turn ON Lamp is not properly aligned in its socket Corrupted Basic Calibration Try to Erase Parameter Blocks see Section 3 2 1 page 12 Remember to run Scanner Maintenance after Erase Parameter Blocks e Defective CBG Board It is possible to override Error 30 from WIDEimage and go through with the scanning Whether the result will be useful or not depends on the actua
25. 031128 GND 3 3V 0 1V GND T1 2 lt gt M 8 69 1 O d E o eso 652 5 C102 8 9 c10 R90 077 889 095 89 c87 14 cat C156 5 C86 43 cis 280 155 2145 512 Ery R42 R40 654 991 Ras 6r g or 322 8 888 8 5 amp 2 8 8 Bu al eb 6 2 Ir 9213 er C109 R87 5 8 3
26. 27 SUx FPGAO7 register error ERROR 50 28 SUx FPGAOS register error ERROR 50 25 SUx FPGAOS register error ERROR 50 55 SUx DB 1 count error 66 ASG MTM 001 031128 Error Code and Description Refer to page a ERROR 50 56 SUx DB data error ERROR 50 57 SUx CNTL RAM error ERROR 50 58 SUx LIN RAM error ERROR 50 59 SUx GAMMA RAM error ERROR 50 60 SUx INDEX RAM error ERROR 50 61 SUx ATBS error ERROR 50 62 SUx LUT A error ERROR 50 63 SUx LUT error ERROR 50 64 SUx LUTCerror 000 0 0 ERROR 50 65 SUx Color space converter data error ERROR 50 66 SUx Color space converter coefficient error ERROR 50 67 SUx Position counter reseterror ERROR 50 68 SUx Position counter count error ERROR 50 69 SUx Data path error 00 0 ERROR 50 70 SUx Data path lengtherror ooo y y O ERROR 50 71 SUx FPGA 8k statuserror o ooo y ERROR 50 72 SUx FPGA 8k done error Y ERROR 50 73 SUx FPGA 10k status error Jo o ooo y ERROR 50 74 SUx FPGA 10k done error 5 ERROR 50 77 SUx FPGA 6k status error ERROR 50 78 SUx FPGA 6k done error ERROR 50 79 SUx FPGA 20k status error ERROR 50 80 SUx FPGA 20k done error ERROR 50 81 SUx FPGA03 function error ERROR 50 90 SUx Sector in write able area of Flash is locked ERROR 50 91 SUx Parameter block erasure failed 24 pe 22 ERROR 50 92
27. Marking Codes for Circuit Boards and Programmed Devices All circuit boards are identified by a 4 letter code where the fourth letter is designating a specific variant of the board A board revision number follows the board identification code The marking of all newer printed circuit boards may be exemplified by the marking of the SUC Board 50 1 which designates SUC Board variant revision 1 The marking code of the older OIBA and OSBC Boards are a little different for example OIBA 1 0 which designates OIB Board variant A revision 1 0 The revision number is updated only if the functionality of the board has been changed Updated boards will always be backwards compatible Programmed components like CPLDs Flash Memory etc are marked with a 3 or 4 letter identification code depending on whether the component is basic or variant specific For example the component marking SUC 003 2 identifies the Interface Controller used on all variants of the SUC Board 003 is a component specific number and 2 is the firmware revision number The variant designation and part number of the circuit boards used for a particular scanner model can be found in the Spare Part List included in the Technical Service Manual 3 2 Downloading Scanner Firmware The scanner firmware is stored in Flash Memory on the SUC Board Scanner firmware is available on http www contex com 11 ASG MTM 001 031128 Firmware is downloade
28. Plate Shield for Eject Roller 6611A221 Base Plate for Motor and Gear Assembly 6629A123 Gear Carriage Assembly 6629A118 Gear Exit Shaft with Guide Pin 6629A121 Feeder Clutch Assembly ACS4200 4600 6629A109 Belt Tightener 6629A119 Driving Belt for Rollers 6629A253 Belt Wheel with flange 6629A104 Belt Wheel for Transport Roller 6629A233 Belt Wheel for Eject Roller 6629A234 General Tooth Wheel 75 teeth 6629A236 LK Optical System Scanning Platen 6665A101 Teflon Tape Roll 30 m KT832495 Pressure Arm Assembly for Scanning Platen 6665A102 Lamp House w o Lamp Filter and Socket 6665A103 Green Glass Filter BG18 6665A224 Lens 1 5 6 58 3 mm Fixed Diaphragm Aperture 6675A215 Mounting for 6675A215 6675A701 Adapter for 6675A215 6675A214 PRC Aperture Plate 6611A209 x x Scanner Accessories USB Cable 0090B051 IEEE 1394 Controller Board FireWire 0090B056 IEEE 1394 Cable with Ferrite 6799D140 AOG PLS 002 031120 Description Part Number ACS 4600 ACS 4200 ACS 4100 3 Service Accessories Camera Adjustment Card 6699 111 Key for Safety Switch 6699A201
29. Restore Parameter Blocks restores the Parameter Blocks from backup pmb Note Always run Scanner Maintenance after Erase Parameter Blocks 12 ASG MTM 001 031128 3 3 Check and Adjustment of the Switch Mode Power Supply SMPS All test points referred to below are shown in Fig 3 1 page 15 All DC voltages are measured relative to CN3 pin 1 2 3 4 5 GND 3 3 1 AC Voltages CAUTION The connector CN1 is connected directly to the line voltage and constitute a risk of electric shock or injury to persons 3 3 2 DC Voltages Ref on Fig 3 1 Ref on SMPS DC Voltage CN3 pin 6 7 8 4333 V 0 1 V CN3 pin 1 2 3 4 5 GND CN2 pin 3 4 5 5 3 V 0 0 1 V CN2 pin 2 12 V 1 0 V CN2 pin 1 24 V 1V 3 3 3 Adjustments CAUTION The output voltages of the SMPS are all factory set and should normally not be adjusted The 5V output voltage should be no more than 5 3 V measured between GND and CN2 pin 3 4 5 SV on the SMPS and no less than 5 1 V measured between GND and C45 left on the CBG Board If the voltage is not within these limits it may be adjusted by potentiometer 5 1 on the SMPS see Fig 3 1 page 15 3 3 4 Fuses The type and rating of the fuse on the SMPS is Fl 4 typeIEC 127 2 2 UL R C CAUTION For continued protection against risk of fire replace only with same type and rating of fuse 3 3 5 Markings No marking 3 3 6 Jumper Settings No jumpers I3 ASG MTM 001 031
30. SUx Parameter block write failed DEEST ERROR 50 93 SUx Profile block erasure failed ERROR 50 94 SUx Profile block write failed 1 2 4 ERROR 50 95 SUx Flash block erasure failed ERROR 50 96 SUx Flash block write failed ERROR 50 99 SUx unknown Flash device type ERROR 50 100 pad task creation failed ERROR 50 101 ped task creation failed ERROR 50 102 pbl task creation failed ERROR 50 103 err task creation failed ERROR 50 104 pio task creation failed ERROR 50 105 pop task creation failed ERROR 50 106 psn task creation failed ERROR 50 107 psc task creation failed ERROR 50 108 psi task creation failed ERROR 50 109 psp task creation failed ERROR 50 110 pts task creation failed ERROR 50 111 pto task creation failed ERROR 50 112 mbPad creation failed ERROR 50 113 mbPbl creation failed ERROR 50 114 mbPcd creation failed ERROR 50 115 mbPio creation failed ERROR 50 116 mbPsi creation failed ERROR 50 117 mbPsp creation failed ERROR 50 118 mbPts creation failed ERROR 50 119 mbPio pending 67 ASG MTM 001 031128 Error Code and Description Refer to ERROR 50 122 pop request failed position unknown ERROR 50 123 pop request failed invalid command ERROR 50 124 pio event ERROR 50 125 psievent ____________ ERROR 50 126 ped event oo o O ERROR 50 127 psc event ERROR 50 128 psimessageevent Z E ERROR 50 131 psp received unknown ma
31. are adjusted by turning the Lens and sliding the Camera Backpiece back and forth 47 ASG MTM 001 031128 Camera Backpiece Lens Camera Compartment PCR Board PCR Aperture Plate Scanning Platen Opal filter for image illumination Condensing Lens for image illumination Condensing Lens for Punched Card Reader IR Filter Lamp Fig 4 1 ACS Optical System 48 ASG MTM 001 031128 Lens mounting Lens Adapter Lens Camera Compartment Focus CCD Tilt Alignment CCD Centering Through holes for Backpiece fixing screws inside d camera compartment Backpiece fixng screw Fixng Screws Camera Backpiece CCD Camera Board Fig 4 2 CCD Camera 49 ASG MTM 001 031128 4 2 CCD Camera Check Adjustment To get access to the lens for adjustment Remove the Scanner Cabinet Remove the lid of the Camera Compartment Notes During adjustment use the lid to cover for stray light that might affect the Light Profile White Signal Level It may be convenient to override the Safety Switch to keep the Lamp ON with open Front Cover Equipment needed e PC with SCANtest 6 and Scammer Maintenance installed and with interface for 1394 or USB Key to override Safety Switch p n 6699A201 e Camera Adjustment Card p n 6699A111 The Camera Adjustment Card is shown in Fi
32. describes the scanner test program SCANtest 6 Chapter 10 contains Wiring Diagram Chapter 11 contains a list of Special Service Tools ASG MTM 001 031128 2 General Description The ACS Aperture Card Scanner model GA66D ACS 4600 ACS 4600 PLUS is described at block diagram level in Section 2 1 2 1 ACS Aperture Card Scanner Models Block Diagram is shown in Fig 2 1 ACS 4600 Block Diagram page 10 The ACS 4600 scanner range consists of GA66D Trade name ACS 4600 ACS 4600 PLUS No of cameras IEEE 1394 USB IEEE 1394 USB Max resolution on 200 dpi scanned image Optical resolution on Aperture 6300 dpi 6300 dpi Scan speed at 200 dpi BASIC PLUS 20 sec 7 sec The basic versions of the scanner ACS 4600 may be field upgraded to the enhanced version ACS 4600 PLUS by replacing the BASIC Smart Card with a PLUS Smart Card The scan area is back illuminated by a halogen lamp The CCD Camera in the scanner contains one 7 926 pixel B W CCD The output signal from the CCD is Light Profile Corrected at pixel level All scanning and image processing functions are contained on only two boards the Camera Board CBGA and the Controller Board SUCE The Aperture Card Scanner has a Punched Card Reader PCRA allowing Hollerith coded information on the cards to be used for automatic setting of the WIDEimage parameters Auto Paper Size and Auto Filenaming The card feeder mechanism is v
33. has been changed When all camera adjustments have been completed run Scanner Maintenance 4 2 3 Check and Adjustment of Scan Width Images of Scan Width adjustments are shown in Fig 4 5 ACS 4600 Focus Signal and Scan Width page 56 The aim of this adjustment is to obtain a Scan Width of 31 9637 mm The Scan Width is correct if the total sum of Scan Width Units SWU at the start and the end of the scanline is 14 1 SWU is either 1 Black Line or 1 White Space of the Scan Width Pattern on the Camera Adjustment Card Adjustment Procedure 2 Always perform the Focus adjustment before adjusting the Scan Width see Interaction below Open the Reject Tray and pull out the card stop Start SCANtest 6 Select Test 9 Select Corrected Light Profile Press Execute 54 ASG MTM 001 031128 Insert Camera Adjustment Card Press Camera Adjustment Select Detail View Scan Width If necessary the position of the card may be adjusted by pressing either the Forward or the Reverse Stop key Loosen the Focus Lock Screw the CCD Focus Alignment Lever the Camera Backpiece fixing screws and the CBG Board fixing screws just enough to allow the Camera Backpiece and the board to be moved Slide the Camera Backpiece back and forth to get total sum of 14 Scan Width Units 0 5 Scan Width Unit at the start and the end of the scanline The tolerance corresponds to a scaling error of approximately 0 1 Because of the i
34. toothed wheel on the Gear Exit Shaft below chassis Pull off the toothed wheel Lift up the Gear Carriage be aware of the spring mounted on the left side of the Gear Carriage To replace the Gear Carriage reverse the order of removal 86 ASG MTM 001 031128 Alignment Bushing Gear Exit Shaft with Guide Pin Gear Solenoids Stepper Motor Rubber Bushings Gear Carriage Gear Carriage Feeding dm Scanning Fig 8 5 Stepper Motor and Gear Assembly 87 ASG MTM 001 031128 8 12 Driving and Rollers See Fig 8 8 page 93 To replace the driving belt it is necessary to remove and reinstall Seven roller shafts e Seven sets of roller bearings Feeder Clutch Assembly Two Toothed Wheels Feeder Clutch This task requires skilled service personnel trained to work with complex mechanical constructions and it is not considered to be a normal service task Generally it is recommended to send the scanner to Contex for replacement of Belts and Rollers please contact Contex Support to get a RMA number 8 13 Separator Unit and Friction Pad See Fig 8 7 page 92 To remove the Separator Unit Remove the Scanner Cabinet Remove the four fixing screws for the Separator Unit see Fig 8 7 page 92 Pull out the Separator Unit To replace the Friction Pad Remove the old Friction Pad from the Pressure Arm Clean the surface of the Pressure Arm thorou
35. 0 and ACS 4200 AOG PLS 002 031120 Description Part Number ACS 4600 ACS 4100 ACS 4200 2 Spare Parts List PCBs MSCA Step Motor Controller 6634D001 OIBA Optical Interrupter Board 6336A001 CBGA CCD Camera Board incl ILX508 6630D001 SUCE Scanner Control Board 6732D005 PCRA Punched Card Reader Board 6632A001 OPBB Operator Panel Board 6636A002 IMCA Interface Module 6631D001 SCR Smart Card Reader assembly 6653D102 Switch Mode Power Supply adjusted 0080A058R01 X Electrical Parts Lamp Socket w wires and mounting screws 66330111 Halogen Lamp 12 20W 0075D014 Stepper Motor with gear wheel 66630101 Rubber Bushing for Stepper Motor 6629A264 Collar Bushing for 6629A264 6629A266 Cooling Fan 6633D119 Feeder Solenoid Assembly 66330115 Gear Solenoid Dual Assembly 6633D112 PVC Cable Fixture Sheet 6653A207 Self locking 3M Nut for 6653A207 3029A238 Cable Ties 0002E009 Self Adhesive Cable Clips 6 mm 0002E032 Self Adhesive Cable Clips 9 mm 0002E026 Safety Interlock Switch 0007E172 Bin Full Switch 0007E182 Reject Tray Switch 0007E183 Input and Feeder Sensor Optointerrupter 0075A024 CCD Sensor ILX508 0075A023 Spacer for CCD Sensor 6635A201 Insulation for SMPS 6738A201 Power Entry Module 6738A122 RFI Filter 0077E038
36. 00000000000000001000000000 26 DC VOUS ES t 26 2272 tense toot 26 353 FEunclond lTest AMT Me D 26 BaD MEN I IIR 26 3 43 Jumper SEWUINGS oce ta e oe e e de 26 BIOS TAINS RR Po 26 3 8 CHECK OF PUNCHED CARD READER BOARD 29 ASG MTM 001 031128 e a 29 3 8 2 Check Phototransistor Outputs 29 383 ae 29 FOA Dae EAD re te te tle uh 29 3 9 CHECK OF OPERATOR PANEL 32 SOD Voltages ota og ee ie eon t dete e eer e 32 3 0 2 Eunctional e tei eee 32 3 93 eee t eee onte 32 32947 teste 32 3 10 CHECK OESMART CARD READER SCR 35 3 10 1 ea deine it 35 3 10 2 UN CHONQL LOS tae ati tetra as dette
37. 128 3 3 7 Hints 3 3 V is used as supply for the SUC CBG IMC and OPB Boards 5 3 V is used as supply for MSC CBG SUC and IMC Boards 12 V is used as supply for the MSC and CBG Board and on the MSC Board for the Fan and Lamp drivers 24 V is used on the MSC Board for the Stepper Motor and Solenoid drivers 14 SI SVR2 3 3V Adjust 6 8 3 3V40 1 __ CN3 1 5 GND gt 5 3V 0 0 1 CN2 2 12V 0 5 CN2 1 24V 1 2 3 5 Mains Input SVR1 see 3 3 3 Connector 5 3V Adjust Fuse see 3 3 4 Fig 3 1 SMPS Test Points 821160 TOO NLW OSY ASG MTM 001 031128 3 4 Check Adjustment of Motor Driver Board MSC All test points referred to below are shown in Fig 3 2 page 17 All DC voltages are measured relative to Test Point GND MSC Block Diagram is shown in Fig 3 3 page 18 3 41 DC Voltages Ref on Fig 3 2 DC Voltage J2 and pin2 0 GND 5 0 V 0 5 V 3 4 2 Stepper Motor Reference Voltages The stepper motor must be stopped for adjustment of the reference voltages Adjust P3 until the voltage on TP6 reads 10 mV 10 mV Adjust P4 until the voltage on TP4 reads 10 mV 10 mV 3 4 3 Functional Test SCANtest 6 Test 5 Lamp Test Test 6 Motor Test 3 4 4 Markings ACS 4600 MSCAdd where dd board revision number 3 4 5 Jumper Settings No
38. Aperture Card Scanner Technical Service Manual ACS 4600 ASG TSM OO1 1 0 Part Number 6699D107 1 DOCUMENT REVISION RECORD 2 LIST OF DOCUMENTS ASG MAINTENANCE MANUAL 3 ACS 4600 SPARE PARTS AND SERVICE ACCESSORIES 9 ACS 4600 1 0 TECHNICAL SERVICE BULLETINS ASG TSM 001 CO ntex Document Revision Record SCANNING TECHNOLOGY CHANGED PAGES DATE AFFECTED BRIEF DESCRIPTION OF CHANGE 031128 BN LM Original issue of document ASG TSM 001 031128 List of Documents 50 001 1 0 ASG Maintenance Manual ACS 4600 AOG PLS 002 1 1 Spare Parts and Service Accessories ACS 4600 TITLE DOC NO PREPARED BY AUTHORIZED DISTRIBUTION ISSUE REVISION DATE AGS MAINTENANCE MANUAL ACS 4600 ASG MTM 001 BN LM JR Tegningsarkiv Svendborg PT Svendborg DD 1 1 1 1 0 2003 11 28 This document is the property of Contex A S The data contained herein in whole or part may not be duplicated used or disclosed outside the Recipient for any purpose other than to conduct technical evaluation This restriction does not limit the Recipients right to use information contained in the data if it is obtained from another source without restriction ASG MTM 001 CO ntex Document Revision Record SCANNING TECHNOLOGY CHANGED PAGES DATE AFFECTED BRIEF DESCRIPTION OF CHANGE 031128 BN LM Original Issue of Document ASG MTM 001 031128 Table of Contents 1481 0 BIGURES
39. B Board Remove the Scanner Cabinet Remove the Front End Base Cover Remove the Bottom Plate Lay the scanner on the swing out chassis side Disconnect the cable from the OIB Board Remove the spring from the Sensor Shutter Remove the two fixing screws holding the mounting bracket for the OIB Board Pull out the mounting bracket and remove the OIB Board Remove the OIB Board from the bracket When replacing the OIB Board see Fig 8 4 page 81 for correct placement on the bracket To replace the OIB Board with mounting bracket reverse the order of removal To get access to the lock screw of the Sensor Arm the shaft with Sensor Arm has to be dismounted see Fig 8 3 Remove the top plate of the Input Hopper Remove the upper right Card Guide of the Input Hopper Remove the two stays Loosen the lock screw of the Sensor Shutter and pull off the Sensor Shutter use 0 9 mm Allen Key Pull out the shaft with the Sensor Arm To reinstall the shaft with Sensor Arm reverse the order of removal 79 ASG MTM 001 031128 Upper Right Card Guide Top P late for Input Hopper Special Stay Stay Lower Right Card Guide Lock Screw Sensor Shutter Spring OIB Board Fig 8 3 Input Sensor Assembly 80 ASG MTM 001 031128 16 8 0 2 Fig 8 4 OIB Board with Bracket 81 ASG MTM 001 031128 Feeder Sensor See F
40. OCK DIAGRAM tton 31 FIG 3 12 OPB COMPONENT 33 FI amp 3 13 OPR DIAGRAM 34 FIG 3 14 SCR COMPONENT LAYOUT 36 PUG 3215 SCR A 37 FIG 3 16 COMPONENT LAYOUT tette tentent tte tte tte tte tte tette od 39 FIG 3 17 ADJUSTMENT OF THE INPUT 04 4 4 441410 41 FIG 3 18 ADJUSTMENT OF THE BIN FULL SENSOR 44 FIG 3 19 ADJUSTMENT OF THE REJECT TRAY 5 46 ACS OPTICAL SYSTEM sects i Dix rne e 48 CCD CAMERA 49 FIG 4 3 ACS 4600 LIGHT PROFILE 1424 4 4 41441 1 14000 52 FIG 4 4 ASC 4600 LIGHT PROFILE CORRECTED 52 FIG 4 5 ACS 4600 FOCUS SIGNAL AND SCAN WIDTH 56 FIG 4 6 ACS 4600 CCD CENTERING AND CCD TILT 60 FIG 4 7 CAMERA ADJUSTMENT 61 FIG 4 8 DETAILS OF ADJUSTMENT PATTERNS ccccccccssssssscssscssecssecesesssesssesssevarevsserssevssevssevsrerenevenes 62 FIG 8 1 PCR APERTURE PLATE cccccssccsscesscesscsscesscesssesscesscesscesssusscessnessnesanesanevanevanesanevarearesanecssesanesenes 76 RATE
41. ON when an aperture card is inserted observe that the Wait LED turns OFF as the card moves on and leaves the Input Sensor 40 ASG MTM 001 031128 Parts below Parts above Chassis Chassis Stop Bracket Card Pressure Sensor Shutter Plate Spring Lock Screw for Sensor Shutter Fig 3 17 Adjustment of the Input Sensor 41 ASG MTM 001 031128 3 12 2 Check of Feeder Sensor The Feeder Sensor consists of an optointerrupter placed above the path of the card just before the Scanning Platen The optointerrupter is directly activated by the upper edge of the aperture card The Feeder Sensor cannot be adjusted Functional Test of the Feeder Sensor SCANtest 6 Test 4 Original Sensor Test The Reject Tray must be closed for the test to work The Ready LED green on the Operator Panel turns ON when the aperture card enters to the Feeder Sensor and it turns OFF when the card leaves the Feeder Sensor 3 12 3 Check of Edge Detector The Edge Detector consists of Phototransistor PT13 of the PCR Board The Edge Detector is activated by the aperture card covering the aperture of PT13 The Edge Detector cannot be adjusted Functional Test of the Edge Detector SCANtest 6 Test 4 Original Sensor Test The Reject Tray must be closed for th
42. Scanner to Test Mode Purpose To switch the scanner back to Test Mode Useful if the scanner gets out of Test Mode e g if it has to be turned OFF ON during troubleshooting 9 1 9 Test 21 SCANdump Purpose To create a file SCANdump con which contains Light Profiles and other scanner data for diagnostics purposes Description The file SCANdump con will be placed in the directory pointed to by the SET TEMP environment variable The files contained in SCANdump con may be unpacked by SCANview 6 by double clicking on SCANdump con The unpacked Light Profiles may be viewed by SCANview 6 If other files are included use an appropriate reader or viewer 98 ASG MTM 001 031128 10 Wiring Diagrams ACS 4600 Primary Wiring Diagram Fig 10 1 100 ACS 4600 Secondary Wiring Diagram Fig 10 2 page 101 99 001 SMPS N 4 2 Fig 10 1 ACS 4600 Primary Wiring Diagram 821160 5 0 INTERLOCK SWITCH 15
43. To remove Front End Base Cover e Open the Front End Cover e Remove six countersunk fixing screws along the front edge of the scanner chassis e Slide off the Front End Base Cover To replace the Front End Base Cover reverse the order of removal 7 3 Bottom Plate To remove Bottom Plate Remove the Scanner Cabinet Remove the Front End Base Cover e Lay the scanner on the swing out chassis side e Remove the fixing screws and lift off the Bottom Plate 12 ASG MTM 001 031128 replace the Bottom Plate reverse the order of removal 7 4 Front End Cover To remove Front End Cover e Remove Front End Base Cover e Remove the two fitted screws used as pivots for the Front End Cover Note that on both of the pivot screws there are two washers placed inside the hinge plates of the Front End Cover To replace the Front End Cover reverse the order of removal 7 5 Power Supply Assembly See Fig 8 9 page 94 The Power Supply Assembly consists of Power Inlet RFI Filter SMPS MSC Board Fan To get access to RFI Filter and power inlet e Remove the Scanner Cabinet e Remove the Front End Base Cover e Remove the Bottom Plate e Remove the five fixing screw for Power Supply Assembly from top side e Remove the five fixing screw for Power Supply Assembly from bottom side e Disconnect all cables except those from RFI Filter and fan Note cable positions for correct reinstallation e Carefully slide the Power Sup
44. acement of SUC Board As all scanner parameters are stored in the Flash Memory on the SUC Board the following steps should be carried out after replacement of the SUC Board e Download Firmware e Run Scanner Maintenance ASG MTM 001 031128 Enter Serial Number of scanner into Flash Memory SCANtest 6 Test 1 The serial number of the scanner is found on the marking label on back of the scanner 23
45. agnostic LEDs OFF 43 ASG MTM 001 031128 Reject Bin Full _ Switch Fixing Screws Cover Plate Fig 3 18 Adjustment of the Bin Full Sensor 44 ASG MTM 001 031128 3 13 2 Check and Adjustment of Reject Tray Sensor The Reject Tray Sensor is shown in Fig 3 19 page 46 The Reject Tray Sensor consists of a micro switch mounted below the bottom of the Reject Bin The Reject Bin Tray activates the micro switch when it is opened fully To adjust the Reject Tray Sensor Remove the Top Cover Remove the Front End Base Cover Remove the L shaped cover plate on the right side of the Reject Bin 2 pcs 4 mm 3 pcs 2 5 mm and 1 pcs 3 mm screws see Fig 3 18 page 44 Loosen the fixing screws of the micro switch Open the Reject Tray fully Move the micro switch towards the tray to the lever is pressed in Check that the switch is activated an audible click is heard when the Reject Tray is closed as well as opened Functional Test of the Reject Tray Sensor SCANtest 6 Test 4 Original Sensor Test Bin Full Sensor must be released for the test to work Reject Tray fully open All LEDs ON Reject Tray not fully open Wait Ready and Diagnostic LEDs OFF 45 5 001 031128 9 0
46. and Adjustment of 58 5 _ GENERAL 50 oko oa oua DN oe va ene cons eua vea eae ENS oono TEKEE el ee ob sepa 63 6 TROUBLESHOOTING 64 6 1 POWER ON SBEBST ES niii eive PET odes 64 6 2 LED INDICATORS ON OPERATOR 244 2 042 00000000000 00000000 000000000000444508 64 6 3 ERROR CODES even nee RE P HER 65 6 3 1 Error Codes displayed on the Operator Panel sse 65 6 3 2 Error Codes displayed on the PC Screen sese eene 65 6 4 TROUBLESHOOTING HINTS si 69 6 5 HOLLERITH CODE READING PROBLEMS 22211 2 24 000001 0600000000000000 0008000000000000 71 7 DISASSEMBLY AND ASSEMBLY 72 74 SCANNER CABINET M 72 7 2 FRONT END BASE COVER HERE OSEE QE S 72 7 3 BOTTOM 72 7 4 ERONT END COVER 73 7 9 POWER SUPPLY ASSEMBLY enrarir o sete see obe 73 8 REPLACEMENT OF PARTES sete ees eon eut eoe ee 74 8 1 PRINTED CIRCUIT BOARDS eee 74 8 2 PCR BO ARD3 duce ee ER GO ERR ER RR RITE NEG TETTE 74 8 3 PCR APERTURE PLATE 75 8 4 TEFLON TAPE ON SCANNING PLATEN
47. ator Panel Description Each key on the Operator Panel will turn a LED ON when pressed Ready Green Reverse Stop Wait Yellow 9 1 4 Test 4 Original Sensor Test Purpose 1 To check the Card Sensors Reject Tray must be closed 2 To check the Reject Bin Sensors Description 96 ASG MTM 001 031128 1 Card Sensors Close the Reject Tray and insert an aperture card Press the Forward Key to feed the card through the card path and as it activates the Card Sensors the following LED indicators on the Operators Panel are turn ON OFF Wait Yellow Ready Green Edge Detector Diagnostic Red 2 Reject Bin Sensors The Reject Tray Sensor turns the Wait Ready and Diagnostic LED ON when it is fully opened When activated the Bin Full Sensor turns the Wait Ready and Diagnostic LEDs that were all turned ON by the Reject Tray Sensor OFF 9 1 5 Test 5 Lamp Test Purpose To test the Lamp and associated electronics Description A message on the screen will inform whether the Lamp is turned ON or OFF Lamp power is turned ON OFF and whether the Light is ON OFF Light is detected or not The Lamp is delayed approx 2 seconds when switched ON Note The cooling fan is turned ON OFF with the Lamp 9 1 6 Test 6 Motor Test Purpose To test the Stepper Motor and associated electronics Description From the menu the motor speed and the direction of rotation can be selected and the Gear and Feeder Solenoids m
48. ay be activated by marking the respective check boxes Check box Checked Not checked Feeder Solenoid activated Feeder Solenoid not activated Feeder Feed and Separator Roller Feed and Separator Roller turns stopped Gear Solenoids activated Gear Solenoids not activated Gear Scanning Rollers turn fast Scanning and Reject rollers turn slowly All solenoids activated Solenoids not activated Both All rollers turn fast Scanning and Reject rollers turn slowly 9 1 7 Test 9 Camera Adjustment Purpose To support CCD Camera adjustments Description Test 9 contains a Software Oscilloscope for check and adjustment of the cameras The following functions can be selected 97 ASG MTM 001 031128 Positioning Adjustment Card for Camera Adjustment D Positioning Adjustment Card for adjustment of CCD Tilt 5 Uncorrected or Corrected Light Profile Special Detail Views for Light Profile Scan Width and Vertical Positioning 2 Load Unoad Save screen images Print screen images Load saved images necessary the position of the card be adjusted by pressing either the Forward the Reverse Stop key content of Detail Views is marked on the upper overview window by red vertical lines The continuous lines refer to the left Detail View and the dashed lines to the right Detail View Note Open Reject Tray before inserting the Adjustment Card 9 1 8 Test 13 Switch
49. be moved Adjust the CCD Tilt Lever to get the same number of Black Lines of the CCD Tilt Pattern at either end of the scanline Adjustment Tolerance Max 2 Black Lines in difference between the start and the end of the scanline 58 ASG MTM 001 031128 Tighten the fixing screws Interaction Check Scan Width and CCD Centering readjust if necessary 59 ASG MTM 001 031128 Software Oscilloscope Card Position Camera Adjustment CCD Tilt Zoom All Light Profile Uncorrected Corrected Execute m Detail View Normal Light Profile Scan Width ACS Special Load Card Unload Card V 7 SWU same number of lines 7 SWU start end CCD Centerin CCD Centering CCD Tilt 9 Fig 4 6 ACS 4600 CCD Centering and CCD Tilt 60 19 Marker for Focus Pattem Marker for CCD Tilt Pattem 2 INSERT THIS END FOR ADJ USTMENT CAMERA ADJ USTMENT CARD P N 6699A111 THIS EDGE DOWNWARDS FOR ADJ U stent View Emulsion side of film Focus Pattem CCD Tilt Pattem Scan Width Pattem DSP Test Pattem Fig 4 7 Camera Adjustment Card 821160 I100 IN LLIN DSV 9 Detail 222222 _ 12 7 opaque 22222222 ioe re i ZA 7 um transparen Detail C 210 opaque 40 um transparent B
50. d remain in the place To replace the PCR Board reverse the order of removal 8 3 PCR Aperture Plate See Fig 8 1 page 76 To remove the PCR Aperture Plate Remove the PCR Board Push the flaps on the left side of the Aperture Plate into the scanner Push the Aperture Plate into the scanner and remove it To replace the Aperture Plate reverse the order of removal Reinstall the PCR Board 75 ASG MTM 001 031128 E Fitted Screws Fixture Screw Fitted Screw Flap Fitted Screw Fixture Screw Fig 8 1 PCR Aperture Plate 76 ASG MTM 001 031128 8 4 Teflon Tape on Scanning Platen See Fig 8 2 page 78 To replace the Teflon Tape on the Scanning Platen Remove the Scanning Platen Pull off the old tape Use a damp soft cloth and a mild detergent for cleaning of the Scanning Platen Apply the new tape and place it as shown on Fig 8 2 page 78 Note Alcohol solvents or other cleansers must not be used for cleaning of the Scanning Platen 77 ASG MTM 001 031128 Use damp soft cloth and a mild detergent for cleaning Alcohol solvents or other cleansers must not be used Teflon Tape Fig 8 2 Scanning Platen 78 ASG MTM 001 031128 8 5 Sensors Input Sensor The Input Sensor is shown in Fig 8 3 page 80 and consists of Optointerrupter Board OIB Sensor Shutter below chassis Sensor Arm above chassis To remove the OI
51. d to the scanner through the IEEE 1394 or USB interface please see readme txt on the firmware disk for download instructions The download program CtxPrgm exe is started by double clicking the self extracting firmware exe file The download program reads the Download Control Switches SW1 and SW2 on the SUC Board to check if the actual firmware and the SUC hardware are compatible The Download Control Switches are factory set and the setting must not be changed If the scanner does not go into Boot Mode when the download program is started the scanner can be forced into Boot Mode by turning it OFF setting SW7 on the SCSI ID Switch to ON see page 35 and turn the scanner back ON The scanner will now be in Boot Mode and new firmware be downloaded as described above When the new firmware has been successfully downloaded turn the scanner OFF set SW7 back to OFF and turn the scanner ON for normal operation 3 2 1 Erase and Restore Parameter Blocks The following two options may be found on the pull down menu by right clicking at the CtxPrgm icon in the title bar of the CtxPrgm window e Erase Parameter Blocks e Restore Parameter Blocks Erase Parameter Blocks erases the Parameter Blocks Basic Calibration in Flash Memory on the SUC Board and save these in the file backup pmb located in the directory pointed to by the SET TEMP environment variable The file backup pmb may be useful for diagnostic purposes
52. e glass 102 TITLE SPARE PARTS AND SERVICE ACCESSORIES ACS 4600 DOC NO AOG PLS 002 PREPARED BN AUTHORIZED JR DISTRIBUTION Tegningsarkiv Svendborg 1 PT Svendborg 1 DD 1 ISSUE REVISION 1 1 DATE 2003 11 20 This document is the property of Contex A S The data contained herein in whole or in part may not be duplicated used or disclosed outside the Recipient for any purpose other than to conduct technical evaluation This restriction does not limit the Recipients right to use information contained in the data if it is obtained from another source without restriction AOG PLS 002 CO ntex Document Revision Record SCANNING TECHNOLOGY CHANGED PAGES DATE AFFECTED BRIEF DESCRIPTION OF CHANGE 1 0 031001 BN All Original Issue of Document 1 1 031120 BN All Correction of description 6634D001 gt MSCA 6633D112 gt Gear Solenoid 0007E182 Bin Full Switch 0007E183 gt Reject Tray Switch AOG PLS 002 031120 Table of Contents 1 Introduction 2 Spare Parts List 3 Service Accessories 1 Introduction This document contains the Spare Parts and Service Accessories for the Aperture Card Scanner model GA66D ACS 4600 ACS 4600 PLUS Note The columns marked ACS 4100 and ACS 4200 have been included for your convenience to show which parts are common for the new ACS 4600 and the old ACS 4100 ACS 4200 The original part list MCO PLS003 still applies for ACS 410
53. e test to work The Diagnostic LED red on the Operator Panel turns ON when the aperture card covers the aperture of PT13 and that it turns OFF when the card no longer covers 1 3 13 Check Adjustment of Reject Sensors The Reject Bin Sensors were not mounted in early versions of the ACS 4600 scanners with serial numbers lower than GA66D3C001Q 3 13 1 Check and Adjustment of Bin Full Sensor The parts of the Bin Full Sensor are Micro Switch Actuator are shown in Fig 3 18 page 44 The Bin Full Sensor consists of a micro switch and an actuator mounted on either side of the left wall of the Reject Bin When the Reject Bin is filled up with rejected aperture cards the actuator is moved towards the left wall of the bin and the switch is activated To adjust the Bin Full Sensor 42 ASG MTM 001 031128 Remove the Top Cover Remove the MCA Board Loosen the fixing screws of the micro switch With the actuator in the not activated position move the micro switch to the lever just touches the actuator Check that the switch is activated an audible click is heard when the actuator is goes from released to fully activated position as well as from fully activated back to released position Functional Test of the Bin Full Sensor SCANtest 6 Test 4 Original Sensor Test Reject Tray must be open for the test to work Bin Full activator released All LEDs ON Bin Full activator activated Wait Ready and Di
54. f the Exit Guide Remove the two fixing screws for the Feeder Solenoid Remove the solenoid the plunger should remain connected to the Clutch Assembly To replace the Feeder Solenoid reverse the order of removal 8 9 Gear Solenoid See Fig 8 7 page 92 To remove the Gear Solenoid Remove the Scanner Cabinet Remove the Front End Base Cover Remove the Bottom Plate Remove the Scanning Platen Remove the Pressure Arm for Scanning Platen Lay the scanner on the swing out chassis side Remove the Cable Fixture Sheet Remove the two bottom side fixing screws for the Gear Solenoid one is partly covered by a toothed wheel Remove the two top side fixing screws for the Gear Solenoid note that the top side fixing screws are shorter than the bottom side fixing screws When replacing the short screws must be used on the top side of the Gear Solenoid the longer screws will damage the coil of the upper solenoid Remove the bracket with the two solenoids 84 ASG MTM 001 031128 Remove the solenoids the two plungers should remain connected to the Gear Carriage To replace the Gear Solenoids reverse the order of removal After replacement check that the Gear Carriage is free to move 8 10 Stepper Motor See Fig 8 5 page 87 To ensure that the gear functions correctly the upper toothed wheels of the Gear Carriage must always engage with the toothed wheels of the motor before the lower toothed wheels of the Gear Carria
55. g 4 7 page 61 and the Detailed Adjustment Patterns Focus Pattern Scan Width Pattern CCD Tilt Pattern are shown in Fig 4 8 page 62 Because the magnification of the CCD Camera is relatively small approx 55 32 the interaction between Focus adjustment and Scan Width adjustment is very strong and it is necessary alternately to adjust Focus and Scan Width until they both are correct 4 2 1 Check of Light Profiles Images of the Light Profiles are shown in Fig 4 3 ACS 4600 Light Profile Uncorrected page 52 Fig 4 4 ASC 4600 Light Profile Corrected page 52 Procedure for check of Light Profiles Start SCANtest 6 Select Test 9 Select Uncorrected or Corrected Light Profile 50 ASG MTM 001 031128 Press Execute Select Detail View Light Profile Compare the image of the Software Oscilloscope with the relevant sample image listed above If the signal levels of the uncorrected Light Profiles differ much from the sample images the scanner might need to be calibrated by Scanner Maintenance Hints If the Light Profile is sloping much from one end of the scanline to the other it may be possible to reduce the sloping by turning the lamp 180 in its socket CAUTION Turn the lamp OFF use the Safety Switch before opening the Lamp Cover Be aware that the lamp may be very hot and may cause skin injury if touched with the bare hand 51 ASG MTM 001 031128 Software Oscilloscope x r Card Position Camera Adj
56. ge engage with the toothed wheel on the Gear Exit Shaft Because the height of the teeth on of the upper toothed wheel on the Gear Exit Shaft is slightly less than standard size the teeth of all the other toothed wheels are standard size this requirement is fulfilled by aligning the shaft of the stepper motor with the Gear Exit Shaft The alignment is obtained by mating a guide pin at the upper end of the Gear Exit Shaft with an alignment bushing at the center of the toothed wheel on the motor shaft To remove the Stepper Motor Remove the Scanner Cabinet Remove the Front End Base Cover Remove the Bottom Plate Remove the Scanning Platen To make the access to the motor fixing screws and later the removal of the motor easier the upper right Card Guide of the Input Hopper should be removed See Fig 8 3 page 80 Remove the top plate of the Input Hopper Remove the upper right Card Guide of the Input Hopper Remove the four motor fixing screws nuts Lay the scanner on the swing out chassis side Remove the Cable Fixture Sheet Pull out the motor and motor cable To replace the Stepper Motor reverse the order of removal 85 ASG MTM 001 031128 8 11 remove the Gear Carriage Remove the Stepper Motor Remove the Gear Solenoid Remove the circlips and washers that are mounted on three of the four motor stays note sequence of removal for correct reinstallation Loosen the lock screw of the
57. ghly Remove the protection film from the self adhesive surface of the Friction Pad Place the Friction Pad on the Pressure Arm exactly as shown in Fig 8 6 page 89 To replace the Separator Unit reverse the order of removal 88 ASG MTM 001 031128 The surface of the Friction Pad should flush with or be above this edge of the Presure Arm The surface of the Friction Pad should flush with or be below this edge of the Presure Arm Friction Pad Pressure Arm Fig 8 6 Pressure Arm with Friction Pad 89 ASG MTM 001 031128 8 14 Remove the top plate of Input Hopper Remove the upper right Card Guide Loosen the two stays and remove the stay closest to the Input Tray Remove the Input Tray To replace the Input Tray reverse the order of removal Exit Tray Remove the upper right Exit Card Guide Loosen the two stays Remove the stay closest to the Exit Tray Remove the Exit Tray To replace the Exit Tray reverse the order of removal Reject Tray Loosen the fixing screw of the left lower Card Guide 3 mm hexagonal head screw at bottom plate Turn the Card Guide to release the Reject Tray To replace the Reject Tray reverse the order of removal 8 15 Lamp and Lamp Socket Lamp Open the Lamp Cover Pull out the Lamp when replacing be careful not to touch the reflecting surface of the Lamp CAUTION Turn the lamp OFF use the Safety Switch before o
58. he OIB Component Layout is shown in Fig 3 16 page 39 3111 Functional Test SCANtest 6 Test 4 Original Sensor Test The Reject Tray must be closed for the test to work OIBA activates Wait LED Input Sensor 3 11 2 Markings ACS 4600 OIBA d d where dd board revision number 38 5 001 031128 Je Fig 3 16 Component Layout 39 ASG MTM 001 031128 3 12 Check and Adjustment of Card Sensors 3 12 1 Check and Adjustment of Input Sensor The parts of the Input Sensor are Optointerrupter Board Sensor Shutter below chassis Sensor Arm above chassis are shown in Fig 3 17 page 41 see also Fig 8 3 page 80 The Sensor Shutter and the Sensor Arm are mounted on a shaft going through a hole in the chassis When a card in the Input Hopper pushes the Sensor Arm it turns the shaft and moves the Sensor Shutter out of the optointerrupter To adjust the switch point of the Input Sensor Loosen the lock screw of the Input Sensor Shutter Press the Sensor Shutter against the Stop Bracket on the OIB Board below chassis and turn the Sensor Shaft until the tip of the Input Sensor Arm above chassis protrudes approx 0 5 mm from the Card Pressure Plate Tighten the lock screw of the Sensor Shutter Functional Test of the Input Sensor SCANtest 6 Test 4 Original Sensor Test The Reject Tray must be closed for the test to work The Wait LED yellow on the Operator Panel turns
59. heck and Adjustment of CCD Centering Images of the CCD Centering are shown in Fig 4 6 ACS 4600 CCD Centering and CCD Tilt page 60 The aim of this adjustment is to position the field of vision of the CCD symmetrically with respect to the microfilm image The field of vision is positioned correctly with respect to the microfilm image if the Black Lines and White Spaces of the Scan Width Pattern are distributed symmetrically with 7 Units 4 Black Lines and 3 White Spaces at either end of the scanline Adjustment Procedure Open the Reject Tray and pull out the card stop Start SCANtest 6 Select Test 9 Select Corrected Light Profile Press Execute Insert Camera Adjustment Card Press Camera Adjustment Select Detail View Scan Width If necessary the position of the card may be adjusted by pressing either the Forward or the Reverse Stop key Loosen the CBG Board fixing screws just enough to allow the board to be moved Adjust the CCD Centering Lever to distribute the Black Lines and White Spaces symmetrically with 7 Scan Width Units 4 Black Lines and 3 White Spaces at either end of the scanline The distribution of Black Lines depends on how accurately the card is guided when it is being moved forward to the scanning position as well as on tolerances on the Adjustment Card itself Some variation is therefore to be expected if the scanning is repeated using either the same or another Adjustment Card In any case at least
60. ia a reduction gear driven by a stepper motor The gear ratio which is selected by the Gear Solenoid is 1 1 for card feeding and 9 1 for scanning The number of steps per scanline depends on the image resolution and the drawing reduction ratio and is controlled by the microcontroller on the SUC Board The Safety Interlock Switch for the Front End Cover disables the Stepper Motor driver circuit MSCA and turns the Lamp OFF via SUCE and signals the Cover Open condition to the SUC Board when the Front End Cover is open The computer Interface Module IMCA contains ASG MTM 001 031128 IEEE 1394 Controller FireWire USB Controller for IEEE 1394 interface respectively USB interface 01 OPERATOR LAMP INTERLOCK PANEL SWITCH GEAR SOLENOIDS REJECT BIN SENSORS FEEDER SOLENOID STEPPER MOTOR D 1394 E A SMPS SUCE 0 1394 SWITCH MODE STEPPER MOTOR POWER SUPPLY CONTROL BOARD SCANNER CONTROL BOARD a USB INTERFACE BOARD 100 240 VAC PRIMARY SECONDARY Fig 2 1 ACS 4600 Block Diagram 821160 5 ASG MTM 001 031128 3 Electrical Check and Adjustments Required Test Equipment Multimeter gt 10 Mohm PC with SCANtest 6 and Scanner Maintenance installed and USB and IEEE 1394 interface SCANtest 6 is described in Chapter 9 page 95 3 1
61. ig 8 7 page 92 The Feeder Sensor consists of an optointerrupter mounted on a plastic block The Feeder Sensor is placed in the path of the card just before the Scanning Platen To remove the optointerrupter Remove the Scanner Cabinet Remove the two screws holding the plastic block Do not over tighten the screws when reinstalling Pull out the plastic block and the optointerrupter Remove the optointerrupter from the plastic block To replace the optointerrupter reverse the order of removal 8 6 Reject Bin Sensors Bin Full Sensor The parts of the Bin Full Sensor are Micro Switch Actuator are shown in Fig 3 18 page 44 The Bin Full Sensor consists of a micro switch and an actuator mounted on either side of the left wall of the Reject Bin As the Reject Bin is filled up with rejected aperture cards the actuator is moved towards the left wall of the bin and eventually activates the switch To remove the Bin Full Sensor Remove the Top Cover Remove the MCA Board Disconnect the cable Remove the fixing screws and the fish plate mind the washers on the screws To replace the micro switch reverse the order of removal After replacement the sensor should be adjusted according to Sec 3 13 1 page 42 Reject Tray Sensor 82 ASG MTM 001 031128 The Reject Tray Sensor is shown in Fig 3 19 page 46 The Reject Tray Sensor consists of a micro switch mounted below the bottom of the Reject Bin When the Rejec
62. il ERROR 50 132 mrsErrorTbl missing entry ERROR 50 133 unknown rebootcommand CE Ea ERROR 50 191 mbPss creation failed ERROR 50 192 pss task creation ERROR 50 193 mbPsspending ERROR 50 194 pss event ERROR 50 195 stitch write failed ____ ERROR 50 196 pmb validation failed ERROR 50 197 pointer outofrange o O ERROR 50 198 unknown camera board ERROR 50 199 unknown SUx CCD combination Z ERROR 50 200 invalid timeout task ooo ERROR 50 201 invalid data length 1 ERROR 50 202 semPsp already owned by this SCSI unit ERROR 50 203 semPsp not released ERROR 50 204 new failed out of memory Z o y O ERROR 50 206 Light profile flash space overrun ERROR 50 207 pkb task creation failed C ERROR 50 210 mbPpw creation failed ERROR 50 211 pus task creation failed ERROR 50 212 mbPus creation failed o ERROR 50 213 pus event ERROR 50 214 psp task delete failed 00000 ERROR 60 82 IMx USB chip error ERROR 60 83 IMx wrong board version installed ERROR 60 85 IMx 1394 chip error 68 ASG MTM 001 031128 6 4 Troubleshooting Hints The scanner does not power up Check the power supply connections Check that all cable connectors are properly inserted into their sockets Check voltages on the SMPS Check the supply voltages on the MSC SUC CBG
63. ilable 65 ASG MTM 001 031128 If SCANtest 6 is started when the scanner is in Error condition it will display Error Code Number and a short description of the error The following error messages may be displayed Error Code and Description Refer to page ERROR 08 147 Invalid Scanner ID Switch setting 69 ERROR 08 149 Invalid Smart Card for this scanner type ERROR 08 208 Keyboard check failed ee el ERROR 30 240 Correction of Camera A failed ____69 ERROR 40 35 Camera not found ERROR 40 39 CBx Camera A AMP RAM error ERROR 40 43 CBx Camera A EVEN LINE RAM error ERROR 40 47 CBx Camera A ODD LINE RAM error ERROR 40 75 FPGA status error ERROR 40 76 CBx FPGA done error ERROR 40 84 Camera cables misplaced ERROR 40 134 Unable to Basic Calibrate ERROR 40 137 Unable to Calibrate Pixel Offset oe ee eed 2 1 2 1 224 ERROR 50 18 SUx Register2error ERROR 50 19 SUx Register3error ERROR 50 20 SUx Registererror ERROR 50 21 SUx Register 8 error ERROR 50 22 SUx register error ERROR 50 23 SUx 03 register error o ERROR 50 24 SUx 04 register error E ERROR 50 26 SUx 06 register error am 2 2 T T SS ERROR 50
64. imately 164 ohms Gear Solenoid above chassis J7 pos 1 and pos 3 approximately 82 ohms e Original Sensor Faults Check with SCANtest 6 Test 4 Original Sensor Test 6 5 Hollerith Code Reading Problems Check the output level of the phototransistors on the PCR Board see Section 3 8 page 29 e Clean the Aperture Plate of the Punched Card Reader Clean the Condensing Lens for the Punched Card Reader 71 ASG MTM 001 031128 7 Disassembly and Assembly CAUTION e Before removing the covers set the power switch to OFF and disconnect the power cord e Ifthe scanner is laid on one of its sides it should be placed on either a support plate or at the edge of the working table so that the scanner does not rest on the Front End Cover e When replacing the Scanner Cabinet be careful not to bend or damage the EMC contact springs that protrude from the Bottom Plate Also make sure that the Scanner Cabinet does not hit any cable connectors that protrude from the circuit boards and that no wires are caught by the Scanner Cabinet 7 1 Scanner Cabinet To remove Scanner Cabinet e Open the Front End Cover e Remove six fixing screws from the Front End of the Scanner Cabinet e Remove two fixing screws from the rear end of the Scanner Cabinet e Slide the Scanner Cabinet backwards until it is separated from the scanner chassis To replace the Scanner Cabinet reverse the order of removal 7 2 Front End Base Cover
65. itch Setting Scanner ID Switch Setting a a ove ove ve T An undefined switch setting may cause the Invalid Scanner ID Error Code to be displayed on the Operator Panel see Section 6 3 1 page 65 CAUTION The Scanner ID Switch setting is stored in the Flash Memory on the SUC Board Every time the scanner is switched ON it reads the switch setting and if it is different from the stored value the new setting will be stored and all other stored scanner parameters Basic Calibration will be cleared to default values This means that the scanner must be calibrated using Scanner Maintenance afterwards to restore the actual values 32 ASG MTM 001 031128 Power On Warm Up Forward Diagnostics A Ready Stop Reverse lt gt 0 0 4 0 0 4 0 0 0 0 0 0 9 J1 pin19 J1 pin15 5V GND 43 SW1 Fig 3 12 OPB Component Layout 33 5 001 031128 ON di b Eom H 8 Fig 3 13 OPB Block Diagram 34 ASG MTM 001 031128 3 10 Check of Smart Card Reader SCR All test points referred to below are shown in Fig 3 14 page 36 All DC voltages are measured relative to test point GND DIP Switch right side pins SCR Block Diagram is shown in Fig 3 15 page 37
66. jumpers 3 4 6 Hints Control signals on J9 pin2 Lamp ON OFF LOW ON 8 Feed Motor Step Pulse pin 11 Feed Motor Direction LOW REVERSE pin 15 Gear Solenoid LOW OFF pin 16 Feeder Solenoid LOW ON 16 GND 12V 1 0V 12 5 24V 1V 12 6 5 3V 0 0 2V 2 3 4 4 4 ASG MTM 001 031128 5V 0 5 1 oO 11171111 123 4 TP4 UUUUUUT UUUUUTIU 11110 C12 R3 7 TUUTTUUT 5 07 09 1013 TTTT 11111111 1014 11111 627 C10 8 DAE C26 R34 UTUTUTTTUT C33 846 R47 R51 R56 R52 731 8 1111
67. l cause of Error 30 69 ASG MTM 001 031128 Error 40 35 40 39 40 43 40 47 40 75 40 76 CBG Board Errors Check that the Lamp is lit Check that all cable connectors are properly seated into their sockets Check the supply voltages on the boards Replace CBG Board Error 40 134 to 40 138 40 170 40 174 40 182 40 186 CBG Board Errors Check that all cable connectors are properly seated into their sockets Check the supply voltages on the boards Check Light Profiles with SCANtest 6 Test 9 see Section 4 2 1 page 50 Erase Parameter Blocks see Section 3 2 1 page 12 Run Scanner Maintenance Replace Lamp Replace CBG Board Error 50 17 to 50 28 50 51 to 50 81 and 50 90 to 50 99 SUC Board Errors Check that all cable connectors are properly seated into their sockets Check the supply voltages on the SUC Board e Replace SUC Board e Run Scanner Maintenance Error 50 100 to 50 214 Firmware related errors Upgrade firmware e Erase Parameter Blocks see Section 3 2 1 page 12 Run Scanner Maintenance Error 60 2 to 60 34 60 82 60 83 IMC Board Errors e Check the supply voltages on the IMC Board e Replace IMC Board Original Feed Problems If the Stepper Motor does not run e Check supply voltage on the SMPS and MSC Board Section 3 3 page 13 and Section 3 4 page 16 Replace MSC Board Remove the Stepper Motor cable connector from 71 on the MSC Board and check the resistance of the
68. nteraction Focus must be readjusted every time the Camera Backpiece has been moved Tighten the fixing screws Interaction Check Focus CCD Centering and CCD Tilt and readjust if necessary When all camera adjustments have been completed run Scanner Maintenance Note The scanning accuracy in the direction of the scanline is determined by the distance between the CCD and the Scanning Platen the microfilm Scaling errors may be corrected by adjusting the position of the Backpiece and readjusting the Focus as follows If the scanned image is too small Move the Camera Backpiece away from the Lens decreasing the number of Black Lines of the Scan Width Pattern If the scanned image is too big Move the Camera Backpiece towards the Lens increasing the number of Black Lines of the Scan Width Pattern The Camera Backpiece should be displaced approx 0 7 mm per 1 error 55 ASG MTM 001 031128 Software Oscilloscope E nj x r Card Position Camera Adjustment CCD Tilt Zoom All Light Profile Uncorrected Corrected Execute Detail View Normal Light Profile Scan Width CCD Tilt SSS ACS Special Load Card Unload Card Save Print Exit Load jeference Image 181710 11 4 4 T 7 SWU 7 SWU Fig 4 5 ACS 4600 Focus Signal and Scan Width 56 ASG MTM 001 031128 4 2 4 C
69. ove the Scanning Platen Lay the scanner on the swing out chassis side Remove the Belt Tightener When replacing the belt tension should allow the belt to be moved approx 10 mm when pressed moderately by hand approx 500 g see Fig 8 8 page 93 Remove the fixing screw and the fitted screw below chassis for the Aperture Plate Remove the fitted screw for the Phototransistor Block 74 ASG MTM 001 031128 When replacing the fitted screws they should be reinstalled before the fixing screws careful not to over tighten either the fitted screws or the fixing screws Remove the five bottom side fixing screws for the Power Supply Assembly Place the scanner in normal standing position Remove the five top side fixing screws for the Power Supply Assembly Slide the Power Supply Assembly 3 to 5 cm backwards Disconnect all cable connectors from the PCR Board When replacing the flat cable from the Operator Panel must be connected to J2 the lower connector and the flat cable from the SUC Board to 71 the upper connector the PCR Board Remove the fixing screw and the fitted screw above chassis for the Aperture Plate Remove the two fitted screws for the Phototransistor Block Remove the two fixing nuts for the PCR Board When replacing the fixing nuts should not be tightened until after the fitted screws have been reinstalled Do not over tighten the fitted screws Pull out the PCR Board the Aperture Plate shoul
70. pening the Lamp Compartment Be aware that the lamp may be very hot and may cause skin injury if touched with the bare hand Note Replace only with original lamps Interaction After replacement of the Lamp run Scanner Maintenance 90 ASG MTM 001 031128 remove the Lamp Socket Remove the Scanner Cabinet Remove the Front End Base Cover Remove the Bottom Plate Open the Lamp Cover and remove the Lamp Remove the Lamp Socket Lay the scanner on the swing out chassis side Remove the Cable Fixture Sheet Pull out the cable and remove the Lamp Socket To replace the Lamp Socket reverse the order of removal 91 T6 Reject Roller Feeder Sensor Scanning Rollers 9 ECT TRAY 4 Fixing Screws for Separator Unit m Separator Unit Separator Roller 2 Feed Roller 2 P di Input Hopper Top Plate Upper Left Card Guide INPUT TRAY Scanning Platen Upper Right Card Guide Fig 8 7 ACS Front End Top View
71. ply Assembly backwards until it is off the scanner chassis To replace the Power Supply Assembly reverse the order of removal 73 ASG MTM 001 031128 8 Replacement of Parts CAUTION e Before removing the covers set the power switch to OFF and disconnect the power cord e Ifthe scanner is laid on one of its sides it should be placed on either a support plate or at the edge of the working table so that the scanner does not rest on the Front End Cover e When replacing the Scanner Cabinet be careful not to bend or damage the EMC contact springs that protrude from the Bottom Plate e Also make sure that the Scanner Cabinet does not hit any cable connectors that protrude from the circuit boards and that no wires are caught by the Scanner Cabinet 8 1 Printed Circuit Boards The locations of the printed circuit boards are shown in Fig 8 9 page 94 When removing printed circuit boards note wire colours and position for correct reinstallation When replacing a defective printed circuit board check that the revision no of the replacement board is the same or higher than the revision no of the defective board see Section 3 1 page 11 After replacement of a printed circuit board always check and adjust the board as described in Chapter 3 page 11 8 2 PCR Board See Fig 4 1 page 48 and Fig 8 1 page 76 To remove the PCR Board Remove the Scanner Cabinet Remove the Front End Base Cover Remove the Bottom Plate Rem
72. rected If necessary the position of the card may be adjusted by pressing either Forward or the Reverse Stop key Loosen the Focus Lock Screw the CCD Focus Alignment Lever the Camera Backpiece fixing screws and the CBG Board fixing screws just enough to allow the Camera Backpiece and the board to be moved Turn the Lens Adapter to get maximum amplitude of the Focus signal The amplitude of the Focus signal Corrected should be as even as possible across the full Scan Width and at the least with Min Max gt 0 7 If the amplitude of the Focus signal varies asymmetrically when focusing the lens the Focus Alignment lever should be adjusted to equalize the change of the signal amplitude at the start and the end of the focus image 53 ASG MTM 001 031128 If the dot on the Lens does not point in upwards direction after focusing indicating the best position of the Lens Mark the upward direction on the Lens Adapter Loosen the Focus Lock Screw Turn the Lens Adapter and loosen the Lens Fixing Screws Rotate the lens to align the dot with the upward mark on the Lens Adapter Tighten the Lens Fixing Screws do not over tighten Turn the Lens Adapter to readjust the Focus and tighten the Focus Lock Screw to secure the Focus setting Interaction The Focus adjustment has a big influence on the Scan Width adjustment Therefore the Scan Width must be checked and readjusted if necessary when the Focus adjustment
73. stment of Contex Wide Format Scanners SCANtest 6 for Win98 2000 Me NT4 0 is available from the Contex web site WWNW contex com When SCANtest 6 has been started the scanner is switched into Test Mode and the Diagnostic LED Indicator on the Operator Panel is turned ON Scanner Test Program Menu Test 1 Scanner Information Test 2 LED Test Test 3 Key Test Test 4 Original Sensor Test Test 5 Lamp Test Test 6 Motor Test Test 9 Camera Adjustment Test 13 Switch Scanner to Test Mode Test 21 Scan Dump If SCANtest 6 is started when the scanner is in Error Mode the Error Code Number and short description of the error will be displayed on the screen 95 ASG MTM 001 031128 9 1 Description of SCANtest 6 9 1 1 Test 1 Scanner Information Purpose To display scanner data and to enter or change the serial number of the scanner The serial number is stored in Flash memory on the SUC Board The following is displayed Scanner Model Firmware Release Firmware Release Date Firmware Build FPGA Revision FPGA Release Date Boot Code Revision Boot Code Release Date Scanner ID Switch SCSI ID Serial Number Lamp Light On Password to reset counter is 9 1 2 Test 2 LED Test Purpose To test the LED Indicators on the Operator Panel Description All LEDs are sequentially switched ON OFF until Test 2 is terminated 9 1 3 Test 3 Key Test Purpose To test the Keys on the Oper
74. t Bin Tray is fully opened it activates the micro switch To remove the Reject Tray Sensor Remove the Top Cover Remove the Front End Base Cover Remove the L shaped cover plate on the right side of the Reject Bin 2 pcs 4 mm 3 pcs 2 5 mm and 1 pcs 3 mm screws see Fig 3 18 page 44 Remove the fixing screws and the fish plate mind the washers on the screws To replace the micro switch reverse the order of removal After replacement the sensor should be adjusted according to Sec 3 13 2 page 45 8 7 Safety Interlock Switch See Fig 8 7 page 92 To remove the Safety Interlock Switch Remove the Scanner Cabinet Remove the Front End Base Cover Remove the Bottom Plate Lay the scanner on the swing out chassis side Remove the two fixing screws for the mounting case of the Safety Interlock Switch Disconnect the cable from the switch note wire colour and position for correct reinstallation Pull out the mounting case of the Safety Interlock Switch Open the mounting case and remove the Safety Interlock Switch To replace the Safety Interlock Switch reverse the order of removal 8 8 Feeder Solenoid See Fig 8 8 page 93 To remove the Feeder Solenoid 83 ASG MTM 001 031128 Remove the Scanner Cabinet Remove the Front End Base Cover Remove the Bottom Plate Remove the Scanning Platen Lay the scanner on the swing out chassis side Remove the Cable Fixture Sheet Remove the left Card Guides o
75. the cards Evaluate the general quality of the scanned image For special service tools for General Maintenance please refer to Chapter 11 page 102 63 ASG MTM 001 031128 6 Troubleshooting If contacting Contex for support always supply the following information Scanner Model Serial Number Firmware revision Description of the problem ScanDump of Light Profiles 6 1 Power On Self Test The following operations are executed when the scanner is switched ON Check Scanner ID Checks if the setting of the DIP switch on the Operator Panel is valid Check if Smart Card is valid for the scanner type All Indicators are ON Hardware Self Test Checks SUC IMC and CBG Boards All Indicators are ON Power Wait Indicators Power Wait Indicators are ON Light Profile Correction The Light Profile is Corrected at power on Power Error 30 and Wait Indicators are ON Thereafter the Light Profile is Corrected whenever the scanner is idle 6 2 LED Indicators on Operator Panel Power LED Green 22 2 Directly connected to 5V Always Green Diagnostic LED Red 0 Wait LED Yellow 10 64 ASG MTM 001 031128 Wait LED Yellow ee ___ Automatic update of Light Profile Correction has been Blinking suspended for a period exceeding the built in update Hint May also occur during intensive scanning in timer or the scanner has been switched ON
76. two windings of the Stepper Motor Winding 1 Green Green striped Winding2 Red Red striped The resistance should be approximately 5 ohms Replace Motor 70 ASG MTM 001 031128 If the Stepper Motor is overloaded high noise level original feed problems e Check supply voltage and the Stepper Motor Reference Voltages on the MSC Board Section 3 4 page 16 e Replace MSC Board If the motor runs without feeding the card or if the image is distorted too long e Check that the lock screws of the toothed wheels on the motor and in the Gear Assembly are all tightened Check that the toothed wheels in the Gear Assembly engage properly Mis feeds in batch mode e There is a small difference in the diameter of the upper roller and the lower roller on the feed roller shaft The Card Pressure Plate of the Input Hopper should be parallel with the shaft of the feed rollers Check if there is a small gap between the upper finger of the Card Pressure Plate and the upper roller when the lower finger rests on the lower roller If there is no gap try to bend the fingers a little to create a gap of approx 0 4 mm Check the Friction Pad of the Separator If the solenoids do not work Check supply voltages on the MSC Board Section 3 4 page 16 e Remove the Solenoid cable from its connector on the MSC Board and check the resistance of the coils Feeder Solenoid below chassis J8 1 and pos 2 approx
77. ures of the phototransistors are covered by an aperture card when measured with a high impedance gt 10 MOhm oscilloscope or multimeter 3 8 3 Functional Test SCANtest 6 Test 4 Original Sensor Test The Edge Detector turns the Diagnostic LED ON OFF 3 8 4 Markings ACS 4600 PCRAdd where dd board revision number 29 ASG MTM 001 031128 PTI 15 GND Edge Detector 202282281 6 S 5 20 S Ri 1000000000 S 5 1 4 R96 2 5 5V DInnnnrnnn IC1 pin20 oH R24 24 1000000000 E R60 11010000000 R55 E M R22 R21 R58 0000000000 1100000000 nuinnnnnnmnm 8 8 2 IC3 13
78. ustment CCD Tilt Zoom All m Light Profile Uncorrected O Execute C CCD Til ACS Special Load Card Unload Card Save Print Exit Load 4 21 4 In Heference Image Fig 4 3 ACS 4600 Light Profile Uncorrected Software Oscilloscope xl r Card Position Camera Adjustment CCD Tilt Zoom All Light Profile C Uncorrected Corrected r Detail View Normal 6 Light Profile C Scan Width C CCD Tilt ACS Special Load Card Unload Card Save Print Reference Image Fig 4 4 ACS 4600 Light Profile Corrected 52 ASG MTM 001 031128 4 2 2 Check and Adjustment of Focus Images of the Focus adjustments are shown in Fig 4 5 ACS 4600 Focus Signal and Scan Width page 56 Adjustment Procedure Always perform the Focus adjustment before adjusting the Scan Width see Interaction below Open the Reject Tray and pull out the card stop Start SCANtest 6 Select Test 9 Select Corrected Light Profile Press Execute Insert Camera Adjustment Card Press Camera Adjustment Select Detail View Light Profile If the camera is completely out of adjustment it may not be possible to run Test 9 in Corrected mode In that case select Uncor
79. with the batch mode or if a card is left in the card path during Original Guide Plate set for Extended Thickness power on Error Condition Diagnostic is blinking see Section Blinking 6 3 1 below Ready LED Green _ Wait No media Media inserted Scanning Error Condition Diagnostic is blinking see Section Blinking 6 3 1 below 6 3 Error Codes 6 3 1 Error Codes displayed on the Operator Panel A blinking Diagnostic Indicator indicates an error condition The error may be identified by an Error Code Number being displayed on the screen and or by the following combinations of blinking F indicators on the Operator Panel ort af Camera Aiit x8 0001 8 8 xs 3 98 3 58 8 seriis I x B 2x B means that the Wait and or the Ready Indicator blinks 1 2 times every time the Diagnostic Indicator is turned ON B B B means that all three indicators are blinking simultaneously 6 3 2 Error Codes displayed on the PC Screen The Safety Interlock Switch must be activated in order to run the Test Programs as well as to operate the Aperture Card Scanner with the Front End Cover open A special service tool Key for Safety Switch p n 6699A201 to override the Safety Switch is ava

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