colortrac s4e service manual-2

UK Office: Kings Hall St. Ives Business Park St. Ives Huntingdon Tel: +44 (0)1480 464618 Fax: +44 (0)1480 464620 Email: [email protected]

Web: http://www.colortrac.com

Colortrac is the Trading Name of Colortrac Ltd and Colortrac Inc incorporating Tangent and ANAtechColortrac Ltd Registered no. 2443087 in England. Registered Office: 115c Milton Road, Cambridge, UK

Colortrac Series 45480e, 4860e, 4280e,4260e, 3680e & 3640e

Service Manual

S4e Service Manual Revision 2.9

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Colortrac Series 4

5480e, 4860e, 4280e, 4260e, 3680e & 3640e

Service Manual

Revision 2.9

©Colortrac Ltd 2004

This document should not be copied withoutprior permission from:

Colortrac Ltd.Kings Hall,St. Ives Business Park,St. Ives,Huntingdon,Cambridgeshire,PE27 4WY.United Kingdom.

Tel: +44 (0)1480 464618Fax: +44 (0)1480 464620

www.colortrac.com

Colortrac Ltd makes no warranty with respect to this document and disclaims any implied warranties ofmerchantability or fitness for a particular purpose. Information in this document is subject to changewithout notice. Colortrac Ltd assumes no responsibility for errors that may appear in this document. Thisversion of service manual supersedes all previous versions of S4e service manuals.


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SECTION 1 – SERVICE MANUAL

Contents

1 INTRODUCTION 5

1.1 Models covered by this manual and tools required 5

1.2 Passwords 7

1.3 Details on how to contact Technical Support 7

2 SAFETY 8

2.1 Safety Warnings 8

3 SYSTEM DESCRIPTION 9

3.1 Scanning Principles 9

3.2 SCANNER ADJUSTMENTS 10

3.3 System Diagram 12

3.4 Camera Boards 13

3.5 Digital Board 14

3.6 Display Boards and Paper Sensors 15

3.7 Ballast Board and Light Sensors 16

3.8 Data Rates 16

3.9 Calibration Sequences 17

3.9.1 Auto-stitch & Manual Stitch 17

3.10 Arrangement of Mirrors and Cameras 19

4 CIRCUIT BOARDS 20

4.1 General Description 20

4.2 Power Supply 20

4.3 Power Supply Replacement 21

4.3.1 Power Supply Voltages 21

4.4 Digital Board 22

4.5 Digital Board Replacement 24

4.5.1 Digital Board Voltages 24

4.6 Ballast Board 25

4.7 Ballast Board Replacement 25


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4.8 Camera Replacement 26

4.9 New Camera Information 27

5 SCANNER ALIGNMENT 29

5.1 Field Service Alignment. 29

5.2 Focus 31

5.3 Magnification 32

5.4 String Alignment 33

5.4.1 Focus / Mag and alignment using PlotCorr Software 36

5.5 Factory Alignment Multi-Camera Models 41

5.6 Factory Alignment 1 Camera Models 45

5.7 Light Level Adjustment 47

5.8 Paper Sensor Setup 48

5.9 Motor Belt Replacement & Adjustment 50

5.9.1 Replacing Tubes 51

5.9.2 Replacing Rollers 52

5.9.3 Replacing Motor and cable 55

6 Firmware Download 56

6.1 Paper Guide Assembly Adjustment 57

6.2 Unpacking Scanner. 59

6.3 Current Software/Firmware Versions 60

6.4 Installation Flow Chart 61

6.5 Fitting Scanning Tape and Springs to PGA 62

6.6 Voltage Readings For the Digital Board 65

6.7 Warranty Procedures 66


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1 INTRODUCTION

1.1 Models covered by this manual

This manual contains information to assist in the repair and maintenance of theColortrac Series 4 Enhanced scanners from Colortrac.

It acts as a reference to service engineers who should already have been on therecommended training courses run by Colortrac, where they would have gained the fulltraining required to work on the Colortrac scanners.

There are 6 models:

Colortrac 5480eWhich has a total scan area of 54” wide x unlimited (by scanner) length.The 5480e has a total of three cameras with a dpi range of 50 to 2400 (interpolated).

Colortrac 4860eWhich has a total scan area of 48” wide x unlimited (by scanner) length.The 4860e has a total of two cameras with a dpi range of 50 to 1800 (interpolated).

Colortrac 4280eWhich has a total of scan area of 42” wide x unlimited (by scanner) length.The 4280e has a total of three cameras with a dpi range of 50 to 2400 (interpolated).

Colortrac 4260e Which has a total scan area of 42” wide x unlimited (by scanner) length.The 4260e has a total of two cameras with a dpi range of 50 to 1800 (interpolated).

Colortrac 3680eWhich has a total scan area of 36” wide x unlimited (by scanner) length.The 3680e has a total of two cameras with a dpi range of 50 to 2400 (interpolated).

Colortrac 3640eWhich has a total scan area of 36” wide x unlimited (by scanner) length.The 3640e has only one camera with a dpi range of 50 to 1200 (interpolated).

All models have adjustable media handling up to 12mm thick.

This manual shows how to replace any of the boards that make up the Colortracscanners. It will also include how to focus, magnify and align the one camera, two-camera version as well as the three-camera version as there is a significant differencebetween them.


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To work on the Colortrac scanners, certain tools will be required. See list below. Theacquisition of these tools is strongly recommended.

1. Oscilloscope2. Three oscilloscope leads3. Metric Allen keys4. Medium sized Pozi-drive screwdriver5. Pot-adjuster screwdriver6. Hex head Spanner Set (Metric)7. Focus and Mag Target8. Cleaning fluid9. Lint free wipes10. Cotton and sticky-tape11. A PC with ScanWorks V2+12. Service CD containing AIS4diag and PlotCorr software (for diagnostics).

Additional services CD's are available from the support department, send an e-mail tosupport address (see next page) giving company name and address to send disk to.


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1.2 Passwords

The following passwords are used during use of AIS4diag while servicing scanners.

action ~ to download firmware using AIS4diagscan ~ to enter full diagnostics testingsrgb ~ To download sRGB table into pre-enhanced S4 scanners

1.3 How to contact Technical Support

It has to be stressed that it is very important for new service engineers to attend theColortrac training course. Please contact the technical support group for information onforth-coming courses.

The course provides hands-on experience with the scanner. The alignment of anyColortrac scanner is almost impossible to obtain without first been shown by a qualifiedtechnical support engineer.

Although Colortrac technical support group will do their best to help any serviceengineer in difficulties in the field, we accept no responsibility if an un-trained engineerdamages any part of the scanner during a field visit, or an end user removes any panelsunder instruction for an service engineer.

Contact numbers for the Technical Support Group:

Tel No: +44 (0)1480 464618

Fax No: +44 (0)1480 464620

E-mail address:

[email protected]


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2. SAFETY

2.1 Safety Warnings

ELECTRICALDo NOT remove this cover from the scanner while it is turned on oroperate the scanner with this coverremoved

It is very important to allow the scanner to discharge for half on hour before removingcover and Ballast board. The ballast board holds up to 400V and can give a large shockif touched when fully charged.

MECHANICAL

The mechanism that operates the lid and the paper handlingassembly can trap fingers please handle with care

WEIGHTSince the weight of the scanner is in excess of 90Kg a minimum of two people arerequired to lift it safely.

ROTATING ROLLERSThe scanner operates two sets of rollers to move theimage across the scanner. These rollers, will grip ties andany other similar articles of clothing, as well as long hairif put near the rollers during operation.

EMC Testing

The Colortrac Enhanced scanner have under gone and conform to EMC and FCC .TheEMC test is carried out to assure that no signals that could cause interference areemitted from the scanner or that no external signal will interfere with the scanner. Seeback for full information.


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3. SYSTEM DESCRIPTION

This section covers the basic principle of the Colortrac scanners and the electronics thatmake up the scanner.

3.1 Scanning Principles

The device at the heart of the scanner is a CCD camera assembly. The CCD (ChargedCoupled Device) is an electrical component that converts light into voltage. There areone, two or three CCD camera assemblies per scanner, dependent on the scannermodel, which are focused on a gap in the extrusions at the top of the scanner. When adocument is moved across this gap, a two-dimensional image is built up by software ona PC.

Each CCD has three rows of light sensitive cells that detect one of three colours; red,green or blue. As a colour is sensed, a voltage is sent through the camera board to thedigital board that will be described in more detail later. The CCD is shown below.

Each light sensitive cell is 8µm by 8µm pixels between each row of coloured cells. Thetotal number of pixels in a row is 7500.

As the Colortrac scanner has a scan width of max 54 ins and an maximum opticalresolution of 400dpi the total number of pixels required is less than the 7500 providedby each camera, the excess pixels are used as an adjustment overlap area betweenadjacent camera assemblies. The adjustment procedure is referred to as “stitching”.

Paper direction

7,500 pixels59.9mm

8 pixelsapart

Red Green Blue


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3.2 Scanner Adjustments

The Colortrac Enhanced scanners are multiple camera scanners, and therefore someadjustments need to be made in order to produce high quality scans.

These adjustments are for:

Focus and magnificationFront/Back StitchingLeft/Right StitchingLight/Dark normalisation (Calibration)Colour delay compensation

The focus and magnification is adjusted mechanically, as is partially the left/right stitchand front/back stitch. Stitching is also compensated for electronically. The calibrationand the colour compensation adjustments are done purely by the electronics of thescanner.

Focus and MagnificationThe resolution of the scan in the X direction is set up by the magnification. This isadjusted by moving the CCD and the lens up or down. As the lens and cameraassembly are lowered the area that is covered by a single CCD increases whicheffectively reduces the magnification. Obviously if the distance between the lens andthe scan line is moved then the system will be out of focus. The focus can be adjustedby changing the distance between the CCD and the lens - this can also effectmagnification.

The passage above described how the magnification is set in the X direction. Focus isset for both the X and Y axis, however, the magnification in the Y axis is set by motorspeed. The faster the motor goes the lower the resolution. The motor speed can beadjusted to compensate for any variation in the system.

In the factory the motor speed is set using the MT8 test and spreadsheet, this figure canusually be found on a label near the digital board, if not then the support department willhave access to it if you contact them.

Front/Back StitchingThe front / back stitch is carried out in order to align the cameras along the line of scan.This is initially achieved by aligning each camera to a string that is stretched across thefull width of the scanner scan line. This adjustment is sufficiently accurate to ensurethat the electronic adjustment can align the cameras into a straight line.For each electronic line of adjustment a complete scan line has to be stored in memory.There is sufficient memory to store fourteen scan lines, which gives a minuteadjustment, therefore it is critical to set this adjustment carefully.


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Left /Right Stitching

The Colortrac Enhanced scanners can contain up to three cameras, which are mountedalong the line of scan. These cameras have got to be adjusted to ensure that there is nogap or overlap in a scan, as illustrated in the simplified diagram below.

The adjustment is carried out in two directions. The cameras are mechanically adjustedduring factory alignment to ensure that there is sufficient overlap between the cameras.

The total number of pixels in a camera is 7500 but not all the pixels are needed. Thisallows us to select electronically which pixels are used, and therefore effectively movethe image electronically. This allows the image to be joined to within a pixel.

Camera boards

Lens

Scan Line

L/Rstitch

Camera 1 Camera 2 Camera 3

Mag.

Focus.


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3.3 System Diagram

Digital Board

Ballast Board

Camera 1 Board

Camera 2 Board

Camera 3 Board

DisplayBoard

Paper SensorBoard 1

Paper SensorBoard 2

PowerSupply

SCSI or FireWireconnector to Host

ProtectionSwitch

PowerInlet/Filter

Motor

Lamp 36 or 58 watt

Lamp 36 or 58 Watt

LightSensorBoard


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3.4 Camera Boards

The main device on the camera board is the CCD. This converts the light in an electricalvoltage, as in ‘Scanning Principles’. The CCD requires a series of clock signals to run,which come from the digital board. The drivers for the CCDs, however, are on thecamera board itself.

The output from the CCD is less than 2V, usually about 0.5V with a DC offset of 6.5V.The analogue amplifier circuitry removes the DC offset and adjusts the scaling to meetthe requirements of the ADC (Analogue to Digital Convertor). The ADC converts theanalogue signal into a digital signal as well as applying the correction for dark and lightnormalisation, more details in chapters 5.4 & 5.5. The normalisation corrections are ona pixel by pixel basis and the data is supplied from the pixel RAM. The brightnessadjustment is carried out in the ADC before the data goes to the TRC RAM. The controlfor the ADC is carried partially via the serial communication system.

During scanning a ‘Gamma Curve’ is applied to the data to be able to increase theresponse of the darker pixels. The ‘Gamma Curve’, shown below, transfer function isapplied in the TRC RAM by using the RAM as a look up table. The data is then passedto the digital board via the ribbon cable.

CCDCCDdrive

ADC

TRCRAM

O/P

Serial Com

RAM

Pixel Correction

Intensity In

IntensityOut Gamma >1


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3.5 Digital Board

The digital board carries out the most data processing. The data from all the camerasarrive at the digital board at the same time. It is necessary to hold one complete line ofdata because camera 1’s data is processed first, followed by camera two and thencamera three for the three camera version of scanner. The data is held in the Line RAMfor each of the cameras which also provide storage for the delays needed for thefront/back stitching.

The three lines of the CCD which represent the three colours;blue, green and red areseperated by eight pixels. The blue data arrives at the digital board first, followed by thegreen and then the red. It is therefore necessary to delay the green by eight lines andthe blue by sixteen lines so that all the colours are presented at the same time on theimage. These delays are provided by the green and blue delay RAM. The data is loadedinto the delay RAMs by the line RAMs, which de-multiplex the information in theprocess. Initially the data is taken from camera 1’s line RAM with the red data goingdirectly to the FPGA (Field Programmable Gate Array), the green data to the greendelay RAM and then the blue data to the blue delay RAM. Then a line of data is takenfrom camera 2 in the same way and then camera 3. The data from both colour delayRAMs are passed to the FPGA.

The FPGA is a programmable logic device which carries out a number of differentoperations. Data is passed from the control RAM to the FPGA on a pixel by pixel basis.Certain bits of the control data are used to select whether a given pixel is used or not.By selecting which pixels are used, the active image from each camera can be movedleft or right. This process allows the images from all three cameras to be stitchedtogether.

FPGA

Control RAM

Palette RAMDSP

Resolution LineDelay

BufferRAM

SCSIInterface

Blue Delay

Green Delay

Line RAM

Line RAM

Line RAM

FireWireconnection


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The modes of the scanner are carried out in the FPGA. These modes include resolutioncontrol, paletting, binary and compression modes.

Variable resolution is achieved by interpolating the levels between pixels. In this way apixel can be constructed which is between two pixels in a line and between lines. Datafrom the control RAM indicates what proportion of each of the four pixels around thedesired pixel is required. The Resolution Delay line keeps a copy of the previous line ofdata in order to allow this calculation to take place.

The palette modes use the palette RAM as a look-up table. The palette RAM loads thepalette mapping that is required and then this is addressed by the RGB data. The outputis then sent to the main computer.

Binary scanning is produced by setting a threshold in the FPGA which is compared withthe incoming RGB.

The data from the FPGA is passed to a 32Mb buffer before being handled by the SCSIinterface circuitry so that the scanner has sufficient time to stop if the host computercannot cope with the data flow.

The microprocessor does not carry out any of the data processing. It carries out a seriesof tasks that control the data, such as loading the FPGA with it’s logic circuitry andsetting up the various delay lines.

3.6 Display Boards and Paper Sensors

The display board controls the operator interface with the scanner, manually controllingthe paper movement throught the scanner by the use of two push buttons shouldoperator intervention be needed. One button controls the forward movement of therollers and the other the rewind movement.

The paper sensors are connected to the display board which indicates if paper isinserted into the scanner and when the paper has completed it’s scan.

The 3 LEDs indicate the status of the scanner. The green LED indicates that thescanner has warmed up and ready for scanning. A flashing green indicates that thescanner is scanning. The amber LED indicates that the scanner is in warm up sequenceor calibrating and the red LED indicates that there is a problem with the scanner.

The display board contains a microprocessor which communicates with the digital boardvia a serial communication system. This communication is bi-directional, the papersensor and push button information is sent to the digital board and the LED status issent to the display board.


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3.7 Ballast Board and Light Sensors

The ballast board controls the striking of the fluorescent tubes that light up thedocument being scanned. The light sensors control the intensity of the light emitted fromthe tubes to prevent the tubes from running at full strength permonently. The ballastboard is also connected to the digital board which controls when the tubes strike duringcalibration.

The ballast board has its own power supply so is only controlled by an analogue signalfrom the digital board to switch the 400V on which is required to strike the tubes.

The light sensor connected to the ballast board is automatic and keeps the tubesconstantly at approx. 80% - 90% of normal running.

3.8 Data Rates

One of the common problems is underestimating the file size and data rates required fora large format scan. Initially consider data file sizes:

Data volume for an E size sheet (42” x 32”) in 400 dpi RGB mode:

42 x 32 x 400 x 400 x 3 = 645 Mb.

This can be reduced to=215 Mb in 256 colour/greyscale=107 Mb in 16 colour= 27 Mb in binary.

Compression can reduce data volume for some drawing types.

Now if data rates are considered:

A width of 32” travelling at 0.75”/Sec at 400 dpi RGB mode gives a data rate of:

32 x 0.75 x 400 x 400 x 3 = 11.5 Mb/Sec.

The SCSI controller maximum data rate = 40Mbytes/Sec or the FireWire data rate of400Mb/sec and therefore can cope with the data produced by the scanner.


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3.9 Calibration Sequences

The scanner does not need to be calibrated before every scan. It is recommened thatthe scanner is re-calibrated once a week / month, depending on colour importance tocustomer, and is done so in the following order:

1. Open lid and remove normalisation target from its holder in the lid.2. Raise the rollers to their highest position by pulling both of the adjustment levers at

the front of the scanner.3. Insert the normalisation target between the rollers from the REAR of the scanner.4. Line up calibration target so that the edge is level with rear of paper guide assembly.5. Lower the rollers down again. Set the levers at the front of scanner to position 4.6. In ScanWorks or Copy Works open the ‘Scanner Setup’ or ‘tools’ option and then

click on ‘Recalibration’ / ‘White balance’.

The scanner will then go through dark normalisation and then light normalisation to setup the dark/light levels so that the two or three cameras (depending on the type ofscanner) are all contributing the same levels to the digital board.Unlike Colortrac Series 3 the dark normalisation takes a lot longer, whereas the lightnormalisation takes only a few seconds. The target will move during the whitenormalisation part of calibration.

When the recalibration has finished a message will indicate that the scanner hascalibrated correctly.

Calibration will fail if the target has dirt or marks on it, if failure occures, reclean target,re-set scanner and re-calibrate.

REMOVE CALIBRATION TARGET BEFORE SCANNING AND REPLACETARGET INTO THE LID.

3.9.1 Auto-stitching and manual stitching

Auto stitch is achieved by placing the auto stitch target supplied with the scannercorrectly, as indicated on the target, face down in the scanner. In ‘ScanWorks’, under‘Data Control’, start the process by clicking on the ‘Auto stitch’ button. This processtakes approx. 6 mins to complete. On completion, either remove the target or continueand run manual stitch to check that stitching is as good as required.

When auto stitching is complete, the scanner might need to be finely adjusted. Theauto-stitch will usually set the scanner correctly, but will sometimes need adjustment.Once the scanner has been stitched to customer satisfaction, they very rarely go out ofstitch. To get the best stitch as possible, use the following method:

Using ScanWorks, under the 'Data Control' tab, run the manual stitch. This will show thestitch values created using auto stitch. Pressing the 'Scan' button will automatically scanthe target, displaying the image in ScanWorks. Zoom into the correct ‘triangle’ on targetby clicking 'View boundary 1' and ‘2’ in turn. Moving the image up or down, look at the


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stitch points between the two cameras. If a discrepancy is see adjust the values bymoving the slider in either direction, remembering to adjust Front/Back stitch valuesfirst. Then re-scan to see what difference has been made. Use the following to identifyhow to move the slider to achieve the correct results.

If the auto stitch fails and the registered values are near 0 or 14, then the scanner willneed to be manually strung aligned, see chapter ‘5.4 String Alignment’.

Decrease Cam1Or increase Cam2FB value

Good Stitch.

Increase Cam1Or decreaseCam2 FB value

Increase Cam1Or decreaseCam2 LR value

Decrease Cam1Or increaseCam2 LR value

Front/Back Left/Right


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3.10 Mirrors and Cameras Arrangement

The cameras, unlike the old Series 3 scanners, use a mirror setup to increase the widththat each camera can see without the extra height of the scanner.

NOTE: These mirrors are very sensitive and should only be cleaned with an air cleaneror lint free optical cleaning cloth. NO chemicals are to be used what so ever in thecleaning of the mirrors.

Mirror 1

Scan width seen by camera

Camera

Light path

Mirror 2


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4. Circuit Boards

4.1 General Description

The Colortrac Enhanced scanners use 7 circuit boards in total, the 5480e & 4280e hasone camera more and the 3640e has one camera less. The circuit boards are not userrepairable and most use design or safety critical components.

Repair therefore, should be left to Colortrac’s Technical Support Group.

Replacement boards can be sourced from Colortrac during the warranty period under itswarranty return procedure, and likewise may be purchased when the warranty periodhas expired or has been breached.

Colortrac will gladly quote for board repairs if required.

Most of the boards look the same as the old series 3 but they are NOT and cannot be interchanged.

SAFETY NOTE

Under fault conditions the ballast board and the power supply may retain some chargefor some period of time after the power has been removed “The safety cover overthese boards must only be removed by qualified trained personnel”

Colortrac series scanners use a split mains supply so the ballast board and the powersupply will still be at mains potential even though the other board’s mains connectormay have been removed.

4.2 Power Supply

The same power supply is common to all models and consists of a single boardmounted onto six metal spacers, mounted to the chassis using screws.

The power supply is of the switch mode type, and is self-sensing to varying supplyvoltages, therefore no adjustments are necessary.

This board has only two connectors TB1 for the power in and the other TB2 for powerout.

Caution

Some of the semiconductor heat sinks are above earth potential whilescanner is in use!


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4.3 Power Supply Replacement

Please ensure that scanner is unplugged from mains and you haveread all the safety notices before proceeding

After waiting the correct period of time remove the PSU as follows:

1) Remove the scanner front panel (remove 5 screws & earth lead).2) Remove left hand side panel (2 screws).3) Remove the safety cover (4 screws).4) Unplug the two connectors.5) Remove the six outer fixing screws on chassis.6) Remove the board complete with its spacers (this process may be made easier if the

ballast board is removed first).7) With the PSU out of the scanner remove the spacer fixing screws taking care to

retain the washers.

Refitting is the reverse procedure, taking care to refit all the washers and screwscorrectly, also ensure that the connectors are the right way around and pushed all theway home.

Refit safety cover before powering up the scanner!

4.3.1 Power Supply Voltages

Pin 8 Pin 7 Pin 6 Pin 5 Pin 4 Pin 3 Pin 2 Pin 13.3V 15V 40V GND GND +6V +5VRed Pink Yellow Black Black White

Notused Orange

Power In Power Out


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4.4 Digital Board

There are now 2 types of digital board for the Colortrac Series 4 scanners. One is theoriginal version with just SCSI connection. The other is the new ‘Enhanced’ version,which also has a FireWire connection. These boards run exactly the same as eachother, but to fit an enhanced board into an original scanner needs to have an upgradeoption purchased before hand. The two types of boards have different Key lock chipsfitted (referred to as the PIC chip). This chip tells the board which scanner model type itis dealing with, the amount of cameras and whether it is using FireWire and or SCSI. Anenhanced PIC can NOT be fitted into an older version board, and visa versa.

When changing these boards please ensure the PIC chip gets transferred to the newboard, unless an upgrade has been purchased in which case a new PIC will already befitted. Take care to observe the position of the PIC chip, as fitting it incorrectly maycause damage to the chip and the new board.

The digital board is electrostatically sensitive so it is advised that E.S.D procedures arefollowed when handling this board, failure to do so may impair the function of the boardor severely shorten its life.

The connections on this board are quite straightforward in principle.J4 at the top of the board connects the voltage rails from the power supplyThe three multi-way connectors at the bottom are the camera ports (J1 (Cam 1), J2(Cam 2) and J3 (Cam 3))

The remaining connectors are J5 Motor drive, J6 Control cable that providescommunications between the Digital, Ballast, Paper Sensors and the Control panel.J9 is a diagnostic socket for factory use.

The remaining socket or sockets (depending on model) are the Ultra Wide SCSIInterface Connectors and the FireWire connector. With these sockets is a bank of DIPswitches, these provide the means of setting the SCSI ID and termination, and alsoselection for firmware downloads etc.

External terminator is no longer required on any Series 4 range of scanners.


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OFF ON

Pictorial for thedip switches asthey should beset in normalscanning mode.

Original Digital Board Fitted to Scanner prior to October 2002

FireWire & SCSI Connectors

Original dip switch position

New dipswitchposition(accessfrominsideonlynow)

Camera connectors

Camera connectors

SCSI Connector


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4.5 Digital Board Replacement

Please observe E.S.D. procedures for this section.

1) Remove rear cover (5 screws).2) Remove left hand side panel (2 screws).3) Remove the two Digital board fixing screws from the rear of the scanner chassis.4) Remove the 2 screws on the right hand side of the board (retain the washers).5) Unplug all the cable connectors (do not pull on the cables).6) Carefully manoeuvre the board out.7) Remove the remaining screws holding the board onto the carrier not forgetting the

nut studs retaining the SCSI connectors.8) Before refitting panels, note motor speed figure written on label next to board9) Refitting is the reverse procedure not forgetting to change the Keylock chip over

from the old board (unless upgraded Enhanced board being fitted leave providedPIC in new board).

10) Power up and reboot PC.11) After reinstalling the digital board, reset the motor speed using AIS4diag.exe

provided to engineers.12) Check and install latest firmware version (contact support for latest firmware)13) Re-calibrate.14) Run Autostitch.

The scanner is now ready for use.

NOTE: The key dongle tells the digital board which scanner it is, thereforethe chip MUST stay with the scanner. Do NOT try changing the chip fromdifferent model of scanner.

4.5.1 Digital Board Voltages

Pin 1 Pin 2 Pin 3 Pin 4 Pin 5 Pin 6 Pin 7 Pin 83.3V GND GND +5V +6V 15V 40VRed

NotUsed Black Black Orange White Pink Yellow


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4.6 Ballast Board

This board can retain some charge so please read the safety sectionand handle with care!

The ballast board comes as 2 different boards for the 2 chassis sizes of Colortracscanners. The wider scanners (5480e & 4860e) use a 58W ballast and the othernarrower models use a 36W ballast, It is VERY important that the correct type is fittedinto the correct model scanner.

Its mains derived power supply provides the 400v DC to run the 2 light tubes. The onboard oscillator circuit firstly provides the cathode warm up and then the striking ramp,settling down to a high frequency flicker-free running mode.

Communications from the digital board and the light sensor board are provided, this lowvoltage circuit is separated from the high voltage by using 3 optical isolators.The purpose of this low voltage circuit is to provide a method of switching the lamps onand off during normalisation, also the light sensor board allows the setting of the tubesto run at approximately 80% - 90% of their full output to extend tube life.

This board has 5 connectors:

JP1 Mains supply inJP3 Lamp 1JP4 Lamp 2JP5 Serial ComsJP7 Light sensor

In addition to these there is also JP6 which is a jumper test point, the purpose of thispoint is to enable the service engineer by fitting a jumper, to override the control circuitryto help decide if the ballast board has failed or if there is a control fault.

4.7 Ballast Board Replacement

Jumper Testpoint

JP7 Light Sensor

JP5 Comms

Power In

JP4 & JP3 to lamps


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4.8 Camera Replacement

Removing the front, bottom and back covers allows access to the cameras. It isimportant not to disturb the left /right orientation of the camera castings or a full factoryalignment will have to be carried out.

The cameras are best changed in sets, so as to eliminate any chance of colourmatching problems between cameras.

The process of changing the cameras are as follows:

1. Remove back and front panels (10 screws).2. Remove bottom panel (14 screws).3. Remove EMC shield cover from camera (8 screws)4. Disconnect J1 connector.5. Remove camera board, along with gasket.6. Place new board with gasket in the correct position on camera cast.7. Replace connectors for that camera (leave EMC shields off until finished aligning)8. Carry out the same procedure for other cameras9. Align camera as in the next chapter.

J1 Camera connector

Serial number

Alignment Test Point(Green channel)

Trigger

Earth point


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4.9 New Camera Information.

The camera boards are the optical part of the scanner, and since the introduction of the series 4 scannerthey have taken a couple of changes. The following list it to help define which camera for which type ofscanner

Any of the original series 4 scanners that are already fitted with the double SCSI Digital board are fittedwith the following cameras:

P001014 Camera Board, including CCD.

If the scanner is fitted with a single SCSI digital board, then the following is true:

If the scanner's serial number has the third from last digit as number 4 (example 42303402) and belowthen fit the following:

P001611 Camera board including CCD

If the scanner's serial number has the third from last digit as number 5 (example 42312502) or above, fit:

P001863 Camera board for a Series4e scanners, (which includes the CCD)

Newer production Flatbeds are fitted with:

P001861 Camera board for a Flatbed or Eagle enhanced scanners.

Unless the flatbed is fitted with separate filter boards. If so, then use the P001611 as Series 4e scannersabove.

The new flatbed camera boards, part number P001861 are fitted with filters for the EMC regulationsrequired for the flatbed scanner. The P001863 boards for series 4 are not, but do have 0V resisters fittedinstead, so both look exactly the same, but the part number written on board will be different.

P001861:With filter packs fitted.For Flatbed scanners

P001863:With 0V Resisters fitted.For Series 4e scanners


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Camera Mounting Arrangement

Cameraboard Drawn by D Austin


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5. SCANNER ALIGNMENT

There are two types of alignment procedures:

1) Factory Alignment2) Field Service Alignment

The Factory alignment process is required only if the mirror bars or the camera castingshave been removed. This alignment requires the use of specialised large targets notcarried by field service engineers.

Field service alignment is straightforward to the trained engineer but requires the use ofan oscilloscope or PlotCorr software.

This process ensures the correct setting of the following:

• Focus

• Magnification (distance of the lens from the scanned document toensure correct width)

• Front back stitch (all cameras are in-line and straight)

IMPORTANT NOTE: The alignment process must be carried out in this order.Even if you only adjust or work on one camera, the alignment must always becarried on all cameras AFTER focus/mag.

5.1 Field Service Alignment

Tools required:

1) A set of Hex wrenches (Allen Keys)2) Oscilloscope 100Mhz dual channel EXT trigger & 2 identical leads3) Alignment string and attachment tape4) Screwdrivers5) Focus and Mag target6) PC with ScanWorks and/or AIS4diag and PlotCorr software.


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Procedure

1) Remove the covers & the paper guide assy.

2) Before proceeding any further clearly mark the relationship of the cameras with thecamera mounting plate as shown below.

3) Rough string alignment. This is required if the camera castings or mirror bars havebeen replaced. The camera needs to be able to see through the gap in the extrusionto be able to see the target so that it can be focused and magnified. The roughalignment is the same as the final alignment (described in next section), but doesn’trequire the accuracy or a lot of time spent on it, roughly is all that is required at thispoint.

Connect Oscilloscope as described on page32

Using pencil, mark camera castingand camera plate to keep correctL / R position. Do this on allcameras. When the 3 lockingscrews are released, the camerahas free movement L/R and F/B.The mark allows you reference tothe factory set L/R position.


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5.2 Focus

This is achieved by using the focus part of the Focus and Mag target.The target is placed over the scan slot above each camera in turn and the ‘green’channel of the CCD is monitored by the Oscilloscope, the adjustment being madeby raising or lowering the lens in its threaded carrier as shown below.

1. Connect 2 leads from Oscilloscope to each camera in turn, one on the ‘Green’channel and the other on the trigger point, see p.26 for test point locations.

2. Place focus part of target over gap in extrusion centrally over camera working on.3. Turn knob (indicated above) until the oscilloscope trace is at it’s peek height like the

good focus shown above. Focus is important as a slightly out of focus camera cancause colour mis-match between cameras.

4. Carry out magnification before moving to next camera.

IMPORTANT NOTE: On completion of focus, you MUST carry out Mag andthen alignment. Alignment must ALWAYS be achieved AFTER focus and Mag.

Turn knob to adjustfocus until scope traceis good.

Oscilloscope trace Out of Focus Oscilloscope trace Good Focus

Focus part of target.


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5.3 Magnification

NOTE: Sometimes before magnification will work, a recalibration is required so that thecameras / scanner can distinguish between B&W properly

Magnification is achieved by placing the appropriate box from target (see above) acrosseach camera in turn and using the SCANNER RUN LENGTH function from theengineering menu of AIS4Diag to measure this width. The adjustment is made byraising or lowering the magnification adjustment knurled nut until the reading on theAIS4diag box reads the same as the values shown below for the different models.

Scanner Model Box used Dpi Run Length Values5480e 17” 400 18 6784 184860e 23” 300 13 6888 134280e 13” 400 18 5184 184260e 20” 300 13 5988 133680e 17” 400 18 6784 183640e 23” 200 9 4592 9

This must be carried out on all the cameras as accurately as possible as it will effect theoverall width of the scan and the accuracy of the scanner.

Focus area of target

Scanner run lengthfor flatbed & S3

Used onColortrac S4e

scanners as wellas the originalpre-enhancedS4 scanner

Mag

nific

atio

n


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Thread string through small hole each side Secure string usingtape at each end

String

ScanSlot

Hole

5.4 String Alignment

This is achieved by threading a piece of alignment string* along the length of the scanslot (gap in extrusion), feeding the string through the small holes in each blue endcasting either side of the extrusions. Using the oscilloscope monitoring the green outputof the CCD the camera castings are moved carefully forward or back to obtain goodalignment using the three adjustment screws. This is carried out on all cameras toensure that they are all looking in a straight line into the scan slot.

* Alignment string is made by taking a real of white cotton and marking a ¼ inch black stripe down one area so that when usedyou see a ¼ inch mark every 2 inches approx.

Scanner Runlengths areadjusted byturning the dial onthe right hand sideof camera


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Loosen all 3 screws and make sure that they are just touching the camera casting.Taking it in turns to adjust the 3 screws will allow you to move the camera castingbackwards and forwards, remember if you tighten the front screws, A & B, then the rearscrew, C, must be loosened (and vica versa) or else the camera mounting bracket willbe forced open and will move the other cameras out of alignment.

Camera out of alignment with string.

Camera as it is seen on the oscilloscope, just as the camera starts to see the string. Ifuncertain as to whether this is the alignment string or not, move the string slightly andyou should see this image moving as well.

Move camera assembly forward/backward as required using thethree adjusting screws marked A B& C.

BA

‘C’ at the rear

String

Camera

Camera out of alignment,move whole camera

Camera slightly out ofalignment, move wholecamera


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Above image shows the camera seeing the line but with the camera slightly twistedacross string.

Correctly aligned camera. To make sure that it is correct, place finger on rim of cameralens and move gently back and forth, the image should move in and out exactly evenlyboth ends of image. If not then the camera is still slightly twisted and fine adjustment isstill needed.

Complete this procedure on all the cameras in scanner, even if you haven’t replaced orworked on any one of them. The autostitch function will eliminate any minor differencesin alignment, but the closer the cameras are aligned the better.

Finally, remove the string, refit the paper guide assy and run auto-stitch from the toolsmenu. If the alignment is too far out, it will fail auto stitch, check the stitch values inAIS4diag software and re-align if necessary. If passes auto-stitch, alignment is nowcomplete.

During the alignment process the 3 screws must not be any tighter than finger tight, thuseliminating any possibility of twisting the mounting bracket and putting the othercameras out of alignment. When you have aligned the camera to a satisfactory position,the 3 screws then need to have a very small amount of torque applied. Do each screwin turn and do NOT return to any of them to apply more after tightening once. ObservePlotCorr and make sure image doesn't change while applying this pressure.

Camera slightly twistedacross string, move 1 end ofcamera, it could be eitherend so try one first, if worsego back and try other

Smallestmovementof Allen Key

3 x Locking and adjustment screws


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5.4.1 Focus / Magnification and Alignment using PlotCorr Software

Focus

This is achieved by using the focus part (fine multiple vertical lines at top, see nextchapter for view of target) of the Focus and Magtarget. The target is placed over the scan slotabove each camera in turn and the ‘green’channel of the CCD is monitored by PlotCorr, theadjustment being made by raising or lowering thelens in its threaded carrier as shown below.

Focus Dial

Magnification Dial

Open PlotCorr software, found on the Service CD in the Diagnostics and drivers folder,making sure to use the one indicated for Series 4 scanners. Tape down the front sensorof the scanner. Click start on the PlotCorr screen and turn off the 'Red' and 'Blue'channels, so that you are only looking at the green channel.

Place focus part of target over gap in extrusions, centrally over camera being workedon.

Turn focus dial (shown above) until the PlotCorr trace is at its peek (widest) width andas even as possible all the way across that camera image, as in the Ref.2 focusexample shown below. If the image starts to decrease again then turn it back to itspeek. Focus is important as a slightly out of focus camera can cause colour mis-matchbetween cameras. Depending on the speed of PC, you might have to wait a fewseconds for screen to catch up with signal.

Move target over second camera and repeat until the image look continuous over thetwo cameras, then focus camera 3 comparing it to camera 2 (only if a 3 camerascanner).


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IMPORTANT NOTE:On completion of focus, you MUST carry out Mag andthen alignment. Alignment must ALWAYS be achieved AFTER focus and Mag.

Magnification

Ref.1. Out of Focus Ref.2. In Focus

PlotCorr software as seen on monitor.

Focus area of target

Scanner run lengthfor flatbed & S3

Used onColortrac S4e

scanners

Mag

nific

atio

n

Turn 'red' and 'blue'channels off afterimage appears on

PlotCorr.


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Magnification is achieved by placing the appropriate target box for the scanner workingon, (see above) centrally across either camera in turn. Using the SCANNER RUNLENGTH function in the engineering menu of AIS4Diag (also on the service CD under'Diagnostics and drivers' folder) to measure the amount of pixels between the blacklines of the target box. Adjust the value of the run length by turning the magnificationadjustment dial (shown on previous page) clockwise or anti-clockwise until the readingon the monitor in AIS4diag reads the same as the large value for the appropriatescanner shown in the table below.

Scanner Model Box used Dpi Run Length Values5480e 17” 400 18 6784 18*

4860e 23” 300 13 6888 134280e 13” 400 18 5184 184260e 20” 300 13 5988 133680e 17” 400 18 6784 183640e 23” 200 9 4592 9

This must be carried out on all cameras as accurately as possible as it will effect theoverall width of the scan and the accuracy of the scanner.

* The small value either side of the central number, is the thickness of the line and may vary, this is un-important and should beignored.

2nd MirrorRefection oflenses in lowermirror

Target area.


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Thread string through small hole each side Secure string usingtape at each end

String

ScanSlot

Hole

STRING ALIGNMENT

This is achieved by threading a piece of alignment string* alongthe length of the scan slot (gap in extrusion), feeding the stringthrough the small holes in each blue end casting either side ofthe extrusions. By using the PlotCorr software and monitoringthe green output of the CCD the camera castings are movedcarefully forward or back to obtain good alignment using thethree adjustment screws. This is carried out on all cameras toensure that they are all looking in a straight line into the scanslot.

* Alignment string is made by taking a real of white cotton and marking a ¼ inch black stripe down one area so that when usedyou see a ¼ inch mark every 2 inches approx.

Move camera assembly forward/backward as required using thethree adjusting screws marked A B& C.

BA

‘C’ at the rear


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IMPORTANT NOTE:

Using a pencil to make a reference mark on both the camera cast and the mountingbracket so the camera can be moved backwards and forwards without loosing the pre-set left right adjustment.

1. Using sticky tape, hold down front paper sensor.2. Run PlotCorr and click 'start' button, this takes a few seconds to start working.

NOTE: Do NOT try to operate motor while PlotCorr is running, as it will cause it tostop working!

3. Stitch off the 'Blue' and 'Red' channel.4. Working on one camera at a time loosen the 3 locking screws and move the camera

physically backwards and forward to the carriage until an image on the screenappears.

Out of alignment, but possible sort of image that might beseen.


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5. Loosen the 3 locking screws until they are only just touching the camera casting.Taking it in turns to adjust the 3 screws will allow you to move the camera castingbackwards and forwards. Remember if you tighten the front screws, 'A & B', then therear screw, 'C', must be loosened (and vica versa) or else the camera mountingbracket will be forced open and will move the other cameras out of alignment.

Camera out of alignment with target.

Camera as it is seen on the monitor (PlotCorr software), just as the camera startsto see the string.

Above image shows the camera seeing the line but with the camera slightlytwisted across string, only make very small movement with Allen key and try bothends to see which makes it look better.

Dotted Line on string

Camera

Camera out of alignment,move whole camera

Camera slightly out ofalignment, move wholecamera

Camera slightly twistedacross line, move 1 end ofcamera, it could be eitherend so try one first, if worsego back and try other


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Correctly aligned camera. To make sure that it is correct, place finger on rim ofcamera lens and move gently back and forth, the image should move up anddown at exactly the same time at both ends of image. If not then the camera isstill slightly twisted and fine adjustment is still needed.

Complete this procedure on all the cameras in scanner, even if you haven’t replaced orworked on any one of them. The autostitch function will eliminate any minor differencesin alignment, but the closer the cameras are aligned the better.

Finally, remove the string; refit the paper guide assy and run auto-stitch from the toolsmenu. If the alignment is too far out, it will fail auto stitch, check the stitch values inAIS4diag software and re-align if necessary. If passes auto-stitch, alignment is nowcomplete.

The scanner will also need to be re-calibrated, this might need to be carried out prior toauto-stitch.

During the alignment process, the 3 screws must not be any tighter than finger tight,thus eliminating any possibility of twisting the mounting bracket and putting the othercameras out of alignment. When you have aligned the camera to a satisfactory position,the 3 screws then need to have a very small amount of torque applied. Do each screwin turn and do NOT return to any of them to apply more after tightening once. ObservePlotCorr and make sure image doesn't change while applying this pressure.

NOTE: PlotCorr runs by doing a full length scan, without moving the motor, therefore, ifit takes too long to make adjustments, then the PlotCorr will freeze image as it reachesthe end of the 'scan'. Pressing 'Stop', leaving for a second, then pressing 'Start' willcommence the PlotCorr image.

Smallestmovementof Allen Key

3 x Locking and adjustment screws


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5.5 Factory Alignment of multi-Camera Scanners.

The alignment of the scanners with 2 or more cameras. Having fitted new cameras thescanner has to be left/right aligned so that the edge of the scanner sees the first edge ofa document.

1. Position the camera castings roughly in centre of camera mounting plate and fingertighten the 3 locking screws. The lower mirror bar is locked off and by looking downthe scanner through the scan line gap between the extrusions move the upper mirrorbar until you can see the camera lenses for each camera in the bottom mirror andlock off.


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2. Do a rough alignment as described it the previous section.

3. Focus and magnify as described in previous section.

4. In AIS4diag set the stitch values to F/B = 7, and L/R = 100, however many camerasthe scanner has, even the one camera scanner.

5. Replace lid into position. Set ScanWorks to ‘Right Justified’ (Scanner Setup) and A4size (Standard sizes), 200dpi, RGB. Insert A4 document with edge nearest paperguide marked with a vertical line to highlight the edge and scan document. Loosenthe single locking screw out of the 3 on camera casting and move casting untilimage has the line at beginning of screen.

6. Insert autostitch target and scan at camera 1 & 2 stitch points. Move camera 2 untilthe diagonal part of the target looks more or less in line.

7. Repeat for cameras 2 & 3 if fitted.

8. String align scanner as normal making sure that no Left/Right movement is madewhen moving casting backwards and forwards during alignment.

9. Autostitch scanner and check values in engineering menu.


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5.6 Factory Alignment of the 1 Camera Scanner.

The alignment of the 1 camera scanner, although very similar to all the other series 4scanners, does have a significant difference in that it has a double bounce off themirrors. That is why the single camera scanner has extra wide mirrors on the bars.

1. Position the camera casting roughly in centre of camera mounting plate and fingertighten the 3 locking screws. The lower mirror bar is locked off and by looking downthe scanner through the scan line gap between the extrusions move the upper mirrorbar until you can see two camera lenses next to each other in the bottom mirror andlock off.


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Note: If one of the lenses looks like half of it is missing then the upper mirror barbrackets are incorrectly fitted.

Both ends brackets the same way around Both end brackets with the bottom bracket reversedand flipped over.

Factory align as the multi-camera scanners but only scan A4 Right justified with stitchvalues set as default.

Obviously, a 1 camera scanner does NOT require auto-stitching.

1st reflection2nd reflection


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5.7 Light Level Adjustment

Light Sensor Board under rear extrusion.

The light levels are reduced to approx. 80% - 90% of their full intensity to allow forwearing of tubes. As the tubes age and will therefore fade, the light sensor board willcompensate by turn up the brightness to allow of this. Inevitably, the tubes will get to apoint where they have faded to below the reduced setting and the sensor can no longercompensate, and will fail calibration, this is the time that the tubes need to be replaced.It is recommended that they are replaced once a year as part of the annual service.

1. Remove back panel.2. Disconnect feedback

connector from Light Sensorboard

3. Power up scanner & PC.4. Open AIS4diag software (use

latest version as earlier onesdon’t work for enhancedscanners)

5. Run ‘Un-normalise’ and ‘darkNormalise’ in that order.

6. Run ‘Camera Info’ on theblue channel.

7. Take note of the middlereading from one camera,usually camera 2.

8. Calculate between 80% -90% of that value.

9. Reconnect feedback connector.10. Adjust variable pot until the calculated value replaces the original value on screen.11. Power off and replace panels.12. Recalibrate.

Feedback connector


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5.8 Paper Sensor Set-up.

The paper sensor informs the scanner when media is in place ready to scan. The papersensor boards are housed in the right hand end casting of the scanner.

1. Remove lid and paper guide assembly.2. Remove right hand end casting. Remember to remove control panel from casting

and make sure still connect to cables.3. Loosen screw ref.1 and check that the

brackets with sensor boards are roughly in thecentre of the slotted holes.

4. Under the sensor arm currently being workedon, place a screwdriver or similar tool underwire loop to prevent from dropping intoextrusion.

5. Lift sensor loop to highest position and loosengrub screw ref.2on end of sensorwire. Allow theweighted extension to drop into the sensor on the board.6. Tighten the grub screw back up.7. Remove screwdriver.8. Loosen screw under sensor locating bracket.9. Holding the sensor loop down, set bracket so that thetop of the slot is just touching the 'Z' shaped armextension.10. Tighten screw.11. Repeat for other sensor.12. Replace paper guide assembly only at this stage.

Screw Ref. 1

Screw Ref. 2


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13. Power up scanner.14. Fed A4 paper landscape into centre of scanner and using control buttons, move the

paper through until it just clears the rear sensor, so that both sets of sensors areactivated.

15. Check that the rear sensor flag is out of the black sensor on the board (see below).16. If not, loosen the screws ref.1 and move bracket and board down until the flag is

clear.17. Retighten screws ref.118. Remove A4 paper.19. Power off scanner and replace end casting and lid.20. Power up scanner.

Check that media will fed into scanner and return correctly after hitting rear sensor.

XShowing sensors and sensor flags as should be seen after paper guide refitted

with media fed into scanner.


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5.9 Motor Belt Replacement and Adjustment.

Periodically the belts that run the drive rollers will need changing. As with all beltsrunning a mechanism, they will wear out or stretch with use.

To Replace belts.

1. Loosen 4 screws holding motor tomotor mount (Fig. 1.)

2. Remove 4 screws holding frontplate of motor mount. (Fig. 2.)

3. Remove front plate allowingaccess to belts.

4. Replace belts, noting the way theoriginal goes around cogs.

5. Replace front plate.

Tightening Motor Belt.

1. Loosen 4 screws holding motor tomotor mount (if not already doneso. (Fig. 1.))

2. Tighten motor belt by apply slightpressure on motor in downwardsdirection, not too great amount asthis will cause the motor to stall athigher speeds.

3. Tighten the same 4 screws up,while still applying pressure.

Tightening Cog Belt.

1. Loosen locking screw on tensionlever. (Fig. 3.)

2. Apply slight pressure to tension lever, not too great an amount as this will cause themotor to stall at high speeds.

3. Tighten tension lever screw up.

Should the scanner stalls or makes screeching noises during fast speeds, i.e. 50dpiB&W, then the belts are too tight and need to be loosened. Alternatively, if the rollerscan move independently or media slips, then the belts are too loose.

Fig. 1.Fig. 2.

Fig. 4.

Fig. 3.


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5.9.1 Replacing Tubes.

The tubes need to be replaced during the annual service of the scanner. Due to thenatural wearing out of the light tubes, AIS recommend the life of a tube is 12months.

Removing Tube.

1. Power down scanner.

2. Remove end casts from scanner.

3. Disconnect control panel from right hand cast.

4. ON ONE LIGHT TUBE ONLY, unclip the tubeconnector cap from the paper sensor end of the light tube.

5. Sliding the tube out of the extrusion will disconnect theconnector cap at other end.

6. Replace the new light tube as below in 'Inserting Tube' before following sameprocedure again on the second tube.

Inserting Tube.

1. Push tube into the hole made empty by old tube. Push all the way until through otherend. Be careful as pushing tube through that it goes in straight line so as not tobreak tube.

2. Holding connector cap in line with end of tube at motor end.

3. From sensor end of tube, turn until the 2 pins are in line with the 2 holes onconnector cap.

4. Pushing tube, locate cap onto light tube.

5. Fit connector cap at sensor end of tube.

6. After changing 2nd tube, replace both end casts.

7. Remove front panel and power up scanner.

8. Set up light levels as in 'Light level Adjustment' (p. 38).

9. Replace front panel and re-calibrate scanner. (p.17)

NOTE: The reason we recommend changing one tube at a time rather than taking both tubes out andfitting the new ones, is to prevent the chance of fitting connectors incorrectly. This could result in theballast board being blown and needing to be replaced.


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Ref. 1

5.9.2 Replacing rollers.

To replace rollers the extrusions do not need to be taken off. The following procedure isthe same for both rollers, but care needs to be taken when putting rollers back in thatthey are the correct way around.

1. Remove top lid cover. Loosen screw on lid as in ref. 1 andslide back to release lid from end plate. (only do this oneend)

2. Remove both end casts, making sure to remove controlpanel from RH cast.

3. Unclip & remove tubes from extrusion, place some wheresafe to prevent breakage.

4. Remove motor assembly, including belts.

5. Carefully remove cogs from roller, NOTE: They are gluedon. By using pliers, brake the glue joint and remove. The cogs are not part of theroller and may need to be ordered separately if broken

6. Remove Paper sensor arms, as ref. 2. By loosening grub screw.

7. Remove blue end plate from paper sensor end of scanner by removing screwsindicated in Ref. 3.

8. Loosen black hex-headscrews holding rollerbearings in place. See Ref. 4.

9. Remove rollerout of extrusion.

10. Remove Paper Sensor Arm Assembly from rollerbearing. Ref. 5.

11. Insert same Paper Sensor Arm Assembly into newroller, making sure fully clipped into location.

Ref. 2.

Ref. 3. (x4)Ref. 4.


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12. Position roller on to extrusion and line up the bearings with the screw holes(particularly the first bearing). As ref. 6, making sure the rubber part of roller iscentral to hole

13. Check that the bearings spin easily on spindlebefore inserting. Setup the first bearing with thelocking washers. Ref. 7. Make sure that thebearing spins without having much L/Rmovement.

14. Insert new roller back into extrusion, with the first bearing going into motor end plate.

15. Screw bearings on to extrusion. A screwdriver is sometimes required to push themin line with holes in extrusion.

16. Fit cog onto shaft using 'Loctite 641' glue (www.loctite.co.uk/PRODUCTS/641.htm).

17. Check that the extrusions and rollers are level by using a metal ruler across bothextrusions (Ref. 8). The tips of the edges should be level with the roller. If not, useshims* to line up theextrusion. If one edge istoo low, place shim*under screw area ofextrusion to raise up toright level.

* A shim is a plastic sheet which is precisely made to specified thickness


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18. Check all the rollers down the length of the extrusion to make sure that they are allaligned.

Correct

IncorrectPlace shim under left hand extrusion to raise to same level as the other.

When extrusions are correct, refit and set-up:

? End plate (recheck extrusion levels as above after fitting end plate, incase ithas moved the alignment

? Paper Sensor Arms (P. 39)? Motor Mount and belts (P. 40)? Tubes (P.41)? End casts and control panel.? Lid Cover.


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Ref.1.

5.9.3 Replacing Motor and cable.

To replace the motor in the series 4 scanner, first remove the old motor as follows:

1. Turn off and unplug power to scanner.2. Remove LH end cast and LH side panel from scanner.3. Unplug motor connector from digital board (Ref.1.)4. Cut off connector and feed from behind boards.5. Remove 4 retaining screws (Ref.2.) from motor.6. Remove motor and cable from scanner.7. Remove motor from plate and fit new motor in place.

8. Feed the new motor cable through chassis as in Ref.3. below.9. Feed Cable behind board.10. Cut wires to length, strip ends and crimp Molex crimps to wires.11. Populate connector as shown in diagram below12. Re-connect connector to digital board J5.13. Replace end cast and side plate.14. Power up and boot PC.

Ref.2.

Ref.3.

Blue Red Green Black White Yellow

Wiring for motor cable connector fordigital board J5


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6 Firmware Download

Firmware update instructions for a Colortrac Series Scanner

1. Shut down scanner and PC.2. Power up scanner, holding the 2 control buttons down together.3. Power up PC.4. Open AIS4Diag (as shown above)5. Locate the latest version of firmware for your scanner using browse button. NOTE:

S4e and original scanners have different firmware.6. Run download by entering password ‘action’ and waiting until complete.7. Shut down scanner and PC.8. Reboot scanner and PC.9. Recalibrate scanner.

Scanner now ready for use.

NOTE: Anything prior to firmware version Vb52 on the Enhanced version*

needs to have the dip switches set on the digital board within the left hand side panel.Setting switch 7 on and powering up scanner takes it into boot mode

* Including pre-enhanced scanners without FireWire.

Browse button

Never changethis value!! !

OFF ON


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6.1 Paper Guide Assembly Adjustment.

The following procedure should be used to achieve the correct pinch between the pinchrollers on the paper guide assembly and the drive rollers.

1. Set both end Lid Adjustment levers to position ‘1’.

2. Loosen the four hex head screws, two either end of lid.


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3. Check for free movement of the paper guide assyby moving in all directions… ..

4. … ..checking that there isn’t any gaps between the rollers and thatthey are sitting flat against each other.

2. Re-tighten the four hex head screws.


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6.2 Unpacking a Scanner.

1. Cut straps around box.2. Remove packaging.3. Check the box inside has the following contents.

? Mains lead? Wooden block.? 4 x Castors.? 4 x Washers.? Resealing Straps.? 12mm Spanner.? 17mm Spanner.? Anti-tilt locking Pin.? Software CD.? Operator Manual.? Auto-stitch target (unless 3640e)? FireWire cable.

4. Unbolt scanner from base.5. Place wooden block under one end of scanner stand.6. Insert castors.7. Repeat for other end.8. Lift scanner off base.9. Connect to mains10. Connect to PC.11. Download ScanWorks, CopyWorks and other required software.12. Turn scanner on and reboot PC.13. Check for focus and alignment.


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6.3 Current Software/Firmware versions.

The following list of software version was correct at the time of release of this servicemanual. Any upgrades or changes will be informed to registered engineers though e-mail bulletins. Any queries please contact [email protected].

New camera boards were introduced for scanners where the third from last digit of theserial number is a ‘5’ (i.e. 42403501) and above. These require a different firmware fromscanners prior to that number, see table below.

Scanner Model Associated S/N ScanWorksVersion*

CopyWorks 2Version*

FirmwareVersion*

Original S44****1**4****2**4****3**

Version 2.3.3 Build 18 Va37

Older EnhancedS4e

4****4** Version 2.3.3 Build 18 Vg54

NewerEnhanced S4e 4****5** Version 2.3.3 Build 18 Vg60

The new cameras used in the latest series 4 scanners are different from perviouscameras fitted (see page 26). By downloading the wrong firmware into a scanner otherthan indicated above, will result in the scanner not seeing the cameras correctly so willsit in a permanent state of warm up and will sit with a flashing amber continually. If thisis the case, put the scanner into boot mode, as shown in ‘Firmware Download’ (page54), and re-install the correct firmware as shown in the table above.

* Information correct at time of issue of service manual.


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6.4 Installation Flow Chart

Is Scanner still packed? No

Yes

Record damage topackage and check'shock-watch' labels

Yes

No

Visually check scanner.Any damage?

Un-pack Scanner

Plug Scanner to mains.Connect to PC via FireWire/SCSI. Does Scanner LEDS and Tubes

come on? No

Yes

Run ScanWorks and run test scan tocheck image. Is Image OK?

Is Mains and Scannerswitched on?

No

Contact Support forfurther advice

Yes

Yes

No

Run re-calibration in 'Data Control' inScanWorks. Does it pass?

Yes

No

Run auto-stitch in 'Data Control' inScanWorks. Does it pass? No

Is Image outof focus.

No

Yes

Refer to Servicemanual and re-

focus and magnifyand align

Has image anylines or un-evencolouring across

Yes

No

Has image out ofstitch, i.e. steps

in image atcamera points.

Yes

No

Contact Support forfurther advice

Scanner is ready forcustomer use.Yes

Check stitch pointsand values, if

necessary re-alignscanner.

NOTE:Before installing scanner, fitthe FireWire/SCSI card to thePC and power up. Check thatdrivers and card are working.Then power down the PCready for installation.


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6.5 Fitting Scanning Tape and Springs to Paper Guide Assembly.

The paper guide assembly has under gone modifications since the creation of the series4 scanner to improve the feed of the old and rolled documents through the paper guideassembly. The following has to be done properly and accurately to ensure good mediatransport.

1. Remove paper guide assembly.

2. Lay PGA on to work area/bench that is flat with the paper hold down facing upwards.

3. Remove one of the end mechanisms, so that the paper hold down can be taken out.NOTE: Make sure the screws, washers and bearings are all removed and kept in asafe place.

4. Cut two strips of Scanning tape to length of the paperhold down, allowing 1cm gap at either end (I.e. tape 2cmshorter that PGA surface).

5. Clean the surface with a cleaning chemical to removeany dirt or oils.

1. Set to '5'

2. Pull out &turn

3. Lift outfrom back ofPGA


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6. Peal back small amount of backing from tape and position tape so that the edge islevel with the pinch roller cut outs.

THIS IS IMPORTANT OTHERWISE THE TAPE WILLOVER LAP THE PAPER HOLD DOWN AND CATCHON THE MEDIA AS IT GOES THROUGH SCANNER.

7. Only whensatisfied that tapeis correctlypositioned stickdown the end with

adhesiveexposed.

8. Peel back small amount of backing at a timeand make sure that the tape stays level with thepinch roller cut outs, as well as making sure thatduring this process the tape does NOT haveripples in it.

9. When the backing is completely removed, make sure the tape is stuck by rubbingover the tape with a cloth. There should be NO bubbles under the tape at all.

10. Using a shape knife, trim the tape away from the cut outsfor the paper sensors making sure that the cut is smoothwithout any rough points.

11. Repeat for opposite side of PGA.


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12. Using finger or fingernail, run along the metaledge of PGA so that the plastic tape is slightlybent downward into the gap where the paperhold down goes.

13. Repeat on other tape.

14. Position and stick the 3 springs on to PGA. 1 in middle & 1 at either end in line withthe middle of the first 2 sets of pinch rollers.

15. Return paper hold down into the PGA making sure springs are pressed under thehold down as it slides along.

16. Put the end mechanism back on, replacing the bearings, washers and screws.

NOTE: Do not over tighten these screws as this may cause the inserts to be pulled out.

17. Return PGA to scanner and set up the pinch distance as shown in '6.1 Paper GuideAssembly Adjustment'.


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6.6 Voltage Readings for the Digital Board

Digital BoardConnector J4

PSUConnector TB2

Pin 1 2 3 4 5 6 7 8Wire R Blk O W P YVolts 3V3 GND 5V 6V 15V 40V

8way Molex connector

Digital BoardConnector J5 Motor

Pin 1 2 3 4 5 6Wire Y W Bk G R BlVolts 40V 40Vsignal*

6way Large Molex connector* Drops to 38V when motor

running

Digital BoardConnector J6 Ballast JP5

Pin 1 3 5 7 9 2 4 6 8 10Volts datasignal 5V 0V_dig

10way T&B Ribbon connector ControlPanel JP1

Sensor Sensor

Pin 1 2 3 4 5 6Wire RFnt RRear WtFnt WtRear BlkRear BlkFnt

Volt 1.169 4.6V 0V Sensor normalVolt 1.169 0.091 0V Sensor activated

6way Small Molex Connector


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6.7 Warranty Procedure.

1. Support and Training1.1. Colortrac shall provide the Distributor with brochures (at cost) and up to date information

concerning the Products in order to assist the Distributor with the sale of the Products in theTerritory, and Colortrac shall endeavour to answer any technical enquires concerning theProducts which are made by the Distributor.

1.2. Colortrac shall provide the Distributor with names of Colortrac's contact personnel for thepurposes of business planning, reporting, purchase orders and servicing and shall notify theDistributor of any changes in such personnel.

1.3. Colortrac shall provide such sales and service training as may be reasonably required by theDistributor such training normally to be at the offices of Colortrac and delivered in English.Where such training is provided other than at the offices of Colortrac the Distributor shallreimburse to Colortrac all travelling and other expenses reasonably incurred by personnel ofColortrac in providing such services.

1.4. The Distributor shall: provide preventative and remedial field service support for the Productswithin the Territory; appoint a suitable number of qualified service personnel and send them toColortrac’s premises for training; purchase adequate spare parts to meet the servicing needs ofthe installed Products.

2. Warranty, Liability and Indemnity2.1. Colortrac warrants to the Distributor that all the Products supplied under this Agreement will be

of reasonable quality and will conform to the specifications published by Colortrac which are ineffect at the time when an order is received. Colortrac warrants the Products and parts thereoffor a period of 24 months from the date of its invoice to the Distributor or 24 months from thedate of installation (as defined on the completed AIS installation report), the total period not toexceed 27 months from the invoice date. The warranty covers defects in material andworkmanship provided that the defects arise from normal use and according to Colortrac'spublished instructions. The warranty does not apply to parts that are affected by normal wearand tear.

2.2. The procedure for returning defective Products or parts thereof shall be: Distributor shall notifyColortrac in writing, by email, fax or telex of the Products or parts thereof believed to bedefective and obtain a Returns Number which must be clearly shown on all items returned;items shall be returned carriage paid by the Distributor to Colortrac unless Colortrac has agreedin writing to an alternative procedure to be followed or for the warranty to be fulfilled on-site byColortrac; Products or parts thereof which are to be repaired or replaced by Colortrac shall bedespatched carriage paid to the Distributor at their normal address, unless otherwise agreed.

2.3. Colortrac shall not, except in respect of death or personal injury or serious property damagecaused by negligence of Colortrac, be liable to the Distributor by reason of any representation orimplied warranty, condition or other term or any duty at common law, or under the express termsof this Agreement, for any consequential loss or damage (whether for loss of profit or otherwiseand whether occasioned by the negligence of Colortrac or its employees or agents or otherwise)arising out of or in connection with any act or omission of Colortrac relating to the manufacture orsupply of the Products, their resale by the Distributor or their use by any customer.

2.4. The Distributor shall indemnify Colortrac against all claims, loss, expenses or damages incurredor arising in connection with: any breach of this Agreement; any violation of any applicable law orregulation; any alteration or modification of any Product by the Distributor; the sale or distributionof any Product known to be damaged or defective; any modification by the Distributor ofColortrac's standard warranty.

colortrac s4e service manual-2

Documents

paper guide

paper guide

upper mirror

inch black

technical

adjusting

0v resisters

hex head screws