Contex HD Ultra X 6000 Technical Service Manual
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Contex HD Ultra X 6000 Technical Service Manual

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Technical Service Guide:
HD Ultra X

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  • Page 1 Technical Service Guide: HD Ultra X...

  • Page 2: Table Of Contents

    HD Ultra X Service Guide Contents Information ..............................4 Revision Table ............................... 4 Scanners covered by this Service Guide: ...................... 4 Design ................................ 5 Block Diagram ..............................6 Wiring Diagram .............................. 7 Camera Module layout (CBT) ........................8 Scanner Control Unit layout (SUX) ........................ 8 Troubleshooting ............................
  • Page 3 HD Ultra X Service Guide Gas Pistons ..............................92 Camera Module ............................94 Adjustments ............................100 Lid Sensor Adjustment ..........................101 Camera Adjustment, Overview ........................103 Camera Adjustment, Light Profile ......................105 Camera, Coarse Focus, Scan Width & Tilt Adjustment ................106 Camera, Focus Final Adjustment .......................

  • Page 4: Information

    This restriction does not limit the Recipients right to use information contained in the data if it is obtained from another source without restriction. This service guide shows images and instructions using the HD Ultra X 6000 model, but all the HD X Series are treated exactly the same.

  • Page 5: Design

    HD Ultra X Service Guide 2. Design Electronics. Block Diagram Wiring Diagram Circuit board layout’s Adjustments. Cross Section View Page 5...

  • Page 6: Block Diagram

    HD Ultra X Service Guide Block Diagram HD Ultra X 6000 HD Ultra X 4200/3600 Page 6...

  • Page 7: Wiring Diagram

    HD Ultra X Service Guide Wiring Diagram HD Ultra X 6000 HD Ultra X 3600/4200 Page 7...

  • Page 8: Camera Module Layout (Cbt)

    HD Ultra X Service Guide Camera Module layout (CBT) Scanner Control Unit layout (SUX) Page 8...

  • Page 9: Troubleshooting

    HD Ultra X Service Guide 3. Troubleshooting Troubleshooting Sequence. Image Quality problems.  Error codes displayed on keypad  Image Quality problems  Dust related errors  Calibration related errors  Curly or Folded originals Note! Before replacing any electrical parts such as SUx (Scanner Control Unit) or the Cameras, the parameter block should be erased and the scanner calibrated.

  • Page 10: Error Codes Displayed On Keypad

    HD Ultra X Service Guide Error codes displayed on Keypad Diagnostic Paper Error Codes displayed on the Keypad. An error condition is indicated by a flashing Diagnostic Indicator. The error may be identified by an Error Code Number being displayed on the screen and/or by the following combinations of flashing (F) indicators on the Operator Panel: See Appendix D for error code description.

  • Page 11: Image Quality Problems

    HD Ultra X Service Guide Image quality problems Streaks that have been introduced in the Calibration either through a worn out Calibration sheet or a dirty scanner.  Clean scanner (replace Glass plate and White back-ground if necessary)  Replace Calibration sheet if worn out or damaged and calibrate scanner. Stitching problems Other issues could be that the scanner simply needs to be calibrated, either because the parameter block has been erased, never been calibrated or that the scanner has been moved around.

  • Page 12: Banding Problems

    HD Ultra X Service Guide Banding problems  Bad/no grey balance calibration (Camera to Camera match). Page 12...

  • Page 13: Part Replacement

    HD Ultra X Service Guide 4. Part Replacement Tools Required Special Service Tools  Optical Adjustment Pattern Common Hand Tools  Torx 6 Straight  Torx 9 Straight  Torx 10 Straight  Torx 15 Straight & Angled  Torx 20 Straight & Angled ...

  • Page 14: Identifying Parts

    HD Ultra X Service Guide Identifying Parts Page 14...

  • Page 15: Parts List

    HD Ultra X Service Guide Parts List Part no. Description Service Parts 0007S046R01 Inlet 0075A160R01 Paper/Lid Sensor (1 pcs.) 0077E038R01 RFI-Filter 0080C031R01 Filter Kit, 92x92 (for 0080C032) 2867G102 Springs for ATAC, RA67G (2 pcs) 2867G107 PSU, 24V/200W, ATM200T 2867G108 SUX Variant A 2867G109 Camera Module, RB67G 2867G110...
  • Page 16 HD Ultra X Service Guide Part no. Description Consumable’s 2867G112 White Background Plate, 60", packed 2867G148 White Background Plate, X42, packed 2867G113 Glass Plate, 60", packed 2867G149 Glass Plate, X42, packed 2867G114 Calibration Sheet, 60", packed 2867G150 Calibration Sheet, X42, packed Refurbishment Parts 0601A005R01 Castors (4 pcs.)

  • Page 17: Replacing Covers

    HD Ultra X Service Guide 5. Replacing Covers Right Hand Side Cover  Tools: T15 Torx Screwdriver  T20 Torx Screwdriver  Prerequisites: none 1. Remove the 4 x T20 screws from the end cover. 2. Remove the 1 x T15 screws from the inside of the end cover. Page 17...
  • Page 18 HD Ultra X Service Guide 3. Remove the 1 x T15 screws from the underside of the end cover. 4. Carefully pull the end cover away from the end of the scanner, making sure not to remove completely because of the control flat-cable to the control panel. 5.
  • Page 19 HD Ultra X Service Guide 6. When refitting the Cover Assembly, reconnect the Flat-cable, by pressing in until it clicks in place. Try to reduce the amount of strain on the cable and connector while doing this to avoid damage to the cable. NOTE: Make sure the flat-cable is inserted so the wire contacts are face DOWN (towards the board).
  • Page 20 HD Ultra X Service Guide 9. Refit the 4 x T20 screws in the Cover Assembly. Page 20...

  • Page 21: Left Hand Side Cover

    HD Ultra X Service Guide Left Hand Side Cover  Tools: T15 Torx Screwdriver  T20 Torx Screwdriver  Prerequisites: none 1. Remove the 4 x T20 screws from the end cover. 2. Remove the 2 x T15 screws from the inside of the end cover. Page 21...
  • Page 22 HD Ultra X Service Guide 3. Remove the end cover. 4. While holding the LH end cover in place, refit the T15 self-tapping screw. 5. Refit the T15 self-tapping screw under the Feed Table Cover. Page 22...
  • Page 23 HD Ultra X Service Guide 6. Refit the 4 x T20 screws in the end cover. Page 23...

  • Page 24: Feed Table Cover

    HD Ultra X Service Guide Feed Table Cover  Tools: T10 Torx Screwdriver  Prerequisites: none 1. Remove the 1 x T10 countersunk screw from the RH side plate. 2. Remove the Paper Guide from the recess in the Feed Table Cover. 3.
  • Page 25 HD Ultra X Service Guide 5. Remove the 5 x T10 screws from along the underside of the Feed Table Cover. 6. Pull the Feed Table Cover forward, and then lift out from the scanner. 7. When refitting the Feed Table Cover, start with the edge underneath the scanner, and rotate around down into place.
  • Page 26 HD Ultra X Service Guide 8. While pressing the Feed Table Cover in place, make sure the locating pins are lined up with the holes in the chassis. 9. Refit the 5 x T10 screws along the underside of the Feed Table Cover. 10.
  • Page 27 HD Ultra X Service Guide 11. Refit the T10 Countersunk screw into end plate. 12. Position the LH paper guide into the gap at the end of the Feed Table Cover. 13. Refit the T10 Countersunk screw into end plate. Page 27...

  • Page 28: Rear Panel

    HD Ultra X Service Guide Rear Panel  Tools: T10 Torx Screwdriver  Prerequisites: none 1. Remove the T10 screws from the Rear Panel. 2. Lift the rear Panel up so the lip of the panel is free from the chassis of the scanner. 3.
  • Page 29 HD Ultra X Service Guide 4. When refitting the Rear Panel, make sure the lip of the panel goes into the chassis, before lowering down into position. 5. Refit the T10 screws. Page 29...

  • Page 30: Otac Top Cover

    HD Ultra X Service Guide OTAC Top Cover  Tools: T10 Torx Screwdriver  Prerequisites: none 1. Open the OTAC Assembly by depressing the Lid Latches at both ends. 2. Loosen the 3 x T10 screws along the front of the Guide Plate, these are inside small holes along the extrusion.
  • Page 31 HD Ultra X Service Guide 4. Lift the Top Cover off from the OTAC. 5. To refit the Lid Cover, with the OTAC at its highest level, position the Lid Cover back on the Guide Plate. 6. Making sure the locating pins go into slots on the OTAC at both ends. Page 31...
  • Page 32 HD Ultra X Service Guide 7. Retighten the 3 x T10 locking screws to hold the Lid Cover down and in place. 8. Press down on the Guide Plate until both ends lock in place to close. Page 32...

  • Page 33: Replacing Parts

    HD Ultra X Service Guide 6. Replacing Parts OTAC Assembly (Guide Plate Assembly)  Tools: T20 Torx Screwdriver  Pliers  Prerequisites: Remove the OTAC Top Cover (see page 30).  Remove the Feed Table Cover (see page 24).  Remove LH &...
  • Page 34 HD Ultra X Service Guide 3. Repeat for the right end, again making sure to use a cloth to prevent the e-clip falling into the chassis. 4. Slide a piece of paper under the Guide Plate Hinge, to prevent the T20 screw falling into the chassis while removing it from the side plate.
  • Page 35 HD Ultra X Service Guide 6. Lift the OTAC and remove the brass spacers at both ends. 7. Carefully push the Gas Piston off from the bracket, making sure not to cause any damage. 8. Repeat for the other end of the Guide Plate. Page 35...
  • Page 36 HD Ultra X Service Guide 9. Carefully lift the Guide Plate off from the chassis. 10. When refitting the Guide Plate, make sure the Gas Pistons go inside of the end plates. 11. Position the Gas Piston over the pillars on the end plates at both ends. Page 36...
  • Page 37 HD Ultra X Service Guide 12. Lift the OTAC and refit the brass spacers at both ends. 13. While pressing down on the Guide Plate, to align the screw holes, and using paper to cover the gap to prevent the screw falling into the chassis, refit the long T20 screw. Do this at both ends of the Guide Plate.

  • Page 38: Glass Plate

    HD Ultra X Service Guide Glass Plate Tools:  None Notes:  Consumable Item 1. Open the OTAC Assembly by depressing the Lid Latches at both ends. 2. Using your finger at one end of the glass, gently lift the glass slightly out of the extrusion. 3.
  • Page 39 HD Ultra X Service Guide 4. Before refitting, use a soft lint-free cloth and carefully clean the under-side of the glass to remove finger prints and any other marks or dust. 5. Align the end of the glass plate with the end of the recess, and gently lower the glass down. 6.
  • Page 40 HD Ultra X Service Guide 7. Clean the top surface of the glass plate to remove any finger prints, marks or dust. 8. Close the OTAC Assembly by pressing down until both end latches click shut. 9. Calibrate the scanner using WIDEsystem. Page 40...

  • Page 41: White Background Plate

    HD Ultra X Service Guide White Background Plate Tools:  None 1. Open the OTAC Assembly by depressing the Lid Latches at both ends. 2. Use your finger to pull the White Background Plate free from the Guide Plate. 3. Pull the White Background Plate free all along the Guide Plate. Page 41...
  • Page 42 HD Ultra X Service Guide 4. Remove the White Background Plate from the Guide Plate. 5. To refit, hook the edge of the White Background Plate, over the lip of the extrusion. 6. Push the back of the White Background Plate up into the recess. Page 42...
  • Page 43 HD Ultra X Service Guide 7. Repeat all along the White Background Plate until it is fully in place, and moves up and down freely. Page 43...

  • Page 44: Led Light Module

    HD Ultra X Service Guide LED Light Module Tools:  T10 screwdriver. Prerequisites:  Remove the OTAC Assembly (see page 33). 1. Remove the ‘K’ plates from both-ends of the Light Module. 2. Remove the T10 screw and the countersunk screw from the left-hand end. 3.
  • Page 45 HD Ultra X Service Guide 4. Retrieve the brass spacers if necessary. 5. Lift the Lighting Module up to access the connector. 6. Disconnect the cable. 7. Remove the LED Lighting Module. Page 45...
  • Page 46 HD Ultra X Service Guide 8. Reposition the Light Module into the re-cess, with the connector at the right hand end. 9. Reconnect the cable connector. 10. Lower the light module fully in place. Page 46...
  • Page 47 HD Ultra X Service Guide 11. Refit the 2 x T10 screws and brass spacers into the right hand end. 12. Refit the T10 screw and the countersunk screw into the left-hand end. 13. Refit the K plates, making sure they are the correct way around, and the locating holes are correctly positioned.

  • Page 48: Idle Rollers

    HD Ultra X Service Guide Idle Rollers Tools:  T10 screwdriver. Prerequisites:  Remove the OTAC Top Cover (see page 30). 1. To remove the Idler Roller Spring Bracket, remove the T10 screw. 2. Remove the Idler Roller Spring Bracket. Page 48...
  • Page 49 HD Ultra X Service Guide 3. Remove all the Idler Roller Spring Brackets. 4. Remove the Idler Roller Unit. 5. Refit the Idler Roller Unit, taking care not to damage the rubber rollers on the metalwork. Page 49...
  • Page 50 HD Ultra X Service Guide 6. Refit the Idler Roller Spring Brackets making sure the holes are at the rear of the brackets and goes over the pillars on the Guide Plate. 7. Refit the T10 screws. 8. Refit the OTAC Top Cover. Page 50...

  • Page 51: Controller Board (Sux Variant A)

    HD Ultra X Service Guide Controller Board (SUX Variant A) Tools:  T10 screwdriver.  Prerequisites: Remove the Feed Table Cover (see page 24).  Remove RH Side Cover (see page 17). 1. Press down on both the locating tabs at either end of the connectors and pull the flat-cable free from the connector.
  • Page 52 HD Ultra X Service Guide 5. Using anti-static precautions, lift the Controller Board from the chassis, remembering to disconnect the USB and Ethernet extension cables that are also attached. 6. Refit the board, making sure the USB and Ethernet go through their relevant cut-outs in the end plate.
  • Page 53 HD Ultra X Service Guide 8. Reconnect all the cables into their correct positions. Push the flat cables in the correct orientation (wire contacts face DOWN), making sure they click into place. 9. Make sure the right cables are in the correct location on the Controller Board. 10.

  • Page 54: Power Supply Unit

    HD Ultra X Service Guide Power Supply Unit  Tools: T10 screwdriver.  5.5mm Wrench  Prerequisites: Remove the Feed Table Cover (see page 24).  Remove RH Side Cover (see page 17). IMPORTANT NOTE: Allow 20 minutes before removing the PSU to allow for any stored power to discharge. 1.
  • Page 55 HD Ultra X Service Guide 3. Disconnect the power wires from the PSU. 4. Use the 5.5mm Wrench to loosen the 4 x Long Spacers. 5. Remove the 4 x Long Spacers. 6. With the PSU moved slightly out, disconnect the cable from the rear connector. 7.
  • Page 56 HD Ultra X Service Guide 8. Before replacing the PSU, reconnect the cable in the far corner, making sure it is pressed fully home. 9. Align the PSU to the chassis spaces and refit 4 x Long Spacers. 10. Tighten using the 5.5mm Wrench. Page 56...
  • Page 57 HD Ultra X Service Guide 11. Reconnect the Power to the PSU, making sure the Red goes on the VO+, Black to the VO- 12. Refit the Protective cover, aligning to the holes of the Long Spacers. 13. Refit the 4 x T10 screws to hold the protective cover in place. Page 57...

  • Page 58: Interconnection Board

    HD Ultra X Service Guide Interconnection Board Tools:  T10 screwdriver. Prerequisites:  Remove the RH Side Cover (see page 17). 1. Gently pull the control panel flat-cable out of the Interconnection Board connector. 2. Remove the 2 x T10 screws holding Interconnection Board in place. 3.
  • Page 59 HD Ultra X Service Guide 4. Replace the Interconnection Board. 5. Replace the 2 x T10 screws. 6. Press fit the Flat Cable from the control panel correctly into the connector. 7. Refit the Cover Assembly. Page 59...

  • Page 60: Drive Belt

    HD Ultra X Service Guide Drive Belt Tools:  T10 screwdriver. Prerequisites:  Remove the LH Side Cover (see page 21). 1. Loosen, but do not remove, the T10 retaining screw. 2. Move the tensioning bracket to its highest position and retighten the T10 retaining screw. Page 60...
  • Page 61 HD Ultra X Service Guide 3. Remove the Drive Belt. 4. Refit the Drive Belt by feeding over all the drive pulleys, tension pulley and motor pulley. 5. With the Drive Belt in place, just loosen the retaining screw and allow the tension bracket to settle into place.
  • Page 62 HD Ultra X Service Guide 6. Before tightening the retaining screw, move the pulleys back and forth to allow the belt to settle into its natural position, then tighten the T10 screw. Page 62...

  • Page 63: Cooling Fan And Filter Kit

    HD Ultra X Service Guide Cooling Fan and Filter Kit Tools:  T20 screwdriver. Prerequisites:  Remove the Feed Table Cover (see page 24). 1. Remove the 4 x long T20 screws from each corner of the Filter Kit. 2. Remove the Filter Kit. Page 63...
  • Page 64 HD Ultra X Service Guide 3. Pull the Cooling Fan Connector out from underneath the chassis, taking care not to damage any of the other cables. 4. Disconnect the Cooling Fan cable connectors. 5. Remove the Cooling Fan unit. 6. Replace the Cooling Fan unit, aligning up with the screw holes. Page 64...
  • Page 65 HD Ultra X Service Guide 7. Reconnect the Cooling Fan cable connectors. 8. Replace the Filter Kit. 9. Align the long T20 screws to the holes in the bracket, and tighten. Page 65...

  • Page 66: Paper Sensor

    HD Ultra X Service Guide Paper Sensor Tools:  T10 screwdriver. Prerequisites:  Remove the Feed Table Cover (see page 24). NOTE: This procedure is the same for any of the Opto-sensors. 1. Remove the single T10 screw from the appropriate Paper Sensor. 2.
  • Page 67 HD Ultra X Service Guide 3. Disconnect the Paper Sensor cable. 4. Reconnect the new Paper Sensor. 5. Refit the sensor pin into the hole in the bracket. 6. Fit the T10 screw to hold the sensor in place. Page 67...

  • Page 68: Inlet Connector And Rfi Filter

    HD Ultra X Service Guide Inlet Connector and RFI Filter Tools:  T20 screwdriver. Prerequisites:  Remove the LH Side Cover (see page 21). 1. To change the RFI Filter: Remove the wires of the RFI Filter. 2. Remove the 2 x T20 screws from the RFI Filter. Page 68...
  • Page 69 HD Ultra X Service Guide 3. Remove the RFI Filter. 4. To remove the Inlet Connector, first remove the T20 screw attaching the earth cable. 5. Remove the 2 x T20 screws holding the Bracket to the chassis, and remove the Inlet Connector Bracket.

  • Page 70: Stepper Motor

    HD Ultra X Service Guide 6. When refitting the Inlet Connector, make sure the locating tabs, go into the cut-outs. Stepper Motor Tools:  T20 screwdriver.  Prerequisites: Remove the Feed Table Cover (see page 24).  Remove the Drive Belt (see page 60). 1.
  • Page 71 HD Ultra X Service Guide 3. Remove the motor from the chassis. 4. Refit in the reverse order. 5. Refit the Drive Belt and Feed Table Cover. 6. Calibrate the scanner. Page 71...

  • Page 72: Feed Rollers & Lid Sensor

    HD Ultra X Service Guide Feed Rollers & Lid Sensor Tools:  T20 screwdriver.  Prerequisites: Remove the OTAC Assembly (see page 33).  Remove the Glass Plate (see page 38).  Remove the Rear Panel (see page 28).  Remove Drive Belt (see page 60).
  • Page 73 HD Ultra X Service Guide 3. Remove E-clip from the Drive Pulley. 4. Remove the Drive Pulley. 5. Remove the 2 x T10 screws and the bearing bracket. Page 73...
  • Page 74 HD Ultra X Service Guide 6. Push the Roller out to be able to get the bearing, and remove the bearing. 7. Remove the Rear Feed Roller. 8. Loosen, but do not remove, the T10 screw holding the Sensor bracket to the chassis. Page 74...
  • Page 75 HD Ultra X Service Guide 9. Lift the sensor bracket out to the slot of the chassis. 10. Disconnect the Sensor Cable, and remove the Sensor. 11. Reconnect the replacement Sensor to the Sensor cable. 12. Refit the Sensor Bracket into the slot (making sure the T10 retaining screw is loose in place on the bracket).
  • Page 76 HD Ultra X Service Guide 13. While holding the Sensor Bracket in place, retighten the T10 screw. 14. Refit the Feed Roller back into the chassis. 15. Refit the bearing back onto the Feed Roller back. Page 76...
  • Page 77 HD Ultra X Service Guide 16. Refit the 2 x T10 screws to hold the retaining bracket on. 17. Refit the Drive pulley onto the Feed Roller Shaft. 18. Refit E-clip to hold the Drive Pulley onto the Feed Roller Shaft. Page 77...
  • Page 78 HD Ultra X Service Guide 19. Refit the rear Feed Roller Cover. Make sure the cut-out goes around the sensor, and the cut outs of the cover goes between the locking screw and the chassis. 20. Refit the Glass Plate. 21.
  • Page 79 HD Ultra X Service Guide 22. While making sure the Feed Roller Plate is level with other end of the scanner is level with the glass, tighten up the lower T10 screw. Tighten all the remaining lower T10 screws, while still making sure the Feed Roller Cover is level with the glass plate.

  • Page 80: Tacho Sensor

    HD Ultra X Service Guide Tacho Sensor Tools:  T10 Torx Screwdriver. Prerequisites:  Remove the Right Hand End Cover (see page 17). 1. Loosen, but do not remove, the T10 screw. 2. Remove the Sensor Wheel. Page 80...
  • Page 81 HD Ultra X Service Guide 3. Gently pull the Sensor until it is released from the bracket. 4. Gently pull the cable connector out from the Sensor. 5. Reconnect the cable connector into the Sensor. Page 81...
  • Page 82 HD Ultra X Service Guide 6. Feeding the cable into the bracket cut-out, reposition the Sensor onto the bracket, making sure not the damage the locating tabs in the process. 7. Make sure the Sensor if fully pressed down. 8. Refit the Sensor Wheel over the T10 screw in the Feed Roller shaft. Page 82...
  • Page 83 HD Ultra X Service Guide 9. Refit the Sensor Wheel over the T10 screw in the Feed Roller shaft. 10. Refit the Right Hand End Cover. Page 83...

  • Page 84: Mirror Unit

    HD Ultra X Service Guide Mirror Unit  Tools: 7mm Spanner / Nutspinner.  T10 Torx Screwdriver.  T20 Torx Screwdriver.  Prerequisites: Remove the Left Hand End Cover (see page 21).  Remove the Right Hand End Cover (see page 17). ...
  • Page 85 HD Ultra X Service Guide 3. Remove the 3 x T10 screws from the Lower Panel. 4. Remove the 2 x T20 screws holding the Foot Bracket on other end of the scanner. 5. Release the Foot Bracket. Page 85...
  • Page 86 HD Ultra X Service Guide 6. Remove the 3 x T10 screws from the Lower Panel. 7. Tilt the scanner back slightly and remove the Lower Panel from the scanner. 8. Remove the 2 x M4 nuts and washers holding the retaining pins in the Mirror Unit. Page 86...
  • Page 87 HD Ultra X Service Guide 9. Lift the end of the scanner up, and prop up using a block, or the foot bracket. See the warning at the beginning of this instruction. 10. Pull out the retaining pin. 11. Pull out the other the retaining pin. Use a screwdriver in the hole of the retaining pin to make this easier if necessary.
  • Page 88 HD Ultra X Service Guide 12. Lower the end of the Mirror Unit, and pull out of the location pins that are on the other side chassis, and remove the unit. 13. Refit the Mirror Unit back into the chassis into the drive belt end of the scanner first. 14.
  • Page 89 HD Ultra X Service Guide 15. Lift the Mirror Unit into place so the grommets of the unit are level with the spacers. 16. Push both the Retaining Pins through the grommet and the Spacer to hold the Mirror Unit in place.
  • Page 90 HD Ultra X Service Guide 18. Refit the 2 x M4 nuts back onto the Retaining Pins. 19. Slightly tilt back the scanner, and refit the lower panel, making sure the pins on the panel, go into the slots in the scanner chassis. 20.
  • Page 91 HD Ultra X Service Guide 21. Refit the foot bracket and refit the 2 x T20 screws. 22. Refit the other foot bracket and refit the 3 x T20 screws. 23. Refit the Rear Panel, the Left and the Right Hand End Covers. Page 91...

  • Page 92: Gas Pistons

    HD Ultra X Service Guide Gas Pistons  Tools: Small Flat Screwdriver.  E-Clip Insertion Tool / Pliers  Prerequisites: Remove the OTAC Assembly (see page 33).  Remove the Mirror Unit (see page 84). 1. Use the small flat screwdriver to prise off the e-clip from the mounting pillar. 2.
  • Page 93 HD Ultra X Service Guide 3. Lift the Gas Piston out from the scanner. 4. Replace the Gas Piston with the shaft first into the scanner. 5. Slide the Gas Piston over the mounting pillar. 6. Use an e-clip insertion tool (or pliers) to refit the e-clip. 7.

  • Page 94: Camera Module

    HD Ultra X Service Guide Camera Module Tools:  T10 Torx Screwdriver Prerequisites:  Remove the Feed Table Cover (see page 24). 1. Disconnect the sensor and stepper motor cable. 2. To release the Camera Flat-cables, press both the locating tabs at either end of the connector….
  • Page 95 HD Ultra X Service Guide ….while gently pulling the cable out. 3. Loosen, but do not remove, the 2 x T10 screw. 4. Remove the T10 screw. Page 95...
  • Page 96 HD Ultra X Service Guide 5. Gently pull the Camera Module and board out of the camera housing. 6. (If necessary) To remove the Camera Board from the Module. Remove the 4 x T10 screws 7. Slide the Camera board out of the module. Page 96...
  • Page 97 HD Ultra X Service Guide 8. Before fitting the Camera Board, make sure the CIS is clean using a lint free optical cloth. 9. Slide the Camera Board into the module 10. Refit the 4 x T10 screws. Page 97...
  • Page 98 HD Ultra X Service Guide 11. Gently push the Camera Module and board into the camera housing. 12. Refit the T10 screw into the Camera Mount. 13. Tighten the 2 x T10 locking screws, but do NOT over tighten to risk damaging the camera lens.
  • Page 99 HD Ultra X Service Guide 14. Press fit the camera flat-cables until they click into place, making sure they are the correct orientation with the wire contacts towards the board. 15. Press fit the camera flat-cables until they click into place, making sure they are the correct orientation.

  • Page 100: Adjustments

    HD Ultra X Service Guide 7. Adjustments Special Tools Needed  Optical Adjustment Pattern Camera Adjustments  Scan Width  Focus  Tilt  Centering Please note: The following pages may show images that have fewer than seven cameras. The adjustment procedure is identical for both the HD Ultra and HD Ultra X models.

  • Page 101: Lid Sensor Adjustment

    HD Ultra X Service Guide Lid Sensor Adjustment Tools:  T10 Torx Screwdriver After refitting the OTAC, or if the Lid always shows as open, use these instructions to make adjustments to the sensor. 1. Press down on the Guide Plate until both ends lock in place to close. 2.
  • Page 102 HD Ultra X Service Guide 3. If the LED does NOT go out when the OTAC is closed, then remove the rear panel (see page 28) to access the sensor, to make adjustments. Remove the T10 screws and lift the rear panel off from the back of the scanner.

  • Page 103: Camera Adjustment, Overview

    Do not attempt any adjustment if you are not trained by a certified trainer, or have been directed to by Contex support staff! The process for adjustments of the cameras are exactly the same as for the original HD Ultra, some images will show the original HD Ultra, but follow the instructions in the same way.
  • Page 104 HD Ultra X Service Guide Index from previous images: 1. Camera Base Fixing Screws. Loosen when adjusting Scan Width. 2. Scan width Adjustment Screw. 3. Focus Lock Screws. Loosen when adjusting Focus. 4. Focus Adjustment Screw. 5. Camera Unit Fixing Screws. Loosen when adjusting Tilt. 6.

  • Page 105: Camera Adjustment, Light Profile

    HD Ultra X Service Guide Camera Adjustment, Light Profile For all cameras: 1. Select RGB (circled with red in image below). 2. Loosen/remove the Stepper Motor Fixing Screw (7). 3. Turn the Vertical Position Adjustment Wheel (8) until the cameras show undisturbed light profiles as shown below.

  • Page 106: Camera, Coarse Focus, Scan Width & Tilt Adjustment

    HD Ultra X Service Guide Camera, Coarse Focus, Scan Width & Tilt Adjustment For all cameras: 1. Open the Original Guide and place OAP in the scan area. Make sure to position the pattern by pushing it fully forwards and to the right. 2.
  • Page 107 HD Ultra X Service Guide 11. Select camera A: 12. Move the motor backwards and keep it in backwards position. 13. Turn the Vertical Position Adjustment Wheel (8) until the 1-8 lines are seen at either end. 14. Loosen the Camera Unit Fixing Screws (5). 15.

  • Page 108: Camera, Focus Final Adjustment

    HD Ultra X Service Guide Camera, Focus Final Adjustment 1. Select Quick Correct. 2. Optical Adjustment Pattern. 3. Select MTF. 4. Select Camera Adj. 5. Adjust the focus until a. The MTF (Red, Green and Blue curves) are over the straight green line. b.

  • Page 109: Widesystem / Service

    HD Ultra X Service Guide 8. WIDEsystem / Service WIDEsystem Service, walk though Description of each individual test in WIDEsystem Service Since this chapter is not scanner specific, some of the illustrations may not apply completely to the scanner you are working on, like number of Cameras and transition areas. Widesystem / Service consist of 17 different tests designed to help you service the scanner.
  • Page 110 HD Ultra X Service Guide Getting access to the Service module in WIDEsystem is done by clicking on the logo in upper left corner of WIDEsystem and selecting Service. A password is required. (contact Support for this password, if necessary) The service module default to the first tab, “Paper Path / Handling.
  • Page 111 HD Ultra X Service Guide Test 46. Paper Sensor Test. Checking all the sensors in the paper path. Tab for test related to Image Quality. Test 9. Camera Adjustment Provides you with a live image of what the Cameras are looking at. “Light Profile”...
  • Page 112 HD Ultra X Service Guide Test 12. Adjust Y-axis Scaling. Here the Y scaling can be adjusted. Scan a known size image measure in Nextimage, compare and adjust. The correction is done in % of the deviation. Test 20. Noise Test This test is very useful if there are image quality issues such as streaks throughout the scan.
  • Page 113 HD Ultra X Service Guide Tab for test related to Electrical components. Test 2. LED Test The LED’s on the Operators panel will flash one at a time. Page 113...
  • Page 114 HD Ultra X Service Guide Test 45. Operator Panel Key Test Each key will get a green check mark once they have been activated. Test 6. Stepper Motor Test The direction and the speed of the motor can be controlled. Page 114...
  • Page 115 HD Ultra X Service Guide Test 31. Lamp and Cooling Fan Test The status of the fan and the lamp Cartridge can be checked. Tab For test related to Electrical components. Page 115...
  • Page 116 HD Ultra X Service Guide Test 42. Backup Calibration and Statistics. Test 43. Restore Calibration and Statistics. Test 44. License System. Page 116...
  • Page 117 HD Ultra X Service Guide Tab for test related to Part replacement. Test 1. Scanner Information. Page 117...

  • Page 118: Firmware Download

    9. Firmware download Firmware Download, walk through. The latest Firmware can be obtained from www.contex.com. Identify the scanner model and download. The computer that will be used for the firmware download needs to have WIDEsystem installed! 1. Execute the file. Example of firmware file.
  • Page 119 HD Ultra X Service Guide 4. Select the scanner that you wish to upgrade and click next. 5. After validating the info, click next. 6. The Firmware program will now unpack, download and activate the firmware in the scanner. Page 119...

  • Page 120: Erase Parameter Block

    Erase Parameter block The Parameter block in the scanner can be erased through the Firmware program. Download the latest Firmware from www.contex.com. Identify the scanner model and download. The computer used for the firmware download needs to have WIDEsystem installed! Follow step 1 through 3 in upgrading firmware.
  • Page 121 HD Ultra X Service Guide Click YES to confirm that you want to Erase the Parameter Block. Only Data that can be restored by a Calibration will be Erased! Click OK to let the scanner reboot. Click on the Exit. The scanner now needs to be calibrated.

  • Page 122: Scanner Terms

    HD Ultra X Service Guide 10. Scanner Terms Activation Code Is the when the product specific License code has been pared with a Scanner serial no. AdaptiveThresholding Advanced 2-D Adaptive Thresholding estimates the background gray level in a window area around each pixel.
  • Page 123 HD Ultra X Service Guide The Black Level is a setting in scan programs used to change dark graytone colors to true black. For example, if one is copying a brochure with a mixture of text and pictures, the text will often be digitized to a color that we may see as black but really is a dark graytone.
  • Page 124 HD Ultra X Service Guide Centre Internationale d’Eclairage (CIE) is an international organization that establishes methods for measuring color. These color standards for color-metric measurements are internationally accepted specifications that define color values mathematically. The first color space model, the CIE xyz, was developed in 1931.
  • Page 125 HD Ultra X Service Guide Photographers and printers measure transmission in base-10 logarithmic density units, where transmission of unity corresponds to a density of 0, transmission of 0.1 corresponds to a density of 1, transmission of 0.01 corresponds to a density of 2, and so on. Density The light stopping ability of a film.
  • Page 126 HD Ultra X Service Guide Edit Modify an entry using standard Windows text-editing techniques. Emulsion The light sensitive silver, coated on the clear acetate film base, that forms the photograph when a picture is taken and the film is developed. Equalizing Distributing all color or tone equally along a density range.
  • Page 127 HD Ultra X Service Guide placed in a regular grid. In color printing it is conventional to use cyan, magenta, yellow and black grids that have exactly the same dot pitch but different carefully-chosen screen angles. Hardware id Is a unique id no for the scanner, based on the scanners serial no and MAC address. Highlights The lightest part of a picture - reproduced as white on the screen or when printed.
  • Page 128 HD Ultra X Service Guide JPEG Compression Joint Photographic Experts Group Compression. A method to save storage space by compressing files. JPEG achieves a high degree of compression by discarding non-important picture detail. JPEG A compressed file format for images. Named after the Joint Photographic Expert Group, JPEG images feature small file size and speed, but lower quality than other formats.
  • Page 129 HD Ultra X Service Guide The set of colors available for an image. PICT A file format for pictures used primarily on the Macintosh. Pixels Per Inch (ppi) A measurement of resolution for scanners, where the individual element is a square picture element (pixel).
  • Page 130 HD Ultra X Service Guide To turn the picture left (clockwise) or right (counter-clockwise) from the orientation in which it was scanned. Runlength Encoding A method of compressing raster or bitmap data by representing “runs” of white or black dots along a scanned line as the number of dots in each run.
  • Page 131 HD Ultra X Service Guide SRGB Hewlett-Packard and Microsoft proposed the addition of support for a standard color space, sRGB, within the Microsoft operating systems, HP products, the Internet, and all other interested vendors. The aim of this color space is to complement the current color management strategies by enabling a third method of handling color in the operating systems, device drivers and the Internet that utilizes a simple and robust device independent color definition.
  • Page 132 HD Ultra X Service Guide Under Color Removal. A color separation setting used on color photographs where cyan, magenta and yellow inks are removed from dark, neutral areas and substituted by black ink. The advantages are a reduction in overall ink usage. See also GCR. Vector Drawing Also called Vector File.

  • Page 133: Error Codes

    HD Ultra X Service Guide 11. Error codes Software related errors System Error: 262-51 Description: Error closing file, corrupted image Image size and resolution exceeds file format limitations. Reduce resolution Corrective Action. or image size System Error: 55-101 Description: No scanner found. Corrective Action.
  • Page 134 If problem persists reinstall the software to correct the issue. System Error: 55-513 Description: The IT8 reference file could not be found on the internet Browse to it manually www.contex.com and retrieve the correct IT8 file or Corrective Action: use standard System Error: 55-523 Description: Sheet not recognized.

  • Page 135: Scanner Related Errors

    HD Ultra X Service Guide Scanner related errors Error code: 100-40035 Keypad error code: ERR_CB Level: Support Correctable Description: CBx, Camera A not found Potential fail comp: CBx; SUx; Cable Corrective Action: Camera board (CBx). Main controller board (SUx). Related cabling. Error code: 100-40035 Keypad error code:...
  • Page 136 HD Ultra X Service Guide Error code: 100-40038 Keypad error code: ERR_CB Level: Support Correctable Description: CBx, Camera D not found Potential fail comp: CBx; SUx; Cable Corrective Action: Camera board (CBx). Main controller board (SUx). Related cabling. Error code: 100-40076 Keypad error code: ERR_CB...
  • Page 137 HD Ultra X Service Guide Error code: 100-08208 Keypad error code: NONE Level: Support Correctable Operator’s panel failed. Description: Potential fail comp: Cable; SKx; SUx Corrective Action: Related cabling. Operator Panel board (SKx). Main controller board (SUx). Error code: 100-08220 Keypad error code: ERR_GENERAL Level:...
  • Page 138 HD Ultra X Service Guide Error code: 100-50231 Keypad error code: BOOT Level: RD Correctable Description: Firmware download is in progress Potential fail comp: Firmware Corrective Action: Firmware. Error code: 100-50234 Keypad error code: NONE Level: User Correctable Description: Scanner is in safe-mode. Potential fail comp: User;...
  • Page 139 HD Ultra X Service Guide Error code: 100-20237 Keypad error code: ERR_GENERAL Level: Support Correctable Description: Cooling Fan 1 error. Potential fail comp: Mech; LMx Corrective Action: Related mechanical parts. Lamp and Stepper Motor driver board (LMx) Error code: 100-20238 Keypad error code: ERR_GENERAL Level:...
  • Page 140 HD Ultra X Service Guide Error code: 100-50603 Keypad error code: ERR_GENERAL Level: User Correctable Description: Unrecoverable scanner state. Potential fail comp: Reboot; Firmware; Software Corrective Action: Please reboot the scanner. Download of the latest firmware and PC application/driver may be required. Reboot scanner.

  • Page 141: Scanner License

    HD Ultra X Service Guide 12. Scanner License Scanner License system, General Brief description of how the Scanner License works. Since this chapter is not scanner specific, some of the illustrations may not apply completely to the scanner you are working on, like number of Cameras and transition areas. ...

  • Page 142: Main Board Replacement

    HD Ultra X Service Guide Main Board Replacement  Prerequisites: After the Main Board has been replace and it has been verified that the scanner is now working correct, the scanner needs to be activated. 1. When the scanner boot up and the scanner is recognised by the PC it will show up in WIDEsystem as “Not Activated”...
  • Page 143 HD Ultra X Service Guide 3. The first dialogue is to set up the Energy Star functions. 4. All Main board (Spare Parts) are shipped, “Not Activated” and without a serial no. 5. In order to activate the scanner you must first type in the Serial no. from the back of the scanner.
  • Page 144 HD Ultra X Service Guide 6. If the PC is connected to the internet through, it’s recommend to do the online Activation (1) for ease and to eliminate unnecessary complication due to typing errors. 7. Please make the proper selections. Once the Next button is clicked, the wizard will activate the scanner according to the stored registered on the server.

  • Page 145: Manual Activation

    Type, or copy, in the Activation code if is available and Click Activate. If the Activate Code is invalid the button will remain greyed out. If the Activation Code is not available selected the guide (2) to continue. Copy the Scanners HW id. Go to the License Activation site www.license.contex.com. Page 145...
  • Page 146 HD Ultra X Service Guide Click “Replaced board in your scanner” Past in the HW id. Fill in the Company info. Click Reactivate Copy the Activation code You can also email or download a PDF with the Activation code if you are not connected with the scanner.
  • Page 147 HD Ultra X Service Guide Type or copy in the Activation code if is available and Click Activate. Since the licensed scanner has the Gigabit interface enabled, it’s recommend to connect via Ethernet. The scanner is now successfully activated. Calibrate the scanner. Page 147...

  • Page 148: Temporary Board Switch

    “Spare Part” Main Board and go through the Activation Wizard. Problem with Activation If the wrong License key have been merge with a new scanner you will have to contact Support to solve the problem. Please Contact support@contex.com with the following info:  Customer Name. ...

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