Contex COUGAR 36 Operating manual

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Technical Service Manual
COUGAR 25 and COUGAR 36
CHAMELEON 25 and CHAMELEON 36
CHAMELEON PREMIER 36
CHROMA Tx 40 and CRYSTAL Tx 40
COUGAR Tx 36, CHAMELEON Tx 36, and PREMIER Tx
COUGAR Sx 25 and CHAMELEON Sx 25
CHROMA XL 42 and CRYSTAL XL 42
MAGNUM XL 54
FSG/TSM/001 (2.4)
Part Number 6799D129

1 DOCUMENT REVISION RECORD
2 LIST OF DOCUMENTS
3
FSG MAINTENANCE MANUAL
COUGAR 25 and COUGAR 36
CHAMELEON 25 and CHAMELEON 36
CHAMELEON PREMIER 36
CHROMA Tx 40 and CRYSTAL Tx 40
MAGNUM XL 54
COUGAR Tx 36, CHAMELEON Tx 36, and PREMIER Tx 36
4 Addendum to FSG/MTM/001
CHROMA XL 42, CRYSTAL XL 42
COUGAR Sx 25, CAMELEON Sx 2
5
6
7
8
9
SPARE PARTS AND SERVICE ACCESSORIES
COUGAR 25, COUGAR 36, CHAMELEON 25,
CHAMELEON 36, CHAMELEON PREMIER 36
CHROMA Tx 40, CRYSTAL Tx 40
COUGAR Tx 36, CHAMELEON Tx 36, PREMIER Tx 36
MAGNUM XL 54
COUGAR Sx 25, CHAMELEON Sx 25
CHROMA XL 42, CRYSTAL XL 42
10 TECHNICAL SERVICE BULLETINS

FSG/TSM/001
Document Revision Record DRR
REV. DATE
CHANGED
BY PAGES
AFFECTED BRIEF DESCRIPTION OF CHANGE
1.0 010919 BN/LM All Original issue of document
1.0a 010927 LM FSG/MTM/001 p.67, Fig. 4-8 corrected
2.0 020808 BN/LM All CHAMELEON PREMIER 36
CHROMA Tx 40, CRYSTAL Tx 40
added
2.0a 021030 LM FSG/MTM/001 p.72, Fig. 4-10 updated
2.1 030507 BN/LM All COUGAR Tx 36, CHAMELEON Tx 36,
PREMIER Tx 36 added
2.2 031031 BN/LM All MAGNUM XL 54 added
2.2a 040107 LM p.4 List of Documents updated
FSG/MTM/001 rev. 2.0 to 2.0a
FSG/TSB/001 Added
2.2b 040427 LM p.4 List of Documents updated
FSG/MTM/001 rev. 2.0a to 2.0b
FSG/TSB/002 Added
2.3 040706 LM FSG/MTM/002 Added (Addendum with Sx 25 and XL 42)
SOG/PLS/013 New spare part list (Sx 25 and XL 42
added)
2.3a 050614 LM FSG/TSB/003 Added
2.4 060511 LM All FSG/MTM/001 (2.3)
FSG/MTM/002 (1.1)
SOG/PLS/013 (1.8)
FSG/TSB/004 added

FSG/TSM/001 060511
List of Documents:
FSG/MTM/001 (2.3) FSG Maintenance Manual
COUGAR 25 and COUGAR 36
CHAMELEON 25 and CHAMELEON 36
CHAMELEON PREMIER 36
CHROMA Tx 40 and CRYSTAL Tx 40
MAGNUM XL 54
COUGAR Tx 36, CHAMELEON Tx 36, and PREMIER Tx 36
FSG/MTM/002 (1.1) Addendum to FSG/MTM/001
CHROMA XL 42, CRYSTAL XL 42
COUGAR Sx 25, CAMELEON Sx 2
SOG/PLS/013 (1.8) Spare Part and Service Accessories
COUGAR 25, COUGAR 36, CHAMELEON 25,
CHAMELEON 36, CHAMELEON PREMIER 36
CHROMA Tx 40, CRYSTAL Tx 40
COUGAR Tx 36, CHAMELEON Tx 36, PREMIER Tx 36
MAGNUM XL 54
COUGAR Sx 25, CHAMELEON Sx 25
FSG/TSB/001 (1.0) Camera Alignment (Camera Motor Drive Belt)
FSG/TSB/002 (1.0) Lamp Driver Adjustment
FSG/TSB/003 (1.0) ATAC Calibration on XL 42
FSG/TSB/004 (1.0) Camera Spare Part Board 6735D001R01

TITLE: FSG MAINTENANCE MANUAL
COUGAR 25 and COUGAR 36
CHAMELEON 25 and CHAMELEON 36
CHAMELEON PREMIER 36
CHROMA Tx 40 and CRYSTAL Tx 40
MAGNUM XL 54
COUGAR Tx 36, CHAMELEON Tx 36, and PREMIER Tx 36
DOC. NO.: FSG/MTM/001
PREPARED BY: BN/LM
AUTHORIZED: JR
DISTRIBUTION: Tegningsarkiv, Svendborg (1)
PT, Svendborg (1)
DD (1)
ISSUE REVISION: 2.3
DATE: 2006-05-11
This document is the property of Contex A/S. The data contained herein, in whole or in part,
may not be duplicated, used or disclosed outside the Recipient for any purpose other than to
conduct technical evaluation. This restriction does not limit the Recipients right to use
information contained in the data if it is obtained from another source without restriction.

FSG/MTM/001
2
Document Revision Record DRR
REV. DATE
CHANGED
BY PAGES
AFFECTED BRIEF DESCRIPTION OF CHANGE
1.0 010919 BN/LM All Original issue of document
010927 LM p. 67 Fig. 4-8 corrected
2.0 020808 BN/LM All CHAMELEON PREMIER 36
CHROMA Tx 40, CRYSTAL Tx 40 added
Manual restructured.
2.1 030507 BN/LM All COUGAR Tx 36, CHAMELEON Tx 36,
PREMIER Tx 36 added
2.2 031031 BN/LM All MAGNUM XL 54 added
2.2a 040107 LM p.31 1st line: TP4/TP5 to TP7 and P1/P2 to P2
p.33 Fig. 3-3: Voltages for TP3/4/5 added
2.2b 040427 LM p.29 Fig. 3.1, CN2, pin2: -12V til +12V
p.30-32 Lamp Driver adjustment changed
2.3 060511 LM All Fig. 3-2, LME: J10 pin 5: Tolerances corrected
3.4.3: Added that LED3 might be off when lamp
has been replaced
Fig. 3-4, CBE: C32, right: Tolerances corrected
Fig. 3-14, SKD: SW1 and SW8 interchanged
3.16, Adj. of Original Sensors: Description updated
54” Scan-Width (page 99) corrected
New error codes added (70-219, 70-221, 08-220,
10-159
Replacing Guide Plate Gas Spring added
Description of Test 30 added

FSG/MTM/001 060511
3
Table of Contents
1. Introduction...........................................................................................................................................10
2. General Description..............................................................................................................................11
2.1 COUGAR 25 AND CHAMELEON 25..................................................................................................... 11
2.2 COUGAR 36, CHAMELEON 36 AND CHAMELEON PREMIER 36................................................... 12
2.2.1 COUGAR 36 and CHAMELEON 36..................................................................................................12
2.2.2 CHAMELEON PREMIER 36............................................................................................................. 13
2.3 CHROMA TX 40 AND CRYSTAL TX 40................................................................................................ 13
2.4 MAGNUM XL 54................................................................................................................................... 15
2.5 COUGAR TX 36, CHAMELEON TX 36, PREMIER TX 36................................................................... 16
3. Electrical Check and Adjustments......................................................................................................25
3.1 MARKING CODES FOR CIRCUIT BOARDS AND PROGRAMMED DEVICES.................................................... 25
3.2 DOWNLOADING SCANNER FIRMWARE ..................................................................................................... 26
3.2.1 Erase and Restore Parameter Blocks................................................................................................. 26
3.3 CHECK AND ADJUSTMENT OF THE SWITCH MODE POWER SUPPLY,SMPS .............................................. 27
3.3.1 AC Voltages........................................................................................................................................ 27
3.3.2 DC Voltages ....................................................................................................................................... 27
3.3.3 Adjustments ........................................................................................................................................ 27
3.3.4 Fuses .................................................................................................................................................. 27
3.3.5 Markings ............................................................................................................................................ 27
3.3.6 Jumper Settings.................................................................................................................................. 27
3.3.7 Hints................................................................................................................................................... 28
3.4 CHECK AND ADJUSTMENT OF LAMP AND MOTOR DRIVER BOARD,LME ................................................ 30
3.4.1 DC Voltages ....................................................................................................................................... 30
3.4.2 Lamp-Driver Adjustment.................................................................................................................... 30
3.4.3 Signal LEDs on the LME-Board ........................................................................................................ 31
3.4.4 Stepper Motor Reference Voltages..................................................................................................... 31
3.4.5 Functional Test................................................................................................................................... 31
3.4.6 Fuses .................................................................................................................................................. 32
3.4.7 Markings ............................................................................................................................................ 32
3.4.8 Jumper Settings.................................................................................................................................. 32
3.4.9 Hints................................................................................................................................................... 32
3.5 CHECK AND ADJUSTMENT OF CAMERA BOARD,CBE (NON TX AND XL MODELS)................................... 35
3.5.1 DC Voltages ....................................................................................................................................... 35
3.5.2 Adjustments ........................................................................................................................................ 35
3.5.3 Functional Test................................................................................................................................... 35
3.5.4 Markings ............................................................................................................................................ 35
3.5.5 Jumper Settings.................................................................................................................................. 35
3.5.6 Hints................................................................................................................................................... 35
3.6 CHECK AND ADJUSTMENT OF CAMERA BOARD,CBF (TX AND XL MODELS) .......................................... 39
3.6.1 DC Voltages ....................................................................................................................................... 39
3.6.2 Adjustments ........................................................................................................................................ 39
3.6.3 Functional Test................................................................................................................................... 39
3.6.4 Markings ............................................................................................................................................ 39
3.6.5 Jumper Settings.................................................................................................................................. 39
3.6.6 Hints................................................................................................................................................... 39
3.7 CHECK OF CONTROLLER BOARD,SUC.................................................................................................... 43
3.7.1 DC Voltages ....................................................................................................................................... 43
3.7.2 Adjustments ........................................................................................................................................ 43
3.7.3 Functional Test................................................................................................................................... 43
3.7.4 Markings ............................................................................................................................................ 43
3.7.5 Switch Settings (Download Control Switches)................................................................................... 43
3.7.6 Jumper Settings.................................................................................................................................. 44
3.7.7 Signal LEDs on the SUC-Board......................................................................................................... 44
3.7.8 Hints................................................................................................................................................... 44
3.8 CHECK OF INTERFACE MODULE,IMB (NON TX AND XL MODELS) .......................................................... 47

FSG/MTM/001 060511
4
3.8.1 DC Voltages ....................................................................................................................................... 47
3.8.2 Adjustments ........................................................................................................................................ 47
3.8.3 Functional Test................................................................................................................................... 47
3.8.4 Markings ............................................................................................................................................ 47
3.8.5 Jumper Settings.................................................................................................................................. 47
3.8.6 Hints................................................................................................................................................... 48
3.9 CHECK OF INTERFACE MODULE,IMD (TX AND XL MODELS).................................................................. 51
3.9.1 DC Voltages ....................................................................................................................................... 51
3.9.2 Adjustments ........................................................................................................................................ 51
3.9.3 Functional Test................................................................................................................................... 51
3.9.4 Markings ............................................................................................................................................ 51
3.9.5 Jumper Settings.................................................................................................................................. 51
3.9.6 Hints................................................................................................................................................... 51
3.10 CHECK OF OPERATOR PANEL,SKD......................................................................................................... 54
3.10.1 DC Voltages ....................................................................................................................................... 54
3.10.2 Functional Test................................................................................................................................... 54
3.10.3 Markings ............................................................................................................................................ 54
3.10.4 Switch Setting (Scanner ID)............................................................................................................... 54
3.11 CHECK OF SMART CARD READER,SCR................................................................................................... 60
3.11.1 DC Voltages ....................................................................................................................................... 60
3.11.2 Functional Test................................................................................................................................... 60
3.11.3 Markings ............................................................................................................................................ 60
3.11.4 DIP Switch Setting ............................................................................................................................. 60
3.11.5 Signal LED on the SCR-Board........................................................................................................... 61
3.12 CHECK OF LAMP SENSOR BOARD,OSB................................................................................................... 64
3.12.1 Functional Test................................................................................................................................... 64
3.12.2 Markings ............................................................................................................................................ 64
3.13 CHECK OF OPTOINTERRUPTER BOARD,OIBA ......................................................................................... 64
3.13.1 Functional Test................................................................................................................................... 64
3.13.2 Markings ............................................................................................................................................ 64
3.14 CHECK OF ATAC MOTOR DRIVER BOARD,MDA................................................................................... 66
3.14.1 DC Voltages ....................................................................................................................................... 66
3.14.2 Adjustments ........................................................................................................................................ 66
3.14.3 Functional Test................................................................................................................................... 66
3.14.4 Markings ............................................................................................................................................ 66
3.14.5 Jumper Settings.................................................................................................................................. 66
3.14.6 Hints................................................................................................................................................... 66
3.15 CHECK AND ADJUSTMENT OF ORIGINAL GUIDE SENSORS (ATAC) ......................................................... 69
3.15.1 Adjustment of Roller Sensor............................................................................................................... 69
3.15.2 Adjustment of Top Position Sensor .................................................................................................... 69
3.15.3 Check of ATAC Position Sensors ....................................................................................................... 70
3.16 ADJUSTMENT OF ORIGINAL SENSORS ...................................................................................................... 76
3.16.1 Adjustment of Switch Point ................................................................................................................ 76
3.16.2 Functional Test................................................................................................................................... 76
3.16.3 Hints................................................................................................................................................... 76
3.17 CHECK OF MEDIA THICKNESS DETECTOR (NOT APPLICABLE TO MAGNUM XL 54)............................... 78
3.17.1 Functional Test................................................................................................................................... 78
4. CCD-Cameras.......................................................................................................................................79
4.1 DESCRIPTION OF CCD-CAMERAS ............................................................................................................ 79
4.2 CCD-CAMERA CHECK AND ADJUSTMENT............................................................................................... 86
4.2.1 Check of Light Profiles....................................................................................................................... 87
4.2.2 Hints................................................................................................................................................... 88
4.2.3 Camera Adjustment Wizard ............................................................................................................... 94
4.2.4 Check and Adjustment of Focus......................................................................................................... 94
4.2.5 Check and Adjustment of Scan-Width................................................................................................ 99
4.2.6 Check and Adjustment of CCD-Centering ....................................................................................... 109
4.2.7 Check and Adjustment of Vertical Positioning................................................................................. 110
4.2.8 Final Check...................................................................................................................................... 113

FSG/MTM/001 060511
5
5. Vertical Alignment and Horizontal Stitching...................................................................................130
5.1 PRINCIPLE OF STITCHING ....................................................................................................................... 130
5.2 VERTICAL ALIGNMENT AND HORIZONTAL STITCHING PROCEDURE....................................................... 133
6. General Maintenance..........................................................................................................................141
6.1 STEP BY STEP PROCEDURE FOR GENERAL MAINTENANCE..................................................................... 141
6.1.1 Remove Top Cover........................................................................................................................... 141
6.1.2 Cleaning of the Scanning Area......................................................................................................... 141
6.1.3 Fluorescent Lamp............................................................................................................................. 141
6.1.4 Check Lamp Driver Adjustment....................................................................................................... 141
6.1.5 Check CCD-Camera Adjustment...................................................................................................... 142
6.1.6 Replace Top Cover........................................................................................................................... 142
6.1.7 Run Scanner Maintenance ............................................................................................................... 142
7. Troubleshooting ..................................................................................................................................146
7.1 POWER-ON SELF-TEST .......................................................................................................................... 146
7.2 LED INDICATORS ON OPERATOR PANEL................................................................................................ 147
7.3 ERROR CODES........................................................................................................................................ 147
7.3.1 Error Codes displayed on the Operator Panel ................................................................................147
7.3.2 Error Codes displayed on the PC Screen......................................................................................... 148
7.4 TROUBLESHOOTING HINTS..................................................................................................................... 152
8. Disassembly and Assembly.................................................................................................................156
8.1 TOP COVER WITH FRONT PROFILE ......................................................................................................... 156
8.2 END COVERS.......................................................................................................................................... 156
8.3 REAR COVER ......................................................................................................................................... 156
8.4 BOTTOM PLATE...................................................................................................................................... 156
8.5 TOP PROFILE (LID)................................................................................................................................. 157
8.6 ORIGINAL GUIDE PLATE WITH ATAC.................................................................................................... 157
8.7 GLASS PLATE......................................................................................................................................... 157
8.8 ENTRY ROLLER SHIELD ......................................................................................................................... 157
8.9 EXIT ROLLER SHIELD............................................................................................................................. 158
8.10 MIRROR CHASSIS................................................................................................................................... 159
8.11 REFLECTOR ASSEMBLY.......................................................................................................................... 159
9. Replacement of Parts..........................................................................................................................161
9.1 FEED ROLLER SHAFT ............................................................................................................................. 161
9.2 ORIGINAL SENSOR ACTUATORS............................................................................................................. 162
9.3 STITCHING WIRE.................................................................................................................................... 162
9.4 FLUORESCENT LAMP.............................................................................................................................. 162
9.5 STEPPER MOTOR.................................................................................................................................... 163
9.6 CAMERA MOTOR ................................................................................................................................... 163
9.7 CAMERA BOARD,CBE/CBF.................................................................................................................. 164
9.8 LAMP SENSOR BOARD,OSB.................................................................................................................. 164
9.9 INTERFACE BOARDS,IMB AND IMD..................................................................................................... 165
9.10 DUST FILTER ON FAN............................................................................................................................. 165
9.11 WHITE BACKGROUND PLATE................................................................................................................. 165
9.12 SLIDER FOR MEDIA THICKNESS ADJUSTMENT ....................................................................................... 166
9.13 ELEVATION MOTOR (ATAC)................................................................................................................. 166
9.14 ORIGINAL GUIDE SENSORS (ATAC)...................................................................................................... 166
9.15 GAS SPRING FOR GUIDE PLATE.............................................................................................................. 167
10. SCANtest 6...........................................................................................................................................171
10.1 DESCRIPTION OF SCANTEST 6............................................................................................................... 172
10.1.1 Test 1, Scanner Information............................................................................................................ 172
10.1.2 Test 2, LED Test.............................................................................................................................. 172
10.1.3 Test 3, Key Test ............................................................................................................................... 172
10.1.4 Test 4, Original-Sensor Test............................................................................................................ 172
10.1.5 Test 5, Lamp Test ............................................................................................................................ 173
10.1.6 Test 6, Motor Test............................................................................................................................ 173
10.1.7 Test 7, Complete Hardware Test..................................................................................................... 173
10.1.8 Test 9, Camera Adjustment ............................................................................................................. 173

FSG/MTM/001 060511
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10.1.9 Test 11, Stitching and Vertical Alignment....................................................................................... 173
10.1.10 Test 12, Adjustment of Y-Axis Scaling............................................................................................. 174
10.1.11 Test 13, Switch Scanner to Test Mode............................................................................................. 174
10.1.12 Test 20, Noise Test .......................................................................................................................... 174
10.1.13 Test 21, SCANdump ........................................................................................................................ 177
10.1.14 Test 27, Camera Adjustment Wizard............................................................................................... 177
10.1.15 Test 28, Original Guide Sensor Test............................................................................................... 177
10.1.16 Test 30, Calibrate ATAC.................................................................................................................. 177
11. Wiring Diagrams.................................................................................................................................178
12. Special Service Tools...........................................................................................................................193