Contex HD Ultra X 6000 Series How to use

Technical Service Guide:
HD Ultra X

HD Ultra X Service Guide
Page 2
Contents
1. Information .................................................................................................................................................4
Revision Table ...............................................................................................................................................4
Scanners covered by this Service Guide:......................................................................................................4
2. Design........................................................................................................................................................5
Block Diagram................................................................................................................................................6
Wiring Diagram ..............................................................................................................................................7
Camera Module layout (CBT)........................................................................................................................8
Scanner Control Unit layout (SUX) ................................................................................................................8
3. Troubleshooting .........................................................................................................................................9
Troubleshooting Sequence............................................................................................................................9
Error codes displayed on Keypad................................................................................................................10
Dust problems..............................................................................................................................................10
Image quality problems................................................................................................................................11
Stitching problems........................................................................................................................................11
Banding problems........................................................................................................................................12
4. Part Replacement ....................................................................................................................................13
Tools Required.............................................................................................................................................13
Identifying Parts ...........................................................................................................................................14
Parts List ......................................................................................................................................................15
5. Replacing Covers.....................................................................................................................................17
Right Hand Side Cover ................................................................................................................................17
Left Hand Side Cover...................................................................................................................................21
Feed Table Cover ........................................................................................................................................24
Rear Panel ...................................................................................................................................................28
OTAC Top Cover .........................................................................................................................................30
6. Replacing Parts........................................................................................................................................33
OTAC Assembly (Guide Plate Assembly)....................................................................................................33
Glass Plate...................................................................................................................................................38
White Background Plate...............................................................................................................................41
LED Light Module.........................................................................................................................................44
Idle Rollers ...................................................................................................................................................48
Controller Board (SUX Variant A) ................................................................................................................51
Power Supply Unit........................................................................................................................................54
Interconnection Board..................................................................................................................................58
Drive Belt......................................................................................................................................................60
Cooling Fan and Filter Kit.............................................................................................................................63
Paper Sensor ...............................................................................................................................................66
Inlet Connector and RFI Filter......................................................................................................................68
Stepper Motor ..............................................................................................................................................70
Feed Rollers & Lid Sensor...........................................................................................................................72
Tacho Sensor...............................................................................................................................................80
Mirror Unit ....................................................................................................................................................84

HD Ultra X Service Guide
Page 3
Gas Pistons..................................................................................................................................................92
Camera Module............................................................................................................................................94
7. 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...............................................................................................................108
8. WIDEsystem / Service ...........................................................................................................................109
WIDEsystem Service, walk though............................................................................................................109
9. Firmware download................................................................................................................................118
Firmware Download, walk through.............................................................................................................118
Erase Parameter block...............................................................................................................................120
10. Scanner Terms...................................................................................................................................122
11. Error codes.........................................................................................................................................133
Software related errors...............................................................................................................................133
Scanner related errors ...............................................................................................................................135
12. Scanner License ................................................................................................................................141
Scanner License system, General.............................................................................................................141
Main Board Replacement...........................................................................................................................142
Manual Activation.......................................................................................................................................145
Temporary Board switch............................................................................................................................148
Problem with Activation..............................................................................................................................148

HD Ultra X Service Guide
Page 4
1. Information
Revision Table
1.0
Original Issue of Document
August 2018
GJV
2.0
Adding HD X 36/42 to service guide
January 2019
GJV
2.1
Added OTAC replacement and Lid Sensor adjustment
March 2019
GJV
2.2
Added Lid Sensor and Tacho Sensor
June 2019
GJV
2.3
Added Mirror Unit and Gas Pistons
July 2019
GJV
2.4
Added warnings about inserting flat-cables correctly
November 2021
GJV
3.0
Revamped Service Guide
June 2022
GJV
3.1
Added Camera Board removal from Camera Module
February 2023
GJV
Document Title.:
HD Ultra X Technical Service Guide
Doc.No.:
FSR/TSG/14162
Preparedby.:
GJV
Distribution.:
St Ives, UK
Issue revisiondate.:
3.1 2nd February 2023
Scanners covered by this Service Guide:
HD Ultra X 6000
HD Ultra X 4200
HD Ultra X 3600
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.
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.
The 3600 series is the 4200 model, but limited by a licence key.

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

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

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

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

HD Ultra X Service Guide
Page 9
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. This will solve the problem in most
cases, especially if the reported problem is about image quality or identifying the calibration sheet.
The Pressure Rollers and the Glass Plate should also be inspected for wear and tear.
Troubleshooting Sequence
This is a suggested
Troubleshooting Sequence
and will work in most cases.
There are always some gray
zones, especially if the
problem is related to image
quality.
Erasing the parameter block
is done though the Firmware
download program, See
page ??.

HD Ultra X Service Guide
Page 10
Error codes displayed on Keypad
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.
1 x F, 2 x F, ... means that the Paper Indicator flashes 1, 2, ... times every time the Diagnostic Indicator is
turned ON.
F, F, means that both indicators are flashing simultaneously.
Dust problems
Streaks that run in the scan direction and seem to come and go during the scan is likely to be
dust.. The strikes are often a darker shade of the color. Clean scanner and original.
Streaks that run in scan direction, that are colour dependent, or a lighter shade of the colour, are
often related to the calibration. Dust that was present in the scanner during calibration, but has
been cleaned away since.
Diagnostic
Paper

HD Ultra X Service Guide
Page 11
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.
Stitching problem between 2 Cameras.

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

HD Ultra X Service Guide
Page 13
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
Torx 25 Straight
Torx 30 Straight
Wrench 5.5 mm
Wrench 7.0 mm
Slotted 0.6 x 10 x 75 mm
Note!
Before replacing any electrical parts such as SUx (Scanner Control Unit) or cameras, try calibrating the
scanner in order to get the scanner to recreate the content of the parameter block. This will solve the
problem in most cases.

HD Ultra X Service Guide
Page 14
Identifying Parts

HD Ultra X Service Guide
Page 15
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
Tacho Sensor
2867G111
Gas Spring, Guideplate, 2 pcs.
2867G116
IBD Variant A
2867G117
Stepper Motor STP-59D1 + Pulley + Damper
2867G118
Cooling Fan, 92x92x25
2867G119
Shaft with Feed-Rollers, 60'' (2 pcs.)
2867G142
Shaft with Feed-Rollers, X42 (2 pcs.)
2867G120
Cover Assy, RHS (incl Operators Panel)
2867G121
USB3.0 + 1Gbit Cable, 0.4m, Panel Mount
2867G122
Drive Belt, S2.1167M 500mm
2867G129
LED Light Module, 60''
2867G143
LED Light Module, 42''
2867G130
Latch Kit for HDU ATAC/OTAC
2867G131
Idle Rollers, HDU X60 (2 pcs.)
2867G144
Idle Rollers, HDU X42 (2 pcs.)
6798G002
ATAC Closed Sensors
6798G008
DC Gear Motor, 12V, 392:1, ø27mm
2867G137
FFC Cable Kit
2867G138
Roller Cover, Front, X60
2867G145
Roller Cover, Front, X42
2867G139
Roller Cover, Rear, X60
2867G146
Roller Cover, Rear, X42
2867G140
OTAC Complete Assy
2867G141
OTAC Tension Spring

HD Ultra X Service Guide
Page 16
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.)
2867G123
Feed Table Cover, RB67G, X60
2867G151
Feed Table Cover, RC67G, X42
6798G012
LHS End Cover, Rx67G
Refurbishment Parts
0601A005R01
Castors (4 pcs.)
2867G123
Feed Table Cover, RB67G, X60
2867G151
Feed Table Cover, RC67G, X42
6798G012
LHS End Cover, Rx67G
Accessories
6798G019
Side Guide, Right (Rx67G)
6798G020
Paperguide (Rx67G)
6798G021
Return Guide (HD Ultra) packed
2867G124
USB3.0 Cable, A/B, 2m
Service Parts
2867G115
Optical Adjustment Pattern, 7C60 (RB67G)
2867G152
Optical Adjustment Pattern, 5C42 (RC67G)

HD Ultra X Service Guide
Page 17
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.

HD Ultra X Service Guide
Page 18
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. Press both of the locating tabs in at the same time to release the Interconnection Board flat-
cable. DO NOT just try to pull the cable out as this WILL damage the cable.

HD Ultra X Service Guide
Page 19
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). Incorrectly inserted cables might result in damage to the Controller Board.
7. While holding the RH end cover in place, refit the T15 self-tapping screw.
8. Refit the T15 self-tapping screw underneath the Feed Table Cover.

HD Ultra X Service Guide
Page 20
9. Refit the 4 x T20 screws in the Cover Assembly.