Lexmark OptraImage 443 User manual

OptraImage 443
Service Manual
Doc. No. 253-0017-01 Rev. 1.01
Lexmark International, Inc.

Lexmark Internal Use Only ii
Table of Contents
Table of ContentsTable of Contents
Table of Contents
1.
1.1.
1. OVERVIEW
OVERVIEWOVERVIEW
OVERVIEW.......................................................................................................................................................... 1-1
1.1 GENERAL NOTES FOR SERVICING.......................................................................................................................... 1-1
1.2 GENERAL PRODUCT DESCRIPTION......................................................................................................................... 1-2
1.3 PRODUCT FEATURES ........................................................................................................................................ 1-2
1.4 PRODUCT SPECIFICATIONS.................................................................................................................................. 1-3
1.5 DEVICE CONFIGURATION..................................................................................................................................... 1-4
1.5.1 Outer View.................................................................................................................................... 1-5
1.5.2 Mechanical Configuration............................................................................................................ 1-6
1.5.3 Wiring Configuration.................................................................................................................... 1-8
1.6 THEORY OF OPERATION............................................................................................................................. 1-9
1.6.1 Introduction ................................................................................................................................... 1-9
1.6.2 Mechanical Section Operation....................................................................................................... 1-9
1.6.2.1 Scanning module drive..................................................................................................................... 1-9
1.6.2.2 ADF mechanism operation............................................................................................................... 1-9
1.6.3 System Description....................................................................................................................... 1-10
1.6.3.1 System Diagram......................................................................................................................... 1-10
1.6.3.2 SCSI interface: ........................................................................................................................... 1-12
1.6.3.3 Video circuit:.............................................................................................................................. 1-12
1.6.3.4 Sensor input................................................................................................................................1-15
2.
2.2.
2. INSTALLATION
INSTALLATIONINSTALLATION
INSTALLATION ..................................................................................................................................................... 2-1
2.1 PRECAUTIONS OF INSTALLATION.......................................................................................................................... 2-1
2.2 UNPACKING PROCEDURE .................................................................................................................................... 2-1
2.3 UNLOCKING YOUR SCANNER............................................................................................................................... 2-3
2.4 CABLE CONNECTION.......................................................................................................................................... 2-4
2.4.1 Power Cable Connection............................................................................................................... 2-4
2.4.2 SCSI Signal Connection................................................................................................................ 2-5
2.4.2.1 SCSI Cable Connection.............................................................................................................. 2-5
2.5 SCSI ID SETTING ........................................................................................................................................... 2-7
2.6 SCSI TERMINATOR.................................................................................................................................... 2-8
3.
3.3.
3. PROBLEM SOLVING
PROBLEM SOLVINGPROBLEM SOLVING
PROBLEM SOLVING............................................................................................................................................... 3-1
3.1 DIAGNOSTICS ............................................................................................................................................. 3-1
3.1.1 Diagnostic Flowcharts................................................................................................................... 3-1
3.1.1.1 Group 1 Error Flowchart (Lamp Assembly)..................................................................................... 3-2
3.1.1.2 Group 2 Error Flowchart (Flatbed) .................................................................................................. 3-2
3.1.1.3 Troubleshooting flowchart: power on to scanner ready......................................................... 3-3
3.1.1.4 Troubleshooting flowchart: online flatbed operation............................................................. 3-4
3.1.1.5 Troubleshooting flowchart: online ADF operation................................................................. 3-5
3.1.1.6 Troubleshooting flowchart: Offline flatbed operation............................................................ 3-6
3.1.1.7 The Power LED does not go on................................................................................................. 3-7
3.1.1.8 Scan module does not move to lock position........................................................................... 3-8
3.1.1.9 Scan module does not move to the home position.................................................................. 3-9
3.1.1.10 Ready and Power LED does not light on............................................................................. 3-10
3.1.1.11 Scan module does not move to the flatbed position ........................................................... 3-11
3.1.1.12 Reading is not performed ....................................................................................................... 3-12
3.1.1.13 Image does not appear ............................................................................................................ 3-12
3.1.1.14 Large jitter ................................................................................................................................3-13
3.1.1.15 Reading position deviation..................................................................................................... 3-14
3.1.1.16 Image unclear........................................................................................................................... 3-14
3.1.1.17 Strange Sound Generated (flatbed)....................................................................................... 3-15
3.1.1.18 Frequent paper jam.................................................................................................................. 3-15
3.1.1.19 Frequent double feed and skew............................................................................................. 3-16

iii
3.1.1.20 Strange sound generated (ADF)............................................................................................ 3-16
4. MAINTENANCE............................................................................................................................................. 4-1
4.1 CLEANING .................................................................................................................................................. 4-1
4.1.1 Cover and Glass............................................................................................................................. 4-1
4.1.2 ADF unit ........................................................................................................................................ 4-2
4.2 MAINTENANCE TOOLS ............................................................................................................................... 4-3
4.3 REPLACEMENT COMPONENTS OUTER VIEW............................................................................................... 4-3
4.3.1 Main Control PCBA....................................................................................................................... 4-3
4.3.2 Optical chassis unit........................................................................................................................ 4-4
4.3.3 Lamp Inverter circuit..................................................................................................................... 4-5
4.3.4 Lamp (Flatbed) .............................................................................................................................. 4-6
4.3.5 Motor unit (Flatbed) ...................................................................................................................... 4-7
4.3.6 Belt (Flatbed)................................................................................................................................. 4-8
4.3.7 ADF unit ........................................................................................................................................ 4-9
4.3.8 Control Panel PCBA...................................................................................................................... 4-9
4.3.9 Parts That Must Not Be Disassembled......................................................................................... 4-10
4.3.9.1 CCD Board Screws........................................................................................................................ 4-10
4.4 SPARE PARTS REPLACEMENT................................................................................................................... 4-11
4.4.1 Notes on Replacement.................................................................................................................. 4-11
4.4.2 ADF Snap-in Pad Module Removal and Mounting..................................................................... 4-11
4.4.3 Document Cover Removal ........................................................................................................... 4-12
4.4.4 ADF Cover Removal & Mounting................................................................................................ 4-13
4.4.5 ADF Optical Chassis Removal..................................................................................................... 4-14
4.4.6 ADF Unit Removal....................................................................................................................... 4-15
4.4.7 ADF Inverter Removal................................................................................................................. 4-16
4.4.8 ADF Lamp Removal..................................................................................................................... 4-17
4.4.9 Upper Housing Removal.............................................................................................................. 4-18
4.4.10 Flatbed Optical Chassis Removal.............................................................................................. 4-19
4.4.11 Flatbed Lamp Removal.............................................................................................................. 4-20
4.4.12 Flatbed CCFL Inverter PCBA Replacement.............................................................................. 4-21
4.4.13 Motor (Flatbed) Removal........................................................................................................... 4-22
4.4.14 The Control Panel PCBA Removal............................................................................................ 4-23
4.4.15 Main Control PCBA Replacement............................................................................................. 4-24
4.4.16 LED & Sensor PCBA Replacement............................................................................................ 4-25
4.5 PCBA VOLTAGE TEST............................................................................................................................. 4-26
4.5.1 Check power supply output voltage............................................................................................. 4-26
4.5.2 Main control PCBA input power (+5V) failure check................................................................. 4-26
4.5.3 LED display PCBA check ............................................................................................................ 4-26
4.6 LUBRICATION ................................................................................................................................................ 4-28
4.6.1 Mechanical unit lubrication......................................................................................................... 4-28
5. PARTS .............................................................................................................................................................. 5-1
5.1 SPARE PARTS AND AFR............................................................................. ERROR! BOOKMARK NOT DEFINED.
6. LABEL AND SCREWS................................................................................................................................... 6-1
6.1 OPTRAIMAGE 443 LABEL PLACEMENT.................................................................................................................. 6-1
6.2 SCREW CLASSIFICATION .................................................................................................................................... 6-2

1-1
1.
1.1.
1. Overview
OverviewOverview
Overview
1.1
1.11.1
1.1 General Notes for Servicing
General Notes for ServicingGeneral Notes for Servicing
General Notes for Servicing
1.2
1.21.2
1.2 Product Description
Product DescriptionProduct Description
Product Description
1.3
1.31.3
1.3 Product specification
Product specificationProduct specification
Product specifications
ss
s
1.4
1.41.4
1.4 Device Configuration
Device ConfigurationDevice Configuration
Device Configuration
1.5
1.51.5
1.5 Theory of Operation
Theory of OperationTheory of Operation
Theory of Operation
This manual is intended to be used by the maintenance engineers. It describes the areas to be maintained, the
installation, the disassembly, and the main trouble shooting guides.
Please take your time to read this manual thoroughly to obtain comprehensive knowledge about the OptraImage 443
before serving the unit.
1.1
1.11.1
1.1 General notes for servicing
General notes for servicingGeneral notes for servicing
General notes for servicing
(1) Before trying to disassemble the OptraImage 443, make sure the power supply cord of the OptraImage 443
is disconnected from the power outlet. Under any circumstance, do not remove or install the connectors on
the OptraImage 443 with the power supply turned ON.
(2) Use caution not to drop small parts or screws inside the unit when disassembling and reassembling. If left
inside, they might cause the malfunction of the unit.
(3) Do not pull the connector cable when disconnecting it. Hold the connector.
(4) When carrying the scanning head unit, put it in an anti-static bag.
(5) Keep the document table glass surface always clean. If contaminated, use a dry clean cloth for cleaning.
(6) Use caution not to injure your fingers or hands when disassembling or reassembling the unit.

Lexmark Internal Use Only 1-2
1.2
1.21.2
1.2 General Product Description
General Product DescriptionGeneral Product Description
General Product Description
OptraImage 443 is a multifunction solution that offers integrated print, copy, fax and color network-scanning
capabilities for increased small workgroup productivity. The OptraImage 443 is easy to use and provides low-cost
access to key office functions, including fax from workstation, network color copying, scanning, and electronic
document routing.
You can hand your document over to OptraImage 443, and in a few steps, OptraImage 443 scans it to the network
and delivers it wherever, to whomever you want. With OptraImage 443, inefficient steps to the mailroom, copier, fax
machine and to your workstation are a thing of the past.
1.3
1.31.3
1.3 Product Features
Product FeaturesProduct Features
Product Features
•Ease of Use
Ease of UseEase of Use
Ease of Use
The control panel on the front of OptraImage 443 looks like a panel on a regular copier with the standard
phone keys added. The operating steps follow the same procedure as that of a regular copier or fax machine.
•A Digital Copier and a Full-function Fax Machine
A Digital Copier and a Full-function Fax MachineA Digital Copier and a Full-function Fax Machine
A Digital Copier and a Full-function Fax Machine
When OptraImage 443 is connected to a Lexmark printer, it is able to perform convenient digital copying. When
OptraImage 443 is connected to telephone line, it is able to perform a full fax function - to send and to
receive faxes.
•Network Scanning
Network ScanningNetwork Scanning
Network Scanning
The OptraImage 443 employs two Color Charged-Coupled Devices (CCD) as the scanning method. Through a
network port at the rear of the OptraImage 443, the product is able to perform network scanning.
•Duplex Scanning through the Auto Document Feeder (ADF)
Duplex Scanning through the Auto Document Feeder (ADF)Duplex Scanning through the Auto Document Feeder (ADF)
Duplex Scanning through the Auto Document Feeder (ADF)
To increase workgroup productivity, the OptraImage 443 is featured with the advance duplex scanning
capability. The scan speed reaches to 20 PPM at 300 dpi resolution while the auto document feeder can hold
up to 50 pages of document at one time.

1-3
1.4
1.41.4
1.4 Product Specifications
Product SpecificationsProduct Specifications
Product Specifications
The OptraImage 443 is designed to meet the following product specifications:
Scanner:
Scanner:Scanner:
Scanner:
Scanner Type Flatbed Scanner with ADF build in
Optical Resolution Flatbed: 300x600 dpi
ADF: 300x300 dpi
Enhanced Resolution 9600x9600 dpi
Scan Speed 10 PPM at 300dpi color for single page scanning
20 PPM at 300dpi Line-art, duplex for ADF
Scan Method Color Charged-Coupled Device (CCD)
Light Source Cold Cathode Fluorescent Lamp (CCFL)
CPU Arm 7 KS32C41000
Scan Area Max. 8.5"x 14.0" (Legal size) for ADF
Max. A4/Letter for Flatbed
Display 16-character x 2 LCD
Image Types 42-bit color(internal)
14-bit gray(internal)
1-bit Line-art, Dither, Error Diffusion
1-bit CMYK in Dither or Error Diffusion
PC Interface SCSI
Copier:
Copier:Copier:
Copier:
Scan Type By Flatbed or ADF
Scan Resolution Flatbed: 300x600 dpi
ADF: 300x300 dpi
INA Card Interface SCSI
Power Requirement
Power RequirementPower Requirement
Power Requirement
Power Source
Frequency
Power Supply
Power Consumption
100~240V full range
50 - 60 Hz
Switching Adapter, Output: 24V 2.5A
<32 W
Scan Accuracy: FlatBed ADF
1. Leading Edge <-1 ~ +2mm <-2.5 ~ +2.5mm
2. Side Edge <-1 ~ +2mm <-2.5 ~ +2.5mm
3. Skew <1mm <2mm
4. Magnification Rate
Tolerance(Horizontal and
Vertical)
-1.5% ~ +1.5% -1.5% ~ +1.5%
Physical Dimension Width: 570 mm/ Depth: 430 mm/ Height: 190 mm
Weight 7 kg
Continued on the next page

Lexmark Internal Use Only 1-4
Environment
Operating
Storage
10°C to 35°C (50°F to 95°F)
20% to 80% R.H.
-40°C to 65°C (-40°F to 149°F)
10% to 90% R.H.
Random Vibration
Unpacked non-op:
Package:
Bump:
Drop
10-200Hz, 0.005 P.S.D. (G^2/Hz)
5-200Hz, 0.015 P.S.D. -6dB/oct
One hour in 3 major axes
Severity: 25g/6ms, 1000times in each direction
Must meet NSTA specification
Drop Point: 1 corner, 3 edges and 6 surfaces
Total 10 times
Acoustic Noise Operating: 58 dB or less
Electrostatic Discharge EC 1000-4-2 ESD Standard
Safety Regulation UL, CSA, TUV/GS, SEMKO
EMC regulation FCC Part 15 Subchapter J Class A
CE Marking, C-Tick
Reliability Conditions
Reliability ConditionsReliability Conditions
Reliability Conditions
1. Monthly Scan Volume 10,000 scans
2. Power-on Time 8.0 hours/day
20 days/month
3. Environment 20 - 30 C
40 - 70% RH (Relative Humidity)
MTBF > 5,000 hours
MSBF 50,000 pages
Scanner Life 5 years or 600,000 scans(excluding the pad
replacement)
MTTR < 30 minutes
Energy Saver Time Less than 45 seconds
Time to First Copy Less than 14.5 seconds
Life of Lamp 15,000 hours
ADF:
ADF:ADF:
ADF:
General Specifications:
-Optical Resolution
-Document Capacity 300x300dpi 50 Sheets
Document:
-Document Size
-Thickness
Max. 8.5" x 14" (W x L)
Min. 4.5"x5.5" (W x L)
0.05~0.15 mm
Paper Feed:
-Jam
- Miss Feed
- Multiple Feed
- Dog Ear
- Time to First Copy
- Acoustic Noise:
1/2,000 pages
1/2,000 pages
1/500 pages
1/500 pages
Less than 14.5 seconds
Operating: 58dB or less
Table 1-
Table 1-Table 1-
Table 1-1
11
1 Product Specifications
Product SpecificationsProduct Specifications
Product Specifications
1.5
1.51.5
1.5 Device Configuration
Device ConfigurationDevice Configuration
Device Configuration

1-5
This section describes the device configuration of the multifunction product.
1.5.1
1.5.11.5.1
1.5.1 Outer View
Outer ViewOuter View
Outer View
Figure 1.1 OptraImage 443 Outer View
Figure 1.1 OptraImage 443 Outer ViewFigure 1.1 OptraImage 443 Outer View
Figure 1.1 OptraImage 443 Outer View
Document
cover
LCD-display
Control
Panel
Paper Feed
Tray
Auto Document
Feeder
Output
Paper Tray
Extension
Extension
Power Switch
Power Port
SCSI Port
SCSI ID
Selector
SCSI Port

Lexmark Internal Use Only 1-6
1.5.2
1.5.21.5.2
1.5.2 Mechanical Configuration
Mechanical ConfigurationMechanical Configuration
Mechanical Configuration
The equipment consists of the following components:
Document Cover
and Paper Tray
Upper Cover
ADF Unit
Lower Unit
Main Control PCBA
Output Paper Tray
Document Cover
ADF Paper Feed Tray
Upper Housing Unit
ADF Cover
Optical Chassis (ADF)
ADF Module
Bottom housing unit
Motor unit
Panel Cover
Panel PCBA
Optical Chassis (Flatbed)
Image Scanner

1-7
Document
Cover
ADF Paper Feed Tray
ADF Module
ADF Cover
Upper Housing
Unit
Output Paper
Tray
Panel PCBA
Panel Cover
Main Control
PCBA
Optical
Chassis
(Flatbed)
Motor Unit
Bottom
Housing
Optical Chassis (ADF)

Lexmark Internal Use Only 1-8
1.5.3
1.5.31.5.3
1.5.3 Wiring Configuration
Wiring ConfigurationWiring Configuration
Wiring Configuration
Figure 1.2 Wiring Configuration
Figure 1.2 Wiring ConfigurationFigure 1.2 Wiring Configuration
Figure 1.2 Wiring Configuration
Control
Panel Board
CCD Board 2
LED Board
Motor
Module
CCD Board 1
Main Control
PCB Board

1-9
1.6 Theory of Operation
1.6.1
1.6.11.6.1
1.6.1 Introduction
IntroductionIntroduction
Introduction
This section explains the theory of operation of this scanner.
The microprocessor in this scanner controls the following functions.
•Interface
•Scanning module drive
•ADF drive
•Reading mode (reading density, document size, half-tone) selection.
Figure 1.3 shows the operation mode sequence.
Reading mode setting
ADF drive/scanning module drive Reading
Figure 1.3 Operation sequence
Figure 1.3 Operation sequenceFigure 1.3 Operation sequence
Figure 1.3 Operation sequence
1.6.2
1.6.21.6.2
1.6.2 Mechanical Section Operation
Mechanical Section OperationMechanical Section Operation
Mechanical Section Operation
1.6.2.1
1.6.2.11.6.2.1
1.6.2.1 Scanning module drive
Scanning module driveScanning module drive
Scanning module drive
The carrier is driven by a 2-phase stepping motor. The stepping motor has a rotation of 1.8°(full step).
And the use of micro-stepping control technique can work the motor to move the scanning module at
1/300 inch/step.
1.6.2.2
1.6.2.21.6.2.2
1.6.2.2 ADF mechanism operation
ADF mechanism operationADF mechanism operation
ADF mechanism operation
The ADF is driven by a 2-phase stepping motor. The stepping motor has a rotation of 1.8°(full step).
The use of micro-stepping control technique enables the motor to move the paper on the ADF at 1/300
inch/step.

Lexmark Internal Use Only 1-10
1.6.3
1.6.31.6.3
1.6.3 System Description
System DescriptionSystem Description
System Description
The OptraImage 443 is a duplex scanner which can scan synchronously both top and bottom size in a
document. It includes one main control board, two optical modules, one ADF module and one LCD panel.
1.6.3.1
1.6.3.11.6.3.1
1.6.3.1 System Diagram
System DiagramSystem Diagram
System Diagram
Figure 1.4 shows the system block diagram.
The main control board controls all the modules built up the OptraImage 443. It includes a RISC. ARM7
as the main controller, two Flash Memory as program area and one EDO RAM as working space, one
89C52 for panel control, two ASIC for flatbed and ADF image processing and each have external 32MB
SRDRAM for data processing, two A/D converter for processing flatbed and ADF CCD signals input, two
sets of motor drivers for driving flatbed and ADF motors, two SCSI controller for data interfacing with
host and printer.
The power is an external 24V/2500mA power adapter for the whole system. There are some different
values inside the OptraImage 443:
+24V Power directly comes from the power adapter and used for flatbed and ADF motor.
+12V Power converted from 7812 to supply flatbed and ADF CCD
+5V Power converted from 34063 to supply 89C52, SCSI controller and some 5V logic.
+5V Power converted from 7805 to supply flatbed and ADF A/D converters and all analog circuit.
+3.3V Power converted from LM2576T to supply ARM7, two image processing ASICs and some 3.3V
logics.

1-11
Figure 1.4 System Block Diagram
Figure 1.4 System Block DiagramFigure 1.4 System Block Diagram
Figure 1.4 System Block Diagram
Video Circuit
Main board
Control
section
SCSI
controller
To host
Optical unit
Lamp unitInverter
Flatbed
motor
Power supply
LED display
Sensor input
ADF section
ADF motor ADF sensor
11
0/
24
0
V
A
C
Control
Panel
SCSI
Controller
To printer
ADF's video
circuit

Lexmark Internal Use Only 1-12
1.6.3.2
1.6.3.21.6.3.2
1.6.3.2 SCSI interface:
SCSI interface:SCSI interface:
SCSI interface:
This scanner and the host are connected via the SCSI interface. It is an 12-bit, asynchronous SCSI
interface and can be connected to both SCSI-1 and SCSI-2 interfaces.
1.6.3.3
1.6.3.31.6.3.3
1.6.3.3 Video circuit:
Video circuit:Video circuit:
Video circuit:
The video circuit of this scanner includes: CCD driving circuit, CCD signal processing circuit.
1 CCD Driving Circuit
The CCD driving circuit is used to generate correct signals to the CCD, so that the CCD
may generate the correct image data.
Pin Assignment for Flatbed Video Circuit J5:
Pin No. Name Function
1 A.G Analog Ground
2 VOR CCD red Channel Output Signal
3 A.G Analog Ground
4 VOG CCD Green Channel Output Signal
5 A.G Analog Ground
6 VOB CCD Blue Channel Output Signal
7 A.G Analog Ground
8 +24Va Analog +24V Power Supply
9 RS CCD Reset Gate
10 Clamp CCD Clamp Signal
11 PH1 CCD Clock Phase
12 PH2 CCD Clock Phase
13 D.G Digital Ground
14 SH Channel Shift Gate
15 D.G Digital Ground
16 +5V +5V Power Supply
17 D.G Digital Ground
18 Lamp V Inverter Power Supply
19 Lamp V Inverter Power Supply
20 H.G Inverter Ground
21 H.G Inverter Ground
22 Home
Sensor

1-13
Pin Assignment for ADF Video Circuit J12:
Pin No. Name Function
1 H.G. Inverter Ground
2 +24V Analog +24V Power Supply
3 GND +5V GND
4 +5V +5V Power Supply
5 GND +5V GND
6 SH Channel Shift Gate
7 RS CCD Reset Gate
8 Clamp CCD Clamp Signal
9 GND +5V GND
10 PH2 CCD Clock Phase
11 PH1 CCD Clock Phase
12 H24G +24V Ground
13 A.G Analog Ground
14 +24Va Analog +24Va Power Supply
Pin Assignment for ADF Video Circuit J11:
Pin No. Name Function
1 A.G Analog Ground
2 VOR CCD Red Channel Output Signal
3 A.G Analog Ground
4 VOG CCD Green Channel Output Signal
5 A.G Analog Ground
6 VOB CCD Blue Channel Output Signal

Lexmark Internal Use Only 1-14
2. CCD signal processing circuit
The video noise suppression circuit is to eliminate the reset noise and low frequency noise of CCD and
then PGA performs video gain control. The “level shift” circuit is used to bias the PGA output to
satisfy the reference bottom requirement of the A/D converter. The “DC-OFFSET Adjust” circuit is used
to adjust the bias level of video signal.
* PGA: Programmable gain amplifier
CCD MUX Video Noise
Suppression
Circuit
R
G
B
DC Offset
Adjust Circuit
Level
Shift A/D
Converter
PGA*

1-15
1.6.3.4
1.6.3.41.6.3.4
1.6.3.4 Sensor input
Sensor inputSensor input
Sensor input
The sensor input includes home position sensor and ADF cover sensor.
1. Home position sensor
The home position of the carrier motor is detected by photo sensor. The photo
transistor transmission to the photo sensor receiver circuit is shown below .
Figure 1.5 Home position sensor
Figure 1.5 Home position sensorFigure 1.5 Home position sensor
Figure 1.5 Home position sensor
The home position is detected when the carrier passes between the LED and the photo transistor.
2. ADF cover sensor
The operation of the ADF cover sensor is the same as that of the home position sensor.
R R
+5V +5V