Service on OS 12000

TS-0737E SU_OS12000_Service_Manual 20.11.2010 ZEUTSCHEL GmbH, Heerweg 2, D-72070 Tbingen-Hirschau, Germany

Service Manual OS 12000 TS-0737E SU_OS_12000_Service_Manual

Table of contents 1
1.1 1.2

Safety........................................................................................ 7
Safety symbols used in this manual and on the Scanner parts ..................... 7 Service and technical rules ................................................................................ 8

2
2.1 2.2 2.3 2.4 2.5

Service / cleaning .................................................................... 9

Rotation brakes ................................................................................................... 9 Operators panel / Micro switches under film.................................................... 9 mirrors .................................................................................................................. 9 CCD board............................................................................................................ 9 windows ............................................................................................................... 9

3
3.1 3.2 3.2.1 3.2.2 3.2.3 3.2.4 3.2.5 3.2.6 3.2.7 3.2.8 3.2.9 3.2.10 3.3 3.4 3.4.1 3.4.2 3.4.3 3.4.4

Installation ............................................................................. 10
Unpacking .......................................................................................................... 10 Components ...................................................................................................... 10 Base .................................................................................................................... 10 Book cradle Comfort............................................................................................ 11 Advanced (optional) ............................................................................................ 11 Glass plate drive (optional only with Advanced book cradle) .............................. 11 Column ................................................................................................................ 12 Monitor carrier optional........................................................................................ 12 Scan head ........................................................................................................... 13 Monitor (optional) ................................................................................................ 13 Computer............................................................................................................. 13 Accessories ......................................................................................................... 13 Location ............................................................................................................. 13 Installation of the OS 12000 ............................................................................. 14 How to do setup the base and column ................................................................ 14 Fix the scan head on the column ........................................................................ 16 Check the Installation .......................................................................................... 18 Check if scan head ( scan line ) is parallel to the book cradle............................ 19

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4
4.1 4.2 4.2.1 4.2.2 4.2.3 4.3 4.4 4.5

Preparing for service ............................................................ 24

Required tools and parts .................................................................................. 24 Maintenance....................................................................................................... 25 Service interval.................................................................................................... 25 Parts subject to wear........................................................................................... 25 Preventive Service .............................................................................................. 26 SCU Parameter .................................................................................................. 27 Firmware ( SCU ) ............................................................................................... 27 Firmware Upgrade ............................................................................................. 28

5
5.1 5.1.1 5.1.2 5.2 5.2.1 5.3 5.3.1 5.3.2 5.3.3 5.3.4

Basic settings ........................................................................ 31

Perfect Book ...................................................................................................... 31 Basics.................................................................................................................. 31 Fire Wire driver on OS12000............................................................................... 31 Setup PC shipped with the scanner ................................................................ 32 Scanner delivered with computer ( preconfigured).............................................. 32 Scanner delivered without the computer ........................................................ 32 Installing OS12000 driver (no pre configured PC).............................................. 32 Installing Perfect book camera (Optional, no pre configured PC) ....................... 33 Installing Omniscan Software (no pre configured PC)......................................... 33 Installing Machine specific parameter (no pre configured PC) ............................ 33

6
6.1 6.2 6.2.1 6.2.2 6.2.3 6.2.4 6.2.5 6.2.6 6.3 6.3.1 6.3.2 6.3.3

Calibration of the OS 12000.................................................. 34

Kalibriervorlagen im Kalibrierung - Kit............................................................ 34 Which Calibration necessary ........................................................................... 35 Start position ....................................................................................................... 35 After Changing Parts ........................................................................................... 35 Other reasons why calibration are necessary ..................................................... 37 Storing Calibrated Data during calibration........................................................... 38 Save calibration datas after calibration .............................................................. 39 Restore calibration Data after changing SCU ..................................................... 40 Start Position of Scan ...................................................................................... 44 Omniscan OS 11.10 SR4 .................................................................................... 44 Check start position with calibration White .......................................................... 48 OS 11.12 ............................................................................................................. 49

Service Manual OS 12000 TS-0737E SU_OS_12000_Service_Manual

6.4 6.4.1 6.4.2 6.5 6.6 6.7 6.7.1 6.7.2 6.7.3 6.8 6.8.1 6.9 6.10 6.10.1 6.10.2

Sharpness .......................................................................................................... 53 Settings up to OS 11.12 SR2 .............................................................................. 53 Settings higher than OS 11.12 SR2 .................................................................... 54 High measurement / Laser calibration ............................................................ 55 Black reference (To reduce the noise of the scanner camera) ..................... 56 Shading ( calculate the differences of the illumination even)...................... 57 SR4 ..................................................................................................................... 57 OS11.12 2D shading ........................................................................................... 62 Check the shading about uniformity .................................................................... 64 Geometric Calibration ....................................................................................... 67 Adjust the System for the geometric correction................................................... 67 Colour management.......................................................................................... 68 Perfect Book calibrations ................................................................................. 71 Inner Calibration .................................................................................................. 76 Outer Calibration ................................................................................................. 77

7
7.1 7.1.1 7.1.2 7.1.3 7.1.4 7.1.5 7.1.6 7.1.7

Scan head .............................................................................. 95

How to disassemble the scan head, take off camea unit .............................. 95 CCD- Unit .......................................................................................................... 104 PCU Board ........................................................................................................ 104 SCU Board ........................................................................................................ 104 Scan Motor ........................................................................................................ 105 Lights................................................................................................................. 111 Laser unit........................................................................................................... 112 Mirrors ............................................................................................................... 113

8
8.1 8.2 8.2.1 8.2.2 8.3 8.3.1 8.4 8.4.1 8.4.2 8.4.3

Base...................................................................................... 114
Frame................................................................................................................ 114 Book cradle...................................................................................................... 114 Comfort.............................................................................................................. 114 Advanced .......................................................................................................... 114 Control / Operator panel ................................................................................. 115 Glass plate ........................................................................................................ 117 Glass plate drive.............................................................................................. 118 Service .............................................................................................................. 120 Malfunction ........................................................................................................ 120 Adjustment ........................................................................................................ 121

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9
9.1 9.1.1 9.1.2 9.2 9.2.1 1.1.1 9.3 1.1.2 1.1.3 9.4 9.4.1 9.4.2 9.4.3 9.4.4 9.4.5 9.4.6

Special Software settings on OS 12000 ............................ 126

Omniscan ......................................................................................................... 126 Special Settings to the Funktion of the Glassplate Drive................................... 126 ROI .................................................................................................................... 132 Perfect Book .................................................................................................... 133 Modify Settings of Perfect Book ........................................................................ 133 Offset of Perfect Book depending on Start position of scan .............................. 134 Firmware Update on OS 11.xx........................................................................ 140 < OS 11.12 ........................................................................................................ 140 >OS 11.12 SR2 ................................................................................................. 141 Bookcopy ......................................................................................................... 143 Password to log in as Admin to calibrate Scanner ............................................ 143 Restoring and Upgrading OS12000 Bookcopy PC System (TS-0668E) ........... 143 Password to unlock Bios of Bookcopy PC......................................................... 143 Mediacenter settings ......................................................................................... 144 File size ............................................................................................................. 144 Update a Bookcopy System .............................................................................. 145

10
10.1 1.1.4 10.1.2 10.1.3 10.2 10.2.1 10.2.2 10.2.3 10.2.4 10.2.5 10.2.6 10.2.7 10.2.8 10.2.9 10.2.10 10.2.11 10.2.12

Errors and solutions ........................................................... 147

Hardware .......................................................................................................... 147 PCU................................................................................................................... 147 Height measurement / invalid height ................................................................. 153 Glass plate drive................................................................................................ 157 Software ........................................................................................................... 167 Error 31390 ....................................................................................................... 167 No Scanner found message. ............................................................................. 168 Could not reset scanner .................................................................................... 168 Error while normalizing motors .......................................................................... 169 LED on the SCU boarb...................................................................................... 170 LED on PCU...................................................................................................... 171 Enter SCU when System is blocked SR4.......................................................... 172 Color alignment ................................................................................................. 175 Perfect Book without curve correction ............................................................... 176 Error while scanning occurred / timeout ............................................................ 178 Error while scanning occurred while using Perfect Book................................... 179 Special Log files to protocol the complete Scan process .................................. 183

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11
11.1 11.2 11.2.1 11.3 11.4 11.4.1

Modification on OS12000.................................................... 185

Scan motor....................................................................................................... 185 PCU board ........................................................................................................ 187 How to change the PCU board.......................................................................... 187 Modification of PCU board on OS 12000 to higher current for motors ...... 192 Add Perfect Book to a OS12000 in the field.................................................. 195 How to add the Perfect Book camera to the scanhead ..................................... 196

Service Manual OS 12000 TS-0737E SU_OS_12000_Service_Manual

1 Safety 1.1 Safety symbols used in this manual and on the Scanner parts

Indicates a general note. Note Indicates to possible danger for persons and the system.

Indicates to possible danger by electricity for persons and the system.

heat

laser beam or bright lights

Service Manual OS 12000 TS-0737E SU_OS_12000_Service_Manual

1.2 Service and technical rules

The OS12000 is powered with 230 / 110 Volt Service on the OS12000 is only when system power is cut off I fit is necessary to do Service work under power then fpllow the rules of savety working

Service is only accepted by technicans trained by Zeutschel

When opening the scanner there ist to take care about sharp edges, electricity, Laser light, bright LED light, moving parts powerd with motor. Follow the rules of safe working

Before doing service work on boards, be shure that power is cut off and that you are grounded to avoit electric unloading to electronic devices

Keep boards in the safety bags to secure them of static unloading and electric shock, ground yourself before unpacking

Boards shipped without safety bags do not be covered by warranty

Service Manual OS 12000 TS-0737E SU_OS_12000_Service_Manual

2 Service / cleaning
2.1 Rotation brakes
The rotation brakes should be changed every 500000 scans

Picture 1

2.2 Operators panel / Micro switches under film

Cleam the operators panel with smooth detergents, take care that the film surface is not damaged by agressiv detergents. If the Film surface is broken then replace the operators panel and take care about right connecting to IO-warrior board

2.3 mirrors
Clean the mirrors when dirt is visible on them. Attention the surface is sensitive First blow the dust with air away then use a microfiber and cleas windows cleaner. Do not scatch

2.4 CCD board

The CCD is covered with glass, but clean it only if dirt is visible. Attention the surface is sensitive If necessary use first air then a microfiber, then clear windows cleaner or Loctide cleaner

2.5 windows
The windows for the light are made of acrylic glass. Clean them as described in 2.3

Attention the surface is sensitive

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Service Manual OS 12000 TS-0737E SU_OS_12000_Service_Manual

3 Installation
Take care to use the short screws for fixing the scan head on the column, and the long screws for fixing the column in the base. If you use the long screws for the scanhead then the nut can be broken off the foam material of the frame

3.1 Unpacking
Check fist the packing for damages 2 Persons are necessary to carry the base Unpack all parts of the carton an lay them carefully on no rough surfaces Check for damages

3.2 Components
3.2.1 Base

1 2

4 5
Picture 2

1 Main Switch

2 Power board

3 Power unit Scanner

4 Power unit Lamps

5 IO warrior

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3.2.2 Book cradle Comfort

Picture 3

3.2.3 Advanced (optional)

Picture 4

3.2.4 Glass plate drive (optional only with Advanced book cradle)

Picture 5

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3.2.5 Column

Picture 6

3.2.6 Monitor carrier optional

Picture 7

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3.2.7 Scan head

1 2

3
Picture 8

4
1 2
Light source

3
Reflecting mirror

4
Rotating brakes

5
Laser unit

Focusing mirror

3.2.8 Monitor (optional) 3.2.9 Computer For Bookcopy scanner there will be a preconfigured PC delivered with the system For scanner using Omniscan there is the PC optional, we recommend to use a PC preconfigured by Zeutschel. If other PC systems are used see the requirement computer 3.2.10 Accessories Foot pedal Foot pedal scan (optional) glass plate (advanced)

3.3 Location
Requirements to the location No direct light sources like sun or illumination, only indirect illumination. The place on which the OS12000 should be installed on has to be even, stable and vibration free

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Service Manual OS 12000 TS-0737E SU_OS_12000_Service_Manual

3.4 Installation of the OS 12000

Every time you want to fix one of the components take care to use the right screw, , the 6x20mm for fixing the column in the base, the 6x16mm for fixing the scanhead on the column, If you screw in a screw lock them tight, and do not brake the nut of the foam them by turning more,
3.4.1 How to do setup the base and column Take care that there is enough place surround the furniture for working on the scanner base: To carry the base two persons are necessary Place it on the furniture that the backside is reachable Open the six screws on the backside of the column to remove the cover on the backside, remove the two screws from the bottom ( Picture 2-3)

Picture 9
1 2 3 3 4 5 Cover back side Column Mounting Part for Head Fixed nut Fixed holder Keyway

Picture 10

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Service Manual OS 12000 TS-0737E SU_OS_12000_Service_Manual

The cover is fixed on the front side The Monitor Holder is to be fixed on the front side of the column with four screws turned in from the back side of the column.

Picture 11

Open the two marked screws (Picture 2-1) on the bottom of the base and take away the cover

Picture 12

Place the column in the base but take care of the wiring, that should placed through the spacers in the column ( Picture 2-3)

Picture 13

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fix it from below with two long screws ( 6x20mm)

Picture 14

3.4.2 Fix the scan head on the column Now set the scan head, the two arrows without number facing to front, at number 6 ( Picture 3-7) on the mounting parts number 3 ( Picture 2-2) of the column and fix it with the shorter screws ( 6x16mm) at number 7 ( picture 37) through the fixed holder ( Picture 3-2 and Picture 2-7 ) by lifting the front of the scan head until the resistance.

Picture 15

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After fixing all the OS 12000 should look like below

Picture 16

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Service Manual OS 12000 TS-0737E SU_OS_12000_Service_Manual

3.4.3 Check the Installation 3.4.3.1 Start Position check after installation SR4

After finishing the installation of Scanner and PC it is necessary to control the positioning of the scan head.
To check the start position of the scanner, see chapter 5.1Start position of scan. To check the parallelity of the scan head scan once without Perfect Book. Control if the line of the clip is parallel to the marks on the book cradle. If no try to turn a little the scan head on the column until the result is parallel See chapter 3.4.4 3.4.3.2 Start Position check after installation OS11.12

After finishing the installation of Scanner and PC it is necessary to control the positioning of the scan head.
The software is doing the check of the start position, every day with the first scan During this process the System is scanning the area of the white reference and corrects the position of start of the scan to the found white reference. Is no difference to the stored position and the stored position found, then nothing is changed to the stored position. Is a difference is found then the start position is corrected and the Offset of Perfect Book is made. The system is doing this check without message, if the position is right. This start position check is possible to do manually

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Service Manual OS 12000 TS-0737E SU_OS_12000_Service_Manual

3.4.4 Check if scan head ( scan line ) is parallel to the book cradle Start Omniscan, when using Bookcopy System then logg in as Admin with password @(shift + 2)Bookcopy and open then Omniscan open a job and adjust the clip size to maximum

Picture 17 Now select the scanner icon

In the following menue disable Perfect Book by unchecking checkbox Use Perfect Book

Picture 18

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Service Manual OS 12000 TS-0737E SU_OS_12000_Service_Manual

Now do a scan of the empty book cradle

Picture 19

Move the upper line of the clip frame to the upper angles on the book cradle

Picture 20

Both angles should be covered with the upper line of the clip Zoom in, that the angles are good visible,

Picture 21

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With the Navigator you can check both sides after zooming in

Picture 22

With a mouse click in the Navigator window it is easy to check the position of the upper line of the clip frame on the left and right side without toughing the clip.

Picture 23

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Picture 24

If the upper line of the clip frame do not cover the left and the right angle then try to turn the scan head on the column a little do a new scan and control the scanned image. If the result is better do the same way until the positioning is right.

Do not turn to hard against the resistance, do step by step

Picture 25

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If the result is worse than the one before, then turn the scan head in the opposite way. For example If the left angle as shown in the following picture is under the line of the clip, then turn the head to right

Picture 26

Do this until both angles are covered wit the top line of the clip

Picture 27

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Service Manual OS 12000 TS-0737E SU_OS_12000_Service_Manual

4 Preparing for service

4.1 Required tools and parts
Required Tools Screwdriver Philips Size PH 0 PH 1 PH 2 2, 2,5 Bullet head 5 Bulled Head To open 5,5 nuts Number 1 2 3 4 5 6 7 8 9 10 Amount 1 1 1 1 1 1 1 1 1 1

Screwdriver Hexagon

Screwdriver Set Hexagon Keys cutter Clamp ruler

For snap rings Not displayed

All screwdrivers and other tools are metric size

7 6 5 8

10 3 2 1 4 9
Picture 28

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Service Manual OS 12000 TS-0737E SU_OS_12000_Service_Manual

4.2 Maintenance
1. Switch off the system and ensure that power is off. 2. Unplug the scanner. 3. Look for enough space around the scanner to be able to service the equipment properly 4. If you have to do maintenance on a advanced book cradle, its helpful `to remove the glass plate to have more space. 5. To clean the mirrors use dry and oil free pressed air or micro fibre Some cleanser do have color included and this color can stay on the mirrows and influence the quality of the light 6. Clean book cradle with vacuum cleaner

4.2.1 Service interval How often it is necessary to do service of the scanner depends on amount of scans and of the scanner

4.2.2 Parts subject to wear The life time of the parts is amounting 500.000 zykles (Scans or activations). After that amount of scans the parts should be replaced The following parts should be replaced: Order-Number E-3648 M-3240 M-3239 MX-6030 MX-6031 MX-6037 B-10199 Naming Switching Bar Operator Panel Advanced Operator Panel Comfort Rotations Brake, kpl. Schubstange, kpl. Rotation Brake, kpl. White Balance Pices 2 1 1 2 3 1 1

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Service Manual OS 12000 TS-0737E SU_OS_12000_Service_Manual

4.2.3 Preventive Service Independence to replacement of the wear parts there should be made a preventive service Parts to be cleaned: Book Cradle Plates Glass Plate of Book Cradle Windows Mirows Optics Locks of the Book Cradle Parts to be cleaned and lubricated - Mirror Drive - Focus Drive - Glass Plate The spindles of the Scan- and Focus-motor should be used with Loctide cleaner and lubricated with Teflon spray. All bearings and gliding surfaces in the glass plate drive should be lubricated to avoid wear. Defective or almost defect parts should be changed: - White Balance - Operators Planel - Switching Bar 4.2.3.1 One shift use We recommend one preventive Service per year 4.2.3.2 Two shift use We recommend two preventive Service per year

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Service Manual OS 12000 TS-0737E SU_OS_12000_Service_Manual

4.3 SCU Parameter

To adjust settings in the SCU settings its necessary to copy the fileOS12000.ini.zeutschel in the directory C:\Programme filesZeutschel\Omniscan11\Driver\OS12000

Very important to remove this file after service to avoid damages and maladjustment by the user / operator. Changes in the Calibration menu are always necessary to save : Changes in SCU Settings always with the button save below calibration data, if there is a 0 in the line then the system is using a default number which is described in the register system settings Changes in other registers with the button save below save to file 4.4 Firmware ( SCU )
On the SCU board are the calibrated datas and the firmware of the scanner stored The version of the firmware is ruled by the setting of assambly ( color or gray) and the version of software used with the scanner Software OS 11.12

Firmware Color Gray Color Gray Color Gray Color V0_0.1.1.13.0.cfp V1_0.1.1.13.0.cfp V0_2.2.0.10.cfg V1_2.2.0.11.cfg V0_2.2.0.16.cfp V1_2.2.0.13.cfp V0_2.2.0.17.cfp

OS 11.10 x x x x x

OS 12.2 32

x X X x

x x X

The latest or current firmware is compatible to older software versions of OS 11.10 SR1 und Bookcopy.

During the firmware upload process there will be asked to shut down and restart the scanner, because of this it is necessary to contact the PC to a separated power source when using a Bookcopy system
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4.5 Firmware Upgrade

After changing the SCU or updating to a higher software version it Is necessary to check if the firmware of the SCU is the right one which the software is recommending. When the firmware is not the version the software is recommending then when starting Omniscan and Bookcopy there is a message box opening and is giving an info message that the firmware is not valid.

Picture 29

If this message appears then go to the calibration menu and there to the register Download

Picture 30

In the OS 11.12 and OS 12.2 you can find the firmware which is current fort he software version by clicking on Browse or seach it in directory C:\Program Files\Zeutschel\Omniscan 12.2-32\Driver\OS12000\Firmware

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Picture 31

Select in the selection window the firmware according to the setting of your scanner, which was recommended. Then click on Download and the process is starting

Picture 32

When starting the process zhere will be from time to time that the lights of the scanne rare flashing and randomly a message will appear to shut down and restart the scanner, After restarting the scanner wait until the scanner has resetted before selecting OK

Picture 33

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Now the main part of the firmware upload is running

Picture 34

If you see this message then the upload is complete, shutdown the sotware and shut down and restart the scanner again

Picture 35

Accept the following error messages with ok

Picture 36

After shutting down the software and the scanner wait several seconds to unload the electronik and restart the system. When staring up Omniscan and Bookcopy and the following message box appear then you have selected the wrong firmware packet

Picture 37

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Service Manual OS 12000 TS-0737E SU_OS_12000_Service_Manual

5 Basic settings
5.1 Perfect Book
5.1.1 Basics Perfect Book

To use Perfect Book an additional camera for the 3-D function and a second fire wire card is necessary.

Firewire cards

The scanner and the 3D-camera need their own fire wire card because they use the whole bandwidth.

Dongle

For Omniscan the dongle needs to have a Perfect Book license For Bookcopy is no dongle necessary, the license is stored on the SCU board. 5.1.2 Fire Wire driver on OS12000 The driver for the fire wire connection of Perfect Book and the Scanner are localised in the directory c:\Program Files\Zeutschel\Omniscan XX.XX\driver\Misc

Picture 38

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The driver of the Perfect Book camera will be updated when updating Omniscan. But only when updating from OS 11.10 to OS11.12 or OS 11.12 to OS 12.2-32bit When updating from OS 11.10 to OS12.2-32 there is necessary to deinstall the driver of the Perfect Book camera When the software OS 11.10 should be updated to OS 12.2-32 then it is necessary to deinstall the drivers of the Perfect Book camera and of the scanner before installing the new drivers and actualize them in the device manager. The actuell drivers for Perfect Book and Scanner are supporting older software.

5.2 Setup PC shipped with the scanner

If the System was factory setup with the additional camera, you find the calibration data on the customer DVD under OS 12000 calibration. \\_Kunden_DVD_Omniscan_Software\OS12000_Calibration_Data 5.2.1 Scanner delivered with computer ( preconfigured) If the computer is delivered with the Scanner, all the calibration data are Already copied to the Omniscan or Bookcopy software. No additional installation is necessary

5.3 Scanner delivered without the computer

5.3.1 Installing OS12000 driver (no pre configured PC) With every Scanner one fire wire card is delivered, install that card in the PC. Connect the scannerto the PC ,after switching on PC an OS12000 the System will come up with the message new hardware found. Insert Zeutschel Customer DVD, and install the driver for the OS12000 from the directory O:\_KUNDEN_DVD_Omniscan\Software\Driver_FireWire_Perfect Book_SCSI_Dongle\FireWire_OS10000R2_OS12000 Driver

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5.3.2 Installing Perfect book camera (Optional, no pre configured PC)

NOTE! Install the software of the 3D camera for perfect book before the camera itself is connected to the PC for the first time.

If the scanner is assambelt with Perfect Book, then a additional firewire card is delivered with the scanner. Switch of the PC and install the card. Install the software pgrflycapture1.6r23.exe for the 3D camera from the OS12000 DVD. It will be found under the path: KUNDEN_DVD_OmniscanSoftware\Driver_FireWire_Perfect\Book_SCSI_Don gle\Perfect Book Connect the FireWire cable of the 3D camera to the additional FireWire card now Open the device manager to reset the driver of the 3D camera. The driver is in the directory: C:Program Files\Point Gray Research\PGRFlyCapture For detail information see TS-0669E
NOTE! use separate cards for OS 12000 and for the 3D camera. Any of these items will need the full FireWire band width

5.3.3 Installing Omniscan Software (no pre configured PC) Please follow the hints on the TS-0481E Omniscan software installation manual 5.3.4 Installing Machine specific parameter (no pre configured PC) On the OS12000 Customer DVD you will find the following folder under \\_Kunden_DVD_Omniscan_Software\OS12000_Calibration_Data

. Copy theses three folders in to the OS12000 driver folder of your Omniscan installation folder. The default path would be: \\c:\program files\Zeutschel\Omniscan11.xx\driver\OS12000\ On scanners which have OS11.10 SR2 or higher on the DVD only the files Kalib for gray scanners and Kalib and Color for color scanners are necessary
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6 Calibration of the OS 12000

Calibrations are necessary in following by changing parameters, for modificating or to have better quality

Use only Zeutschel calibration tools of the calibration kit according to the scanner type for calibrating and take care to use the right calibration tool fort he calibrations it is designed for.
6.1 Kalibriervorlagen im Kalibrierung - Kit

Shading Calibration Target

A2 K-3224 / A1 M2836

see 6.7

Geometric Calibration Target

A2 M-3556 / A1 M-3568

see 6.8

Perfect Book Outer Calibration Target Auflagen Perfect Book

A2 M-3557 / A1 M-3559

see 6.10.3

Sharpness controll Targets

UTT Target Laser Calibration Tool A1 / A2 MX-6417 see 6.5

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6.2

Which Calibration necessary In the following list is described which calibration are at different status of the scanner necessary and in which series they have to be doen.

Important for all calibration is that the start position is exact in the right position
6.2.1 Start position OS 11.10 ( chapter 6.3.1) When parts have been changed: SCU, Light barrier, White Balance With each service, movement of the scanner. When the scan has wrong colors or too dark or bright OS 11.12 or higher (chapter 6.3.3) When SCU has Use only calibration datas belonging to the scanner

( serial number), Bookcopy Bits will be overwiten if used wrong datas

been changed and no calibrated datas are available White Balance changed 6.2.2 After Changing Parts Change of Lamps Calibration Perfect Book Adjust compl. Black Reference Shading 2D Shading Perfect Book Outer Calibration chapter 6.10.1 6.6 6,7.1 6.7.2 6.10.3

Change SCU (E-3652) without Calibrated Data Calibration Start position Black Reference Shading 2D Shading Geometrie Scharpness Laser
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chapter 6.3 6.6 6.7.1 6.7.2 6.8 6.4 6.5

Service Manual OS 12000 TS-0737E SU_OS_12000_Service_Manual

Change of SCU (E-3652) with Calibrated Data Calibration Calibrated Data with Restore from file in SCU Funktion check Start Position if necessary Schwarzreferenz if necessary Shading if necessary 2D Shading Geometrie if necessary Schrfe ggf.if necessary Laser chapter

6.3 6.6 6.7.1 6.7.2 6.8 6.4 6.5

Change of PCU E-3653 Calibration Laser Change von Perfect Book Camera MX Calibration Perfect Book Adjust Perfect Book Outer Calibration Change of White Balance B-10199 Calibration Start Position Schwarzreferenz Shading 2D Shading Perfect Book Outer Calibration if necessary chapter 6.3 6.6 6.7.1 6.7.2 6.10.3 chapter 6.10.1 6.10.3 chapter 6.5

Cange of Light Barrier E-3790 Calibration Start position Perfect Book Outer Calibration if necessary chapter 6.3 6.10.3

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6.2.3 Other reasons why calibration are necessary Perfect Book Adjust chapter 6.8.1 chapter

Reason Position of Lamps changed manually Position of Matrix Camera changed Matrix Camera changed Perfect Book Outer calibration chapter 6.8.3

Reason Start Position changed Curve correction not acceptable Middle of the book not found After replacing the camera unit, if necessary Position of Perfect Book Camera changed After Update from OS 11.10 to 11.12 when the curve correction is not acceptable

Perfect Book Inner Calibration

chapter6.8.2

Reason Setting of Ocular of Perfect Book Camera changed Kalib Data lost Geometrie chapter 6.6.1

Reason Immage not corrected the right way (Trapezoid). Shading chapter 6.5.1

Reason Illuminationof the Book cradle not uniformly horizontal checked with Shading Target After Black Referenz After change of White Balance 2D Shading chapter 6.5.2 chapter 6.5.1

Reason After Shading Illumination of the whole Book Cradle is not uniformatly Test Programm Omniscan oder Photoshop

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6.2.4 Storing Calibrated Data during calibration When calibrating with OS 11.12 and higher there will be opened a menue to store the datas of the calibration, The directory proposed is, C:\Program Files\Common Files\Zeutschel\CalibData , an alternativ directory can be selected

Picture 39

A window is following signs that the datas are save select OK

Picture 40

Blackref_0.hsi BlacKref_1hsi CalibMachineParams.bin OS12k.geo Shading_0.his Shading_1hsi 2D_Shading_mG.his 2D_Shading_oG.his ZeutschelValues.bin

Black Reference without Glass Black Reference with Glass modificated Parameter / Start Position Data of calibration of Geometrie Data of calibration of Shading without Glass Data of calibration of Shading with Glas Data of calibration of 2D_Shading without Glas Data of calibration of 2D_Shading with Glas Scanner ID / Serial Number depending Datas

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6.2.5 Save calibration datas after calibration After calibrating the scanner it is possible to save the Calibration data with Save to file. With this actuel datas it is possible to restore the calibration datas in the case the SCU is damaged without possibility to save the calibration datas. Go to the calibration menuand select Save to file under calibration data

Picture 41

In the next opening window select the directory where to store the datas and select OK for procedure

Picture 42

At the end the window is opening that the datas are saved

Picture 43

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6.2.6 Restore calibration Data after changing SCU

All calibration Datas can be restored to SCU expect the 2DShading datas. Use only calibration datas belonging to the scanner (serial number), Bookcopy Bits will be overwitten if used wrong datas
When there was necessary to change the SCU board, then it is possible to restore the datas of the old SCU (E-3652) if stored in working status,. If there are no current calibration data available it is possible to use the origin data on the scanner DVD to setup the scanner, but then it is necessary to check all calibration and to do a new 2D-Shading

Picture 44

Select Restore from files and in the following menu Ja

Picture 45

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I the following window there is possible to select the where the calibration datas should be restored The standard directory is C:\Program Files\Common Files\Zeutschel\CalibData If the data are stored in a different directory then select it in this windows With each scanner there is a DVD delivered with the scanner data on. Since Feb. 2010 are the complete calibration Data stored on the DVD . For scanner produced before that date there are not all data available, In this case there is necessary to calibrate the scanner

Use only calibration datas belonging to the scanner (serial number), Bookcopy Bits will be overwitten if used wrong datas

Picture 46

When starting the restore process with OK the system is starting to restore the calibration data one after the other In the next window the current data to be restore is displayed, by selecting ffnen the selected data is restored, the system is demanding one data after the other.

Picture 47

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Picture 48

If there are data not available and ffnen is selected then there is an error message that for example Blackref_1.hsi is not found

Picture 49

In this case agree with OK or when datas are missing select Abbrechen

Picture 50

The procedure is selecting the next datd or finish the restore

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Are wrong calibrated data used which do not belong to the scanner then a window is opening wih an error message that the serial number of the scanner is not the same as in the calibration data and all Bookcopy bits are deleted.

Picture 51

If the right data have been used then the next window is opening. Select OK to save the data to the SCU

Picture 52

Select OK to finalize the process.

Picture 53

After the restore process there is necessary to check the function of the scanner complete and at the moment a 2D-Sading calibration necessary

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6.3 Start Position of Scan

6.3.1 Omniscan OS 11.10 SR4 After installation of the scanner and the software , it is necessary to check the start position of the scanner. With the right start position it is save that the scanner is checking the white balance but the white balance has to be fixed in the right position Go to the clip settings and select maximum size, Then lay a ruler on the book cradle in scan direction like shown in Picture 44 and 45. Scan once

Picture 54

Picture 55

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Scan once without Perfect Book. The scan should start at 14 mm If not try first to solve the problem with the check of the installation. If there is no possibility to reaches the 14 mm ( +/- 1mm), then only then try to adjust the start position with modification of the Calibrated machine parameters,

Use the scanner Symbol to enter settings or right click the mouse on the virtual book cradle

Picture 56

Select Settings

Picture 57 Next menu select register Scan Settings

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Picture 58

Next menu select calibration Open in menu calibration the register SCU Settings and there the register Calibrated machine parameters

Picture 59 Changing light barrier position in the calibrated machine parameter Make a note with the data you want to change Increasing the number moves the start position closer 0 Decreasing the number moves in the opposite way Store the changes always with the button save below calibration data If the scan starts at 14mm the adjustment is finishes
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when there is a O in the line you want to change please take care that this 0 means that this is default , you find the default settings in the Scanner settings. If there is a 0 you have to write in the default number

Take care about changing the Settings 880 is max for focus and when the settings for the start position is too hight the scamotor is moving the mirrors against block

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6.3.2 Check start position with calibration White To test with the program if the with reference is taken well go to calibration menu and press there button Start under calibrate white. When using a color scanner the do first a scan with high Quality

Picture 60

Then the scanner gives out a live image of the with reference, by covering the white reference step by step from the operators direction, is the possibility to locate the position where the scanline is facing on the white reference.

Picture 61

Take care to use the primary FPGA, if not the live image looks like following

Picture 62

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6.3.3 OS 11.12 With the relase OS 11.12 there is a new feature, which is checking daily at the first start of the software the positioning of the start position depending on the the white reference position. After the installation of the scanner, the drivers and software start Omniscan. First go to the calibration menue and check with Open a job and do one scan. If nothing with the start position have changed, there is only a scan made of the area of the white reference. If the programm found not the correct position of the white reference, then a window will appear 6.3.3.1 Manual Start Position Adjustment To do the position check manually, go the settings and select more or click on the scanner symbol in the symbol line.

Picture 63

At first clear the book cradle and check the white reference, that nothing covers it. Click on the button Scan area position and start the routine. Now the system is scanning the bookcradle. After the scan a window is opening and showing the found start position depending to the white reference position. The system is calculating the difference of the position of the green lines to the position of the first black horizontal line to the position which is stored
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the last time. After the scan a window is opening where the positioning of the green lights depending on the first black line is shown.

Picture 64

If the green lights are covering the first black line at once then click on OK. A menue is opening and tells that the position is ok, click on OK. No modification on the position of start and Perfect Book is necessary to do

Picture 65

When the green lines are not covering the first black line then they can be moved with the button UP and Down pixle per pixle to the first black line.

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Picture 66

Or the green lines are far away from the first black line then it is possible to move the green lines in one step by clicking Upper Borderto the upper part of the window, then moved with the button UP and Down pixle per pixle to the first black line. If the green lines are covering the first black line click on OK Now the system is calculating the offset of the start position The next menue is giving the offset of the start position click on OK

Picture 67

The system is now correcting the start position

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The next menue is giving the offset for Perfect Book, click on OK

Picture 68 The system is now correcting the Perfect Book calibration, click on OK You will have no message and after the check the scan is starting. If the programm is not finding the white reference the you will have a error message

Picture 69

After pressing OK there is appearing again the window with the green lines Move the green lines to the first black line as described and try again.

The correction of the middle finding is corrected automatically

If this error appears check the installation, and copy the Kalib Datas to the directory, \\c:\program files\Zeutschel\Omniscan11.xx\driver\OS12000\

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6.4

Sharpness The min. Sharpnes for A2 is 4,5 and 4.0 for A1 To check the sharpness of the scan lay 5 Resolution test Chards in a 45 angle on the book cradle. With a Advanced System block the glass plate 0 Position, and open the glassplate, switch off the laser. Scan once, now press the 1:1 button and two times the +on the keyboard. Now check the resolution it should be min 4,5 in all corners and the middle of the book cradle. If the scan is not sharp enough there are two reasons

1. The 0 position of the book cradle is not in focus 2. The laser is misadjusted see high measurement 6.4.1 Settings up to OS 11.12 SR2 Follow 4.1 and open in menu calibration the register SCU Settings

Picture 70

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Change the number of the focus position switch default pos Store the changes always with the button save below calibration data

Make a note with the data you want to change Try once with 10 higher and when no visible effect then try 10 lower than the original number In direction of effect change then step by step until the best result 6.4.2 Settings higher than OS 11.12 SR2 With the newer software there the procedure has changed, it is not necessary to change the settings in the calibrated machine parameter. Change the number under Focus calibration and select Set, then do a reset and check the sharpness

Picture 71

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6.5

High measurement / Laser calibration High measurement is done with the Laser unit For calibration a 30 mm tick tool is necessary Calibrating the high measurement go to menu calibration Open in menu calibration the register calibration

Picture 72

Fix the book cradle even to 0 position, lay a white paper on the book cradle and start the hight calibration, the laser is checking the distance to the bookcradle, next the system is asking to lay a Tool with a hight of 30 mm on the book cradle where the laser is pointing on. The laser is checking then the 30 mm tool. After calibrating the laser, is the system is asking about saving the calbrated datas give the resolution test chard on the book cradle on the area where the laser is pointing to, select start to begin calibration follow the menu. Close the menu. Scan once a test chart in 0 position and check the sharpness a second scan with two test charts, one in the laser pointing area on top of the 30 mm tool Check the sharpness again, the one on the tool have to be sharp the lower one less sharp The calibration of the high measurement is finished.

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6.6

Black reference (To reduce the noise of the scanner camera) Press the button start under Black Reference Calibration and follow the menu.

Picture 73

At first a white reference is made when you accept with yes, then cover the small window on the bottom side of the scan head and accept the menu.

Picture 74

Check the scan and if it is ok then agree with yes.

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6.7

Shading ( calculate the differences of the illumination even)

6.7.1 SR4 With the Shading procedure there will be egalized the difference between the two light beams If shading is necessary place calibration paper on book cradle. Then go to the calibration menu to start the shading Open in menu calibration the register calibration You can choose depending to your system without glass plate, with glass plate ore both

Picture 75

Tray first with the 240, when the results are not acceptable You can change the numbers for better results You can select once shading for both or seperare for glass plate or without If it is an OS 12000 advanced the shading procedure start with glass plate open

Picture 76

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At first you will be asked to lay the calibration target on the book cradle

Picture 77

First the withe reference is checked and after the scan the reference scan is displayed

Picture 78

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After the scan a image with a part of the raw scan is shown, where the uneven brightness on the raw image is displayed. This is caused because the OS 12000 has two light sources , and the effect is that the center of the image is more bright than the outside part. If there are traces on the image visible , there are several reasons possible. Dust or dirt on the shading target Dust or dirt on the CCD Dust or dirt on the ocular Dust or dirt on the scan mirror Dust or dirt on the glass The cable of the focus motor are not fixed and covering the CCD The CCD is damaged By checking the CCD, the ocular, the scan mirror and the glass plate, where the CCD is tracing the book cradle though. Is there dirt or dust on the CCD then First try with pressed air ( oil free) Use a microfiber textile but only wipe in one direction Do not rubb ore use sharp tools Clean the mirrors only with with windows cleaner The CCD is covered with glass, and is allowed to be cleaned with solvants

If there is dirt which cannot be removed or the shading target is dirty and there is no possibility to clean the CCD or get a new shading tool, Then there is a possibility to do the shading with the dirt but if the dirt is disappearing then there are bright stripes on the image

Picture 79

Now do the same like with glass plate closed.

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Picture 80

If you accept the shading is stored to the scan head. Now check the settings in the test mode settings, they should be like in

Picture 81

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Now scan the calibration paper with Omniscan check if it is a proper scan. Check the Quality of the scan for example with Photoshop / Histogram The scan should have an even brightness. The maximum is 253 but the highest of the scan should be less. About max 250 The result for both test scans should be almost the same brightness. A difference of max 5 is acceptable. If you have a higher difference you should do again shading with the bad one. Now shading is finished

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6.7.2 OS11.12 2D shading With the OS11.12 there is a new feature called 2D shading First do a normal shading and then the 2D shading. With the normal shading we calculate the brightness of the light beam according to the scanned area in horizontal. With the 2D shading we calculate the brightness based on the normal shading, even on the whole book cradle For a Bookcopy system there is only a shading without glass plate necessary, for an Advanced system it is necessary to do one shading with and without glass plate

Picture 82

, then cover the whole book cradle with. the shading material

Picture 83

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Press start to do the 2D shading, then a menue appears to tell you to cover the book cradle with the special shading paper

Picture 84

By pressing ok the system is starting the shading with the first scan

Picture 85

Picture 86

If there is no influence about light or dirt on the paper visible then press ok

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6.7.3 Check the shading about uniformity

To check the quality of the shading with a test tool in the calibration menue

Picture 87

Select Test Programms

Picture 88

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Picture 89

Lay the shading paper on the book cradle that the book cradle is covered

Picture 90

Picture 91

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The system is now controlling the brightness and gives a result

Picture 92

If all is OK you see all positions marked with OK, if not do the shading again

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6.8 Geometric Calibration

6.8.1 Adjust the System for the geometric correction To adjust the Omniscan software follow the steps At first start Omniscan and open a job With a right click on the right side you enter a menu, select settings The following menu opens

Picture 93

Select in Standard parameters maximum Then select scan settings and select more to open the calibrations menue

Picture 94

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Press the button start under Calibrate Geometries and the Scanner is scanning once. There is a menu appearing which is asking if the image is good Check the position of the calibration tool on the image, the top row should be parallel to the frame and no black frame over the first row of the dots. If not move the calibration tool until it is in the right position and select no. When the position is right then accept and as next the system is calculating the correction.

Niemals mechanische Vernderungen an der Objektiveinstellung der Matrix Kamera durchfhren

Picture 95

When the calculation gives an error message then check the position again And start a new calculation. When the calculation is finished there is a message that is asking about writing data to the scan head accept and the calculation is stored. After the calculation check the test mode Settings

Picture 96

6.9 Colour management

The colour profiles are presetted and delivered with the OS 12000 scanner To activate the colour profile it is necessary to activate in menu settings

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Picture 97

Select register colour management

Picture 98

Select browse and select the profile in C:\Programme\Zeutschel\Omniscan11\Driver\OS12000\Color

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Picture 99

Select the profile for glass plate or without glass plate OS12000_mG.icm =with glass plate OS12000_oG.icm = without glass plate Activate with open and check Automatic Select the in following menu auto and close the menu

Picture 100

Now the profile is working

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6.10 Perfect Book calibrations It is important that in the Omniscan installation the Kalib belonging to the scanner is copied in. If Perfect Book is not working good, after replacing the CCD-Camera, replacing the LED- light sources or the calibrating data it might be necessary to calibrate the Outer calibration. If the 3D-Camera has to be replaced it is necessary to calibrate the Inner Calibration at Zeutschel, the datas are then delivered with the camera

never do a mechanical adjustment of the ocular of the matrix camera

Picture 101

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6.10.1 Adjust With the calibration Adjust we are able to check the delay of the two light beams to the scan line of the scanner camera.

At first lay a white paper with a straight line with 3 x X crossing the line on the book cradle press the button start below adjust

Picture 102

Adjust the position of the paper until the 3 x X are seen as one line

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Picture 103

Now adjust the light beams to the line Cover one light source and adjust the other one to the line of the paper. The beam should have a size of about 10 to 15 mm. To adjust the beam you can open the screws of the holders on each side of the light Beams and adjust the beam to the middle of the line and to a maximum width of max.10 to 15 mm. If the light is switching off you can relight it with pressing YES. If the light beams are adjusted press NO Then a menu opens where you have to select the aperture, to have the right aperture look from below the scan heat to the optic of the Perfect Book camera:

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If there is something readable on the optic If there is nothing readable on the optic

then select 4.8 then select 4.5

If in the selection window of the Focal Length 4.6 is listed then select then use 4.4 manualy, with OS11.12 use 4,5 in that case

Picture 104

Picture 105

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If you press OK, the next menu opens there is the possibility to check the positioning of the Perfect Book Camera. If the light beam is between the two green lines then ok If not you have to open the screw of the Perfect Book camera and adjust the position until the light beam is between the two green lines. If all is fixed press OK

Picture 106

Mit Exposure time und Gain the brightness of the beam can be adjusted Exposurer time max 1.2 Gain max 40

Abbildung 6-38

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Now you are asked to cover the book cradle with the shading calibration tool Press OK and follow the menus After the last scan you get a result about the delay of the light beams to the scan line

Picture 107

Both results should be less than 0,5 and the difference between left and right should be less than 0.5. If not try the adjustment of the lamps again 6.10.2 Inner Calibration The Inner calibration is calibrated at production of the scanner or by Zeutschel Service

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6.10.3 Outer Calibration The Outer Calibration is for the OS11.10 SR4 and the OS11.12 only in the Images different you see during installation

Picture 108

There is a new feature with the OS11.12 SR2, there is then the possibility to select the calibration target for the Outer calibration. There will be a new calibration tool created with that software version that there is the possibility to calibrate all scanner with the same calibration tool.

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6.10.3.1

With OS11.10 SR4

Look the book cradle in 0 position. Place the spacers with a hight of min. 40 mm on the Book cradle

Picture 109

It is possible to use for example 38mm filmrolls, they have a size about 40mm. Always thake care that the spacers you use have the same size Lay the calibration target on the spacers

Picture 110

Go to the calibration menu and select Start \ Outer Calibration

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Picture 111

In the following menue you have to select the aperture of the Matrix camera, A wrong selected aperture can cause an bad calibration

Picture 112 If there is something readable on the optic If there is nothing readable on the optic then select 4.8 then select 4.5

If in the selection window of the Focal Length 4.6 is listed When using OS11.12 use 4,5
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Picture 113

The small scan window with the blue stripes is the live image of the Matrix camera. The bigger scan is of the scanner camera, the smaller with the blue stripes of the matrix camera Check if the brightness on this image is not higher than 230 max, or if you have red spots on the images or the brightness is higher than 230 then select No and reduce the exposure time. You can check the brightness by toughing the brightest area with the mouse and then you can read the brightness in the top line If the brightness on the this image is lower than 180 then rise the exposure time until the brightness is a little under 230 or the max exposure time is reached.

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Picture 114

Check if in the scan of the scanner camera the tool is centered and horizontal If not select no and move the tool, start a new scan, do this until it is right. You can check the level if you tough the first top line at the outer crossing with the mouse. In the top line of the Image of the scanner camera there are several numbers, the first is x- Position, the second is the y-position the other The y-position is given out while toughing the line with the mouse, do this on both sides to check the level. Try to center and level the horizontal of the top line of the image of the scanner camera as good as possible.

Picture 115

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If the live image of the Matrix camera is not totally showing all crossings then there are two possibilitys Change the position of the Martrix camera manually see Adjust 6.9.1 Move the light beam a little lower than the two green lines and try again the Outer Kalibration, doe this way until the live image of the Matrix camera is compleate visible

Picture 116

Select OK if the level is good and on both images are all crossings visual, the end of the lines should be more than half visual, then the result should be good.

Picture 117

If you press OK then the next window appears to calibrate the 0 level Take away the spacers and lay the tool on the book cradle

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Picture 118

Picture 119

Press ok and a new scan is made. Select yes and check the new scan like the scan like before

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Picture 120

The scan on this level is good when on both images are all crossings visual, the end of the lines should be more than half visual, then the result should be good. Try to center and level the horizontal of the top line of the image of the scanner camera as good as possible. The more exact the level is positioned the more exact is the result of Perfect Book If the scan is good then select ok

Picture 121

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At the end of the calibration the result of X-slanting and Y-slanting should be between -1.8 up to 1.8. If the numbers are higher than 1.8 then do the calibration again

Take the calibration tool off the book cradle. If the result is good press OK and lay the control tool on the Book cradle and control the Result on the scan all levels with the same high should have the same colour.

Picture 122

The calibration is finished

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6.10.3.2

With OS11.12

First prepare the calibration tools for the Outer calibration of Perfect Book Look the book cradle in 0 position. Place the spacers with a hight of min. 40 mm on the Book cradle

Picture 123

It is possible to use for example 38mm film roll, they have a size about 40mm. Always thake care that the spacers you use have the same size Lay the calibration target on the spacers

Picture 124

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Go to the calibration menu and select Start \ Outer Calibration

Picture 125

In the following menue you have to select the aperture of the Matrix camera. A wrong selected aperture can cause an bad calibration

Picture 126

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If there is something readable on the optic If there is nothing readable on the optic

then select 4.8 then select 4.5

If in the selection window of the Focal Length 4.6 is listed then select then use 4.6 Select OK to start the calibration

Picture 127

The small scan window with the blue stripes is the live image of the Matrix camera. The bigger scan is of the scanner camera, the smaller with the blue stripes of the matrix camera The brightness will be checked by the system and gives out error messages about the brightness.

Picture 128

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Picture 129

Ist he brightness ok then the following message will appear

Picture 130

To change the brightness use the upper slider

Picture 131

Check if in the scan of the scanner camera the tool is centered and horizontal If not select no and move the tool, start a new scan, do this until it is right. You can check the level if you tough the first top line at the outer crossing with the mouse. In the top line of the Image of the scanner camera there are several numbers, the first is x- Position, the second is the y-position the other
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The y-position is given out while toughing the line with the mouse, do this on both sides to check the level. Try to center and level the horizontal of the top line of the image of the scanner camera as good as possible. If the live image of the Matrix camera is not totally showing all crossings then there are two possibilitys Change the position of the Martrix camera manually see Adjust 6.9.1 Move the light beam a little lower than the two green lines and try again the Outer Kalibration, doe this way until the live image of the Matrix camera is compleate visible The second way is to use the Offset in the menu of the Outer calibration, like shown below. With the slider it is possible to move the start position of the live image of the matrix camera vorwards or backwards, until all the crossings are compleate visible If you move the slider to left then the crossings are moving down.

Abbildung 1

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Picture 132

The colored image indicates that in this level there quality of the calibration is good the calibration When there are black areas in the color s then the calibration will fail. If that happens check the exposure time , the aperture and the basic settings as shading and black reference.

Picture 133

Select OK if the level is good and on both images are all crossings visual, the end of the lines should be more than half visual, then the result should be good.

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Picture 134

If you press OK then the next window appears to calibrate the 0 level Take away the spacers and lay the tool on the book cradle

Picture 135

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Picture 136

Press ok and a new scan is made. Select yes and check the new scan like the scan like before

Picture 137

The scan on this level is good when on both images are all crossings visual, the end of the lines should be more than half visual, then the result should be good. Try to center and level the horizontal of the top line of the image of the scanner camera as good as possible. The more exact the level is positioned the more exact is the result of Perfect Book
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If the scan is good then select ok

Picture 138

At the end of the calibration the result of X-slanting and Y-slanting should be between -1.8 up to 1.8. If the numbers should be closed to 0 as possible, acceptable results should be lower than 1.8 then do the calibration again

Take the calibration tool off the book cradle. And place the 3D tool on the book cradle

Picture 139

Ad the end of the calibration with a version higher than OS11.12 there is the 3D Test image included too

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7 Scan head
7.1 How to disassemble the scan head, take off camea unit
In some cases it is necessary to take off the camera unit out of the scan head to have access to focus motor, scan mirror, CCD or focus unit. When the scan head is assembled then first open the cover of the scan head.

Picture 140

Next open the 3 covers of the EMV cover to disconnect all connectors.

Picture 141

When the EMV cover is removed then disconnect the fire wire connection and the power connection
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Now disconnect the ground connection to the Perfect book camera

Picture 142

Next cut all strippers, locking the cables to the frame of the camera unit

Picture 143

Next cover tha glassplate with paper to avoid scratches when removing the mirrows out of the scan head

Picture 144

Picture 145

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Next remove the snap ring which locks the lever of the rotation brake to the mirror with the special pliers displayed in the tool list

Picture 146

Next hook off the lever of the rotation brake

Picture 147

Next open the screws locking the bolts on which the mirrows rotate

Picture 148

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Picture 149

The hot melting glue, marked with yellow arrows should be kept on the mirror

Picture 150 Next release the snap ring locking the mirrors to the axis of the camera unit with a screw driver with a flat blade. Take care this snap ring will jump away, so take care not to loose it.

Picture 151

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Now pull out the bolt and release the mirror Take care this snap ring will jump away, so take care not to loose it.

Picture 152

Please use not too much force to lift and turn the mirrors. If something is jamming then please do not pull more, to avoid damage to the system

Picture 153

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Next remove the grounding cable of the Perfect Book camera from the camera unit and unplug the fire wire connection to the Perfect book camera

Picture 154

Next open the 4 screws locking the camera unit to the scan head

Picture 155

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Next lift the camera unit out of the scan head, take care about the light barrier and the cables

Picture 156

Now there is access to the bottom side of the camera head

Picture 157

To have acess to the focus unit open the two screws on the bottom side and remove the cover

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CCD-Unit

CCD Unit Top View

Picture 158

1 2 3 4 5 6 7 8 9 10 11 12 13 14

Light barrier Positioning Scan Motor Frame CCD - Unit Scan mirror carrier PCU Board SCU Board Holder CCD Board CCD Board Focus Unit Bearing Bolt Scan Motor Base Plate Scan Motor Dumper Flag Positioning Scan Motor

CCD Unit bottom View

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Picture 159 15 16 17 18 19 20 Screws Cover Spring Scan Mirror Fixation Scan Mirror Gear

Camera head with new scan motor

Picture 160

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7.1.1 CCD- Unit To remove the CCD-Unit at first unplug the connectors X1, X7, X9, X11, the connector to the LED from the PCU board and the connector X7 from the SCU board. Then open the screws XXX to release the bolts of the Guiding device of the mirrors Pull the mirrors in direction to outside out of the fixing device Pull the mirror to the backside while pressing the guiding device a little out of way. Unscrew the four screws on the frame of the CCD-Unit. Now lift carefully the front of the CCD-Unit to an upright position, then turn it clockwise and lift it out of the scan head. Take care about connectors and wiring of the light barrier of the scan motor. Mount the CCD-Unit the opposite way

7.1.2 PCU Board To remove the SCU board at first disconnect all connectors on the PCU board, then remove the nuts from the PCU board, then remove the PCU board. Replace the PCU board the opposite way

7.1.3 SCU Board To remove the SCU board at first disconnect all connectors on the PCU board and SCU board, then remove the nuts from the PCU board, then remove all spacer screws, then remove the SCU board Replace the boards the opposite way

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7.1.4 Scan Motor The scan motor is turning the mirror of the CCC unit and the light positioning during the scan. The motor is connected to the mirror with tooth wheel gear. This gear has a minimal play If is necessary to change the scan motor you have to follow at first 4.1.1 and then unscrew the two screws to release the scan motor. It is helpful to mark the position of the two tooth wheels and the connector to the dumper. Replace the motor in the same position and screw in the two screws. Mount the CCD-Unit following 4.1.1 After reconnecting all connectors it is necessary to calibrate the scan motor Start the system and open the Omniscan software Place the calibrating paper on the book cradle and scan once Check the scan for Waves and shaking lines If the scan is not perfect it is necessary to adjust the tooth wheel gap Open the upper screw a little and give a little more or less pressure to the motor to increase or decrease the tooth wheel gap. It is a delicate adjustment and needs longer time. After calibrating the scan motor it is necessary to adjust the start position. 7.1.4.1 Rack wheel gear

Picture 161

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7.1.4.2 Spindle driven motor

Picture 162

To take off the motor the two nuts that fix the motor to the camera frame, Turn the spindle of the motor counterclockwise( sight from back side of scanner) until the motor is released , To connect the motor follow the opposite way

Picture 163

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Picture 164

7.1.4.2.1

Maitenance of spindel driven motors

If the spindle driven motor has a rough running or it is jamming, then check about the lubrication or if dust or dirt is blocking the movement of the tread. In that case unmount the motor ( see Picture 98) by releasing the two nuts, and turn the spindelcounter clockwise to release the motor of the tread . To unmount the shaft with the inserted nut you have to unscrew the bolt Where it is locked on.

Picture 165

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Picture 166

Take off the motor and unscrew the shaft with the inserted nut

Picture 167

Clean spindle and inserted nut with Loctide cleaner

Picture 168

If necessary recut the tread with a tread cutter M 8X1, assanble all and check the funktion

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Focus Unit 7.1.4.3 Focus unit To change the focus motor you have first to dismount the CCD-Unit, the PCU board and the SCU board See 5.1.1 CCD-Unit, 5.1.2 PCU board, 5.1.3SCU board Open the two screws on the button cover and lift the cover

Picture 169 7 8 20 21 22 CCD Board Focus Unit CCD Tooth wheel Mirror Tooth wheel Motor

Below the cover is the focus unit fixed with two pins and locked with two screws from the top of the CCD- unit.

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Picture 170 1 2 3 4 5 6 7 8 9 10 11 12 13 14 Adjustment screw for reverence focus Nut Micro switch reverence focus Motor focus Insert nut Screw Fixation angle Motor axis Frame ocular Base plate Linear bearing Cover Spring Screw ocular

7.1.4.4 Changing the motor of the Focus Unit To change the Focus motor open the screws of the motor, Next open the screw (6) and take away the angle to release the insert nut, pull out the motor. Drill the insert nut off the motor axis and drill it on the axis of the new motor on the same position. Take care of the direction of the insert nut replace the new motor and Mount the motor following the opposite way. Never do adjustment on screw 1!!!!!! Remount everything and start Omniscan

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7.1.5

Lights Normally the light of the OS 12000 should last the lifetime of the scanner. For replacement a special software and calibration tool is necessary.

Change always both light units together

Picture 171

First shut off the system and open the cover of the scan head, Disconnect the light unit, open the screws on both sides, take off the light units and replace them with the new units, reconnect them. For adjusting the light beam go to the calibration menu see 5.8.1 Adjust

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7.1.6 Laser unit

Picture 172 1 2 3 4 5 6 7 8 9 10 11 Base Laser unit Ground plate Distance Laser module Damper Shutter Motor shutter Screw Screws Screws Nut

The Laser is preadjusted and in the case that it is not working the right way, it is necessary to change it. Switch off the system disconnect the laser unit of the PCU board, open the four screws and lift it up. Now unscrew the two screws holding the laser on the unit and change the laser. To mount the new one follow the opposite way Connect the new laser unit to the PCU board. After mounting a calibration of the high measurement is necessary.

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7.1.7 Mirrors In the scan head are located different kinds of mirrors

2
1 Side reflectors 2
Reflectors moving the beam

3
Focusing reflectors

See spare part list

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8 Base
8.1 Frame 8.2 Book cradle
The book cradle is fixed in the frame with six screws from the bottom. To unmount the book cradle tilt the OS 12000 carefully and open the six screws and take off the book cradle. Disconnect X1,X2,X3 on the E3749 PCB IO Warrior 40 USB and X7 E-3750 PCB Controller book cradle Take off the book cradle. 8.2.1 Comfort The comfort book cradle is useful for sheet of paper, magazines and normal books, with a smaller size of the book spine With the look button on the operators panel it is possible to look the book cradle in different positions depending on with page it is necessary to scan. 8.2.2 Advanced The advanced book cradle is useful for every material to scan thicker books

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8.3 Control / Operator panel

Picture 173

If one ore more switches on the control panel have no function there is on the CD is special tool Bookcopy Panel to check all switches on the panel

Picture 174

All functions on the operator panel and the book cradle can be checked. When a switch is pressed it is marked on the screen, with it function. If something is damaged with the operators panel or the IO-warrior board Then for example the scanner is scanning continously then one of the Positions for scan is blocked when you press an Other scan button than the one which is switching permanent, then the mark is turning to the activated one and returns to the damaged one after releasing the scan button. In that case it is necessary to change the IO-Warrior board E-3749 Which is fixed in the scanner base under the operators panel. The IO-Warrior board is connected to the operators panel with a flat ribbon cable, take care when removing the operators panel

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Picture 175

Picture 176

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8.3.1 Glass plate The glass plate is pressing down the surface of the book, sheet, or magazine, that it is flat and even to improve the quality of the scan The glass plate is locked on both sides with mounting brackets, locked with two screws on each. On the operators side here is a handle shaft, which is positioned with a bullet on both sides in the holders. The bullets will release the handle shaft when the operator want to open the glass plate manually when it is closed to avoid damages to the glass plate and the mechanic. Dust, dirt, fingerprints can influence the quality of the scan Clean the glass plate with windows cleaner and dry it with soft textile Scratches and damages on the surface of the glass plate can influence the quality of the scan, or will cause that the glass plate can break while moving. In that case it is necessary to replace the glass plate before it is breaking To check the right positioning of the glass plate drive move the glass plate to 0 position and lay a level on the glass plate. The positioning is good when the glass plate is even and the book cradle is pressed a little down

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8.4 Glass plate drive

The glass plate drive is pressing the glass plate down the surface of the book, sheet, or magazine, that it is flat and even to improve the quality of the scan Detail glass plate drive

Picture 177

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Picture 178

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19

Cam disk 0 Cam disk40 Control board Glass plate Handle Cam plate 45 -90 Micro switch Glass plate lever Motor Motor lever Spring Power Unit Mounting bracket Glass plate holder Holder right Holder left Locking mechanism 90 Towing arm Motor axis

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8.4.1 Service For normal service its normally necessary to clean and lubricate all moving parts and check the function of the system Lubrication: thin machine oil or Teflon Spray Lubricate the bearings of the shaft with oil If springs are noisy than lubricate them wit Teflon Spray If the running surface of the glass plate lever has a visual wear out or there is metal abrasion in the base it will be necessary to lubricate the running surface with oil, or replace the bearing and the lever (8) If one of the bearings is running rough it is necessary to replace it

8.4.2 Malfunction Some tests have to run under power Open the six screws ant open the cover the lifting on the column side and lift it away from the frame. If the glass plate is not possible to move down to 0 remove the glass plate At first check the power supply Check the fuse on the control board Check the function of the switches and the rollers of the micro switches Check the motor with an external power source 12Volts DC

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8.4.3 Adjustment 8.4.3.1 Basic adjustment

Picture 179

Original adjustment The position of the glass plate is depending on Micro switches Active means pressed Position Glass plate Close motor 0 Open motor 45 Open manually 90 Manually pressed to 0 Position shaft Micro pressed 0 2,3,4,5,6 45 1,5,6, 90 1 0 2,5,6 switch Not pressed 1 2,3,4 2,3,4,5,6 1,3,4

Angel of glass plate result from positioning of the micro switches Micro switch number Angle 1 0 2 40 3 45 4 45 5 45-90 6 45-90

It is a corresponding system and several micro switches depend to others

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On the CD is a special tool BookcopyPanel to check the function of the micro switches.

Picture 180

Open the tool and move the glass plate with the operator panel to 0,45 , from 45 manually to 0 and open then manually to 90; when all micro switches work well at every position should appear a hook

If one hook did not appear check the micro switches and their positioning.

Mark always the basic position of micro switches, cam disks and levers before changing a positioning At 0 position the motor lever should be a little more than even in a right level to the glass plate lever take care that the lever is not turning over.

The motor lever must not move on the highest point and should only move low

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Picture 181

At 90 the glass plate is fixed lightly with a screwed in bullet 20 21 22 23 24 25 26 Spring Hook Look screw Screw Bearing Spring Screw with bullet

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8.4.3.2 How to change parts Micro switch: shut off system and disconnect the micro switch, and check it with a multi meter Lever: If the lever of the glass plate is damaged and needs to be replaced Switch off the system and take off the glass plate (4) by opening the two screws of the mounting brackets (13) Open the six screws of the cover of the glass plate drive and lift up the cover. Open the screw in the centre of the glass plate holders (14) and all other marked screws, pull both glass plate holders off the shaft Now the shaft is free to move to left or right

Picture 182

Push the shaft to the side until the part, which is necessary to remove, is free to take away. To take off the glass plate lever or the spring it is necessary to release the spring (11), to have no tension on the glass plate lever Always replace the bearing of the motor lever when it is necessary to replace the glass plate lever. To replace the motor lever follow the same way like before. Open the fixing screw and slight it off the motor shaft. Replace the bearing or the whole lever and adjust the position Lay two equal spacer under the lever and fix them even.
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It is helpful to use an external power source to move the motor because It is a delicate adjustment and it could cause damage to the motor and misadjust the other settings of the glass plate drive. After fixing all the opposite way check the positioning carefully. 8.4.3.3 Adjustment after replacement of parts After changing a micro switch check the switching point with the tool BookcopyPanel, if there is no hook than check and adjust the position of the micro switch.

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9 Special Software settings on OS 12000

9.1 Omniscan
9.1.1 Special Settings to the Funktion of the Glassplate Drive 9.1.1.1 Activating automatic scan after closing the Glasplate with the drive to 0 Position 1. Step: Open the Omniscan.xml in the directory C:\Programme\Zeutschel\Omniscan.xx.xx with WordPad Editor

Picture 183

2. Step: Select StartScanOnGlas>false</StartScanOnGlas> change false in true to activate the funktion.

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Picture 184

3.Step: Store the changings close Wordpad and start Omniscan

Picture 185

4.Step Activate Auto on the operators panel! Now is when the glassplate is closed to 0 the scan started automatically.

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9.1.1.2 Disable Errormessage Glassplate not ready If the glassplate drive is not closing the glassplate compleatly or it is not possibility to close the glassplate compleatly, then every scan a error message appears Glassplate not ready To disable this error message 1. Step: Open the Omniscan.xml in the directory C:\Programme\Zeutschel\Omniscan.xx.xx with WordPad Editor

Picture 186

2. Step: select <WarnIfGlassPlateOpen>true</WarnIfGlassPlateOpen> change true with false

Picture 187

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3.Step: Store and close Wordpad

Picture 188

The error message is now disabled and will not appear when the glassplate is not closed compleatly

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9.1.1.3

Disable automatic Glassplate detection

Um diese Funktion abzuschalten 1.Step: Open the Omniscan.xml in the directory C:\Programme\Zeutschel\Omniscan.xx.xx with WordPad Editor

Picture 189

2. Step: select <OverrideGlassPlate>true</OverrideGlassPlate> change true to false to disable this funktion

Picture 190

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3.Step: Select store and close Wordpad.

Picture 191

Now the automatic detection is disabled

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9.1.2 ROI 9.1.2.1 ROI Frames jump away If the frames in ROI jump away, switch off automatic adaption in the clip setting 9.1.2.2 Problems with ROI On serial scanners are Problems with ROI, write in line <ROIFullWidth>false</ROIFullWidth> the word true instead of false <ROIFullWidth>true</ROIFullWidth>

Picture 192

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9.2 Perfect Book

9.2.1 Modify Settings of Perfect Book If Perfect Book has problems with darker / brown pages of books there is a way to modify the settings of the Matrix camera to get better results To change the sensity for the Matrix camera, if Perfect Book gets no 3D Data of dark pages, there is a possibility to change in the directory Kalib/ Kalibrierung.ini the exposureTime or the gain, please increase them only step by step, because when they are setted too high then not brown or white pages will be too bright. Than we have the problem in the opposite way.

Picture 193

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1.1.1 Offset of Perfect Book depending on Start position of scan

9.2.1.1

only until OS 11.10 SR4

Offset of Perfect Book after changing start position in SCU setting After changing the start position in the SCU settings, then Perfect Book will not find the correct position of the middle of the book. There is a way to do a OFF-set to correct this effect In the Kalib you find a Test_sheet.pdf, print out the test sheet, unscaled, Take the distance between 10 crossings, it should be about 19,97 cm a little moreore less is ok. Place the Test sheet in landscape in the middle of the book cradle

Picture 194

Go with the scanner symbol in Omniscan to the menu OS120000

Picture 195

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Select 3D position in this menue.

Picture 196

You are asked to lay the test target on the book cradle, lay it on there landscape in the middle and right angle. The book cradle should be fixed in 0 position Press ok to start the Offset calculation with ok It will be scanned several times, wait the following menu

Picture 197

Check the top number necessary replace it with the number from the test sheet. Then agree with ok

.
Picture 198

Next window is showing the calculated correction. Agree with OK

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Picture 199

After the Offset calculation go back and do a reset Then scan a book with Perfect Book , and check if the middle of the book is found exactly If the result is good ok. If not scan the copy the original Kalib data to the software and scan the test Sheet again and increase or decrease the number a little. An other way is to calibrate Perfect Book again new, it is described in the manual,

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9.2.1.2

Only OS 11.12

9.2.1.3 Automatic start position finding and offset Perfect Book With the relase OS 11.12 there is a new feature, which is checking daily at the first start of the software the positioning of the start position depending on the the white reference position. To do the position check manually, go the settings and select more or click on the scanner symbol in the symbol line.

9.2.1.3.1

For Operators

Picture 200

At first clear the book cradle and check the whitereference, that nothing covers it. Click on the button Scan area position and start the routine. Now the system is scanning the bookcradle. After the scan a window is opening and showing the found start position depending to the white reference position. The system is calculating the difference of the position of the green lines to the position of the first black horizontal line to the position which is stored the last time. After the scan a window is opening where the positioning of the green
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lights depending on the first black line is shown.

Picture 201

If the green lights are covering the first black line at once then click on OK. A menue is opening and tells that the position is ok, click on OK. No modification on the position of start and Perfect Book is necessary to do

Picture 202

If the green lines are far away from the first black line then it is possible to move the green lines in one step by clicking Upper Borderto the upper part of the window. With the button UP and Down the green lines can be moved pixle per pixle to the first black line. If the green lines are covering the first black line click on OK Now the system is calculating the offset of the start position
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The next menue is giving the offset of the start position click on OK

Picture 203 The system is now correcting the start position The next menue is giving the offset for Perfect Book, click on OK

Picture 204 The system is now correcting the Perfect Book calibration, click on OK

9.2.1.3.2

For Technican only

Picture 205

With this start position correction

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9.3 Firmware Update on OS 11.xx

When updating software OS11.XX it could be necessary to ugrade the firmware, too. 1.1.2 < OS 11.12 To upgrade firmware with OS 11.10, it is necessary to download the firmware which is recommended from the Zeutschel download page.

It is important to adjust a color scanner to scanning color in High Quality and the PC should be connected to separate Power connection.
. Go to calibration menu and select download

Picture 206

Select browse and select the firmware which is depending to the scanner type and cklick on download and follow the menu. It is depending to the status of the scanner if the following message box appear or not, it is not always appearing

Picture 207

Switch off the Scanner, wait a few seconds and restart it, wait until the scanner has internal resetted. You see that when the lights are flashing once and you hear a silent beep.

Picture 208

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1.1.3 >OS 11.12 SR2 To upgrade firmware on OS 11.12 , the firmware is written in the Omniscan directory during installation in the directory C:\Program Files\Zeutschel\Omniscan11.12\Driver\OS12000\Firmware

It is important to adjust a color scanner to scanning color in High Quality and the PC should be connected to separate Power connection.

Picture 209

Select browse and select the firmware which is depending to the scanner type in the opening window.

Picture 210

and click on open and in the following menu on download.

Picture 211

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It is depending to the status of the scanner if the following message box appear or not, it is not always appearing

Picture 212

Switch off the Scanner, wait a few seconds and restart it, wait until the scanner has made an internal reset You see that when the lights are flashing once and you hear a silent beep.

Picture 213

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9.4 Bookcopy
9.4.1 Password to log in as Admin to calibrate Scanner To calibrate a Bookcopy scanner, use the keyboard which is delivered with the scanner. Close Bookcopy with Alt-F4 and press Alt-Ctrl-Del to log off and logg in as Admin The Password is @Bookcopy , on the US-keyboard you create the @ with the combination shift 2 9.4.2 Restoring and Upgrading OS12000 Bookcopy PC System (TS-0668E) If certain errors accumulate when using the bookcopy software, or on the operating system level, extending even to total system failure, then it is possible to restore the PC system via an image file. You can also use an image file to update the OS12000 Bookcopy PC to a new image version with improved functions. There is a separate manual to describe these steps (TS-0668E_SU_RestoreBookcopyPC).

9.4.3 Password to unlock Bios of Bookcopy PC To upgrading and restoring the Bookcopy PC it is necessary to unlock the Bios with the following Passwords Optiplex 750 /750 @Bookcopy Optiplex 760 atBookcopy switch the USB device to Boot , then close Bios and start with restoring and upgrading. After finishing change the settings of the USB device back to no boot .

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9.4.4 Mediacenter settings If the storage medium is not found then check in the bookcopy .ini, If the removable drives have the same naming as in the device manager. If there is a problem with the naming of the drives increase the numbers of drives in the bookcopy.ini to 23 drives and name them driveX=naming

Picture 214

9.4.5 File size In older version the compression rate is adjusted to high Enter the bookccopy.ini with WordPad and change the number to 80

Picture 215
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9.4.6 Update a Bookcopy System

To update a Bookcopy system with more Software options like e-mail, Media-Center, etc. it is necessary to change the Bookcopy bits in the scan head. This is only possible when an OS 11 Dongle is added to the system
9.4.6.1 Update Bookcopy system with extended features Start the system, shut down Bookcopy software log in as Admin and start Omniscan. Go to the calibration menue and select download

Picture 216

there is a key delivered from Zeutschel to update the system, select this key with browse license file open this key with with Apply

Picture 217

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In the following menu click on yes.

Picture 218

The new feature is now added to the system.

Picture 219

After the message that the system is updated close Omniscan and restart the system. To check if the update was writing in the right Bookcopy Bits, Go to Omniscan and open the menue Set Serial Number

Picture 220

Here you can see the options of the Bookcopy System, the ones which are marked are available 9.4.6.2 Adapt a Media Center later to a OS12000 Bookcopy To adapt a MediaCenter later to a OS120000 Bookcopy, first install the Media Center. Follow the Update process see 9.4.5.1 and update with the licence key Now the Media Center is ready to work
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10 Errors and solutions

10.1 Hardware
1.1.4 PCU 10.1.1.1 Broken off Parts by using wrong tools

It happens very often that parts of the boards are damaged when opening or locking the nuts to change a board. With a tool like shown on the picture below there are very easy broken off parts of the board

Picture 221

Picture 222

In that case is it necessary to replace the board

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Picture 223

Use tools like displayed in the upper picture to avoid damages to the electronic

Picture 224

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10.1.1.2

No Perfect Book after changing PCU

When after changing the PCU the Funktion of Perfect Book is not available

Picture 225

Then it could be that while reconnecting the cables to the PCU board the connectors X11 and X12 had been mixed.

Picture 226

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Picture 227

In that case the resistor L 105 is burned and in bad case the connecting paths are burned too. In that case you have to replace the PCU board with a new b and take care about reconnecting the cables

Always take care that the connectors are at the right position to avoid damages to the electronic

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10.1.1.3

No reset function after changing PCU board

10.1.1.3.1

Wrong position of connectors

When after changing of the PCU bord, the motors are running against block and /or the the scanner is not able to reset it is possible that the connectors for the motors had been mixed or for the light barrier and the end switch of the Focus unit.

Picture 228

1 2 3 4

Motor 1 Motor2 Light barrier Scan motor Micro switch Focus motor

Scan motor Focus motor

When the focus motor was running against block then it could be necessary to take off the camera head and move the focusmotor in a position where the micro switch for end position is not pressed

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10.1.1.3.2

The cable connecting PCU and SCU is not plugged in

After starting the scanner and the software the scanner cannot be reset

Picture 229

Check if the connectors of the flat ribbon belt are locked the right way

Take care while removing the flat ribbon cable , not to break away thecable from the connector

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10.1.2

Height measurement / invalid height If after checking the height of the book with the laser , the following error message appears,

Picture 230

There are several possibilitys o The calibration of the laser has changed Do a new height measurement o The cable from the PCU board to the laser is damaged Check the cable and replace if necessary o The optic of the laser is dirty Clean the optic o The laser is damages Replace the Laser module o The laser shutter is not opening or shutting right Check and repair the shutter o The PCU board is not changing the analog signal from the laser to a digital Signal change the PCU board o The SCU board is not working with the digital signal of the PCU board Change the SCU board 10.1.2.1 Errors while height measurement

10.1.2.1.1

This error appears with OS11.12 SR1 and higher

Picture 231

Reason for this o After update 2D shading was not made Do a 2D shading o After changing the SCU board the 2D shading was not made Do a 2D shading o After changing SCU the calibrated datas had not been loaded to the head Load the calibrated datas to the head
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10.1.2.1.2

Message two times the same value

When after the height measurement this error appeases then the height which was checked on level 0 and on the 30mm tool was the same.

Picture 232

Reason for this can be o Laser module is damaged Change the laser module o Laser shutter is not working the right way Check and repair the shutter o Laser module optic is dirty Clean the optic o Connecting cable to the laser module is damaged Check the connecting cable o PCU board is not compiling analog in digital signal Change the PCU board o SCU board is not recognizing the different signals Change the SCU board

10.1.2.1.3

Message during calibration that difference is more than 5

Picture 233

Reason for this can be Laser shutter is blocked Check the laser shutter Laser shutter is not moving the right way Check the laser shutter Changing the book cradle level during calibration Block the Book cradle

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10.1.2.2

Laser is not shutting

When the laser shutter is not closing then it could be that someone pressed the laser shutter out of position and it is jamming while moving.
Spring

Stop

Lasershutter

Lasermodule

Picture 234

Try to get the laser back in position by pulling it a little down, for example with a allen screw driver. But take care it is a thin material and bend very easy. If it is not possible to free the laser shutter, while fixed in the scanhead, it is necessary to take of the whole laser unit, After reinstallation of the laser it is necessary to adjust the Matrix camera to the old position, and if necessary do after calibration of the hight measurement an other Outer Calibration

When the laser shutter is not closing then it could be that someone pressed the laser shutter out of position and it is jamming while moving.

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1 2 3

5
Picture 235

1 Shutter

2 Laser module

3 screw

4 spring

5 Motor

When the laser shutter is not opening compleate and it is not blocked then check the spring of the shutter, it is helpful to turn the position of the spring on the shutter at 180

Picture 236

If you hear a permanent sound like a motor is running with high speed after pressing the scan button, than it could be that the shutter has loose from the motor shaft, lock it with the screw 3
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10.1.3 10.1.3.1

Glass plate drive No function on the glassplate drive

Check first with the Bookcopy panel test program if the glassplate drive is recognized Possible reasons: No function at all wether with operators panel nor foot switch Check power, Check connection to IO warrior Check if USB connector is plugged in on the IO warrior Check the 5 V LED2 on the PCB controller e- book cradle Check the 24V LED1 on the PCB controller e- book cradle Power unit gets no power Check the connection from the PCB Power supply to the power supply Shortcut If there is a shortcut in the power output direction, then the power supply is regulating down PCB controller e-bookcradle is not working power is good The fuse is burned, check or replace the fuse The relais is jamming , change PCB controller e- book cradle Connecting cable from IO Warrior is defect Check the cable connecting the on the PCB controller e- book cradle with the IO warrior board 10.1.3.2 Glasplate drive is closed at 0 and not opening

3,4

5,6
1 0 2 40

1
3 45 4 45

2
Picture 237

5 45-90

6 45-90

Possible reasons
157

Microswitch 5,6 for45 - 90 is nor pressed at 0 Check position of micro switch 5,6

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10.1.3.3 Glass plate opening after closing if button down is pressed or opening by itself with a book under the glass plate Micro switch 1 for 0 is not adjusted at right position and permanent pressed Adjust micro switch 1 to right position Build in Block for avoiding turning round the lever of the motor

If you have problems to adjust the glass plate drive, then order the block which avoids that the lever of the motor is moving more than the 0 position

Picture 238

Picture 239

To build in this block you have only to unscrew the screw 1and place the block on the position like shown on the image. Lock it with the screw which is delivered with the block

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10.1.3.4

Glassplate is stopping before 0

Possible reason Cam wheel for 0 is not adjusted to the right position Adjust the cam wheel to the right position The motor does not get enough power to move the glassplate completely down Check if the PCB controller e- book cradle is giving enough power to the motor One of the bearings moving in the guiding area of the glass plate lever Check if one of the levers are damaged or not lubricated, replace or lub them The motor or the gear is damaged is damaged Change the motor by releasing the marked screws

Picture 240

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10.1.3.5

Glassplate is shifting and not locked tight in the holder

If the glass plate is moving in the holders of the glass plate drive, and the screws of the holder are locked tight.

Picture 241

Reasons The distance of the fixing block and the Glass plate carrier is to wide when the screws of the block are tight. Take off the glass plate and check the protection guard, if the double adhesive tape is getting loose, or pressed too much together.

Picture 242

In that case replace the double adhesive tape If the tape looks good then check the block which locks the glass plate drive is locked well

Picture 243 Grind a little of the bottom side of the block away that , by locking the screws block is pressed deeper and locks the glass plate tight

Picture 244

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10.1.3.6

Change the motor of glass plate drive

Open glassplate to 90 Remove cover of glassplate drive If necessary bring drive mechanically to 90, unplugg scanner

Picture 245

Press down the glassplate to 0 after opening the holders of the glass plate,

Picture 246

Block on both sides the levers when glassplate at 0

Picture 247

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Disconnect all cables Take away the glass plate and open the 8 screws holding the drive unit on the bottom of the base of the scanner

Picture 248

Open the four Philips screws on the back side

Picture 249

When lifting out the drive unit take care about the ground cable and power cable

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Open all screws of the the holders of the motor . Take care not to move the 45 micro switch.

Picture 250

Open the screws locking the levers on the shaft of the motor Remove the connecting screws

Picture 251

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Move the side holders aoutside

Picture 252

If necessary push the holders on the bearings outside

Picture 253

There is now more place to move the shaft of the motor out of the one bearing , then turn the motor and pull the shaft to the other side.

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Picture 254

Turn out the motor Build in the motor in the opposite way. Fix the levers on the on the shaft of the motor and take care that they have the same level .

.
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Picture 255

Picture 10.1.3.5

Glassplate is shifting and not locked tight in the holder 256

Loock all screws, ring the drive unit back to the base, contact all connectors. Do not forget the blocks Start the unit

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10.2 Software
10.2.1 Error 31390

Picture 257

Picture 258

Solution: Delete Omniscan XML indirectory C:\Programme\Zeutschel\Omniscan11.10_SRxx , Omniscan is creating a new Omniscan.XML when starting the next time.

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10.2.2

No Scanner found message. If in Omniscan the errormessage appears that no scanner is found

Picture 259

Then there are several possibilitys: Scanner is not switched on Start scanner before starting the PC The Software was started before the scanner has initialized Start scanner before starting the PC Scanner is disconnected Check the Fire wire connections and if scanner is recognized in the device manager The SCU board gets no power Check the power supply The SCU shows a red LED The firewire connection failed or reset failed check system

10.2.3 Could not reset scanner Possible reasons Scanmotor is jamming Check motor, if motor is damaged replace Check if spindle is jamming in inserted nut, clean relub Scanmotor is moving flag against resistance Check light barrier Check PCU Focusmotor is jamming Check motor, if motor is damaged replace Light barrier out of function Check function of light barrier, if damaged replace Light barrier not recognized by PCU Change PCU Micro switch out of function Send camera head to Zeutschel Micro switch not recognized by PCU Change PCU PCU out of function no power to motors Change PCU or modificate PCU to higher current

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10.2.4 Error while normalizing motors

Picture 260

Possible reason Scanmotor is jamming Check motor, if motor is damaged replace Check if spindle is jamming in inserted nut, clean relub Scanmotor is moving flag against resistance Check light barrier Check PCU Focusmotor is jamming Check motor, if motor is damaged replace Light barrier out of function Check function of light barrier, if damaged replace Light barrier not recognized by PCU Change PCU Micro switch out of function Send camera head to Zeutschel Micro switch not recognized by PCU Change PCU PCU out of function no power to motors Change PCU or modificate PCU to higher current

Picture 261

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10.2.5 LED on the SCU boarb The SCU board fire wire connection on the board is damaged On the SCU Board there are 6 LED , in normal function there are two green light on and one if flashing. If a red LED is light on then the initialisation of the SCU failed, A orange LED is light on when the SCU is initialized but not reset from the Program

Picture 262

1
1 green flashing off Off off

2
2 orange off off Off off

3
3 red off off on off

4
Picture 263

5
5 green off off off on

6
4,6 green on on off on

Line 2 (horizontal) is the showing the colors of the LED Line 3 (horizontal) is the showing the status after starting the scanner without connection to PC Line 4 (horizontal) is the showing the status after starting software Line 5 (horizontal) is the showing the status during scanning Line 5 (horizontal) is the showing the status after self check failed
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10.2.6 LED on PCU On the PCU board are during normal Status 3 LED powered on If one ore more LEDs are off when scanner is switched on then check following possibilitys

3
Picture 264

1 V4
green On Glowing little Off Off On Off Off Off

2 V6
green

3 V5
green On Glowing little On Off

Line 2 (horizontal) is the showing the colors of the LED Line 3 (horizontal) is the showing the status normal Nothing to do Line 4 (horizontal) is the showing the status when power connection is not plugged in Plug in power connection Line 5 (horizontal) is the showing the status without connection to SCU and power connection plugged in Check Power of SCU and connection to SCU Line 5 (horizontal) is the showing the status scanner switched off Nothing to do

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10.2.7 Enter SCU when System is blocked SR4 After changing the number for the start position and focus position too high or to low then the Scanner cannot reset and Omniscan 11.10 is not startin With the SR4 First go to the Os 11.10 directory C:\program files\Driver\OS12000\Param

Picture 265

Open in the directory the folder OS12000.cfg with the editor

Search there the line NORMALIZE_AT_SCANNER_INIT <1> 1 and change it to NORMALIZE_AT_SCANNER_INIT <1> 0
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Picture 266

Picture 267

Save it and close everything Start now the scanner wait until the light has switched on Start now Omniscan Go to the Calibration menu and select there SCU settings Check the settings you have changed
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Picture 268

Change and save the right number to the settings Go to the Scanner Settings and scroll down to Motor normalize at Init. Check the checkbox

Picture 269

Close everything and check now if Omniscan is starting the right way

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10.2.8

Color alignment If you have color alinement in the image of a scan without Perfect Book, Then go to the calibration menue and check the number of the flag The number should be 1 and if there is a 0 in the checkbox then change it to 1 and press set

Picture 270

When the number is 1 then press the button start to swap the color channels. You will be asked, if you are shure that you want to change the datas to the head. Accept with yes. Do a reset before you start to scan Now the channels are in line

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10.2.9 Perfect Book without curve correction Reasons when Perfect Book is not available or not working The Kalib data are not copied to the software The driver of the Perfect Book camera has not the right version The option Perfect Book is not available on the dongle The fire wire cable of the Perfect Book camera is not plugged in The driver for the Perfect Book camera is not installed The fire wire cable of scanner and Perfect Book camera are plugged in the same fire wire card. The Matrix camera is not working There is no Trigger signal from the PCU board The Trigger cable is not plugged in the Matrix camera When Omniscan after the installation is working with Perfect Book without curve correction, then check if all datas of the Kalib are copied the right way. To check the datas in the Omniscan directory and open the Kalibrierung.ini If your Kalib directory shows only 5 files, then this is the original Kalib of the installation and no calibrated datas had been copied

Picture 271

If the calibrated datas are copied the right way, then the Kalib directory shows 7 files SR4 with OS 11.12

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Picture 272

If the calibrated datas are copied the right way and Perfect Book is not working, Then check in the Kalib directory the Kalibrierung.ini ( see picture 10-3) When you open the Kalibrierung.ini and you find there
dir = C:\Program Files\/ schrittweite = 4 templateCount = 11; template = 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0

11.4.1 How to add the Perfect Book camera to the scanheadinstead of

dir =C:\Program Files\Zeutschel\Omniscan11.10_SRxxx\Driver\OS12000\PerfectBookCalibrationLog/ schrittweite = 4 templateCount = 11; template = 10.67 17.00 35.67 80.17 139.33 174.50 137.67 60.17 23.33 13.67 10.67

then the datas had not been copied right. In that case try to copy the calibrated datas again ore copy them one by one in the Kalib directory and check then if they are copied right

Please be shure that you have Admin rights when you copy the Kalib datas

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10.2.10 Error while scanning occurred / timeout

Picture 273

Reason The PC has too less working memory free Check the 3GB option in the boot.ini Other program are influencing the data flow, for example virus scanners Check system that nothing influencing the data flow One of the motor is blocked while moving forward Check the motors and free movement of mirrors One of the motors is blocking The PCU is providing too less current for the motors, change PCU A motor is damaged, change motor

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10.2.11 Error while scanning occurred while using Perfect Book 10.2.11.1 When the Firewire cables are plugged in in the same fire wire card

With the scanner is once for the scanner a fire wire card and for Perfect book a second card delivered with the scanner, use always only one fire wire cable for one card. The scanner and the Perfect Book Camera are using the whole bandwith of the fire wire card. 10.2.11.2 When the Kalib datas are not copied No 3d calibration data

If this error appears check the installation, and copy the Kalib Datas to the directory \\c:\program files\Zeutschel\Omniscan11.xx\driver\OS12000\

10.2.11.3

The 3d calibration blongs to an other scanner This error message appears when o changing the SCU board and not select the right serial number. With a replacement SCU board there is the possibility to change SN and ID once o Check if the serial number of the SCU board is the same than of the scanner The SN and ID of the SCU board can be changed one , after writing in only the Zeutschel customer support can change the Settings online, by sending the SCU to Zeutschel or by a technican of Zeutschel personell o when using Kalib of an other scanner Checking the DVD which is together with the scanner about SN of scanner

Picture 274

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10.2.11.4

The calibration belongs to another Matrix camera

Picture 275

Reason : Using a Kalib of another scanner Check Kalib on DVD and copy them again After changing Matrix camera there are not chanded the Kalib and no Outer Calibration Copy Kalib datas from the DVD which was coming with the Matrix camera The Matrix camera is not working with Perfect Book The Part L105 is damaged Check the PCU board see 10.1.1.1 The cable is not connected to the Matrix camera Check the cable to the matrix camera The Matrix camera is damaged check Replace the Matrix Camera use the Kalib of this camera and follow Adjuat , Outer calibration The trigger cable ( green ) is not plugged in after changing PCU or SCU Check cables on camera head The cable to the Matrix camera is not plugged in

10.2.11.5

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Picture 276

Check if the plug us pressed well in the socked The pins of the socket on the Matrix camera are bend to the side

Picture 277

Unplugg the cable to the Matrix camera and check the pins, Bend them to the right position and plug in the connector

Picture 278

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10.2.11.6

Error message Start position is different to calibration

Picture 279

Reason: Scanner is connected to customer PC and started with OS 11.12 first time without Kalib datas Copy Kalib datas and do once a scan area position check After Installation of a new version of the software the first scan is started without Kalib datas copied Copy Kalib datas and do once a scan area position check

In that case the start position of the scanner is different to the stored position of the Perfect Book calibration.Start Omniscan, open a job and press the scanner icon.In the next menue select Scan area position to check the start position of the scanner and of the Kalib, with Scan area position Accept the changing the system is offering you , With that automatic start position finding the correction of the start position and the Offset of Perfekt Book are made autimatically
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10.2.12

Special Log files to protocol the complete Scan process If with a Diag file there are not enough information to target the problem Of the scanner or the software, then there is the possibility to create extended log files Go to the OS12000.ini in Omniscan or Bookcopy and write at the end two new lines, for OS 12000 HQ to OS12000HQ.ini [Debug] debugmode=1

Picture 280

Then with every new start of the software a new Log file is created.

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Picture 281

Delete this files after the problem is solved, and delete the two lines In the OS12000.ini

Picture 282

If the two lines in the OS12000.ini are not deleted, then the system is creating with every start of the programm a new Log file

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11 Modification on OS12000
11.1 Scan motor
If the scanner is fitted with a rack weehl gear motor and it is necessary to change tis motor, it will be replaced with a new version of drive . See TS-0716DE After the change of the Motor we have to modify the scanner type in the SCU settings Go to calibration select there Set serial number and press the button Switch from rack wheel to spindle driven OS12000

This is only a one way calibration and it is not possible to return

Picture 283

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Accept the menu New Spindle drive with OK

Picture 284

Now the device type is changed to motor with spindle drive

Picture 285

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11.2 PCU board

11.2.1 How to change the PCU board Changing of the IO- Warrior board If there is a Problem with the IO warrior board, for example that the scanner is scanning countinously, and the reason is checked with the Bookcopy Panel Test Program, see chapter And it is necessary to change the IO warrior Board then follow the advice. Switch off scanner and PC

Take care about static unloading, by grounding yourself

To change the IO-Warrior board it is necessary to remove the operators panel Under which the IO-Warrior board is located

Picture 286 To lift the operators panel use a screwdriver with a thin blade

Picture 287
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Lift the operators panel carefully with the screwdriver on one side and lift it up carefully,

Picture 288 It is locked with a double adhesive tape

Picture 289 When you lift the operators panel then take care about the flat ribbon cable which is connecting the operators panel to the IO-Warrior board

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Picture 290

To disconnect the flat Ribbon cable pull the top part of the connector a little

Picture 291

Next disconnect all connectors, on the Picture IO-Warrior of a OS1200 Advanced is displayed

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Picture 292

After disconnecting all connectors open the two screws which are holding the board in position. Take care not to loose the spacers which are between board and the base

Picture 293

After changing the board fix the board with the two screws ad reconnect all cables

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Picture 294

Lay the Operators panel on the base, switch on the system and check with the BookcopyPanel test program

Picture 295

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11.3 Modification of PCU board on OS 12000 to higher current for motors

With some of the OS12000 scanners with the splindle motor might be necessary to give a higher current to the motor to avoid a block of the motor after a longer switch off period To give more current to the motors it is necessary to replace four SMD resistances on the PCU board.

Picture 296

For that modification you need a SMD soldering system or if you use a soldering iron, then you need a thin top.

When you fix the resistances take care to place them on the right position and do not use too much tin-solder, not to contact other parts or conducting paths Take always care about static unloading which could cause damages to the board
When the resistances are changed then the average mode in Omniscan is working only in mode 1 and 2

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How to replace the resistances Switching off the system Open all the covers of the connectors and unplug all connectors take away the cover of the board.

Picture 297

Next open the four nuts to release the PCU board

Picture 298

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Lift up the two capacitor carefully

Picture 299

Now use a soldering iron with a thin front part and take off the four resistances

Original Resitance 1R50 New Resistance 1R00

Original Resitance 1R00 New Resistance R820

Picture 300 Replace the resistances 1R00 with R820 and 1R50 with 1R00 you can use the old 1R00 to replace the 1R50. Bend the capacitors back to their position Now give the board back to the scanner following the opposite way. Start up the system and do a test run. If the scanner is not starting properly then check if the tin-solder has contact to other parts or to conducting path
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11.4 Add Perfect Book to a OS12000 in the field

When a OS12000 is not fitted with Perfect Book from production and it is necessary to add Perfect Book later and it is not possible to send the scan head to Zeutschel, Then follow this advice. Intemps of the Perfect Book Update Package 1 Perfect Book camera 2 Set of screws 3 CD with Kalib Datas 4 Special driller to cut the whole for the Perfect Book camera

Perfect Book Camera

Picture 301 Scan head without camera head and laser module

Picture 302
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11.4.1 How to add the Perfect Book camera to the scanhead

1. Step Before starting prepare everything For cutting the whole for the Perfect Book camera we need a drilling machine to which the special driller is fitting A vacuum cleaner to remove the waste after cutting the whole for Perfect Book. Philips screw driver 3 and 1 2. Step Switch off the system and open the scan head Remove the laser module by unscrew the four screws which look it to the frame and place it out of range. The cables can stay connected

Picture 303

Now cover the camera head that no waste is possible to reach the CCD Unit

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3.Step Now cut the whole with the special driller by cenring the driller to the prefixed position in a right angle.

Picture 304 Take the Perfect Book Camera and fix it with the screws of the Update Package. Do not forget to remove the protection cap

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Picture 305

Picture 306 Remove the cover of the PCU

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Service Manual OS 12000 TS-0737E SU_OS_12000_Service_Manual

Picture 307

Now contact the white and green cable (red) to the PCU and the black to the ground of the CCD-board

Picture 308

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Service Manual OS 12000 TS-0737E SU_OS_12000_Service_Manual

Picture 309

4. Step Now copy the Kalib file from the CD to Omniscan to the directory C:/ program files/Zeutschel/OS XX.XX/driver/OS12000 5. Step Calibration Now follow Adjust and then Outer Calibration in the Service manual to calibrate Perfect Book see Chapter 6.8

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