Exxtra ExxtraSetter Exxpress 300 User manual

INSTALLATION
AND
OPERATION
MANUAL
Document 100.OM-M
Revision .01a- Initial Release
Revision Date: 24 December 1996
Take it to the Maxx!™
© Copyright Exxtra Corporation 1992, 1994, 1996
All rights reserved. Reproduction, adaptation, or translation, for any purpose other than the purchaser's personal use,
without prior written permission of Exxtra Corporation is prohibited, except as allowed under the copyright laws.
www.exxtra.com

ExxtraSetterMaxxima 300 OPERATOR'S MANUAL
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PREFACE
What you can learn from this manual
This manual introduces the user to the ExxtraSetter imagesetter engine, – its installation,
features, operation and maintenance. Having prior experience with film based imagesetting
systems is of great benefit, although it is not absolutely necessary in order to make use of this
manual. This manual does not cover service of the imagesetter engine, nor does it cover the
necessary details of system integration with a host computer andRIP software, or the workings of
the host computer and RIP.
Manual Overview
Chapter 1 — Read This First!- Unpacking and Installation- provides information on unpacking
the machine, power requirements, environmental considerations and hook up to a host Raster
Image Processor (RIP) computer.
Chapter 2 — Getting Acquainted with Your Imagesetterprovides an introduction to the
imagesetter features, and an overview of key components.
Chapter 3 — Selecting Photographic Mediaprovides guidelines regarding the selection of
photographic media including film, paper and polyester plate.
Chapter 4 — Using the Imagesetter Control Paneldescribes the function and operation of the
front panel keys, indicators, and menu system.
Chapter 5 — Basic Operating Proceduresdescribes the way the imagesetter works with the host
system, and provides procedures for film loading, density calibration, and media usage tracking.
Chapter 6 — Maintenance and Adjustments describes Operator serviceable maintenance
functions.
Chapter 7 — Solving Imagesetter Problems explains how to isolate and fix some occasional
problems such as dirt in the optical path.
Chapter 8 — Repackaging the Imagesetter for Shipment or Relocationdescribes how, and
emphasizes the importance of proper packaging of the machine.
Appendix A— Imagesetter Specificationsis a listing of the features, performance specifications,
environmental requirements, and media requirements for the imagesetter engine.
Appendix B— Front Panel Status and Error Messageslisting describes all of the front panel
messages and what, if anything, to do when and if they occur.
Appendix C— Regulatory Statementslists the various governmental testing, safety and
certification statements.
Conventions
♦Unless otherwise noted, the termfilm is generally used throughout this manual as a generic
term meaning all photographic media including paper and polyester based film and plate.
♦RIP — Raster Image Processor, can be either software or hardware. Supplies external control
and rasterized binary data to the imagesetter engine for printing.
♦Unless otherwise noted, the termsimagesetter, ExxtraSetter, Maxxima, engine, output
device, and printer refer interchangeably to the basic image setting engine,not including the
host computer, interface or RIP.

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♦The Imagesetting Systemrefers to the integrated system of the imagesetter, the host computer
(Macintosh, PC, work station, etc.), the Hardware Interface (standard Exxtra parallel Video,
requiring a plug-in card or optional SCSI) between the host and the imagesetter, and the RIP
and its driver.
♦YELLOW indicates the yellow Light Emitting Diode(LED) located on the front panel is
blinking.
♦RED indicates the red Light Emitting Diode (LED) located on the front panel is on.
♦indicates that the control panel audible indicator (beeper) sounds.
♦Bold type is used for message text that appears on the imagesetter control panel
display.
♦Italic is used for emphasis
♦indicate control panel keys.
Notice
Exxtra Corporation makes no warranty of any kind with regard to this material, including, but
not limited to, the implied warranties of merchantability and fitness for a particular purpose.
Exxtra Corporation will not be liable for errors contained herein or for incidental consequential
damages in connection with the furnishing, performance, or use of this material.
Differences may exist between this manual which supports the latest configuration of
ExxtraSetters and earlier revisions. In most cases they are not significant.
The information contained is this document is subject to change without notice.
Trademark Credits
Canon is a trademark of Canon Corporation. ExxtraSetter, Exxpress, Maxxima, Virtual Drum,
You Can’t Beat a Virtual Drum, Take it to the Maxx, and the Exxtra logoare trademarks of
Exxtra Corporation. Pagi-Set is a trademark of Eastman Kodak Company.Macintoshis a
registered trademark of Apple Computer, Inc.

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CONTENTS
PREFACE................................ ................................ ................................ .............. i
What you can learn from this manual..................................................................................................... i
Manual Overview..................................................................................................................................... i
Conventions.............................................................................................................................................. i
Notice ...................................................................................................................................................... ii
Trademark Credits.................................................................................................................................ii
CONTENTS................................ ................................ ................................ ......... iii
1. READ THIS FIRST! - UNPACKING AND INSTALLATION.............................. 1
1.1 Unpacking......................................................................................................................................... 1
1.2 Power Requirements......................................................................................................................... 2
1.3 Setup Location and Environmental Considerations......................................................................... 2
1.4 Initial Imagesetter Setup................................................................................................................... 3
2. GETTING ACQUAINTED WITH YOUR IMAGESETTER................................ . 4
2.1 Key features - General Description.................................................................................................. 4
2.1.1 Virtual DrumTechnology................................ ................................ ................................ .... 4
2.1.2 Film Handling ................................ ................................ ................................ ......................... 4
2.1.3 Operator Controls................................ ................................ ................................ .................... 5
2.1.4 Electronics................................ ................................ ................................ ............................... 5
2.1.5 Power Supply................................ ................................ ................................ ........................... 5
2.1.6 Interfaces................................ ................................ ................................ ................................ . 5
2.1.6.1 Exxtra Parallel Video Interface................................ ................................ .................... 5
2.1.6.2 Remote Diagnostic Port................................ ................................ ............................... 5
2.2 ExxtraSetter Imagesetter Parts Identification................................................................................. 6
2.2.1 Machine Identification Label................................ ................................ ................................ ... 6
2.2.2 Inside of the User Compartment................................ ................................ ............................... 7
2.2.2.1 Imager................................ ................................ ................................ ......................... 7
2.2.2.2 Support Rings................................ ................................ ................................ ............. 7
2.2.3 Sensors and Safety Interlocks................................ ................................ ................................ ... 8
2.2.3.1 Door interlock................................ ................................ ................................ ............. 8
2.2.3.2 Out of Paper Sensor (OOPS)................................ ................................ ....................... 8
2.2.3.3 Out of Cassette Switch (OOCS)................................ ................................ ................... 8
3. SELECTING PHOTOGRAPHIC MEDIA................................ ........................... 9
3.1 Films, Paper and Plates.................................................................................................................... 9
3.2 Darkroom Bulk Load and Daylight Bulk Load versus Disposable Cassette................................... 9
3.3 Specific Recommendations............................................................................................................. 10

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4. USING THE IMAGESETTER CONTROL PANEL................................ ........... 11
4.1 Introduction..................................................................................................................................... 11
4.2 When to Use the Control Panel....................................................................................................... 11
4.3 Control Panel Layout...................................................................................................................... 11
4.3.1 The LCD Display................................ ................................ ................................ ................... 11
4.3.2 The Control Panel (LED) Indicators ................................ ................................ ...................... 12
4.3.3 The Control Panel Audible Indicator (Beeper) ................................ ............................. 12
4.3.4 Control Panel Keys................................ ................................ ................................ ................ 12
4.3.4.1 The Control Panel Keys................................ ................................ ............................. 12
4.3.4.2 Hot Key combinations (depress these keys simultaneously):................................ ....... 13
4.4 Control Panel Menu Tree............................................................................................................... 14
4.4.1 Menu Operation................................ ................................ ................................ ..................... 15
4.4.2 Main Menu — Commonly Used Status Displays and Adjustments................................ ......... 15
4.4.3 Maintenance Menu................................ ................................ ................................ ................ 17
4.4.4 Option Menu................................ ................................ ................................ ......................... 17
4.4.5 Selftest Menu................................ ................................ ................................ ......................... 18
5. BASIC OPERATING PROCEDURES................................ .............................. 20
5.1 Introduction..................................................................................................................................... 20
5.1.1 How The Host RIP Works With the Imagesetter................................ ................................ ..... 20
5.1.2 Description of a Typical Printing Cycle................................ ................................ .................. 20
5.1.2.1 Imagesetter turn-on................................ ................................ ................................ ... 20
5.1.2.2 Front-end/RIP commands - initialization................................ ................................ ... 20
5.1.2.3 RIPing................................ ................................ ................................ ....................... 20
5.1.2.4 Imaging................................ ................................ ................................ ..................... 21
5.1.2.5 Setup for next job................................ ................................ ................................ ...... 21
5.1.3 Stop/Start Operation................................ ................................ ................................ .............. 21
5.1.4 Resolution Selection................................ ................................ ................................ .............. 21
5.1.5 Gray Scale Calibration................................ ................................ ................................ ........... 21
5.2 Loading the Bulk Load Supply Cassette with Film........................................................................ 22
5.3 Loading Film into the Imagesetter................................................................................................. 23
5.4 Setting Proper Exposure Density.................................................................................................... 25
5.5 Film Supply Tracking..................................................................................................................... 26
5.5.1 Resetting the Display Counters................................ ................................ .............................. 27
5.5.2 Setting the Film Feed Length................................ ................................ ................................ . 27
5.5.3 Setting the Feed B4 (before) cut length................................ ................................ .................. 27
5.5.4 Setting the Supply Film Length................................ ................................ ............................. 27
5.5.5 Setting the Film Low Warning................................ ................................ ............................... 28
5.5.6 Removing Exposed Film for Developing................................ ................................ ................ 28
6. MAINTENANCE AND ADJUSTMENTS................................ .......................... 29
6.1 Servicing Knife................................................................................................................................ 29
6.1.1 Need for Knife Service................................ ................................ ................................ ........... 29

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6.1.2 Operator Knife Service Procedure................................ ................................ .......................... 29
6.2 Replacing a Fuse............................................................................................................................. 30
6.2.1 Need for Fuse Replacement................................ ................................ ................................ .... 30
6.2.2 Operator Fuse Service Procedure................................ ................................ ............................ 30
6.3 Cleaning.......................................................................................................................................... 30
6.3.1 Cleaning the Inside Components................................ ................................ ............................ 30
6.3.2 Cleaning the Outside of the Cabinet................................ ................................ ....................... 31
6.3.3 Cleaning Air Inlet filter ................................ ................................ ................................ ........ 31
6.4 Lubrication of Moving Parts........................................................................................................... 31
6.4.1 Lead Screw................................ ................................ ................................ ............................ 31
7. SOLVING IMAGESETTER PROBLEMS................................ ......................... 32
7.1 Imagesetter Display Messages and Recommended Actions........................................................... 32
7.2 Solving Image Quality Problems.................................................................................................... 32
7.2.1 Scratches ................................ ................................ ................................ ............................... 32
7.2.1.1 Slow Scan Direction (Width of Film)................................ ................................ ........ 32
7.2.1.2 Fast Scan Direction (Length of Film)................................ ................................ ........ 32
7.2.2 Horizontal Light Or Dark Lines (Laser Light Obstruction or Blockage)................................ . 33
7.2.3 Vertical Unexposed (light) Lines................................ ................................ ........................... 33
7.3 Problem Solving Checklist.............................................................................................................. 33
7.3.1 Introduction................................ ................................ ................................ ........................... 33
7.3.2 Is There a Control Panel Message?................................ ................................ ........................ 33
7.3.3 Is there a 'Ready' Message?................................ ................................ ................................ .... 34
7.3.4 Does the Knife Jam Frequently?................................ ................................ ............................. 34
7.3.5 Does the Imagesetter Engine Run Self Tests?................................ ................................ ......... 35
7.3.6 Are the Imagesetter and RIP Interface Communicating?................................ ........................ 35
7.3.7 Is the Film Consistently, Uniformly Underexposed (Light)?................................ ................... 35
7.3.8 Film Feeding Problems - ‘Popping’ Sound When Feeding Film and/or ‘Short’ Film Feeds.... 35
7.4 Where to go for More Help............................................................................................................ 36
7.5 Remote Diagnostics......................................................................................................................... 37
7.5.1 Modem requirements................................ ................................ ................................ ............. 37
8. REPACKAGING IMAGESETTER FOR SHIPMENT OR RELOCATION......... 38
APPENDIX A — IMAGESETTER SPECIFICATIONS................................ ......... 39
APPENDIX B — FRONT PANEL STATUS AND ERROR MESSAGES.............. 40
APPENDIX C — REGULATORY STATEMENTS................................ ................ 45
REVISION LOG................................ ................................ ................................ ...46
INDEX................................ ................................ ................................ .................. 47

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1. READ THIS FIRST! - UNPACKING AND INSTALLATION
1.1 Unpacking
The Imagesetter and line cord are packed
into a heavy duty reusable cardboard
carton. Usually, this carton and the separate carton containing the Supply Cassette and Output Cassette are packaged
into a re-useable wooden crate.
KEEP THESE CARTONS AND THE CRATE AND THEIR PACKING MATERIALfor re-use should the imagesetter have
to be relocated or returned to the factory for service. Equipment not returned in the original packing may void
warranties! Replacement of this packaging is costly.
Open the wooden crate as follows:
1. Pry off the spring clips on the top (there should be6of these clips).
Use a prybar, large pliers, or a large screwdriver. Warning: these
clips are powerful springs that can cause bodily harm if not
constrained when removed. Take proper precautions!Do not
lose these clips!
2. Remove the top wooden crate panel.
3. The front of the crate can be also removed for improved access by
removing the 4 securing screws.
4. Remove the top foam insert - take care not to rip it!
5. Remove the smaller (cassette) carton.
6. With two people,remove large carton.
7. Replace the front crate panel if removed, using the screws, and use
the crate for storing the other packaging materials.
Unpack the larger carton as follows:
1. Slice through the tape on the top of the carton and open
the top.
2. Remove the top two foam inserts.
3. With two people, grab the unit on the bottom at each of the
long ends and lift the unit out of the carton. Be careful not
to hold or lift the unit by the unpainted stainless steel lips
on the front of the cabinet. When relocating unit, always
LIFT unit, — do not slide.
4. Usea 5/16” nut driver or a screwdriver to loosen the hex
head white plastic screws in the two red ‘LIP LOCKS’
located on either end of the film exit lips.These LIP LOCKS
are shipping brackets that help to maintain the alignment
of the unit during the rigors of shipping. Failure to
properly use theLIP LOCKS whenshipping the unit can
cause optical alignment and knife operational problems.
5. Keep all of this packing material together for possible
future use.
Refer to Chapter 8 — Repacking Imagesetter for
Shipment or Relocationfor repacking instructions.
Caution!
The imagesetter weighs approximately 95 pounds (41 kg).
Two people should unpack and position the unit.
Supply and Output
Cassettes
Wooden Crate and Foam

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1.2 Power Requirements
The imagesetter engine requires power supplied in the range of 90 to 130 volts or 180 to 260 volts and 50
to 60 Hz single phase. The imagesetter power supply will automatically sense the incoming voltage and
adjust accordingly. Total power required is 175 watts maximum.
1.3 Setup Location and Environmental Considerations
The following site requirements are necessary for proper operation of the imagesetter:
♦A sturdy, flat and level surface with at least 7 inches (18 cm) clearance behind the unit and 5 inches
(13 cm) of table top in front of the unit. At least 10” of clear space must be available above the unit to
allow the cover to fully open. The supporting surface should securely support the 90 pound (41 kg)
weight of the imagesetter plus anything else to be located on the same table.
NOTE: No other machinery should be located on or near the imagesetter table. Vibration from such
machinery can interact with the imagesetter and cause undesirable artifacts on film.
♦A well ventilated room. Dust and/or smoke in the environment will degrade the optical system
requiring more frequent servicing of the imagesetter. Generally, the room should be air conditioned
and smoke-free with no food or drink allowed in the immediate area.
♦Pick a location away from direct sunlight or other direct lighting. Normal indirect office lighting or
slightly subdued lighting is best. Brighter lighting will decrease the fog-free time of the film in the
imagesetter.
♦A steadily maintained ambient temperature in the range of 64°- 84°F (18°- 29°C). For best
repeatability results, avoid the extremes of this range and keep the film and imagesetter at the same
temperature for several hours before imaging. Avoid abrupt temperature changes (greater than 2°F per
hour).
♦Maintain the relative humidity between 35% and 85%, non-condensing. Again, for best repeatability
results, avoid the extremes of this range and keep the film and imagesetter at the same humidity for
several hours before imaging. Film emulsion is very sensitive to humidity, — the physical size of the

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film is affected by relatively small changes in humidity. This may affect the registration of successive
film separations.
♦Low humidity also contributes to problems related tostatic electricity, such as film jams, improper
film feeding, and certain undesirable artifacts on developed film.
1.4 Initial Imagesetter Setup
1. Locate the imagesetter in a place that meets the requirements outlined in Section 1.3.
2. Install the main line cord into the receptacle in the back of the imagesetter and into the wall socket.
(Machines supplied for installation in North America come with the appropriate line cord. Because
of all the different types of main power receptacles throughout the world, units shipped outside of
North America require the user or equipment dealer to supply the correct line cord. The cord must be
compatible with the IEC320 receptacle on the back of the imagesetter and should be shielded).
3. Attach the interface cable (not supplied with imagesetter, but usually supplied with the RIP interface
card) from the 50 pin ‘D’ connector on the back of the imagesetter to the interface card in the host
computer. See instructions supplied with the interface card for more information.
4. Follow manufacturer's and/or integrator's instructions for setup and interconnection of the interface
card, host computer and the RIP.
5. Turn the imagesetter ON using the switch located next to the line cord receptacle.
6. See Chaper 5 — Basic Operating Proceduresfor film loading and calibration information.

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2. GETTING ACQUAINTED WITH YOUR IMAGESETTER
2.1 Key features - General Description
ExxtraSettersare compact, desktop film recordersthat produce film quality comparable to floor standing,
internal drum recorders of significantly higher cost. The film to film repeatability of the ExxtraSetter is
typically within ±.0005over the entire 12.5" x 18.75" field. This is unlike some of the bestcapstan
technology machines of similar cost, that can only come close to this specification on consecutive films
under ideal operating conditions. The Maxxima has a minimum spot size (measured at 50% power) of
10µm which produces superb image quality atresolutions of3600 DPI. For high quality color separation
applications, the ExxtraSetter can only be compared to other drum-type recorders of much higher cost and
complexity.
2.1.1 Virtual Drum Technology
Exxtra ImageSetters utilize Virtual Drum technology, — a unique imaging technology of the internal drum
category used for imagesetters that provides the high repeatability and superb image quality required for
the production of 200and 300 line screen color separation master films.
This technology enables the ExxtraSetter
to be a true desktop imagesetter that
meets the highest standards needed for
color printing for up to A3 or tabloid
size images.
The Virtual Drum is created by forming
the film into a cylindrical shape by
wrapping it around two support rings
and tensioning it with rollers at both
ends of the film web. The quality of the
system is enhanced by surrounding the
laser writing beam with a pair of "clam
shells", which confine stray light and
perfect the cylindrical shape locally.
Image quality is further enhanced by the
Virtual Drum, which, unlike rigid drum
structure surfaces, does not reflect laser
beam pass-through back to the emulsion
and create undesirable halo effects on the
film.
2.1.2 Film Handling
Supply Cassette
Film is roll fed from a 50 meter (max.) supply cassette.
Initially, each roll is manually threaded around the drum
and through the rollers, and latched into place by closing
the output pinch roller. Film feed is controlled
automatically through the computer interface or
manually by the front panel operator control.
Supply Cassette

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‘Exxtra Capacity’ Output Cassette
The Exxtra Capacity output cassetteis standard with the Maxxima model. It contains a spooling
mechanism which will accept 50 feet (15 meters) or more of exposed0.004” (0.1mm) thick film or
polyester plate.It will accept somewhat less photographic paper.
The Exxtra Capacity output cassette is identified by labels inside the finger recesses of the cassette handles.
Knife
A motorized razor knife cuts the exposed film from the remaining web. The blade is long life tungsten
carbide and all four corners of the blade are interchangeably usable.
2.1.3 Operator Controls
The Operator's control panel includes a four line by 20 digit liquid crystal display, five push-button keys,
three LED lamps and a beeper. The display conveniently provides for all Operator functions, as well as
service and maintenance functions.
2.1.4 Electronics
A single printed circuit logic board provides the interface and all machine controls. Laser drive electronics
are located on the Imager Assembly. Electronic interlocks and limit sensors are utilized to provide carriage
motion limits, knife limit, out-of-film sensing, cassette present sensing, and cover closed interlocking.
2.1.5 Power Supply
The power supply is auto ranging to accommodate the mains supply in most locations in the world. Only
175 Watts of power are required.
2.1.6 Interfaces
2.1.6.1 Exxtra Parallel Video Interface
The standard interface to the RIP computer is the Exxtra Parallel Video interface. This interface requires a
third party interface card and interconnecting cable for the host RIP computer.
2.1.6.2 Remote Diagnostic Port
An RS232 port is provided which can be connected to a common external modem or a local computer.
Service Personnel can take control of the imagesetter for the purposes of diagnostics and firmware
upgrades.

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2.2 ExxtraSetter Imagesetter Parts Identification
2.2.1 Machine Identification Label
The identification label includes information and certifications required by various regulatory
organizations. Included on this label is the machine Serial Number which should be referenced when
requesting technical information. Note that the Maxxima is Model Number300 M.

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2.2.2 Inside of the User Compartment
2.2.2.1 Imager
The Imager assembly consists of a pair of precision machined aluminum castings (sometimes referred to as
the Clam shells) that support the laser, optics, switchable aperture, laser electronics, and spinner motor
assembly. As the spinner motor rotates laser light is projected onto the film plane through the opening
between the two Clam Shell halves. The Clam Shells are mounted to support rails by means of linear
bearings. This assembly is transported across the image area by a motor driven lead screw assembly. The
outside diameter also serves the purpose of defining the imaging radius of the Virtual Drum to the tight
tolerances required for repeatability between exposures.
2.2.2.2 Support Rings
The Support Rings are constructed of the same material as the Clam Shell castings. The function of the
Support Rings are to form the basic drum shape while maintaining the overall alignment between film and
Clam shells.

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2.2.3 Sensorsand Safety Interlocks
The condition of each of the interlock sensors described below, as well as some others whose operation is
invisible to the operator, is reported to the host computer. How the host software deals with these messages
may be different for a given host. Consult the documentation supplied with theRIP for more information.
2.2.3.1 Door interlock
The door interlock switch arrangement is made up of two (for redundancy) magnetic switches mounted in
the cover of the imagesetter. These switches are activated by two magnets in the Base Plate of the machine
when the door is closed. These switches must be satisfied in order for the imagesetter to turn on the laser.
2.2.3.2 Out of Paper Sensor (OOPS)
The OOPS is located in the film supply compartment. When film is properly loaded into the machine, the
sensor is satisfied. When the film runs out or is removed the sensor reports this to the imagesetter which
inhibits any further imaging and displays an message on the display.
2.2.3.3 Out of Cassette Switch (OOCS)
The OOCS is a magnetic switch located inside the imagesetter cabinet that senses the presence of a magnet
located in the Output Cassette. If the Output Cassette is not mounted to the front of the cabinet, the
imagesetter will not allow a film feed from the front end. Film feeds from the imagesetter front panel are
not inhibited. A message will appear on the control panel.

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3. SELECTING PHOTOGRAPHIC MEDIA
3.1 Films, Paper and Plates
Photographic media requirements:
• Emulsion: 780 Nanometer sensitivity, wound emulsion side inwards
• Material width: 13.3 ± .040 inches (338 ± 1.0 mm)
• Core: 2 inch (51 mm) inside diameter
• Thickness: 0.004 inches (0.1 mm) - See note 1
• Bulk load length: up to 165 feet (50 meters) - See note 2 andSection 3.2below
Note 1 - The substrate can be either paper or polyester film. Recommended film thickness is 0.004 inches
max., however thicker films up to 0.007 inches can be used without damage to the imagesetter.
Note 2 - Some film suppliers use thinner cardboard cores and other techniques that will allow as much as
200 feet (60 meters) of bulk load film to fit into the supply cassette.
Differences in Density (Dmax)
Photographic media from different manufacturers varies greatly in sensitivity, achievable Dmax, gamma —
the exposure sharpness (γ) and other factors which affect overall image quality. Of these, the sensitivity of
the media is the only factor that the user can compensate for with the imagesetter. This is done with the
adjustment. The adjustment can also compensate for small changes in processor
performance. Further, many film manufacturer's products vary, albeit to a lesser degree, from lot to lot,
which may require further density compensation by the user.
Static
In addition to the image quality criteria described above,the ability of different films to dissipate static
electricity can become an important issue when operating in low humidity environments. Many films
maintain very high levels of static charge when used at relativehumidityapproaching 35% and below;
these static charges can cause film feed problems and undesirable film artifacts.The anti-static properties
of films vary greatlybetween brands, and may need to be a consideration in film selection.Static related
issues tend to be most problematic during cold winter months in non humidity-controlled operating
environments.
NOTE:
It is possible that photographic media could meet the above guidelines and still not yield
satisfactory results because of abnormal characteristics of the material or operating
environment of which Exxtra has no control.
For this reason Exxtra recommends testing any photographic material before
purchasing large quantities.
3.2 Darkroom Bulk Load and Daylight Bulk Loadversus Disposable Cassette
The film Supply Cassettesupplied with the imagesetter will easily accommodatebulk load films of up to
165 feet (50 meters) long of 0.004 inch thick material on a two (2) inch (51 mm) core. Somedaylight bulk
load film packaging have caused problems because of daylight protective packaging material interfering
with the free motion of the film.
Some 200 foot (60 m) bulk rolls work well, while others cause some problems because they are either
rolled too loosely, have a thicker core tube, or come with additional length of material. This can cause the
roll of film to be a tight fit into the cassette and result in film feed jams.

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To date, several different manufacturers 100 foot (30 meter) and 150 foot (45 meters)disposablecassettes
have been used successfully. Some disposable cassettes cause film feed problems because too much force is
required to pull film from the cassette. Bulk load products tend to be less expensive and easier to get than
their disposable cassette counterparts. Each user has different requirements and should at least feel free to
try different products so as to best suit their needs. Again, Exxtra recommends thoroughly testing any
photographic material before committing to large quantities.
3.3 Specific Recommendations
Film manufacturers are continuously making changes to their product lines to enhance the performance of
their products. The following films have been tested extensively and perform well.They are by no means
the only film products that work well.
Konica IR-100E2 film - spec 925 - 100 feet (31m) daylight bulk load - Catalog 6128-137925
Kodak Pagi-Set IR film - spec 820 - 200 feet (60 m) darkroom bulk load - Catalog 163 3619
Kodak Pagi-Set IR paper - spec 173 - 150 feet (45 m) disposable cassette - Catalog 361 4625
We recommend that you consult your imagesetter dealer or check the Exxtra Corporation Internet Web site
at www.exxtra.comperiodically for current recommendations and information on new film products.

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4. USING THE IMAGESETTER CONTROL PANEL
4.1 Introduction
This section describes the workings of the Imagesetter control panel, including descriptions of status and
error messages which tell the operator what the machine is doing and help in diagnosing any problems that
occur. This section also describes the menu system that allows the operator to communicate directly with
the imagesetter. This menu system gives the user the ability to set up and monitor imager engine based film
counters and warnings, and run internally generated test patterns including a density test that simplifies
obtaining an optimum Dmax setting.
4.2 When to Use the Control Panel
Many of the Control Panel user functions are typically duplicated by the host computer system andRIP.
Once film is loaded there is little or no reason for the user to communicate directly with the imagesetter
through the Control Panel. The Control Panel's main function is for diagnosis of problems that may arise,
film cutting , and feeding film during film loading procedures. Other than that, it is sometimes
convenient to perform functions such as setting up proper exposure and film supply tracking, without
involving the host computer.
4.3 Control Panel Layout
ExxtraSetter Control Panel Layout
The front panel consists of a 4 line by 20 characterLCD module, 5 push button switches or keys, 3LEDs
and an audio transducer (beeper).
4.3.1 The LCD Display
The top line of the LCD is defined as the Status line. It displays the current status/error condition of the
machine. A complete listing, explanation and action listing can be found underAppendix B — Front
Panel Status and Error Messages.
The second line of the LCD is defined as the Menu selection line. This line, used in conjunction with the
Up and Down Arrow and Select keys, is used to move around and make selections in the menu system. A
description of the menus and how they function can be found inSection 4.6.1 — Menu Operation.

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The Third line displays the cassette status. This line displays the amount of film in the cassette both in
length and number of pages. It also displays the condition.
The forth or bottom line keeps track of thefilm usage. This line displays both the amount of film used
(since resetting ) and the amount of film left in the Supply Cassette (since resetting
).
Film units are displayed in either ric (M) or lish (ft, in) units depending on the selection of
found in the
4.3.2 The Control Panel (LED) Indicators
Red LED RED - BUSY - Flashes while a self-test or external job is in progress.
Yellow LED YELLOW - SERVICE - Flashes to indicate that Operator action is required.
Green LED GREEN - POWER ON - Illuminates continuously when power is applied.
4.3.3 The Control Panel Audible Indicator (Beeper)
• The Beeper will emit a ½ second sound once to indicate an error.
• Clearing the condition causes a 0.2 second beep.
• Completing an external job or an internal group test causes two short beeps.
Refer to Appendix B — Front Panel Status and Error Messageslisting for a definition and appropriate
action for each message.
4.3.4 Control Panel Keys
4.3.4.1 The Control Panel Keys
FILM FEED KEY- advances film by the predetermined length that has
been programmed through the /
selection. Pressing the Film Feed key while the film feed is in progress
causes the film feed to terminate immediately. This allows the user to
perform a short film feed without re-programming the default
.
CUT KEY - causes a length of film to feed (as determined by the
/selection) and the knife to travel from the left side
(home position) to the right side and then back to the home position.
Media is cut on the left to right pass.
UP ARROW KEY- either scrolls the menu up in the menu modeor
increases the displayed parameter in the program mode.
DOWN ARROW KEY -either scrolls the menu down in the menu modeor
decreases the displayed parameter in the program mode.
SELECT KEY - selects the current menu entry. If the current menu entry
is a programmable parameter, then the keyboard mode toggles between the
menu modeand the program mode ->.

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4.3.4.2 Hot Key combinations (depress these keys simultaneously):
IMAGER HOME - Same as in Maintenance Menu, but can be used anywhere
IMAGER AWAY - Same as in Maintenance Menu, but can be used anywhere
TOGGLE MENU - to top of menu tree and back again
MACHINE RESET - Same as in Maintenance Menu, but can be used anywhere

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4.4 Control Panel Menu Tree