Microtech Xpress XL User manual

Xpress XL
Disc Production System
Hardware Manual
Revision 3
003-0085-03

Contents
Regulatory Compliance Statements ........................................................... 1
Introduction..................................................................................................3
Introducing Xpress XL........................................................................................................ 3
Xpress XL Specications .................................................................................................... 4
Installation & Set Up ....................................................................................5
Disc Production Workspace............................................................................................... 5
Checking Your Shipment ................................................................................................... 6
Unpacking Xpress XL ......................................................................................................... 6
Xpress XL Contents............................................................................................................. 7
Xpress XL Assembly Procedures ....................................................................................... 8
Operation.................................................................................................... 11
Powering Up the Xpress XL ............................................................................................. 11
The Xpress XL Desktop..................................................................................................... 12
Checking the Xpress XL Software Conguration........................................................... 13
Calibrating Xpress XL....................................................................................................... 15
Placing Discs on Spindles ................................................................................................18
Shutting Down Xpress XL ................................................................................................18
Maintenance ..............................................................................................19
Microtech Support ........................................................................................................... 19

1
Regulatory Compliance Statements
Notice for USA
Federal Communications Commissions (FCC) Statement
is equipment has been tested and found to comply with the radiated energy limits
for a Class A digital device, in accordance with FCC CFR 47 Part 15 Rules and
Regulations. (1) is device may not cause harmful interference, and (2) this device
must accept any interference received, including interference that may cause unde-
sired operation.
Notice for Europe
European Standards
is equipment conforms to the EMC Directive (89/336/EEC) by compliance with the
following European standards:
EN 55022:1998 + A1:2000, CISPR 22:1997 + A1:2000 (Emissions):
EN 50024:1998 + A1:2001, CISPR 24:1997 + A1:2001 (Immunity):
EN 60950:2001 First Edition (Safety)

2

3
Introduction
Introducing Xpress XL
is section will provide all the information you need to unpack, install, congure
and use this system.
Xpress XL Parts
e following section shows and identies all the important parts of your Xpress
XL. ese components will be referred to later in the manual; take a few moments to
become familiar with them.
e main parts of the Xpress XL production system are indicated below (front view).
Reject Spindle (R)
6 Disc Writers
Spindle #5
Spindle #4
Spindle #3
Spindle #2
Spindle #1
Switch Panel
Printer 2
Printer Plate
6 Disc Writers
Drive Encosure
Handholds
Printer 1
Digital Camera
(ImageAligner )
2
Light Shield/
Camera Mount
Elevator
Arm
Hoist
Camera Support
Boom
Disc
Readers
Base Unit/
PC Enclosure
Spindle (L)

4
e elevator contains all automation elements including the hoist and the disc
transport arm.
e hoist is part of the elevator and raises/lowers the arm.
e arm contains a disc gripper mechanism which holds discs during transport. e
arm can rotate to reach all disc positions (spindles, disc writer drives and printer).
e drive enclosure holds the disc writers and acts as a platform for the printer.
e disc writers are the drives that write to blank discs. e exact number of writ-
ers installed (from 1 to 4) depends on your particular system. Writers can be CD-R,
DVD-R, or a mix.
e PC module contains the entire PC including disc readers, hard disk and power
supply.
e disc reader reads master discs to be duplicated and other tasks. e disc reader
drive is a DVD-ROM drive.
e disc spindles hold discs in various stages of processing. ere are ve full height
spindles for holding blank and completed discs, and two shorter reject spindles. All
spindles can be lied o and on for easy disc handling.
Xpress XL Specications
•Dimensions:
28.4” w X 26.4” d X 34.7” h [722mm x 671mm x 882mm]
•Weight:
System without printers: 226 lb. [103 kg]
System with printers: 274 lb. [124 kg]

5
Installation & Set Up
Disc Production Workspace
e workspace for the Xpress XL disc production system should be in an environment
free of dust and debris. Contamination can adversely aect production yield, degrade
the quality of the discs produced, and reduce the life of the equipment. A typical
oce environment will provide the necessary cleanliness, temperature, and humidity
control required to maximize system performance and service life.
e workspace should have the following features:
Sturdy workspace
A working surface sturdy enough to support a total weight of 200 lbs.
Large workspace
A large enough workspace: a recommended minimum of
60” W x 48” D x 36” H, with 36” of clearance above. Also allow enough room on the
workspace for the monitor and keyboard.
Electrical power
e production system needs adequate power and enough power receptacles. Ensure
that the power receptacles are properly grounded. e average power require-
ment for the entire system is 250 watts. e peak requirement may reach 400 watts.
Microtech recommends using a surge protector and/or power conditioner for optimal
setup.
Adequate lighting
ere should be enough light both for operating the equipment and for examining
the discs you produce and print. In addition, if the ImageAligner option is installed,
adequate lighting for the digital camera to capture disc images is recommended.
(Adequate light must be available even when the system is running jobs unattended
aer-hours). Direct sunlight or spotlights can adversely aect the robotic sensors of
the Xpress XL as well as aecting the performance of the ImageAligner.
Document storage
Keep the documentation and soware handy for future assistance, trouble shooting,
etc.
Important Unpacking
Information
Be sure to save all packing
material in case you need to
move or ship your system.
Microtech Systems will
only accept merchandise
returned in the original
shipping container.

6
Checking Your Shipment
Before unpacking Xpress XL:
•Check shipping cartons against table below
•Check for shipping damage
e shipment should include the following number of cartons:
System Conguration Number of Cartons
No printer 6
System with printers 8
System with printer and ImageAligners option 10
Please examine all of the shipping cartons. If any cartons are missing or damaged,
notify the shipping carrier as soon as possible, then contact Microtech technical sup-
port at [phone]. Technical support is available Monday through Friday from
7:30 AM to 6:00 PM Pacic Time. Please contact us with any questions or problems
during the unpacking, installation, and set up of the Xpress XL disc production sys-
tem. If the shipping cartons are present and not damaged, start setting up a workspace
for your production system.
Unpacking Xpress XL
ere are ve basic Xpress XL congurations:
1. Basic system only (no printer)
2. Basic system with 2 XpressJet (inkjet) printers
3. Basic system with 2 Perfect Image (thermal transfer) printers
4. Basic system with the 2 Perfect Image (thermal transfer) printers and
ImageAligner for printing on pre-printed discs
5. Basic system with 2 K2 (photo retransfer) printers
A printer (and ImageAligner for printing on pre-printed discs) can be added to a
basic system. Ask your dealer or sales representative about upgrade kits.
All Xpress XL congurations are equipped with up to twelve CD-R or DVD-R writer
drives and one reader drive.
Moving Xpress: never
pick up the main unit by
grasping the tower, this
action will damage the
unit. Always lift using the
handholds in the sides of
the units base.

7
Xpress XL Contents
Listed below are the contents of each box.
Box # 1
Base Unit (housing PC Module)
Manual
Soware Key
Accessory Box (inside Box #1)
Keyboard
Mouse
Cables (Xpress XL Power Cord, and Serial Cable)
Printer Plates
Arm Assembly
Box #3
Drive Enclosure
Box #4
Elevator
Box #5
Spindles
Box #6
Monitor
Box #7 Printer (w/ cables)
Box #8 (optional 2nd printer)
Printer (w/ cables)
Box #9 & 10 (identical contents in each box – optional ImageAlilgner II Cameras)
Digital Camera
Camera Support Boom
Light Shield/Camera Mount Disk
umbscrews (3 Male and 1 Female)
Camera Cable
Calibration Disc
During unpacking, visually
inspect parts for dents,
scratches or other damage.
If any parts are damaged,
call Microtech’s Customer
Support Department
at 650-596-1900
between the hours of
7:30 a.m.- 5:30 p.m. PST

8
Xpress XL Assembly Procedures
Base Unit
1. Place base unit on work surface.
2. Set keyboard, mouse, soware key, and cables aside for later connection.
Drive Enclosure
1. Place drive enclosure on top of base unit (back of enclosure ts ush with back of
the base unit.)
Caution – do not pinch any wires!
2. Loosen thumbscrews (3) from the back of the drive enclosure to remove back
plate of drive enclosure and set aside.
3. Finger-tighten thumbscrews (6) on the bottom of the drive enclosure to secure it
to the base unit.
4. Replace back panel of drive enclosure.
Elevator
1. Place elevator securely onto pegs on base unit (center of drive enclosure).
Caution – do not pinch any wires!
2. Firmly tighten thumbscrews (3) inside drive enclosure to secure handler module
to drive enclosure.
Cabling
1. Drive enclosure ATX (24-pin) power cable connects to back of elevator.
2. Connect power from lower power supply to back of elevator to right of the ATX
connector.
3. Connect three ribbon cables and two black AUX cables located underneath fans
on right to their respective connectors on back of elevator. Each connector is
unique and will only t one receptacle.
4. Connect Drive Cables (12). Cables are tied so that reach should dictate which
drive each plugs into.
5. Replace back of drive enclosure and tighten thumbscrews.
Arm to Elevator
1. Remove threaded knob from underside of hoist (on elevator).
2. Line up holes on rear end of Arm with pins on hoist.
3. Replace threaded knob and nger tighten to secure arm to hoist.
4. Connect arm to hoist with small ribbon cable.
5. Place long spindles on locations 1 – 5.
6. Place short spindle on location R.
7. Place short spindle on location L.
8. Replace packing material in shipping box and store for moving/shipping.

9
Disc Printer Option
e Xpress XL is designed to handle two printers. A base plate must be installed for
each printer. ere are le and right base plates labeled - PL = Printer Le;
PR = Printer Right. Le and right orientation is determined by facing the front of the
Xpress Unit.
1. Slide Printer Base Plates into slots on top of drive enclosures.
2. Slide printer plate forward to lock in. e two pins on back of printer drive plate
t into corresponding holes in drive cage.
3. Place Printer onto pegs on surface of Printer Base Plate. Each printer is labeled
‘Le’ or ‘Right’ on the back. is is important so that the numbers on the cables
match the proper port on the proper printer.
Printer Connections
Following are instruction for all printer connections. For easy reference, the cables
and ports are numbered.
Perfect Image - Right Side
1. Connect light grey serial cable between port on back of printer and COM1 on
back of Xpress XL base unit.
2. Connect dark grey parallel cable between port on back of printer and the parallel
printer port on back of Xpress XL base unit.
3. Connect printer power cord to port on back of printer, plug opposite end into
standard electrical outlet.
Perfect Image - Le Side
1. Connect the light grey serial cable with USB adapter between port on back of
printer to USB port (COM3) on back of Xpress XL base unit.
2. Connect USB cable between port on back of printer to USB port on back of
Xpress XL base unit.
3. Connect printer power cord to port on back of printer, plug opposite end into
standard electrical outlet.
PRINTERS ARE READY FOR INITIAL TESTING
XpressJet II - Right Side
1. Connect parallel cable between port on back of printer and port on back of Xpress
XL Base Unit.
2. Connect serial control cable between port on back of printer and port on back of
drive enclosure (marked printer right).
3. Connect printer power cord to port on back of printer, plug into standard electri-
cal outlet.
XpressJet II - Le Side
1. Connect USB cable between port on back of printer and port on back of Xpress
XL Base Unit.
2. Connect serial control cable between port on back of printer and port on back of
drive enclosure (marked printer le).
3. Connect printer power cord to port on back of printer, plug into standard electri-
cal outlet.
PRINTERS ARE READY FOR INITIAL TESTING

10
K2 Printer - Right Side
1. Connect parallel cable between port on back of printer and port on back of Xpress
XL Base Unit.
2. Connect serial control cable between port on back of printer and port on back of
drive enclosure (marked printer right).
3. Connect printer power cord to port on back of printer, plug into standard electri-
cal outlet.
K2 Printer - Le Side
1. Connect USB Cable between port on back of Printer and port on back of Xpress
XL Base Unit.
2. Connect serial control cable between port on back of printer and port on back of
drive enclosure (marked printer le).
3. Connect printer power cord to port on back of printer, plug into standard electri-
cal outlet.
PRINTERS ARE READY FOR INITIAL TESTING
Installing Software Key
1. Install Soware Key into any open port on back of Xpress XL Base Unit.
Installing ImageAligner Option
1. Place Camera Support Boom on top of Printer Base Plate behind Elevator.
2. Tighten attached knobs (3) to secure Camera Support Boom to threaded holes in
Printer Base Plate.
3. Line up pegs (2) and threaded rod on top of Light Shield/Camera Mount Disk
with holes on bottom of camera support boom.
4. Finger tighten knob onto threaded rod to secure Light Shield/Camera Mount
Disk to Camera Support Boom.
5. Attach Camera to Mount by nger tightening attached thumbscrew.
6. Connect camera Cable between port on side of Camera and USB port on back of
Xpress XL base unit.
7. Secure camera cable to Camera Support Boom using attached cord clips
8. Repeat procedure for 2nd camera.
PRINTERS ARE READY FOR INITIAL TESTING
Additional Cables
1. Connect Xpress XL main power cord to port on back of base unit, plug into
standard 110v electrical outlet. Connect power cord for drive enclosure power
supply into standard 110v electrical outlet.
2. Connect serial cable from COM2 on back of base unit to Host COMM on back of
drive enclosure.
XPRESS XL IS READY FOR INITIAL TESTING

11
Setting Up Printers on an Xpress-XL
Create a separate Windows printer for each printer. It is best to give them meaningful
names like:
‘Rimage Perfect Image Printer - Le’
‘Rimage Perfect Image Printer - Right’
1. For each printer created above set the correct port.
2. Right-click on the printer’s name, select Properties, then click on the Ports tab.
3. For USB printers, you may have more than one USB port to choose from.
4. You’ll test your port selection later in these instructions.
5. Start the conguration program Start -> Programs -> ImageMaker -> Congure
ImageMaker.
6. Select the printer names you have created in step #1 and be sure you specify that
they are in the correct locations.
7. Put a disc in each printer and click on the Test button for each.
8. If the printer does not print or the wrong printer prints, go back and check your
port setting. Also check the printer properties and make sure the printer is not
oine.
For Rimage printers, select the proper serial port for each printer’s control cable.
When all is working correctly close the conguration program.
1. Start the Xpress calibration utility Start -> Programs -> ImageMaker -> Xpress
Calibration.
Make sure that both printers are properly congured. If either printer is grayed-out
then check its control connection. For a Rimage printer this means check the serial
port setting via the conguration program. For all other printers make sure that the
control cable is plugged into the printer and into the back of the XL. If that fails, check
that the cable from the back of the XL to the Bashful board is connected and properly
seated.
Once the printers are properly detected, make sure their trays operate correctly by
clicking on the Open/Close button followed by the Le Printer or Right Printer
button.
Make sure the printers are calibrated correctly. For the Rimage printer the recom-
mended calibration is closer to the front pins. is is because the disc will be slid
back during placement. e opposite is true for all other printers; the recommended
calibration is toward the back as the disc will be slid forward during placement. In
either case, you do not want to calibrate too far o as the calibrated position is where
the gripper will attempt to pick up the disc.

12

13
Operation
Once the Xpress XL is set up, test it to make sure everything is operating properly.
is chapter covers two quick test procedures. e rst is an automated test, that
conrms that the system mechanics are working, and that discs can be picked up,
dropped and moved around correctly. e second part of the test actually makes
disc copies to verify that the system’s electronics and disc writer drives are working
properly.
Powering Up the Xpress XL
•Press and release the power switch, located on the control panel on the front of
system.
•Xpress XL is a Microso Windows-based system. Upon powering up the system
for the rst time, Windows will ask you for some general system set-up informa-
tion, including an agreement to licensing terms, your time zone, computer name,
password and network preferences. You will also be asked to validate Windows
by entering the Product Key, which is located on the back of the system. Aer
this process is nished, you may activate Windows at this time, or skip the activa-
tion. If you choose to skip, you will be required to activate Windows within the
next 30 days.
Aer your login information has been validated, the Windows desktop will appear,
and you may begin using the system.

14
The Xpress XL Desktop
Important icons and other parts of the desktop
MyDisc icon
Starts the standard MyDisc program used to create master images of custom discs
from which to make copies. Using MyDisc for making discs is covered in the soware
manual.
ImageMaker EZ icon
Starts the disc duplication program used to make disc copies. Instructions for using
ImageMaker EZ are covered in the soware manual.
DiscPrint icon
Starts the DiscPrint program, the “stand-alone” version of the ImageMaker EZ disc
layout editor, used to create and modify disc printing layouts.
Xpress XL Calibration icon
Starts the Xpress XL calibration utility used for calibrating the system.
CD-Remote icon
Starts the CD-R background process and is only necessary should you need to
restart the process. CD-R starts automatically when it is needed.
Windows taskbar
When a program is started (e.g. MyDisc), a button for that program will appear in
the taskbar (located at the bottom of the desktop screen). If a program has been
minimized (still running, but not displayed on screen), or if it has disappeared behind
another program’s window, clicking its taskbar button will make it appear on screen.

15
Checking the Xpress XL Software Conguration
Before performing the initial test on the production system, check the system
conguration to ensure that certain items are set properly. is is done through the
ImageMaker (soware) conguration utility.
Start the conguration utility
Click the Windows Start button, located on the lower-le corner of the desktop. From
the menu that pops up, work through the submenus to select ProgramsImageMaker
Congure ImageMaker . e conguration dialog, shown below, will open.
Check the following conguration items to make sure they’re set correctly:
If a printer is installed, it must be identied in the printer settings and options
Select the printer names and position on the Xpress XL (le or right) from the drop
down menu and set the port in the following eld accordingly. (If there’s no printer,
ignore this setting.)

16
If Your Printer Is A Select This Type On This Port
Perfect Image (black-only or color thermal transfer) #1 Rimage Printer COM1
Perfect Image (black-only or color thermal transfer) #2 Rimage Printer COM4
XpressJet II #1 MT XpressJet N/A
XpressJet II #2 MT XpressJet N/A
K2 (photo retransfer) #1 TEAC N/A
K2 (photo retransfer) #2 TEAC N/A
If there are dual Rimage printers, one is called Rimage Perfect Image Printer Le, and
the other is called Rimage Perfect Image Printer Right. ‘Le’ is COM3 and ‘Right’ is
COM1.
To test either printer, place the disc on the printer tray and click ‘Test’ button for
corresponding printer. e printer will print the word ‘test’ on the disc. If it does not,
check the cabling on the printer and the port settings in printer driver.
If no printer is installed at any position (le or right) you must select “none” for that
post ion.
•Save any changes made. If any changes to the conguration have been made click
the Update button before closing the utility. If no changes have been made, click
Close.