Xpress - Avcom

Microtech Systems, Inc.
2 Davis Drive
Belmont, CA 94002 USA
Phone 650/596-1900
Fax 650/596-1915
Web microtech.com
email info@microtech.com
Xpress
Disc Production System
Hardware Manual
Revision 4
Document # 003-0075-04 Revised April 2004

Regulatory Compliance
Statements
Notice for USA
Federal Communications
Commissions (FCC) Statement
This 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) This device may not cause harmful
interference, and (2) this device must accept any
interference received, including interference that
may cause undesired operation.
Notice for Europe
European Standards
This 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)

Contents
Introduction ....................................................................................................................................... 1
Introducing Xpress........................................................................................................................................2
Xpress’s Parts .............................................................................................................................................................2
Xpress Specifications................................................................................................................................................4
Setting Up Xpress.............................................................................................................................. 5
Disc Production Workspace....................................................................................................................................6
Checking In Your Shipment ...................................................................................................................................7
Unpacking Xpress .....................................................................................................................................................7
Xpress Contents.........................................................................................................................................................8
Xpress Assembly Procedures ..................................................................................................................................9
Xpress Basics .................................................................................................................................... 13
Powering Up Xpress ...............................................................................................................................................14
The Xpress Desktop................................................................................................................................................15
Checking the Xpress Software Configuration..................................................................................................16
Initial System Calibration.....................................................................................................................................17
Testing Xpress .........................................................................................................................................................19
Placing Discs on Spindles.....................................................................................................................................20
Shutting Down Xpress ...........................................................................................................................................21
Calibrating Xpress........................................................................................................................... 23
Calibrating Xpress ..................................................................................................................................................24
Microtech Support..................................................................................................................................................25
Index .................................................................................................................................................. 27
Contents

Introduction

Hoist
Reject Spindle
Spindle #4
Spindle #3
Spindle #2
Spindle #1
Control Panel
Floppy Disc Drive
2 Introduction
Introducing Xpress
This section will provide all the information you need to unpack, install,
configure and use this system.
Xpress’s Parts
The following section shows and identifies all the important parts of
your Xpress. These components will be referred to later in the manual;
take a few moments to become familiar with them.
The main parts of the Xpress production system are indicated below
(front view).
Elevator
Digital Camera for
(ImageAligner) option
Disc Readers
Light Shield/
Camera Mount Disk
Camera Support Boom
Handhold
Disc Printer
Arm
Printer Plate
Drive Enclosure
Disc Writers
Base Unit (PC Enclosed)

Light Shield/Camera Mount Disc
Camera Support Boom
Drive Enclosure
Base Unit
Printer
The elevator contains all automation elements including the hoist and
the disc transport arm.
The hoist is part of the elevator and raises/lowers the arm.
The arm contains a disc gripper mechanism which holds discs during
transport. The arm can rotate to reach all disc positions (spindles, disc
writer drives and printer).
The drive enclosure holds the disc writers and acts as a platform for the
printer.
The disc writers are the drives that write to blank discs. The exact
number of writers installed (from 1 to 4) depends on your particular
system. Writers can be CD-R, DVD-R, or a mix.
The PC module contains the entire PC including disc readers, hard disk
and power supply.
The disc readers read master discs to be duplicated and other tasks.
Typically, one reader will be a CD-ROM reader and the other will be a
DVD-ROM drive.
The disc spindles hold discs in various stages of processing. There are
four full height spindles for holding blank and completed discs, and one
shorter reject spindle. All spindles can be lifed off and on for easy disc
handling.
Xpress Back View
Camera
Elevator
Printer Base Plate
Introduction 3

Power Switch
4 Introduction
Xpress’s Control Panel
The control panel on the front of Xpress’s base unit contains the power
switch and several indicator lights.
Besides the labeled indicator lights for power and the hard drive, there
are four lights in a column, these lights are used to indicate the activity
on drives or buses.
Xpress Specifications
• Dimensions:
23” w X 23” d X 31” h [58mm x 58mm x 79mm]
• Weight:
System without printer: 135 lb. [61 kg]
System with printer: 155 lb. [70 kg]
Disc Drive
Activity Lights
Floppy Drive

Setting Up Xpress

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 Setting up Xpress
Disc Production Workspace
The workspace for the Xpress disc production system should be in an
environment free of dust and debris. Contamination can adversely affect
production yield, degrade the quality of the discs produced, and reduce
the life of the equipment. A typical office environment will provide the
necessary cleanliness, temperature, and humidity control required to
maximize system performance and service life.
The 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.
Electrical power
The production system needs adequate power and enough power
receptacles. Ensure that the power receptacles are properly grounded.
The average power requirement for the entire system is 250 watts. The
peak requirement may reach 400 watts. Microtech recommends using a
surge protector and/or power conditioner for optimal setup.
Adequate lighting
There 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 necessary (adequate light must be available
even when the system is running jobs unattended after-hours). Direct
sunlight or spotlights can adversely affect the robotic sensors of the
Xpress as well as affecting the performance of the ImageAligner.
Document storage
Keep the documentation and software handy for future assistance,
trouble shooting, etc.

Moving Xpress: Never pick
up the main unit up by
grasping the tower, as this
can damage the unit.
Always lift it using the
handholds in the sides of
the unit’s base
Checking In Your Shipment
Before unpacking Xpress:
• Check shipping cartons against table below
• Check for shipping damage
The shipment should include the following number of cartons:
SYSTEM CONFIGURATION NUMBER OF CARTONS
No printer 3
System with printer 4
System with printer and
IMAGEALIGNER option
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 support at (650) 596-1900. Technical support is available
Monday through Friday from 7:30 AM to 6:00 PM Pacific Time. Please
contact us with any questions or problems during the unpacking,
installation, and set up of the Xpress disc production system. If the
shipping cartons are present and not damaged, start setting up a
workspace for your production system.
Unpacking Xpress
There are four basic Xpress configurations:
1. Basic system only (no printer)
2. Basic system with the Signature IV or Signature Pro (inkjet)
printer
3. Basic system with the Perfect Image (thermal transfer) printer
4. Basic system with the Perfect Image (thermal transfer) printer and
ImageAligner for printing on pre-printed discs
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 configurations are equipped with up to four CD-R or DVD-R
writer drives and an additional 1 or 2 reader drives.
Setting up Xpress 7
5

Optional
Xpress Contents
8 Setting up Xpress
Box # 1 Contains
Base Unit (housing PC Module)
Keyboard
Mouse
Software Key
Cables (Xpress Power Cord, and Serial Cable)
Box #2 Contains
Drive Enclosure
Elevator
Arm
Printer Base Plate (w/ Printer Option Only)
Box #3 Contains
Monitor
Cables
Box #4 Contains
Printer
Cables (Data Cable, Power Cord, Control Cable {Signature Pro only})
Box #5 Contains
Digital Camera
Camera Support Boom
Light Shield/Camera Mount Disk
Thumbscrews (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 7:30 – 5:30 PST
Microtech Systems will only accept merchandise returned in the
original shipping container.

Xpress Assembly Procedures
Base Unit
1. Place Base Unit on Work surface.
2. Set keyboard, mouse, Software Key, and cables aside for later
connection.
Drive Enclosure
1. Remove thumbscrews (2) from the back of the Drive Enclosure –
set aside.
2. Remove back plate of Drive Enclosure.
3. Place Drive Enclosure on top of Base Unit (back of enclosure fits
flush with back of the Base Unit.)
Caution – do not pinch any wires!
4. Finger-tighten thumbscrews (6) inside Drive Enclosure to secure
it to Base Unit.
Elevator
1. Place Elevator securely onto pegs on Base Unit (center of Drive
enclosure).
Caution – do not pinch any wires!
2. Finger-tighten thumbscrews (2) inside Drive Enclosure to secure
Handler Module to Drive Enclosure.
Cabling
1. Drive Power Cable (indicated by blue dot) – connect the Drive
Power cable to port with the corresponding blue dot.
2. Fan Power Cable (indicated by yellow dot) – connect the Fan
Power Cable to port with the corresponding yellow dot.
3. Control Cable (indicated by red dot) –- connect the Control
Cable to port with the corresponding red dot.
4. Connect two ribbon cables from under fans to the Arm located
on the Elevator – Undo the twist-tie holding them together –
push into connectors firmly until connector locks.
5. Connect Drive Cables (4)
6. Replace back of Drive Enclosure.
7. Replace and tighten thumbscrews.
Setting up Xpress 9

10 Setting up Xpress
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 finger tighten to secure Arm to
Hoist.
4. Connect Arm to Hoist with small “phone” cord.
5. Place long Spindles on locations 1 – 4.
6. Place short Spindle on location 5.
7. Replace packing material in shipping box and store for
moving/shipping.
Disc Printer Option
1. Slide Printer Base Plate (from Box #2) into slots on top of drive
enclosure.
2. Finger-tighten two thumbscrews to secure Printer Base Plate to
Drive Enclosure.
3. Place Printer onto pegs on surface of Printer Base Plate.
Printer Connection
Perfect Image
1. Connect data cable between port on back of Printer and COM1
on back of Xpress Base Unit.
2. Connect Printer Power Cord to port on back of Printer, plug
opposite end into standard electrical outlet.
3. Install Software Key into any USB port on back of Xpress Base
Unit.
Note: If using ImageAligner Option, insure that Software Key is installed
in Parallel Port on back of Xpress Base Unit.
Signature Pro
1. Connect Data Cable between port on back of Printer and port on
back of Xpress Base Unit.
2. Connect Control Cable between port on back of Printer and port
on back of Drive Enclosure.
3. Connect Printer Power Cord to port on back of Printer, plug into
standard electrical outlet.
4. Install Software Key into any USB port on back of Xpress Base
Unit.
PRINTER IS READY FOR INITIAL TESTING

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. Open Camera Lens.
6. Attach Camera to Mount by finger tightening attached
thumbscrew.
7. Connect Camera Cable between port on top of Camera and port
on back of Xpress Base Unit.
8. Secure Camera Cable to Camera Support Boom using attached
cord clips
PRINTER IS READY FOR INITIAL TESTING
Additional Cables
1. Connect Xpress Main Power Cord to port on back of Base Unit,
plug into standard 110v electrical outlet.
2. Install Software Key into any USB port on back of Base Unit.
Note: With ImageAligner option, install Software Key into Parallel Port on
back of Base Unit.
3. Connect Serial Cable from back of Base Unit in COM2 to back of
Drive Enclosure.
XPRESS IS READY FOR INITIAL TESTING
Setting up Xpress 11

Xpress Basics

14 Xpress Basics
Once Xpress is set up, test it to make sure everything is operating
properly. This chapter covers two quick test procedures. The first is an
automated test, that confirms that the system mechanics are working,
and that discs can be picked up, dropped and moved around correctly.
The 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 Xpress
• Press and release the power switch (located on the control panel on
the front; see page 3 for its location.)
• Xpress is a Microsoft Windows-based system that needs to go
through its boot-up process. As shipped from Microtech, each
system is set up to log you in as the user Administrator, with no
password (leave the password field blank in the login dialog). Once
the system is set up and running on your network, create a new user
account and make a practice of logging in as that user.
After your login information has been validated, the Windows desktop
will appear, and you may begin using the system.

The Xpress Desktop
Important icons and other parts of the desktop
The 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 software manual.
The ImageMaker EZ icon
Starts the disc duplication program used to make disc copies.
Instructions for using ImageMaker EZ are covered in the software
manual.
The 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.
The ImageMaker MJ (“Classic”) icon
Starts the optional ImageMaker MJ software for disc duplication. Please
refer to the software manual.
The Xpress Calibration icon
Starts the Xpress calibration utility used for calibrating the system.
The CD-REMOTE icon
Starts the CD-REMOTE background process and is only necessary should
you need to restart the process. CD-REMOTE starts automatically when it
is needed.
The 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 deskstop 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.
Xpress Basics 15

See the software manual
for a complete explanation
of all the ImageMaker
configuration items.
16 Xpress Basics
Checking the Xpress
Software Configuration
Before performing the initial test on the production system, check the
system configuration to ensure that certain items are set properly. This is
done through the ImageMaker (software) configuration utility.
Start the configuration utility.
Click the Windows Start button, located on the lower-left corner of the
desktop. From the menu that pops up, work through the submenus to
select Programs�ImageMaker�Configure ImageMaker. The
configuration dialog, shown below, will open.
Check the following configuration items to make sure they’re set
correctly:
If a printer is installed, it must be identified
Select the printer name in the field labeled My disc printer is …, and set
the port in the following field accordingly. (If there’s no printer, ignore
this setting.)
IF YOUR PRINTER IS A SELECT THIS TYPE ON THIS PORT
Perfect Image (black-only or color thermal transfer) Rimage Printer COM1
Signature IV (color inkjet) CD Color Printer IV LPT1
Signature Pro (color inkjet) CD Color Printer Pro LPT1
Identify the type of ImageAutomator system
In the field labeled The ImageAutomator is a model …, select Xpress.
• Save any changes made. If any changes to the configuration have
been made click the Update button before closing the utility. If no
changes have been made, click Close.

Initial System Calibration
One of the programs included with the system is a calibration utility.
This utility includes a quick initial system test for checking the basic
disc-transporting functions. Follow the procedure below to run this test.
Prepare for the checkout procedure
Place a few discs on spindle 3. Start the calibration utility program by
double-clicking the program’s desktop icon, shown here to the left. The
calibration utility’s window will open (shown below).
Set up and run the quick test once
The test will simulate a single disc being copied. Click the single test
cycle button to start the test.
1. A disc will be picked up from spindle 3.
2. The top disc writer drive tray will open and the disc will be placed
into the tray.
3. The disc writer drive tray will close, then open.
4. The disc will be picked up from the disc writer, and the drive tray
will close.
Note: If a printer is installed, the printer tray will open, and the disc will
be placed in the tray: The printer tray will close, and the disc writer drive
tray will close. The printer tray will then open, and the disc will be
picked up from the printer tray, and the printer tray will close.
5. If no printer is installed, the disc will be picked up from the disc
writer drive tray and dropped on spindle 4.
Xpress Basics 17

18 Xpress Basics
Observe the following carefully during quick test
• Arm centers on spindle
• Disc is dropped in center of drive writer tray
• Disc is dropped onto output spindle
If Printer is installed
• Disc is dropped in center of printer tray
• Disc is dropped directly onto output spindle
If the single initial test fails, run the continuous test to locate the
problem—Make sure there are several discs on spindle 3. Click the
continuous test button at the lower right to run the same test
continuously.
Disc handling problems are not always repeatable. Accurate calibration
is important to achieve reliable operation. It is recommended that you
run the continuous test through several hundred discs to insure proper
calibration.
After starting the test, this button name will automatically change to
Stop Continuous. To stop the test, click this button.
If the problem recurs, calibration (adjustment) of the system is necessary.
(See the following chapter, Calibrating Xpress for complete
instructions.)

Testing Xpress
After the system has passed the previous test, complete the testing
process by actually making disc copies. To do this use the disc
duplication program, ImageMaker EZ using the following procedure:
Start the disc duplication program
Click the program’s desktop icon. The duplication program will open,
and the main window will appear (see illustration below).
Place several blank discs on spindle 3
The third spindle from the left. Refer to the diagram on page 2.
Click the button to make disc copies from a
pre-existing disc image
The window will change when this is done, and some additional input
fields will appear.
Select the disc image to use to make copies from.
Find the field labeled Disc Name near the top. Click the arrow at the
right of this field to open a list box of available images. There are two
images included with every Xpress system, one for systems with a
printer installed and one for systems without a printer. (The one for
printer-equipped systems will also print the disc copies.) Click on your
system type to select it.
Click Start to begin the test
If the quantity has not been changed, only one copy will be made. A
blank disc should be picked up from spindle 3 and delivered to one of
the disc writer drives. After the disc is “burned” (and printed if a printer
is installed), it will be picked up from the drive and placed on spindle 4.
Xpress Basics 19

Spindle #1
Tertiary Input Spindle (3 rd
200 discs)
Spindle #2
Secondary Input Spindle
(2 nd 200 discs)
20 Xpress Basics
Placing Discs on Spindles
As an automated disc production system, Xpress transports discs to
various processing stations internally. The operator’s only physical task
is to load blank discs for processing on the input spindle(s) and remove
finished discs from the output spindle(s).
The diagram below shows the location and function of the various
spindles, viewed from above.
Spindle #3
Primary Input Spindle (1 st
200 discs)
Spindle #5
Reject Spindle
Spindle #4
Output Spindle
Each spindle holds 200 discs. To process a total of 600 discs with only 4
spindles, some spindles must be used to hold both blank and written
media (not at the same time). To start, blank media are loaded on
spindles 1, 2 and 3 and spindle 4 is left empty. Blank discs will be
retrieved from spindle 3 and completed discs will be placed on spindle 4.
When all discs have been removed from spindle 3, the whole operation
shifts by one spindle and blank discs will be retrieved from spindle 2 and
completed discs will be placed on (the now empty) spindle 3. When all
discs on spindle 2 have been used, the operation will shift one more time
and blank discs will be retrieved from spindle 1 and completed discs will
be placed on spindle 2. When all 600 discs have completed, there will be
discs on spindles 2, 3 and 4 and nothing on spindle 1.
When the disc production software is started, the production system
automatically resets itself to take discs from spindle 3 and places finished
discs on spindle 4. This is true even if the system was previously taking
discs from spindle 2 or spindle 1.
Whenever the disc production software is started, blank discs must be
loaded on spindles 3, 2 and 1 and spindle 4 must be empty.

CAUTION: Do not shut
down the system if there
are any production jobs
running on it. It may not
be obvious if a job is
running, since a job could
be in the pre-mastering
phase. Use the CD-REMOTE
Management Center to
check the status of current
jobs (see software manual
for details).
Shutting Down Xpress
When the job completes, please follow the standard Windows shut down
procedures.
Xpress Basics 21

Calibrating Xpress

Calibrating Xpress
24 Calibrating Xpress
To work properly, Xpress needs to be correctly calibrated. Xpress is
calibrated at the factory and should not need recalibration. Improper
handling during shipping may make this step necessary. If discs are not
picked up from the input spindles, are being dropped off the trays or
output spindles or are going into drive or printer trays cockeyed, the
system must be recalibrated.
Calibration means making adjustments to the disc production system so
the operation runs smoothly.
Prepare for the calibration procedure
Place a few discs on spindles 1, 2 and 3. Start the calibration utility
program by double-clicking its desktop icon. The calibration utility’s
window will open.
Adjust the spindle calibrations
Click the Calibrate Position button and click on the button for the
spindle you wish to calibrate (S1 for example). The disc transport arm
will move over to the top of the spindle, move down close to the top of
the spindle and then stop.
If the arm is not centered exactly over the spindle, the calibration of the
spindle must be corrected. Use the two arrow buttons and to “bump” the
position of the arm counter clockwise or clockwise respectively. When
the arm is centered, click the Save button to accept the change. Recheck
the alignment by repeating this step. Click the Cancel button if no
change is necessary.
Repeat this step for spindles 1-4.
Adjust the calibration of the reject spindle
Click the Calibrate Position button and then the Rej button. A message
warning you to close all printer and drive trays will be displayed. Click
OK when all trays are closed. The disc transport arm will move over and
down to the reject spindle. As above, make any necessary adjustments
and click the Save button to accept the new position.
Adjust the drive calibration
There is no separate calibration for drives 1-4. Only one of the stations
(D1-D4) must be calibrated. Have at least one disc on spindle 3 and one
of the drive trays open. Click the Calibrate Position button and the D1
button. The disc transport arm will pick up a disc from spindle 3 and
move it over to the drive. Once it senses the drive tray, the arm will
move back and stop above the drive tray.
Check that the disc is properly centered above the drive tray and that it
is clear of the front of the drive. Drive trays are slightly beveled so it is
okay if the disc is a bit forward of center. When the position of the disc is
correct, click on the Save button.

Microtech Support
If you are having problems with your Xpress, before calling Microtech
Systems support line please check the following:
1. Check all external connections
2. Check for good power
3. Make sure your system is on a sturdy and level surface
4. Check the tightness of the thumbscrews that hold the main
assemblies together
If none of these solutions solve the problem, please have the following
information available before calling Microtech Systems support.
1. Serial number (3-4 digit number located on the back of the system or
under the keyboard),
2. Detailed description of problem(s) experienced.
Microtech Systems
2 Davis Drive
Belmont, CA 94002
650-596-1900
Hours: 7:30 a.m. – 5:30 p.m. PST
support@microtech.com
www.microtech.com
Calibrating Xpress 25

Assembly Procedures................................................ 9
Control Panel.............................................................. 4
Desktop Icons ........................................................... 15
Initial System Calibration ....................................... 17
Initial System Checkout .......................................... 19
Microtech Support ................................................... 25
Placing Discs on Spindles ....................................... 20
Shutting Down the System..................................... 21
Index
Software Configuration ...........................................16
Specifications ..............................................................4
Starting the System ..................................................14
System Calibration ...................................................24
Systems Parts ..............................................................2
Windows NT
starting Windows .................................................14
Xpress Parts.................................................................8
Index 27