Stingray 52/63

Operator Guide

554 Clark Rd.

Tewksbury, MA 01876
Phone (978) 851-0207 Fax - (978) 851-7016 AG12373 Rev. 1
 Stingray 52/63
Operator Guide
This guide reflects the Stingray 52/63 Operator Guide as of October, 1999.
© copyright ECRM Incorporated 1999

Information on ordering additional copies of this manual may be obtained by writing or calling:

ECRM Order Processing

554 Clark Road
Tewksbury, MA 01876

Phone No. (US) - (978) 851-0207 — Fax (US) - (978)-851-7016

Phone No. (UK) - (44) 1923-218255 — Fax (UK) (44) 1923-218256
Phone No. (Hong Kong) - 852-2-564-8989 — Fax (Hong Kong) 852-2-564-8821

Visit our web site: www.ecrm.com

Proprietary Notice

The information contained within this guide is the property of ECRM Incorporated. No transmission,
reproduction, transcription, storage in a retrieval system, translation into any language, or other use is
permitted in whole or in part in any form without first obtaining written permission of ECRM Incor-
porated.
List of Trademarks or Registrations, ECRM® is a registered trademark of ECRM Incorporated, PelBox® is a registered
trademark of ECRM Incorporated, KnockOut® 4550 is a registered trademark of ECRM Incorporated, KnockOut®/PRF
is a registered trademark of ECRM Incorporated.

AG12373 Rev. 1
Table of Contents

Introduction 1-1

Product Compliance 2-1

DEFINITIONS 2-1
CSA - Canadian Standards Association 2-1
DOC - Department of Communications 2-1
IEC - International Electrotechnical Commission 2-1
FCC - Federal Communications Commission 2-1
LASER 2-1
LASER Product 2-1
LASER Radiation (Light) 2-2
LASER System 2-2
Operation and Maintenance 2-2
Service 2-2
TÜV 2-2
VDE 2-2
LASER SAFETY 2-3
LASER Product Classification 2-3
DESCRIPTION OF LABELS 2-5
Identification and Certification Label (Ratings Plate) 2-5
LASER Warning Labels (Non-interlocked covers) 2-6
LASER Warning Labels (Interlocked Covers). 2-7
PRODUCT SAFETY 2-9
CSA 2-9
TÜV 2-9
ELECTROMAGNETIC EMISSIONS 2-10
FCC - USA 2-10
DOC - CANADA 2-11
EMC Directive - EUROPE 2-11

Control Panel 3-1

INTRODUCTION 3-1
MENU KEYS 3-2
USING SYSTEM MENUS 3-3

AG12373 Rev 1 TOC-1

Table of Contents
Table of Contents

Operation and Maintenance 4-1

INTRODUCTION 4-1
SETTING UP THE SYSTEM 4-2
System Setup 4-2
User Setup 4-9
LOADING MEDIA INTO A 400 FOOT INPUT CASSETTE 4-13
INSTALLING MEDIA INTO THE SYSTEM 4-17
CLEARING MEDIA JAMS 4-20
Input Side of Buffer 1 Jam 4-20
Exit Buffer Jam 4-21
Buffer bag jam 4-22
STATUS MESSAGES 4-23
TRANSPORT STATUS DISPLAY 4-28
ERROR MESSAGES 4-32
ROLLER CLEANING PROCEDURE 4-33
Lazy Loop Rollers: 4-33
Internal Drive Rollers: 4-35
AIR FILTER CLEANING PROCEDURE 4-37
EMPTYING THE PUNCH TRAYS 4-38
CLEANING THE SYSTEM 4-38

Appendix A - Diagnostic Menu A-1

TOC-2 AG12373 Rev 1

Introduction 1
Introduction
This book provides the information you will need to operate
your imagesetter. Some of the topics covered are: Laser Regu-
lations, The Control Panel, Operating Menus, Loading Film
Into the Cassette, Loading the Cassette into the System, and
Status and Error Messages.

Section 2 contains important safety information about the laser

and the covers and interlocks that the system contains to pre-
vent accidental exposure to the laser beam. Please read this
information carefully.

ATTENTION!
This symbol is used throughout the Operator Guide
to alert you to cautions, warnings and other
important notes.

AG12373 Rev. 1 1-1

1 Introduction

WARNING
LIVE CIRCUITS BEFORE MAINS SWITCH!

AC power is connected to the Voltage Selector

Switch, Line Filter, AC Fan Fuse, AC Fan, and Mains
Switch. This circuit does NOT shut off when the
mains switch is turned off. To remove power from this
circuit, unplug the AC Line Cord from the rear of the
system.

1-2 AG12373 Rev. 1

Introduction

IMPORTANT!
System fan is ALWAYS ON!
Prior to connecting the imagesetter to the AC mains sup-
ply voltage, ensure the AC Fan Line Voltage Selector
Switch (located on the bottom of the rear panel) is set for
proper mains supply voltage.
On Line Processor SCSI Interface PelBox Interface
Connector Connector Connector

AC Fan Line Voltage

Selector Switch

WARNING!
If the AC Fan Line Voltage Selector Switch is set incorrectly
when the imagesetter is plugged in, damage may occur to
the imagesetter.

IMPORTANT NOTE!
If mains supply voltage is removed from the imagesetter
(turning off the fan) while the imagesetter is connected to
online film processor, remove the cover on the film pro-
cessor. This will prevent the film processor fumes from
getting into the imagesetter.

AG12373 Rev. 1 1-3

1
Introduction

1-4 AG12373 Rev. 1

Product Compliance 2
Product Compliance
Definitions
CSA - Canadian Standards Association
An agency responsible for testing products for compliance to
Canadian law.

DOC - Department of Communications

The Canadian government department responsible for creating
Canadian laws regarding electromagnetic emissions.

IEC - International Electrotechnical Commission

An international agency whose purpose is to write or approve
standards for product design and safety.

FCC - Federal Communications Commission

The agency of the U.S. Government responsible for setting
limits for electromagnetic interference created by certain prod-
ucts.

LASER
A device in which atoms, when stimulated by focused light
waves, amplify and concentrate these waves, then emit them in
a narrow, very intense beam.

LASER Product
A device which incorporates a LASER system.

AG12373 Rev. 1 2-1

2 Product Compliance

LASER Radiation (Light)

The process in which energy in the form of rays of light is sent
out through space from atoms as they undergo change. This is
non-ionizing radiation. Essentially it is harmless to humans,
however damage to the retina of the eye can result if the beam
is viewed directly.

LASER System
A LASER and its power source.

Operation and Maintenance

User functions such as operating the product and replacing
film.

Service
Repair/alignment functions, performed by a trained service
technician.

TÜV
An independent German agency responsible for testing prod-
ucts for compliance to German laws and VDE standards.

VDE
German Institute of Electrical Engineers, the organization
which provides technical assistance used by the German gov-
ernment when creating laws.

2-2 AG12373 Rev. 1

Product Compliance

LASER SAFETY
LASER safety is regulated by the Center for Devices and
Radiological Health (CDRH), Food and Drug Administration
(FDA), U.S. Department of Health and Human Services
(DHHS). The system is in compliance with the Regulations for
the Administration and Enforcement of the Radiation Control
for Health and Safety Act of 1968 (as amended) Chapter 1, sub-
chapter J, 21CFR 1040.10(h).

There are other LASER safety standards which apply to the

system. One is EN60 825:1993, Safety of Laser Products. Also,
CSA reviews LASER safety as it relates to product safety, how-
ever CSA does not have a specific standard which applies.

LASER Product Classification

LASER products are classified by the amount of LASER light
accessible to the operator. Products are classified in Classes I
through IV, where Class I emits the least LASER light, and
Class IV emits the most LASER light. The system is classi-
fied as a Class I LASER Product which contains Class
IIIb LASER Systems. This classification means the operator
is exposed to no hazardous LASER light during operation or
maintenance. The LASER itself, however, is a Class IIIb
LASER device, and emits visible and/or invisible LASER light
which is considered hazardous by FDA published limits.

AG12373 Rev. 1 2-3

2
Product Compliance

CAUTION WARNING!
You should never remove any of the covers bearing LASER
warning labels (see Description of Labels section below). Any
adjustment or other work performed inside the system should be
performed by a trained service technician. When properly operated
with covers in place, you cannot be exposed to LASER light that
exceeds the acceptable limitations of a Class I LASER Product as
defined and described below.

Maximum Accessible Light

The maximum accessible continuous wave LASER light dur-

ing operation and maintenance is less than 0.39µW.

Service Radiation

The maximum accessible continuous wave laser light during

service is less than 10mW.

WARNING!
Use of controls or adjustments or performance of procedures
other than those specified in this manual may result in hazardous
LASER light exposure. This warning does not apply to operating
and maintenance procedures provided the covers with warning
labels are not removed.

2-4 AG12373 Rev. 1

Product Compliance

DESCRIPTION OF LABELS
Identification and Certification Label (Ratings Plate)
The identification and certification label is attached to the rear
exterior surface of the unit, adjacent to the appliance inlet.
Refer to Figure 2-1 — “LASER Identification and Certification
Label”.

Figure 2-1 — LASER Identification and Certification Label

AG12373 Rev. 1 2-5

2
Product Compliance

LASER Warning Labels (Non-interlocked covers)

Several covers are not interlocked, and are not designed to be
opened by the operator. These covers are securely fastened to
the unit. They are identified by the LASER warning label.
Refer to Figure 2-2 — “LASER Warning Labels (Non- Inter-
locked Covers)”.

Figure 2-2 — LASER Warning Labels (Non- Interlocked Covers)

2-6 AG12373 Rev. 1

Product Compliance

LASER Warning Labels (Interlocked Covers).

Several covers are interlocked and may be opened during main-
tenance. The interlocks protect you from LASER or mechani-
cal hazards as long as the covers are open and the interlocks
have not been “defeated”. Interlocked covers are identified by
the LASER warning label. Refer to Figure 2-3 — “LASER
Warning Labels - Interlocked covers”.

Figure 2-3 — LASER Warning Labels - Interlocked covers

AG12373 Rev. 1 2-7

2
Product Compliance

Fuse Labels

Fuse labels are located near each fuse holder. They indicate the
correct rating of the fuse. Only a like replacement fuse should
be used. Note that a label which has a “T” in it means that the
fuse is of the time delay (slow blow) type; e.g. T4.0 A 250V ~
would indicate a 4 Amp slow blow fuse and 4.0 A 250 V~
would indicate a 4 Amp non-time delay (normal or fast blow)
fuse.

Information for the mains fuse in the appliance inlet is found

on the certification label. (Refer to Figure 2-1 — “LASER
Identification and Certification Label”.)

DANGEROUS VOLTAGE!
This symbol identifies parts that have dangerous voltages inside.
Do not attempt to open these covers.

2-8 AG12373 Rev. 1

Product Compliance

PRODUCT SAFETY
The system was submitted to independent agencies for testing
to product safety standards. These agencies are CSA for North
America, and TÜV for the European Union (EU).

CSA
The CSA standards which cover the system are C22.2 No. 950-
93 (UL1950) Safety of Information Technology Equipment
including Electrical Business Equipment.

TÜV
The standards to which TÜV tests the system are:

EN 60 950:10.92, Safety of Information Technology Equip-

ment including Electrical Business Equipment.
In addition, EN 60 825:1993 (IEC 825-1:1993) Safety of Laser
Products also applies.

AG12373 Rev. 1 2-9

2
Product Compliance

ELECTROMAGNETIC EMISSIONS
FCC - USA
The standards for electromagnetic emissions are Vol. II, Part
15, Subpart J of the FCC rules. The system was tested to Class
A limits. The following statements are required by the FCC:

WARNING!
Changes or modifications to this unit not expressly approved by the
party responsible for compliance could void your authority to oper-
ate the equipment.

Note: This equipment has been tested and found to comply with
the limits for a Class A digital device, pursuant to Part 15 of the
FCC Rules. These limits are designed to provide reasonable pro-
tection against harmful interference when the equipment is oper-
ated in a commercial environment. This equipment generates,
uses, and can radiate radio frequency energy and, if not installed
and used in accordance with the instruction manual, may cause
harmful interference to radio communications. Operation of this
equipment in a residential area is likely to cause harmful interfer-
ence in which case you will be required to correct the interference
at your own expense.

Shielded cables must be used with this unit to ensure compliance

with the Class A FCC limits.

2-10 AG12373 Rev. 1

Product Compliance

DOC - CANADA
The Canadian Department of Communications requires com-
pliance with the Radio Interference Regulations, CRC c.1374.
The statement “This digital apparatus does not exceed the Class
A limits for radio noise emissions from digital apparatus set out
in the Radio Interference Regulations of the Canadian Depart-
ment of Communications” is found on the Certification and
Identification Label on the exterior rear surface of the unit. See
Figure 1.

EMC Directive - EUROPE

The system complies with the EMC Directive (83/336/EEC)
and was tested to EN 55 022 Class A and EN 50 082-1.

Compliance with applicable regulations depends on the use of

shielded cables. It is the user who is responsible for procuring
the appropriate cables.

This equipment has been tested concerning compliance with

the relevant RFI protection requirements both individually and
on the system level (to simulate normal operation conditions).
However, it is possible that these RFI requirements are not met
under certain unfavorable conditions in other installations. It is
the user who is responsible for compliance of his/her particular
installation.

AG12373 Rev. 1 2-11

2
Product Compliance

2-12 AG12373 Rev. 1

Control Panel 3
Control Panel

IMPORTANT NOTE!
Wait 30 minutes after power-up before running a job.

Introduction
The following chapter describes the functions of the Control
Panel. See Section “Transport Mode “in Chapter 4 for Trans-
port Display messages.

ONLINE
SERIAL
Status Display

Advance Key

Cut Key

Stop Key

Figure 3-1 — Control Panel

AG12373 Rev. 1 3-1

3 Control Panel

Menu Keys
The following is a brief description of the Control Panel Menu
Keys and their function.

Control Panel Menu Keys

KEY DESCRIPTION
MENU This key is used to enter the Menu System.

SELECT This key is used to cycle through the available choices

within a menu, or cycle through numeric values within a
numeric field.

NEXT This key is used to move to the next menu, or to move the
cursor to the right within a numeric field.
PREV This key is used to move to the previous menu, or to move
the cursor to the left within a numeric field.

STOP This key is used to jump from anywhere in the menu

system to the Save Setup menu or to stop the Spinner
Motor (with the exception of the Calibration Menu) when
you are not in the Menu System. This key also interrupts
“Recording Image”.
ADVANCE This key is used to advance media. Press this key to
advance the media. Once you stop pressing the key, the
media stops advancing.

CUT This key is used to advance and Cut Film prior to

processing.

3-2 AG12373 Rev. 1

Control Panel

Using System Menus

The menu system consists of a series of menus used to set up
system parameters (i.e., resolution, exposure, etc.) Enter the
menu system by simply pressing the MENU Key. Move
through the menus by using the PREV and NEXT keys. To exit
from anywhere in the menu, press the STOP key.
The NEXT key moves the cursor to the right and the PREV
Key moves the Cursor to the left. The SELECT Key scrolls
you through the available values (0-9).

Cursor Moves
Press From To

NEXT 020 020

PREV 020 020

SELECT 020 021

For example, if you are in the EXPOSURE window and Expo-

sure is set to 020 and you want to change it to 025 perform the
following:

Cursor Moves

Press From To

NEXT 020 020

SELECT 020 021

SELECT 021 022

SELECT 022 023

SELECT 023 024

SELECT 024 025

AG12373 Rev. 1 3-3

3
Control Panel

Use the NEXT key to move the cursor from 020 to 020. Now
use the SELECT Key to scroll through the numbers 0 through
9. Stop at the 5. The new value will read 025. Pressing NEXT
again will bring you to the next window.

When you move through the menus, the currently selected

menu will appear in the display window. To change the menu
selection, press the SELECT key until the desired choice is
displayed, then move out of that window using the NEXT,
PREV or STOP keys.

NEXT and PREV are also used to step through the digit posi-
tions for windows that have numeric fields. If you press NEXT
when the cursor is under the right-most digit, the window will
display the next menu. If you press PREV when the cursor is
under the left-most digit, the window will display the previous
menu.

Each time the system is turned on, the parameters are loaded
from a special memory. Any changes that you make to the
parameters will remain in effect until the system is turned off,
at which time they will be lost unless they are saved in this
memory. Each time you exit the menu system you will be given
the choice of saving your changes.

The last menu prior to exiting the menu system, is the SAVE
SETUP menu. Save Setup Yes is the default. If you want to
save your changes, then press NEXT.

3-4 AG12373 Rev. 1

Operation and
Maintenance
4
Operation and Maintenance
Introduction
This section describes Menu Operation. The Menus are divided
into three major sections. Once you press the MENU Button,
you can Select the USER SETUP, SYSTEM SETUP, or
DIAGNOSTICS menu options. For the most part, this section
will cover the SYSTEM SETUP and USER SETUP options
so you can setup your unit for operation. Refer to Figure 4-1
and Figure 4-2 while performing the following. Using
SERIAL mode may change some of these settings.

The DIAGNOSTIC options are mainly for Trained Service

Technician use and should be performed by a qualified techni-
cian.

Ensure Power is switched ON prior to running through the fol-

lowing menus. The Power switch is located on the right side
panel of the system. (0 = OFF and 1 = ON.)

AG12373 Rev. 1 4-1

4 Operation and
Maintenance

SETTING UP THE SYSTEM

The SYSTEM SETUP option should be performed first.
SYSTEM SETUP allows you to step through setups such as
ENGLISH/METRIC, AUDIO ALERTS, IMAGE SPACING,
PUNCH SELECTION, MAXIMUM CASSETTE LENGTH,
CUT TRAILER LENGTH, IMAGE OFFSET, SPINNER
TIMEOUT, and SAVE SYSTEM SETUP.

System Setup
To perform the system setup, do the following:

1. Access your SYSTEM SETUP. From the

ONLINE/OFFLINE window, press the MENU
key. Press the SELECT key until MENU
OPTIONS / SYSTEM SETUP is displayed.
2. Make your selections. Refer to Figure 4-1 “Sys-
tem Setup Menu Map” and follow it to change
the desired settings. (Note: The default for
UNITS OF MEASURE is English. If you wish
to operate in the metric system, remember to
change this setting.)
3. Finish your setup. When you have completed all
the settings, the system terminates the setup. Or
you may press the STOP key at any time (i.e. if
you are changing only some settings).
4. Save your setup. You will now be prompted to
SAVE THE SETUP. Select YES. Now you can
continue with the USER SETUP Menus. (Refer
to Figure 4-2 “User Setup Menu Map”).
Note: Punch selections will only appear if punches are installed.

4-2 AG12373 Rev. 1

Operation and Maintenance

MENU OPTIONS Select

SYSTEM SETUP TRANSPORT MODE TRANSPORT MODE
Next
Select A BUFFER PROCESSOR BUFFER CASSETTE
ENGLISH/METRIC ENGLISH/METRIC Next Next
ENGLISH METRIC
Select BUFFER SIZE CASSETTE SIZE
Next VALUE IN feet VALUE IN feet
LANGUAGE Next Next
* ENGLISH FRANCAIS DEUTSCHITALIANO ESPANOL
BUFFER SIZE CASSETTE SIZE
Next
Select
* (00-33): nn * (00-13): nn
AUDIO ALERTS? AUDIO ALERTS? Next
ENABLED DISABLED
TRAILER LENGTH
Next VALUE IN .1 in
Next
TRAILER LENGTH
P Next Select Select * (004-200): nnn
PUNCH SELECTION PUNCH SELECTION PUNCH SELECTION Next Select
HEAD PUNCH ONLY HEAD/TAIL PUNCH DISABLE PUNCHES IMAGE OFFSET
IMAGE OFFSET
Next Next Next SHIFT RIGHT SHIFT LEFT
Select
POSITION HEAD POSITION HEAD IMAGE SPACING Next Next
OUTSIDE OF IMAGE INSIDE OF IMAGE VALUE IN .001 in
IMAGE OFFSET IMAGE OFFSET
Next Next Next VALUE IN .001 in VALUE IN .001 in
POSITION HEAD POSITION HEAD IMAGE SPACING Next Next
VALUE IN .001 in VALUE IN .001 in * (0500-2000): nnnn
Next Next Next * SHIFT RIGHT
BY (000-300): nnn *BYSHIFT LEFT
(000-300): nnn
HEAD OUTSIDE BY HEAD INSIDE BY Next
* (0000-3000) : nnnn *(0000-0500) : nnn
A SPINNER TIMEOUT
Next Next TIME IN minutes

Next
If Head Only
000 = NO TIMEOUT
If Head/Tail * (000-999): 000

Select MEDIA TYPE

MEDIA TYPE
OFFSET TAIL FROM OFFSET TAIL FROM 7 mil
END OF IMAGE
4 mil
HEAD PUNCH
Next Select
Next Next Select
HEAD TO TAIL POSITION TAIL POSITION TAIL LASER DIODE BIAS
VALUE IN .001 in OUTSIDE OF IMAGE INSIDE OF IMAGE %(000-100):000
Next
Next Next Next
HEAD TO TAIL TAIL OUTSIDE BY TAIL INSIDE BY Select
* 0-600000:nnnnn VALUE IN .001 in VALUE IN .001 in SAVE SYSTEM
SETUP? NO/YES
Next Next Next
TAIL OUTSIDE BY TAIL INSIDE BY
* (0000-3000): nnnn
Next
* (0000-0500): nnn
* To make numeric selections:
Next Next - If on first digit, moves cursor
IMAGE SPACING to the right.
IMAGE SPACING
VALUE IN .001 in If on last digit, proceeds to the
VALUE IN .001 in
p next menu selection.
Prev - moves cursor to the left or to the
Note: Punch menus IMAGE SPACING IMAGE SPACING previous menu selection.
appear only if punches
are installed.
*(0500-2000): nnnn *(0500-2000): nnnn Select - increments selected digit.
A
Figure 4-1 System Setup Menu Map

AG12373 Rev. 1 4-3

4
Operation and Maintenance

System Setup Options

ENGLISH/ This window allows you to set the UNITS OF
METRIC MEASURE to either ENGLISH or METRIC units. This
applies to all System Setup and User Setup values
except for Media Type. Film Counter values will
correspond to this setting.
Note 1: All values are actually stored in English
units and converted to metric for display when in
Metric Mode. This may lead to small round-off
errors due to conversion.

LANGUAGE ENGLISH This window allows you to choose between English,

FRENCH French, German, Spanish and Italian for the Control
GERMAN Panel display.The default is ENGLISH.
SPANISH
ITALIAN

AUDIO ENABLED This window defaults to AUDIO ALERTS “ENABLED”.

ALERTS DISABLED It allows you to turn off/on the audio beep to indicate
that a cut has been performed, that you are out of film,
or that you are at the end of an image.

PUNCH This option allows you to choose operation with: HEAD

SELECTION PUNCH ONLY, HEAD/TAIL PUNCH, or DISABLE
PUNCHES.

HEAD PUNCH ONLY

You have the option of positioning the center of the
head punch inside or outside of the image
(in thousandths of an inch or in millimeters.)

" English INSIDE OF IMAGE

0-.500" (in.001") Set the center of the punch inside of image by 0-500 (in
Metric .001 inches) or 0-1270 (in .01mm).
0-1270(in.01mm)

4-4 AG12373 Rev. 1

Operation and Maintenance

System Setup Options

" English OUTSIDE OF IMAGE
0000-3000 Set the center of the punch outside of image by
(in .001 inches)
0000-3000 (in .001 inches) or 0000-7620mm
Metric
0000-7620mm (in .01mm).
(in .01mm)

" HEAD/TAIL PUNCH

Set the HEAD PUNCH as above. The TAIL PUNCH
can be: OFFSET TAIL FROM HEAD PUNCH or
OFFSET TAIL FROM END OF IMAGE. If offset
from the end of the image, the center of the punch
may be set inside or outside of the image.

OFFSET TAIL FROM HEAD PUNCH

English Offset the center of the tail punch from the head
00000-60000 punch by 00000-60000 (in .001 inches) or
(in .001 inches)
000000-152400 (in .01mm). Max 5 ft or 1.524
Metric
000000-152400
m. Note that the punch may be placed as much
(in .01mm) as 1.7” inside the image, but any distance
greater than 0.5” may interfere with image
spacing.

OFFSET TAIL FROM END OF IMAGE

Offset the center of the tail punch either INSIDE OF
IMAGE or OUTSIDE OF IMAGE.

" TAIL INSIDE OF IMAGE

English Offset the center of the tail punch from the end of
0000-0500 image by 0000-0500 (in .001 inches) or 0-1270 (in
(in .001 inches)
Metric .01mm). Maximum .5 inches or 12.7 mm.
0000-1270
(in .01mm)

" TAIL OUTSIDE OF IMAGE

English Offset the center of the tail punch from the end of
0000-3000 image by 0000-3000 (in .001 inches) or 0-7620 (in
(in .001 inches)
.01mm). Maximum 3 inches or 76.2 mm.
Metric
0000-7620
(in .01mm

AG12373 Rev. 1 4-5

4
Operation and Maintenance

System Setup Options

"
outside of image
-a-
inside of image

-d- -b-

inside of image
-c-
outside of image

-a- Head Punch Margin.

-b- Image area includes registration marks,
crop marks, RIP Margins and page.
-c- Tail Punch Margin.
-d- Offset Tail Punch from Head Punch

4-6 AG12373 Rev. 1

Operation and Maintenance

System Setup Options

IMAGE Enter the space desired between images in .001” (.01
SPACING mm). Image spacing is as follows:

0500-2000 PUNCHES DISABLED (or not installed): From end of

(1270-5080) image to start of image. 0.5” to 2” (12.7mm to 50.8mm)

0750-2000 HEAD PUNCH ONLY or TAIL REFERENCE HEAD:

(1905-5080) From end of image to center of head punch. 0.75” to 2”
(19.05mm to 50.8mm).

0750-2000 HEAD/TAIL PUNCH, TAIL OUTSIDE IMAGE: Center

(1905-5080) of tail punch to center of head punch. 0.75” to 2”
(19.05mm to 50.8mm).

1250-2000 HEAD/TAIL PUNCH, TAIL INSIDE IMAGE: 1.25” to 2”

(3175-5080) (31.75mm to 50.8mm).
NOTE: If your RIP already sets spacing between
images, you can set this variable to Min = 1.0.
This space is generated before the start of the
image.

TRANSPORT BUFFER Choose the Buffer Processor option if you are

MODE: PROCESSOR outputting to an online processor. Choose the Buffer
Cassette option if you are outputting to a cassette.
BUFFER This window allows you to set a limit on the amount of
CASSETTE film sent to the output cassette or to an online
processor. If your output cassette or your processor
BUFFER English can only handle a certain amount of film, you can enter
PROCESSOR 0-33 feet a number in this window to set the limit. For example, if
Metric your output cassette can handle only 10 feet of output,
0-10 meters set the MAXIMUM CASSETTE LENGTH to 10. Then
BUFFER once the system has sent 10 feet of output to the
CASSETTE English output cassette, the system will perform an automatic
0-13 feet cut at the end of the image.
Metric NOTE: The system WILL NOT cut in the middle of a
0-08 meters job. If a job is processing, and has reached the 10
foot limit, it will wait until that job is done, then cut.

AG12373 Rev. 1 4-7

4
Operation and Maintenance

System Setup Options

CUT English This window allows you to set the trailer length (in
TRAILER 0.4”-20” tenths of an inch or mm). The trailer is the amount of
LENGTH Metric space left between the end of the image and the cut.
10mm-508mm

IMAGE English This window allows you to set the image to shift right or
OFFSET 0.000” to 0.300” to shift left (in .001 inches or .01mm). English: 0 to 300
Metric thousandths of an inch. Metric: 0 to 760 hundredths of
0 mm to 7.6 mm a millimeter.

SPINNER 0-999 This window allows you to set the amount of time (in
TIMEOUT minutes minutes) that the machine idles before the spinner
times out (shuts off). The default setting is 000 minutes,
which means never shut the spinner down. The reason
for this is that wear on the air bearings occurs ONLY at
start-up and at shut-down.

MEDIA TYPE Media Type 1 This option allows you to choose between two media
Media Type 2 type calibrations, which include image sizing and laser
diode bias settings. The factory default is Media Type 1,
which is calibrated for 4 millimeter thick media.

LASER 000%-100% Independent laser diode bias levels can be saved for
DIODE BIAS media types 4 mil and 7 mil. The default value is 100%.
Percent of laser diode bias applied can be adjusted to
reduce background fog on sensitive media.

SAVE YES/NO This window allows you to save the current setups in
SETUP memory. If you choose Yes, the current setups will be
saved in memory. If you choose No, the current setup
values you have just entered will be used until the
system is powered down. When the system is powered
up, the last saved setup values will be used.

4-8 AG12373 Rev. 1

Operation and Maintenance

User Setup
To perform the user setup, do the following:

1. Access your USER SETUP. From the ONLINE/

OFFLINE window, press the MENU key. Press
the SELECT key until MENU OPTIONS /
USER SETUP is displayed.
2. Make your selections. Refer to Figure 4-2 “User
Setup Menu Map” and follow it to change the
desired settings.
3. Finish your setup. When you have completed all
the settings, the system terminates the setup. Or
you may press the STOP key at any time (i.e. if
you are changing only some settings).
4. Save your setup. You will now be prompted to
SAVE THE SETUP. Select YES.

AG12373 Rev. 1 4-9

4
Operation and Maintenance

MENU OPTIONS
USER SETUP

Next Select Select

INTERFACE MODE INTERFACE MODE INTERFACE MODE
LOCAL TEST PATTERNS SERIAL

Next Next Next

∆ TEST PATTERNS
TEST PATTERN # 0-6

Next

EXPOSURE LEVEL
(000-255): nnn ∆
If Test Pattern 4,5 or 6 is chosen To make numeric selections:
Next Select Next - If on first digit, moves cursor
If Test Pattern 1, to the right.
ASPECT RATIO 1:1 If on last, or only, digit, proceeds
2 or 3 is chosen NO
B to the next menu selection.
ASPECT RATIO Prev - moves cursor to the left or back
1:1? YES Next
∆
to the previous selection.
** PEL RESOLUTION Select - increments selection or digit.
Next
2540dpi
RESOLUTION
2540 DPI Next
∆ LINE RESOLUTION
Next
nnnn dpi

Next
∆ *** MEDIA WIDTH
635MM (25.0”) A B

*** Media Widths Next

Select
25.0” (635) OVERSCAN OVERSCAN
22.0” (559) ON OFF
20.5” (521)
18.1” (460) ** Resolutions
Next
1000 dpi
Select
COUNTER COUNTER DISPLAY 1016 dpi
Only these values DISPLAY INPUT CASSETTE 1200 dpi
OUTPUT BUFFER
are selectable 1270 dpi
Next Next
through the front 1446 dpi
panel. The other INPUT CASSETTE 1524 dpi
values are select- VALUE IN feet 1800 dpi
able in the input Next 2032 dpi
Next
cassette. 2400 dpi
∆ ∆ INPUT CASSETTE 2540 dpi
SAVE USER
SETUP? NO/YES (000-400): nnn
3048 dpi
3556 dpi

Figure 4-2 User Setup Menu Map

4-10 AG12373 Rev. 1

Operation and Maintenance

User Setup Options

INTERFACE LOCAL The options that you can scroll through (with the
MODE SELECT key) for the INTERFACE MODE will
SERIAL appear. The options are LOCAL, SERIAL, and
TEST PATTERNS. The TEST PATTERNS option
should only be used by a qualified service tech-
TEST PATTERNS
nician. For now, choose either LOCAL or
SERIAL by pressing the NEXT key.

LOCAL Exposure Level LOCAL mode allows you to manually enter the
(000-255) RESOLUTION and EXPOSURE through the
control panel. If you choose LOCAL, you can
Aspect Ratio enter the desired exposure value. After you enter
the desired value, press NEXT to bring you to
YES / NO
the ASPECT RATIO window. Then you will have
the choice of setting the ASPECT RATIO 1:1. If
Pel Resolution you choose YES to ASPECT RATIO 1:1, the
nnnn dpi system will record your resolution equal in the
line and pel direction. If you choose NO, you can
Line Resolution set the pel and line resolution independently with
nnnn dpi the LINE RESOLUTION and PEL RESOLUTION
options. Finally, you set the MEDIA WIDTH. The
Media Width sets of choices are 460mm (18.1”), 520mm
(20.5”), 560mm (22.0”), and 635mm (25.0”), or
460mm (18.1”) and 520mm (20.5”), depending
on recorder type.

SERIAL SERIAL mode allows greater host control of the

system’s RESOLUTION variable. EXPOSURE,
MARGINS, and NEGATIVE are also controlled
by the RIP.

MEDIA WIDTH 460mm (18.1”) This window allows you to set the media width.
520mm (20.5”) NOTE: This option is not set from SERIAL mode.
560mm (22.0”) If the media width needs to be changed while in
635mm (25.0”) SERIAL mode, change temporarily to LOCAL
OR: mode, make the desired change, and switch
460mm (18.1”) back to SERIAL mode.
520mm (20.5”)

AG12373 Rev. 1 4-11

4
Operation and Maintenance

User Setup Options

OVERSCAN ENGLISH OVERSCAN is used to record over the entire
0.16” width of the film, which is useful when outputting
negatives. This feature will add approximately
METRIC 0.16” (4.06mm) to the selected media width. If
you want this option, ensure OVERSCAN is set
4.06mm
ON.
NOTE: This option is not set from SERIAL mode.
If OVERSCAN needs to be changed while in
SERIAL mode, temporarily switch to LOCAL
mode, make the desired change, and switch
back to SERIAL mode.

COUNTER ENGLISH OUTPUT BUFFER:

DISPLAY 0-400 feet This window displays how much film has entered
OUTPUT the output buffer since the last cut. The counter
BUFFER METRIC display resets to 0 after each cut. See #2 below.
0-122m
INPUT CASSETTE:
This window allows you to keep track of how
much media is left in the input cassette.
1. When you install an input cassette,
enter the amount of film in the current
cassette in the Input Cassette Counter
Display window. (e.g., if you have a 100’
roll of film, enter 100 in the Input Cas-
sette Counter Display window).
2. As the system uses the film, it subtracts
the amount from the value entered.
(e.g., if you had used 25’ of film, the
Input Cassette Counter Display would
read 75’, indicating how much film is left
in the input cassette).

SAVE SETUP YES / NO This window allows you to save the current
setups in memory. If you choose YES, the
current setups will be saved

4-12 AG12373 Rev. 1

Operation and Maintenance

IMPORTANT!
If you change input cassettes before a roll has been completed, it may be
helpful to mark how much film is left on the outside of the cassette. If at a
later time you want to re-install the cassette, enter the number on the
outside of the cassette in the Input Cassette Counter Display window.

WARNING!
When using the emergency output cassette

Although the recorder will allow images to be recorded when the output
cassette is absent, film fogging may occur.

LOADING MEDIA INTO A 400 FOOT INPUT CASSETTE

WARNING!
Move only the Adjustable Hub Assembly.

The position of the Fixed Hub Assembly sets the centering of the media
and should not be moved except in the following two situations:
(1) The width of the media in use changes and an adjustment is
needed.
(2) The media shaft must be exchanged to accommodate a new
media width whose width setting is not available on the media
shaft in use.

You should practice loading an empty film roll before loading a

new roll in the dark room. To load media into a 400 foot input
cassette, place the empty cassette on a convenient, flat surface
with the Media Exit Slot toward you and do this:

AG12373 Rev. 1 4-13

4
Operation and Maintenance

1. Open the cassette. Unhook the Side Latches.

Refer to Figure 4-3 “Inside View of Input Cas-
sette”. Swing the top of the cassette open, away
from you.
2. Lift out the Shaft and Hub Assembly and place it
on the table before you in the same orientation.
The upper edges of the Fixed and Adjustable Hub
Assemblies are flattened to the side. Use these
two flats as handles.
3. Remove the Adjustable Hub Assembly. The
Adjustable Hub Assembly is on the right. The
Fixed Hub Assembly on the left has an Identify-
ing Hole and a conspicuous label, “DO NOT
REMOVE THIS END”. Lift the Spring Detent
up and out of the groove and slide the Adjustable
Hub Assembly off. If an empty media roll is on
the shaft, you may feel a slight pop as the spring-
loaded Adjustable Hub Assembly pushes out.

Flat Flat Adjustable Hub Assembly

(handle) (handle) Shaft
Identifying Hole

Media Exit Slot

Spring
Detent

Side
Latches

Fixed Hub Assembly Side Latch

Figure 4-3 Inside View of Input Cassette

4-14 AG12373 Rev. 1

Operation and Maintenance

4. Set the Fixed Hub assembly for media width, if

necessary (you may need to exchange the media
shaft). See Figure 4-4. Snap the Fixed Hub
Assembly Spring Detent into the proper groove.
5. If you are loading either 12'' or 18'' media, install
a Spacer Disk on the Fixed Hub Assembly.
Note: If you are loading 12'' media, use the 12.2'' groove. If you are loading 18'' media, use
the 18.11'' groove.
6. Install a roll of media on the Shaft and Hub
Assembly. Position the roll with the dull, emul-
sion side of the media toward you as it unrolls.
Emulsion
With the Fixed Hub Assembly on your left, press
the roll over the shaft and onto the Fixed Hub
Assembly.
7. Install the Adjustable Hub Assembly. Press it on
from the right. You will feel pressure from the
spring-loading of the Hub Assembly just before
the Detent Spring snaps into place in the proper
groove. You must push the Hub Assembly until
the Detent Spring snaps into place and the side-
wall of the media is against the Hub Assembly.
8. Install the loaded Shaft and Hub Assembly. Use
the two flat handles on the Hub Assemblies to lift
the loaded assembly into the cassette so that the
media rolls off the top of the roll and out the
Media Exit Slot. Make sure that the ends of the
shaft slide into their holders in the cassette.
9. Feed one foot (0.3 meter) of media out of the cas-
sette. Close the cover of the cassette and secure
the Side Latches. This is the end of the Loading
Procedure.

AG12373 Rev. 1 4-15

 4
4-16

Figure 4-4 Grooves for Different Media Widths

635mm 25.00"
610 mm 24.00"
484 mm 23.00"
559mm 22.00"
549mm 21.60"
530mm 20.90"
510mm 20.10"
498mm 19.60"
FA40015 462mm 18.20"
406mm 16.00"
356mm 14.00"

450mm 17.70"
460mm 18.10"
FA40016 472mm 18.60"
508mm 20.00"
520mm 20.50"
550mm 21.70"
572mm 22.50"

Operation and Maintenance

597mm 23.50"
625mm 24.60"
AG12373 Rev. 1
Operation and Maintenance

Installing Media Into The System

CAUTION!
POSSIBLE PINCH HAZARD

Keep hands clear of door hinges when opening and closing

doors.

With power on, do the following to install film in the system.

1. Remove top cover.

2. Lift the buffer cover to the upright position. See
Figure 4-6.
3. Open the front media door.
4. Extend the cassette shelf brackets (Figure 4-5).
5. Lift the dancer roller handle until it stops, then
push the handle back and drop down to lock the
dancer roller assembly in place.
6. Raise the roller release arm to the up position
(Figure 4-5).
7. Set the input cassette onto the cassette shelf
brackets.
8. Feed media through the input pinch rollers.
9. Continue to feed the media until it comes through
the cutter and can be seen through the open buffer
cover.
10. Slide the input cassette in until it locks into place
in the brackets.
11. Move the shelf brackets back into the in position.

AG12373 Rev. 1 4-17

4
Operation and Maintenance

12. Grasp the media at the open buffer cover and pull
the media with a light tension. Move the media
back and forth to be sure it is leading straight.
13. While holding the media at the buffer end, lower
the dancer roller assembly into the down position
by pulling forward on the handle and lowering
the assembly down slowly by the handle until it
bottoms out.
14. While still holding the media at the buffer end,
lower the roller release arm to the down position
to engage the drive roller.
15. Close the front cover.
16. Press the cut button on the control panel. Remove
the cut media.
17. Lower the buffer cover into the down position.
18. Put the top cover on.
19. “ONLINE EXPOSED MEDIA” will display on
the menu display.

CAUTION!
LOWERING THE FILM DOOR

Pull the door forward and allow it to close itself. Don’t force it
down: this may cause damage to the door.

4-18 AG12373 Rev. 1

Operation and Maintenance

Dancer Imaging Dancer Assembly

Roller Roller Handle

Lazy Loop
Pinch Roller

Input
Cassette

Cassette Shelf
Brackets
Roller Release
Arms

Figure 4-5 Installing Media - System With Dancer in the Up Position

AG12373 Rev. 1 4-19

4
Operation and Maintenance

CLEARING MEDIA JAMS

CAUTION!
POSSIBLE PINCH HAZARD

Keep hands clear of door hinges when opening and closing

doors.

Input Side of Buffer 1 Jam

1. Grab top cover handles. Lift to remove.
2. Lift open the buffer cover.
3. Lift up the buffer drive roller assembly.
4. Pull film clear of the jam.
5. Close the buffer cover.
6. Replace the top cover.
7. The Status display on the control panel will read
ONLINE EXPOSED MEDIA.
8. Press SELECT to advance past the exposed
media.

4-20 AG12373 Rev. 1

Operation and Maintenance

Buffer Cover

Rear Access Plate

Buffer Drive Roller

Assembly

Figure 4-6 Buffer Jams

Exit Buffer Jam

1. Grab top cover handles. Lift to remove.
2. Remove the rear access plate, by unscrewing the
thumb screws at the right and left sides of the
plate.
3. Lift up the buffer drive roller assembly.
4. Pull the film free of the jam.

AG12373 Rev. 1 4-21

4
Operation and Maintenance

5. Replace the rear access plate and tighten the

thumb screws.
6. Replace the top cover.
7. The Status display on the control panel will read
ONLINE EXPOSED MEDIA.
8. Press SELECT to advance past the exposed
media.

Buffer bag jam

1. Remove the top cover of the recorder.
2. Remove the right side panel.
3. Lift up the buffer drive roller assembly.
4. Reach through the access hole and locate the slit
in the bag.
5. Reach into the bag and pull the film free of the
jam.
6. Replace the right side panel.
7. Replace the top cover.
8. The Status display on the control panel will read
ONLINE EXPOSED MEDIA.
9. Press SELECT to advance past the exposed
media.

4-22 AG12373 Rev. 1

Operation and Maintenance

STATUS MESSAGES
The following table describes Status Messages that may appear
in the system display window.

STATUS MESSAGES

MESSAGE DESCRIPTION

POWER UP

JA1064 1.0 During the power up self-test, the system displays the
JA1065 1.0 program part numbers, and version number.

STATUS / MODE
ONLINE Image exposure level and resolution are controlled from the
LOCAL User Setup Menu.

ONLINE The system is controlled through the serial (SCSI pel)

SERIAL interface.

OFFLINE The system outputs internal Test patterns (for service).

TEST PATTERNS

STATUS / EXCEPTION
ONLINE Indicates that there is a prior job in the system. This message
JOB IN PROCESS is displayed at the successful conclusion of a record cycle
and is cleared with cut or exposed media.

ONLINE A system cover was opened and media exposed.The system

MEDIA EXPOSED! will automatically advance exposed media prior to the next
job. You may manually clear this message by initiating a cut or
by pressing SELECT.

OFFLINE A system cover or panel is not closed. Close the cover or

COVER NOT CLOSED panel and continue.

AG12373 Rev. 1 4-23

4
Operation and Maintenance

STATUS MESSAGES
OFFLINE The punch has not parked completely (is not in home
PUNCH NOT PARKED position, and media may be locked). Go to the DIAGNOSTIC
PARK PUNCH window. (To access the DIAGNOSTIC PARK
PUNCH window, from ONLINE/OFFLINE press MENU, then
press SELECT until DIAGNOSTICS PARK PUNCHES
appears. Once in this window you must press NEXT to PARK
PUNCH. Refer to Appendix A for Diagnostic Menu Map.
Note: Covers must be closed to park punches.

OFFLINE The system has detected the end of the media. Once media
OUT OF MEDIA is flushed from system, install more media and continue.

OFFLINE The cutter blade has not parked. Go to the DIAGNOSTIC

CUTTER NOT PARKED PARK CUTTER window. (To access the DIAGNOSTIC PARK
CUTTER window, from ONLINE/OFFLINE press MENU, then
press SELECT until MENU OPTIONS DIAGNOSTIC
appears. Then press NEXT again. Then press SELECT until
DIAGNOSTIC PARK CUTTER appears. Once in this window
you must press NEXT to PARK CUTTER.) The cutter will
then try to cycle correctly. If it does not, contact Customer
Support. Refer to Appendix A for Diagnostic Menu Map.
Note: Covers must be closed to park the cutter.

ONLINE There is no output cassette on the system. In cassette mode,

NO CASSETTE you may record without a cassette, but it must be mounted to
complete the cut cycle. The cassette sensor is ignored when
in processor mode.

SYSTEM SHUTDOWN The STOP button has been pressed, the spinner has shut
WAITING down, and won’t spin up until a new image is recorded. This
message persists only while the STOP key is pressed.

OFFLINE The recorder has detected the pinch roller is not parked.
PINCH NOT PARKED Diagnostic/Park Pinch

OFFLINE The Drive Roller has been left in the open position. Open the
DRIVE DISENGAGED cover and close the drive roller to clear this message.

OFFLINE The film load access door on the transport Buffer 2 is open.
BUFFER DOOR OPEN

4-24 AG12373 Rev. 1

Operation and Maintenance

STATUS MESSAGES

SYSTEM ERROR
SYSTEM ERROR #n A fatal error has occurred. Press the PREV key to restart the
PREV TO RESTART system. See “Error Messages” for a list of messages.

RECORD CYCLE
CORRECTING MEDIA The Media Correction sequence is done once prior to each
image and is repeated five times if cover has been opened
(while media was loaded) as follows:
Drive roller advances (lazy loop drive motor halted).
Dancer Roller moves up as media is pulled tight.
Media becomes tight and drive roller slips, aligning media.
Lazy loop is created (see CREATING LOOP below).

CREATING LOOP Lazy Loop Drive Motor runs following the slipping of the Drive
Roller during the CORRECTING MEDIA sequence. The Lazy
Loop Drive motor runs until it makes a 2.5 inch lazy loop.

TESTING SPINNER The spinner has just been started or is changing speed. The
recorder is waiting for the spinner speed to settle.

PUNCHING HEAD The head punch is punching the media.

ADVANCE TO IMAGE The system is advancing media to the image.

RECORDING IMAGE The system is currently recording an image.

FILM COUNT: nn.n

PRESS PREV This message occurs if the STOP key is pressed during a
TO CONTINUE record cycle. To continue, press the PREV key.

ADVANCE TO TAIL The system is advancing the media to the tail.

FILM COUNT: nn.n

PUNCHING TAIL The tail punch is punching the media.

FILM COUNT: nn.n

ONLINE This message occurs after the image is recorded and before
JOB IN PROCESS the cut cycle.

AG12373 Rev. 1 4-25

4
Operation and Maintenance

STATUS MESSAGES

ADVANCE
ADVANCING MEDIA The ADVANCE key has been pressed and the system is
FILM COUNT: nn.n advancing media.

END OF MEDIA ACTIONS

End of Media actions are initiated automatically when the system detects an empty
input cassette. These actions automatically flush media from recorder.

RECORDING IMAGE The system has run out of film while recording. Record cycle
OUT OF FILM will abort. Out of film message may occur anytime the system
advances media.

OFFLINE The system has run out of film. The system will beep three
OUT OF FILM times then attempt to flush the drive.

FLUSHING DRIVE The system is flushing media from the drive following a
OUT OF FILM detected end of media.

FLUSHING BUFFER The system is flushing media from the buffer following a
OUT OF FILM detected end of media.

WAITING FOR The system is waiting for the buffer to be ready. This message
BUFFER READY may also occur during a cut cycle.

OFFLINE Once the Buffer is ready, the system is ready for film
OUT OF FILM replacement. Replace the film to continue.

CUT CYCLE ACTIONS

Cut cycle actions are initiated whenever the user initiates a cut, or when the
maximum buffer size or cassette size has been reached.

INSTALL CASSETTE The cassette is not in place and the cut cycle cannot be
TO CONTINUE started. Install the cassette.

CLOSE PROCESSOR The processor is not sensed and the cut cycle cannot be
TO CONTINUE completed. Move system up against the processor.

4-26 AG12373 Rev. 1

Operation and Maintenance

STATUS MESSAGES
ADVANCING MEDIA The system is advancing media during the cut cycle.
FILM COUNT: nn.n

CUTTING MEDIA This message occurs whenever the cutter blade is in motion.
FILM COUNT: nn.n

REMOVE CASSETTE This message occurs after a cut has been completed to
TO CONTINUE remind you to remove the output cassette. This message
occurs in cassette mode only.

WAITING FOR The system is waiting for the buffer to transfer media from
BUFFER READY buffer 1 into either buffer 2 or the cassette.

AG12373 Rev. 1 4-27

4
Operation and Maintenance

Transport Status Display

T R A N S P O R T I D L E
B U F F E R 1 C L E A R

Figure 4-7 Transport Status Display Window

The Transport Status window displays the buffer state. The
messages are shown below in order of occurrence

The following table shows messages that may appear on the

Transport Status Display, and explains what each message
means.

Transport Status Display Messages

MESSAGE DESCRIPTION

POWER UP
DB50 TRANSPORT Displays the program part number, JAxxxx, and revi-
JA0969 1.4 sion, n.n, during power up and self test.

PROCESSOR MODE OPERATION

TRANSPORT IDLE The Transport is ready to accept media into buffer 1.
BUFFER 1 CLEAR

TRANSPORT ACTIVE The Transport detected media in buffer 1.

BUFFER 1 AWARE

TRANSPORT IDLE The Transport has locked media into rollers.

BUFFER 1 LOADING

4-28 AG12373 Rev. 1

Operation and Maintenance

Transport Status Display Messages

TRANSPORT PAUSED The PelBox is cutting media.
CUT IN PROGRESS

TRANSPORT PAUSED Media from prior job detected at output of transport.

JOB AT OUTPUT
TRANSPORT PAUSED The processor is connected but is offline.
PROCESSOR OFFLN.

TRANSPORT PAUSED The processor is connected and online, but is not

PROCESSOR BUSY ready.

TRANSPORT ACTIVE The media is crossing buffer 2.

MOVING MEDIA

TRANSPORT ACTIVE The media has been detected at output: The transport
MEDIA AT OUTPUT will wait processor threading delay time (0.20 Seconds)
before loading buffer 2.

TRANSPORT ACTIVE Transferring media from buffer 1 to buffer 2.

BUFFER 2 LOADING

CASSETTE MODE OPERATION

CASSETTE MODE The transport is ready to accept media into buffer 1.
BUFFER 1 CLEAR

CASSETTE MODE The transport detected media in buffer 1.

BUFFER 1 AWARE
CASSETTE MODE The transport has locked media into rollers.
BUFFER 1 LOADING

TRANSPORT PAUSED The PelBox is cutting media.

CUT IN PROGRESS

TRANSPORT ACTIVE The media is crossing buffer 2.

MOVING MEDIA

AG12373 Rev. 1 4-29

4
Operation and Maintenance

Transport Status Display Messages

TRANSPORT ACTIVE The transport is loading media into cassette.
CASSETTE LOADING

TRANSPORT PAUSED The transport is prompting user to remove cassette

REMOVE CASSETTE before starting next job.

TRANSPORT ERROR MESSAGES

TRANSPORT ERROR
FLAP 1 CURRENT - The transport has detected a problem operating a
flap, lift, or roller motor.
TRANSPORT ERROR - The flap or lift may be obstructed.
FLAP 2 CURRENT - The flap, lift, or roller motor wire may be shorted.
TRANSPORT ERROR - Call Service if problem persists.
LIFT 1 CURRENT

TRANSPORT ERROR
ROLLER CURRENT

TRANSPORT ERROR
FLAP 1 TIMEOUT - The transport flap or lift has not arrived at its desti-
nation on time.
TRANSPORT ERROR - The flap or lift may be obstructed.
FLAP 2 TIMEOUT - The flap or lift wire may be loose.
TRANSPORT ERROR - Call Service if problem persists.
LIFT 1 TIMEOUT

4-30 AG12373 Rev. 1

Operation and Maintenance

Transport Status Display Messages

TRANSPORT ERROR - The media did not reach the sensor on time.
SENSOR TIMEOUT - Sensor 3 does not detect leading edge of media
within 30 seconds when MOVING MEDIA.
- Sensor 4 does not detect the trailing edge of media
when BUFFER 2 LOADING.
- Sensor 4 does not detect the trailing edge of media
when LOADING CASSETTE.
- The sensor leads may be loose.
- The sensor may be out of alignment.
- The sensor may be bad.

TRANSPORT ERROR - You have initiated abort by pressing the STOP key
KEYPAD ABORT while the roller was moving media.

TRANSPORT ERROR - The Transport has failed to remember setup values

EEPROM CRC stored in EEPROM.
- The Transport may have lost power while you were
storing values.
- Press PREV left arrow on the Transport Controller
Board to clear this error. Default values will be
stored to EEPROM.
TRANSPORT ERROR - Power-On Self-Test error.
VOLTAGE HIGH - Power input(s) to transport PCB is/are missing or
out of tolerance.
TRANSPORT ERROR - The connector may be loose or missing.
VOLTAGE LOW

TRANSPORT ERROR - Power-On Self-Test error.

SENSOR STATE - The transport program cannot resolve the current
state of transport.
- The sensor leads may be loose.
- The sensor may be out of alignment.
- The sensor may be bad.

All error messages should be reported to Customer Service.

AG12373 Rev. 1 4-31

4
Operation and Maintenance

ERROR MESSAGES
The following error messages require that you contact
Customer Support.

ERROR MESSAGES

MESSAGE MEANING
SYSTEM ERROR #1 DC drive motor error.

SYSTEM ERROR #2 No Spinner Index error.

SYSTEM ERROR #3 No ACTIVE VIDEO error.

SYSTEM ERROR #4 Cutter error.

SYSTEM ERROR #5 DC Lazy Loop error.

SYSTEM ERROR #6 Head Punch error.

SYSTEM ERROR #7 Tail Punch error.

SYSTEM ERROR #8 Pinch error.

SYSTEM ERROR #9 Spinner speed test failure

CHECK POWER ERRORS:

24V LO Power on self test error.

24V HI "

+/-15V LO "

24V LO, +/-15V LO "

24V HI, +/-15V LO "

+/-15V HI "

24V LO, +/-15V HI "

24V HI, +/-15V HI "

4-32 AG12373 Rev. 1

Operation and Maintenance

ROLLER CLEANING PROCEDURE

The rollers in the drive section of the system require periodic
cleaning in order to perform efficiently. If the rollers become
contaminated with oils and paper dust, they will not perform
efficiently. In order to keep them in good working condition,
they should be cleaned every two weeks, depending upon film
usage (based on 8 hours of use per day). This will ensure
repeatability and prevent film slippage. Only the internal rollers
specified in this procedure should be cleaned. All other rollers
should be cleaned by a qualified service technician.

Lazy Loop Rollers:

CAUTION!

Ensure the cleaning cloth does not get caught in the rollers.

NOTE!
Depending upon the amount of contamination, you may need
more than one cleaning cloth to thoroughly clean the rollers.

1. Open the front door.

2. Remove the top cover.
3. Remove film and the input cassette from the sys-
tem, exposing the lazy loop drive roller. See Fig-
ure 4-8.
4. From the ONLINE or the OFFLINE state, press
the MENU key.
5. Press SELECT until DIAGNOSTICS appears.
6. Press NEXT once.

AG12373 Rev. 1 4-33

4
Operation and Maintenance

7. Press SELECT until UNWIND MEDIA appears.

8. Press NEXT once.
9. Clean exposed portions of the metal lazy loop
pinch roller with “Fantastik” (p/n HB2456)
applied sparingly to a clean, lint-free wipe.
10. Manually turn the roller (free-wheeling) to
expose more of its surface.
11. Continue to turn the roller and to clean each sec-
tion of the roller gently as it is exposed until the
entire roller is clean.
12. Repeat steps 9. to 11. using 70% isopropyl alco-
hol instead of “Fantastik” to remove any residue
of the “Fantastik”.

Dancer Imaging Dancer Assembly

Roller Roller Handle

Lazy Loop
Pinch Roller

Input
Cassette

Cassette Shelf
Brackets
Roller Release
Arms

Figure 4-8 Roller Cleaning

4-34 AG12373 Rev. 1

Operation and Maintenance

13. Clean exposed portions of the rubber lazy loop

drive roller with 15% isopropyl alcohol applied
sparingly to a clean, lint-free wipe.
14. Press ADVANCE to expose a new section of the
roller, then release ADVANCE. Don’t clean the
roller while it’s turning.
15. Continue to advance the roller and to clean each
section of the roller gently as it is exposed until
the entire roller is clean.

Internal Drive Rollers:

1. Clean exposed portions of the metal capstan
roller with “Fantastik” (p/n HB2456) applied
sparingly to a clean, lint-free wipe. See Figure 4-
8.
2. Press ADVANCE to expose a new section of the
roller, then release ADVANCE. Don’t clean the
roller while it’s turning.
3. Continue to advance the roller and to clean each
section of the roller gently as it is exposed until
the entire roller is clean.
4. Repeat steps 1. to 3. using 70% isopropyl alcohol
instead of “Fantastik” to remove any residue of
the “Fantastik”.
5. Press STOP to return the system to the ONLINE
/ OFFLINE state.
6. Turn imagesetter power off.
7. Clean exposed portions of the metal transport
roller with “Fantastik” (p/n HB2456) applied
sparingly to a clean, lint-free wipe.
8. Manually turn the metal transport roller to expose
a new section of the roller for cleaning.

AG12373 Rev. 1 4-35

4
Operation and Maintenance

9. Continue to advance the roller and to clean each

section of the metal transport roller gently as it is
exposed until the entire roller is clean.
10. Repeat steps 7. to 9. using 70% isopropyl alcohol
instead of “Fantastik” to remove any residue of
the “Fantastik”.
11. Clean exposed portions of the rubber transport
output roller with 15% isopropyl alcohol applied
sparingly to a clean, lint-free wipe.
12. Manually turn the rubber transport output roller
to expose a new portion of the roller for cleaning.
13. Continue turning the rubber transport output
roller by hand and cleaning the exposed portions
until the entire roller is cleaned.
14. Install the input cassette and thread the film.
15. Lower the front door.
16. Replace the top cover.

4-36 AG12373 Rev. 1

Operation and Maintenance

AIR FILTER CLEANING PROCEDURE

The air filter in the system is located near the bottom of the
right panel. This should be cleaned periodically (when you
notice that it’s getting dusty). The amount of time between
cleanings will vary depending upon where the system is located
and how often it is used.

Top Cover
Top Cover
Handles

Control Panel
Back Panel
Flathead mounting
(inside on both
Transport Status Display sides)

Front Cover Right Panel

Front Panel
Left Panel
Back Panel

Interface
Connector
(Located in center
bottom of
Punch Trays back panel)
(Under the system)
Air Filter
Locating pins
(inside of left
and right
side panels)

Figure 4-9 System component locations

AG12373 Rev. 1 4-37

4
Operation and Maintenance

CAUTION!
POSSIBLE PINCH HAZARD

Keep hands clear of door hinges when opening and closing

doors.

1. Remove the air filter from right side panel.

2. Wash it with detergent in warm soapy water.
3. Rinse carefully in clear water.
4. Let dry.
5. Replace the air filter.

Emptying the Punch Trays

The punch trays collect the residue from the punched media
and should be emptied on a regular basis (e.g. every 500 punch
cycles). The trays are located underneath the system, parallel to
the floor. They slide in and out on a rail. To empty punch trays:

1. Pull the punch tray out by the handle.

2. Empty the punch tray.
3. Push the punch tray back in on its rail.

Cleaning the System

Clean the external panels with a general purpose cleaner. Vac-
uum internal dust and small debris from the system.

Note: Only qualified field technicians should clean the inte-

rior of the system.

4-38 AG12373 Rev. 1

Appendix A A
Appendix A - Diagnostic Menu
To access the Diagnostic menu from the ONLINE/OFFLINE:

1. Press MENU (The Menu Options User Setup is

displayed).
2. Press SELECT (MENU OPTIONS SYSTEM
SETUP is displayed).
3. Continue to press SELECT until the MENU
OPTIONS DIAGNOSTICS is displayed.
Refer to Section 4, “Operation and Maintenance”.

AG12373 Rev. 1 A-1

A Appendix A

MENU OPTIONS
DIAGNOSTICS

Next

Select Select Select Select

DIAGNOSTICS DIAGNOSTICS DIAGNOSTICS
C UNWIND MEDIA PARK CUTTER PARK PUNCHES
B
Next Next Next

PRESS
ADVANCE TO DIAGNOSTICS DIAGNOSTICS
UNWIND MEDIA PARKING CUTTER PARKING PUNCHES

Next Next Next

A * If media does not cut, and

locks between drive and buffer,
(tugs between the two), press
Select Select Stop at WAITING FOR
DIAGNOSTICS
B DIAGNOSTICS
RESET BUFFER EPROM VERSION
C BUFFER READY Window,
then initiate a cut.
** When WAITING FOR
Next Next BUFFER READY, only press
STOP if Media Jam occurs.
DIAGNOSTIC EPROM VERSION
RESETTING BUFFER JAxxxx n.n.n

Next Next

WAITING FOR EPROM VERSION

BUFFER READY JAxxxx n.n.n

Next
A
Stop

ONLINE/OFFLINE
NO CASSETTE

Figure A-1 — Diagnostic Menu

A-2 AG12373 Rev. 1

 Index

A E
AIR FILTER CLEANING PROCEDURE .. EEPROM CRC .. 4-31
4-37 end of the image .. 4-7
air filters .. 4-37 English .. 4-4
Audio Alerts .. 4-2, 4-4, 4-8 ENGLISH/METRIC .. 4-2
audio beep .. 4-4 English/Metric .. 4-4
automatic cut .. 4-7 ERRORS .. 4-32
EXPOSURE .. 3-3
B
BUFFER 1 AWARE .. 4-28, 4-29 F
BUFFER 1 CLEAR .. 4-28, 4-29 FLAP 1 CURRENT .. 4-30
BUFFER 1 LOADING .. 4-28, 4-29 FLAP 1 TIMEOUT .. 4-30
BUFFER 2 LOADING .. 4-29 FLAP 2 CURRENT .. 4-30
Buffer Cassette .. 4-7 FLAP 2 TIMEOUT .. 4-30
Buffer Processor .. 4-7
buffer state .. 4-28
Buffer Status .. 4-28 H
Head Punch Margin .. 4-6
HEAD/TAIL PUNCH .. 4-5
C
CASSETTE MODE OPERATION .. 4-29
current setups .. 4-8 I
cut .. 4-4 Image area .. 4-6
CUT IN PROGRESS .. 4-29 Image Offset .. 4-2, 4-8
Cut Trailer LENGTH .. 4-2 Image Spacing .. 4-2, 4-7
Cut Trailer Length .. 4-8 input cassette .. 4-13
Cutter .. 4-24 INSIDE OF IMAGE .. 4-4

D J
DB50 TRANSPORT .. 4-28 JOB AT OUTPUT .. 4-29
default .. 4-8
Diagnostic Park Punch .. 4-24
Diagnostics .. 4-1 K
KEYPAD ABORT .. 4-31

AG12373 Rev. 1 Index-1

Index
L Punch Tray .. 4-38
LIFT 1 CURRENT .. 4-30
LIFT 1 TIMEOUT .. 4-30
limit .. 4-7
LOADING CASSETTE .. 4-29, 4-30
M ROLLER CURRENT .. 4-30
machine idles .. 4-8
Maximum Cassette .. 4-7
Maximum Cassette LENGTH .. 4-2
Maximum Cassette Length .. 4-7
MEDIA AT OUTPUT .. 4-29
MEDIA JAMS .. 4-20
Media Widths .. 4-10
MENU .. 4-2, 4-9
Menu Button .. 4-1
Menu Operation .. 4-1
Menu Options .. 4-2, 4-9
Metric units .. 4-4
MOVING MEDIA .. 4-29
O System Setup .. 4-1
Offset .. 4-5
online processor .. 4-7
ONLINE/OFFLINE .. 4-2, 4-9
output cassette .. 4-7
OUTSIDE OF IMAGE .. 4-5
P
Power switch .. 4-1
processor .. 4-7
PROCESSOR BUSY .. 4-29
PROCESSOR MODE OPERATION .. 4-28
PROCESSOR OFFLN. .. 4-29
punch .. 4-24
Index-2
R
REMOVE CASSETTE .. 4-30
Resolutions .. 4-10
roller cleaning .. 4-33
S
Save Setup .. 4-8
Save Setup No .. 3-4
Save Setup Yes .. 3-4
Save System Setup .. 4-2
Save the Setup .. 4-2, 4-9
saved setup values .. 4-8
SELECT .. 4-2, 4-9
SENSOR TIMEOUT .. 4-31
Spinner Timeout .. 4-2, 4-8
spinner times out .. 4-8
start of the image. .. 4-7
Stop .. 4-2, 4-9
T
Tail Punch Margin .. 4-6
trailer length .. 4-8
TRANSPORT ERROR MESSAGES .. 4-30
TRANSPORT IDLE .. 4-28
U
Units of measure .. 4-2
units of measure .. 4-4
UNWIND MEDIA message .. 4-34
User Setup .. 4-1
AG12373 Rev. 1
Index

V
VOLTAGE HIGH .. 4-31
VOLTAGE LOW .. 4-31

AG12373 Rev. 1 Index-3

Index

Index-4 AG12373 Rev. 1