STEP BY STEP INSTALLATION PROCEDURE FOR

D-CARRIER EPSON (mod. EE)

In the following pages you’ll find step by step instructions how to install
correctly D-Carrier systems based on Epson LCD’s. The instructions
areIvalid both in case of regular and LED systems. Additional information
for LED systems will be supplied on an addendum included at the end of
this presentation. A Noritsu 2301 minilab has been selected to explain the
procedure, however the method explained is valid for any minilab provided
that the D-Carrier installed is based on Epson 1400x1050 LCD matrix. The
procedure is not applicable for D-Carriers featuring Sony 1280x1024 and
Sony 1600x1200 LCD matrix.
 Basic requirements

The following procedure for Epson D-Carrrier requires a Kitinterface SW

version higher than 3.25
The firmware version of the Eeprom installed inside the Control Unit
must be KLCD 4.00 or higher
SW and firmware versions lower than the above indicated are not
suitable.

The monitor resolution must be equal

or higher than the basic LCD resolution
(1400x1050).
A monitor with resolution 1600x1200 is
a suitable device.
 Control Units models B and C

Control Unit Model B Control Unit Model C

The procedure is applicable in case that the D-Carrier System adopts

Control Units models B or C. The versions B and C differ practically
for the fact that the DDSync and I2C boards are included inside the
case in case of the Control Unit model C
 Control Unit Model B

The Control Unit model B features both DDSync and I2C boards, as well as
their connecting cables, external to the Control Unit case. The firmware of
the Eeprom installed inside must be KLCD 4.00 or higher

DDSync

I2C
Cotrol Unit Model C

The Control Unit model C features both DDSync and I2E boards internal.
The wiring connections are therefore simplified. The Control Unit model C
requires an Eeprom with firmware version KLCD 5.00 or higher.

Control Board inside

the case
 Installation steps

The purpose of this presentation is to supply instructions to install

correctly D-Carrier Systems based on Epson 1400x1050 LCD. The
presentation doesn’t cover, or will briefly mention, usual installation
steps as electrical connections, focusing, filter wheel position
calibration etc.
The step by step procedures included are summarized in the following
page:
 Installation steps

1. Kitinterface SW installation
2. Setup configuration
3. Setting the default values
4. Focusing procedure
5. Centering the image of the video board output
6. Pre setting the standard gamma values: 850 - 3850
7. Balancing the exposure times
8. Checking Move 64 file print
9. Calbration of the DelayMultiPrint value and micro movements
10. Pre masking application
11. Uniformity compensation
12. Gamma values fine tuning
13. Final check of the mask uniformity and elimination of the presence of lines after
Gamma values fine tuning
14. Checking black and white saturation
 1 – Kitinterface SW installation

As mentioned above, the

version of the Kitinterface SW
must be 3.25 or higher. After
the SW installation is
completed the Kitinterface
program generates on the
desktop three shortcuts:

• Kitinterface.exe
• Mask.exe
• Piezo.exe
As a difference with respect to the
previous Kitinterface SW versions
no option has to be added to the
shortcuts Kitinterface.exe,
Mask.exe e Piezo.exe.
Once the Kitinterface Sw has been installed a new directory named
Kitinterface is generated. Inside the Kitinterface directory are saved all
the files relative to the D-Carrier installed.
Please note that the extension of the configuration files including all
the setting information is *.ini.

It is now possible to initialize the

SW for the D-Carrier.
 2 - Setup configurations for D-Carrier EE

Once the SW is operative the

page Startup option selection
is visualized on the monitor as
shown at the right side. The
mandatory options to be
enabled are highlighted in red
color. In case that the D-
Carrier is a LED version the
options highlighted in blu must
be enabled as well.
NOTE: The remaining options available on the previous page must
be selected according to the model of minilab. Careful attention has
to be placed when enablying FlipPiezoH and FlipPiezoV parameters.
Usually the above two parameters are standard, however they may
be inverted during the installation. More details are included inside
the section Setting Move 64.
 3 – Setting the default values

The default values need to be set inside the pages Piezo and Epson,
under the Parameter section. To access this page press at the same
time CTRL+SHIFT+F12 after that the program has been initialised.

• The micro-movement pre-set values are not definitive. They must be

properly modified for the system in use by applying the SW Piezo.exe
as it will be explained in the following.

• The figures applied to Epson are fixed. They do not need to be

modified.
 Piezo deafault values

Epson default values

 4 – Focusing procedure

The focusing menu differ according to the minilab. In any case the best
results can be achieved by setting the minilab zoom value close to its
maximum magnification value. With this device the pixels are easily
detected. To adust the focus usually it is sufficient to open the minilab
shutter to detect the LCD light projection on the paper deck plane.

NOTE 1.
In case of D-Carrier featuring a filter wheel it is necessary to select the
geen filter and to open the D-Carrier head shutter before proceeding.
NOTE 2.
In case of D-Carrier LED enable the output LedR, corresponding to the
red LED’s, under menu Test (there is no shutter on LED D-Carriers).
 A D-Carrier featuring a filter wheel
is shown at the left side only for
explanation purposes. The
procedure for LED version is
exacly the same.

The image shows the adjusting

screws for focusing and the
blocking screws to be tightened
after the focusing procedure has
been completed. The focus must
Adjusting screws
Blocking screws
be as sharpen as possible on all
the area of projection of the LCD
on the paper deck.
5 – Centering the image of the video board output

The Epson Test option is used to

center the image out of the video
board to the LCD matrix.

It is better to use a very small

enlarging factor to complete this
setting. It is necessary to expose an
image on the paper deck as it has
been done for the focusing procedure
(see .1 and .2 on the Focusing
procedure paragraph)
The aim of the procedure is to make
visible the four white perimetral lines of
the file projected. To shift the image
press the arrow key on the PC
keyboard. The image is shifted in
digital mode bt the I2C board.

Warning: to get available the full area

of the LCD it is necessary to shift the
image until one shift in excess on top,
bottom, right and left makes one or
more lines to disappear Lines that must be made visible on the
focus meter screen. Probe located on the
paper deck
Once the image is centered correctly it is necessary to save the setting
done by pressing the key enter. Pressing enter the Epson option is quit
as well.

The setting above modifies

the Left and Top values
inside the Epson option, on
the Parameter page.

The nominal values

according to the video board
used are:

GE force 4200
Left= -20 Top= -72,

Ati Radeon 9600

Left= -24 Top= -72

6 – Presetting the standard gamma values 850 - 3850

Before beginning to work on the photographic

section it is necessary to pre set the white, black
and contrast levels compatible with the Epson
LCD device.

The appropriate values for white and black

levels are respectively:

White: 850 (lowest point)

Black: 3850 (highest point)
White
The contrast level is roughly determined by the
white and black level values.

At the end of the fine tuning calibration the white

Black
and black values are usually close to the pre set
levels.
 7 – Balancing the exposure times

Before printing it is necessary to select a paper size which includes the full
LCD projection area, leaving at each of the four sides a white border.

It is suggested to set the minilab zoom value at a 70% level with respect to
the maximum magnification.

After this is done it is possible to make a rough pre balancing of the R,G,B
exposure times in order to get a suitable print out of the Black&White file.

A suitable prints must feature a good white (with density close to the
unexposed paper) a well saturated black and an average grey color
balanced central rectangle.
The Black &White Setup file to be printed is
located on the section Test Print.
To balance the colors of the
picture modify the Master
Balance RGB exposure
times, on section Photo
Channel,
 8 – Checking move 64 file print

By printing the Move 64 file it is

possible to check whether the
direction of the micro movements is
correct

In case it is necessary to invert the

direction of micromovements from
horizontal to vertical or vice versa go
to the SW starting setup page.
Re start the D-Carrier program and
change the options
FlipPiezoV and/or FlipPiezoH
Example of correct micro
movement settings

Mov. Hor. 0

Mov. Hor. 1

Mov. Hor. 2

Mov. Ver. 0
Mov. Ver. 1
Mov. Ver. 2
A wrong micro movement
setting results on a twin line,
horizontal or vertical as shown Example of wrong vertical
micro movement setting
inside the cyrcles. Note that
the red arrow must be located
on top left side in order to
detect the direction of the
micro movement (horizontal or
vertical)

Example of wrong horizontal

micro movement setting
9 – Calibration of the DelayMultiPrint parameter and micro movements

An optimum calibration of the micro movements

is mandatory to get optimum print results to
avoid the presence of a visible background net
generated by the LCD pixels

The file to be printed and then used to

optimize the micro movements is located
on the TestPrint section. The file name is
MicroMoveAutoTest. It has to be printed with
the parameter Resolution Enhance enabled.

Resolution Enhance is to be enabled from

now on unless clearly stated.
The aim of the procedure is to make invisible the LCD pixels on the
pictures. The task is done in two steps:
A - phasing the DelayMultiPrint, section General – Parameter
B – calibration of the micro movements by the Piezo.exe software

A – Setting the DelayMultiPrint value

Modify the DelayMultiPrint value,

section General – Parameter, to
put in phase the micro
movements and the sub images
generated with the R,G,B,
exposure times
 Mov.V 2 Mov.V 1 Mov.V 0

Mov.H 0 The aim of the procedure is to get

the same density of the horizontal
and vertical shifted lines.

Mov.H 1 If H 0 and V 0 are darker, the

DelayMultiPrint value must be
decreased (or increased).

Mov.H 2
If H 2 e V 2 are darker, the
DelayMultiPrint value must be
increased (or decreased).

Note that both the three bars H and V have different density and uneven
color in case that the DelayMultiPrint parameter is heavily unbalanced.
Delaymultiprint value to be adjusted finely

The image at the left side shows

an example of a wrong
DelayMultiPrint value setting.
Note that until the setting is not
done at the optimum value the
dots internal to the rectangle
show different density and/or
color.

The range of the nominal values

of the DelayMultiPrint parameter
is 0 to approx 80.
 B – Calibration of micro movements

This procedure requires the program Piezo.exe on the desktop. After that
the DelayMultiPrint parameter has been properly set it is possible to scan
the print generated by the Micro move auto test just calibrated. After the
program is active select the scanner used and acquire the image.

Scan the image by framing the

surface to be acquired on the
grey external frame. The
rectangular area to be scanned
must be included inside the
dark borders of the print.
The acquisition must be done to get a 2 to
3 Mb file. For this purpose it is necessary
to modify the dpi value on the scanner
setting menu in order to get the figures
above reported.

Once the program has completed automatically the 8

steps to locate the position of the dots, it generates a
window that shows the values Current piezo input
(values available on Parameter – Piezo H) and New
Piezo Input (values generated after scanning). The
last ones have to be noted down and copied on the
3xcolumn Parameter – Piezo H.
 The above scanning step has to be
repeated both for the vertical and
horizontal image

In the second case the New Piezo Input

values are to be written down and typed
on the x3 column Parameter - Piezo V.
 Though the SW is offering for an automatic
update of the parameters it is suggested to
note down the values and to copy them after
the program Piezo.exe is closed.

This procedure is suggested to avoid that the file may not be

overwritten.The refreshing of the .ini file in fact doesn’t happen in case
that both Piezo.exe and Kitinterface.exe are open at the same time.
The procedure has to be repeated until the values Current Piezo Input
and New Piezo Input differ for less than +/- 10 digits.
The procedure above refers to the case of 9 mico movements (resolution 3)
The same procedure has to be done in case of 4 micro movements (resolution 2)
 10 – Pre masking application

After a suitable calibration of the

micro movements has been
completed the next step is to
compensate the insufficient
intrinsyc diffusion homogeneity of
the LCD device.

This is achieved by the Diffusion

Test procedure, Test Print section.

NOTE: the Diffusion Test must be

printed all times with level
parameter set at –1 and Resolution
Enhance enabled.
A print made by an Epson LCD, with
no compensation, shows a darker
dark top right area
area on the top right corner (the
print has to be looked at with the red
arrow located on the top left side).
The pre masking procedure is aimed
to compensate at a considerable
extent the large difference of density
before running the usual masking
procedure.

Scan the uncompensated image by the Mask.exe program available on the

desktop
NoiseMidLevel enabled Epson LCD

Select Epson
(1400x1050) LCD on the
page shown at the left
side.

The NoiseMid L must be

enabled all times

Select the scanner

model used (Select
Source)

Contrast mask disabled For pre masking the resolution is

to be fixed at 600 DPI
Before acquiring the image modify, if necessary, the default scanner
balancing values:
• Gamma = 1 (linear)
• High light = 255
• Shadows = 0
• Contrast mask: disabled
The surface to be acquired must be selected (framed) exactly at the outer
limits.
Set at 600 dpi the fixed resolution (only for the pre masking).
Start scanning by the key acquire
The image has to be
rotated, if necessary, until
the red arrow is positioned
on the top left corner (see
at page 39). Press the key
Premask. The SW
generates automatically the
pre mask file for he LCD in
use. The SW calls as well
for the next step: to save
the file generated.

Key to press to create

the pre mask
 The procedure is
completed after having
saved the file generated
inside the Kitinterface
folder.

The name of the file

needs to have a format
premask[minilabname], in
our case:
premasknoritsu2301.

It is now possible to shut down the program Mask.exe by the key Close.
To enable the pre mask compensation file inside Kitinterface.exe enter the
section Parameter – Epson – MaskVMID 0, select and apply the file saved

As a first attempt, keep valid the other defaults values. After having pressed
Accept Setup it is possible to print the first Diffusion Test

Clicking on the
Mask key it is
necessary to load
the file just saved
inside the directory
Kitinterface
i.e. premask
[minilabname]
According to the photographic results of the first Diffusion Test it is
possible to modify some values of the pre mask parameters to improve
as much as possible the density uniformity of the print just done.

MASK VMID PERC: this parameter represents the percentage of

application of the pre mask. By increasing this value (even above 100)
it is possible to reduce the density of the area usually darker, on the top
right side, and increase the density on the opposite diagonal.

MASK VMID GAMMA: this parameter can be modified in case that the
diffusion test shows a lighter or darker central area. It makes even the
density on the central area of the diffusion test print.

MASK VMID LIMIT: It need to be increased in case that very light spots
are detected on the middle and top right area (which is usually the
darker one).
 Example of a lighter
central area. It requires
the Mask VMID
Gamma value to be
decreased

Example of light bottom left

area and dark top right area. It
requires the Mask VMID Perc
value to be increased
 Light spot on the right area. It
requires the Mask VMID Limit value to
be increased

Parameter values other than the ones indicated on the previous pages i.e
Mask VMID OUT, Mask VMID IN and Mask VMID LEVEL must be kept at
255.

The results of any change of the Mask VMID Perc, Mask VMID Gamma
and Mask VMID Limit has to be checked by printing a further Diffusion
Test. The procedure has to be repeated until getting the best uniformity
printing results in terms of uniformity and density on the full printed area.
 10 a – Pre masking II procedure

The Pre masking II procedure can be applied instead of the standard

pre masking procedure described above.

The Pre masking II procedure allows to exploit better the dynamics of

Epson LCD’s signals. The possible signal saturation effect that
sometimes can be detected after several masking steps with the
standard procedure is practically avoided.

The Pre masking procedure can be applied in case that Mask.exe

SW version 2.6 or higher are installed. The Procedure is made of two
steps, combined. This generates a better file as a starting point to
apply the next uniformity procedure. The parameters Mask VMID
Perc, Mask VMID Gamma and mask VMID Level are not necessary.
Proceede as the normal pre masking procedure shown on the previous
paragraph, the only exception is to use the command Premask II instead of
Premask

As a difference with respect to the

Pre masking step
number
Give a name to the pre
masking file before
generating Premask II
normal pre masking procedure, this
new procedure requires to name both
the file and step done before
proceeding further with the key
Premask II. Two files are automatically
generated in the Kitinterface directory,
respectively
mask_[filename]_0.noise mask_[filename]
_0.bmp.

Command to use to
create the Premask II file
The file to be loaded on the Parameter – Epson – Mask has extension .bmp

Load the file mask_

As a difference compared to the [filename]_0.bmp
normal procedure the values:

• VMID Perc is set to 0

• VMID Gamma is set to 100

• VMID Limit is set to 0.

These values are fixed. Don’t

change them
As in the normal procedure the
remaining VMID values are fixed at VMID Perc = 0
255. VMID Gamma = 100
VMID Limit = 0
As said above the Premask II procedure is made of two steps. It is
therefore necessary to scan again the picture printed after the first
pre-compensation is done and repeat the Premask II pre-
compensation step taking care to remember to type for the second
pre-compensation step 1 on Mask Step. The SW combines
automatically the two files generated and save them into the
Kitinterface folder. The file to load to Parameter – Epson – Mask is
mask_[filename]_comb.bmp ( instead of mask_[filename]_0.bmp).

After the pre-compensation procedure has been completed the

diffusion mask can be created.
 11 – Uniformity compensation (Diffusion Test)

After having completed the pre-

masking procedure go on to the
next step, i.e. the uniformity
compensation. This step allows to
get a perfect uniform Diffusion Test
print, both in color and density, by
removing all the vertical lines. Use
again for this purpose the Mask.exe
file available on the desktop and the
file Diffusion Test (Resolution
Enhance enabled).
The last good Diffusion Test made by he pre-masking procedure is
acquired using the program Mask.exe taking care to leave a small
white border on each of the four side of the image so that the scanner
reads the complete projected area generated by the LCD.

The resulting file after the acquisition

is made should have a weight of 70
to 90 Mb. As it was done for the pre-
masking procedure the scanner
parameters must be set to:

Gamma = 1 (linear)

• High Light = 255

• Shadows = 0

• Contrast mask disabled

 Corners limiting the
rectangular image

The acquired image is

rotated until the red arrow is
located on the top left corner
(see at pag. 39), frame the
image exactly at the four
limiting cornersi (Top Left,
Top Right, Bottom Left,
Bottom Right). Press the key
Process to create the
compensation file.
On the box Optic type the name of the compensation file just created (usually
the lens type in use e.g.. ZoomNoritsu2301). The next box refers to the
number of the step done. In the box MarginH, MarginV, ShiftH e ShiftV type
the value of the margins available in Photo Channel, in case that the lens
used to create the diffusion mask is a fix focus lens and it has been necessary
to introduce margins to get the perimetral white border for the Diffusion Test.

Margins
Mask name
Number of Mask Step

List of the Noise Masks

saved and number of
steps

Save the file generated by the Save Noise

command. The name of the file just
created is visualized in the box Noise List.
The file is located inside the Kitinterface
folder.
Close the program Mask.exe and load the
compensation file to the program
Kitinterface.exe, Technical Setup option,
box Mask 0. The value of the percentage
has to remain fixed at 200.

Value of
Selection of the file percentage of
generated mask application
noise_Name_0.noise at 200
inside
Kitinterface folder
 Noise Correct and
Resolution Enhance
must be ever enabled
from now on

Print again the Diffusion

Test, enabling from now on
the option Noise Correct so
that the file loaded on
Technical Setup, box Mask
0 is operative.
Repeat the procedure to create a second diffusion mask, typing the
same name under the option Optic, however type 1 on the Mask Step
box (corresponding to the second masking step). Save the file by
Save Noise. In the Noise List box are listed both the file just
generated and the previous one. Select both and process them
together by the Combine command. A new file named noise_[Nome].
comb is generated. Load it again on Technical Setup. From now on
the name of the file to load for the next steps is the same.

The procedure is to be iterated until the final print has good uniformity
without evident vertical lines.

NOTE: Be careful to combine all the previous files by the Combine

command noise_[name]_[number].noise avoiding to include noise_
[nome].comb.
 12 – Gamma values fine tuning

File Simple Gray Scale that

can be used to calibate he
After having obtained a good gamma values

uniformity on the last difusion test

make some prints to check the
white, black and contrast results. A
suitable reference file to be printed is
Test.bmp, inside the Kitinterface
folder, or the Simple Grey Scale,
located inside the Test section.
 Contrast values fine tuning
Low contrast Gamma High contrast Gamma

ML
M
MH

To increase the contrast of the pictures increase the slope of the

gamma curve by moving up the ML point (this is achieved by
decreasing its value) and lowering the MH point (by increasing its
value)
 Badly shaped Gamma curve

In case that MH and ML are modified

too heavily it is necessary to adjust the
extreme points H and L to get a smooth
curve with only three slopes.

Gamma curve with

nominal values
 Black value adjustments

To increase the density of the darker

steps of blacks on the grey scale
increase the slope of the upper
portion of the Gamma curve (Low
tones). It is possible to increase
slightly its maximum value (usually
3850) to increase the maximum
density.

Maximum signal level

ML and L values to corresponding to the
decrease to increase blacks on the prints
the density of the blacks
 White values adustments

To increase the density of the first

low density bars on the grey scale
increase the slope of the Gamma
curve in correspondence to the high
tones (lower portion of the gamma
curve). It is possible to increase
slightly also the value of the minimum
point (usually set at 850)

Minimum signal level

MH and H values to decrease corresponding to the
to increase the density of the white of the prints
light grey bars
 13 – Final check of the mask uniformity and elimination of the
presence of lines after Gamma values fine tuning

After having adjusted the gamma values,

and mainly if large modifications have
been made, it is possible that some
vertical lines having uneven density may
appear again. It is sufficient to process
one or two additional steps of the
diffusion test procedure to get rid of them
(see par. 11).

Some vertical lines are visible after having

adjusted the gamma values. They can be
removed by processing one or two
additional diffusion masks steps
 14 – Checking the saturation level of white and black

The last step is to check the saturation level of the white and black
signals. This step is done by using the option Preview and the monitor
set at 1600x1200 resolution.

Load first the Black Frame file (Resolution Enhance disabled). Check on
the screen whether totally white areas are present (if it is so it means that
the blacks are saturated). Exit from the Preview option by pressing three
times Enter. Check for saturation for all three R,G,B exposures.

In case of saturated areas go back to the Gamma option and decrease

slightly the maximum value (normally set at 3850) and check again for
saturation. Repeat the procedure until no saturation effect is present.
A similar check has to be done for saturation effect on the white signals.
Use the file Uniform Color Test with values set at 255, 255, 255 (digital
white).

In case of presence of saturation black areas will appear. To get rid of them
increase slightly the minimum value of the Gamma curve (usually set at
850) until the saturation effect disappear.

Uniform Color Test set at 255 255 255

Black Frame i.e. Digital white