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Copyright © 2004, Ioline Corporation, All Rights Reserved
Printed in the United States of America
Text Revision 1, PN 107204
February, 2004
All Trademarks Are The Property Of Their Respective Owners
USING YOUR
100 System Cutter
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Ioline
A. Dust Cover
B. Carriage Rail
C. Drive Shaft Marker
D. Platen
E. Carriage
F. Idler Wheel
G. Pinchwheel
H. Drive Shaft Segment
J. Pinchwheel Lever
K. Keypad
Figure 1. The Ioline 100 System Cutter.
B
K
J
G
A
D
E
H
C
F
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Ioline
TABLE OF CONTENTS
THE 100 SYSTEM CUTTER .................................... 4
SAFETY AND PRECAUTIONS ................................ 4
INSTALLATION ........................................................ 5
Unpack the Cutter...............................................5
Assemble the Cradle ..........................................5
Attach the Cutter.................................................5
Prepare the Area ................................................5
Connect the Cutter to the Computer ....................5
Power On ...........................................................5
Installing the Ioline Control Center .......................5
OPERATION ............................................................. 6
Keypad Controls .................................................. 6
The Ioline Control Center .................................... 7
Changing System Settings..................................8
Menu Bar Features.............................................8
Screen Menu Options .........................................8
Cutting a Design................................................. 10
General Guidelines...........................................10
Power On .........................................................10
Loading the Material.........................................10
Aligning the Material and Pinchwheels on the Optional
Stand ..........................................................10
Adjusting the Pinchwheels ................................ 11
Locking the Pinchwheels Off of the Platen ......... 11
Installing a Blade and the Blade Foot ................12
Installing a Blade Holder or Pen ........................12
Adjusting Blade Exposure and Force................12
Sending a Cut File to the Cutter ........................13
Pausing Cutting ................................................13
Canceling a Cut................................................13
Suggested Settings ..........................................14
Guidelines for Plotting Pens..............................15
How to Pounce .................................................16
Stencil Cutting ..................................................16
COMMUNICATION TESTING.................................17
Communication Test .........................................17
Testing the Cutter Serial Port ............................17
Testing the Computer Serial Port ......................17
TROUBLESHOOTING............................................ 18
Troubleshooting Chart.......................................18
LED Codes ......................................................19
Troubleshooting the Parallel Port.......................19
ROUTINE MAINTENANCE .................................... 20
Replacing the Blade .........................................20
Cleaning the Drive Shaft ...................................20
Calibration........................................................20
END NOTES ........................................................... 22
Getting Help .....................................................22
The FCC Wants You to Know.............................23
Your Comments Are Requested........................23
Customer Service.............................................23
Limit of Liability Statement ................................23
GLOSSARY ............................................................ 24
INDEX ..................................................................... 26
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THE 100 SYSTEM CUTTER
Thank you for purchasing an Ioline cutter. To make designs, you also need a
computer with design software. After you have used the design software to
create a design, you will send it as a cut file to the Ioline cutter. The cutter will
receive the file and cut the design. Check the following items before you
begin making designs:
• The design software, which helps you design, must be loaded into the
computer according to the installation instructions. If you have any questions about the computer or the software, you will need to call the dealer.
• The computer sends a cut file to the cutter to create the designs. The
computer must be assembled and installed correctly before you connect
it, by cable, to the cutter.
• The cutter will cut the design exactly as you have designed it. The design
will be cut from the material that you have loaded into the cutter.
• There is a specialized software program that comes with the cutter called
the Ioline Control Center. You can load this software utility into a PC
compatible computer and use it to adjust cutter settings and perform
system diagnostics. Most design software provides drivers for Ioline cutters. Contact the maker of your design software if you need assistance
with drivers.
SAFETY AND PRECAUTIONS
Please read these safety guidelines before beginning operation of the cutter.
The cutter uses a very sharp blade when cutting. The parts can move quickly.
Always observe the following safety precautions:
• Do not allow the material to become suddenly taut between the cutter
and a roll of material during cutting. A service loop of unrolled material
is required for problem free operation. Using the Autoloop function (enabled in the Control Center) will create the required service loop by
gently pulling a set amount of material from the roll before cutting.
Ioline recommends using the Autoloop function when cutting on a roll
of material.
• Do not try to repair the machine without factory authorization. Only
qualified service personnel should attempt any disassembly or access to
internal components. If external mechanical adjustments are necessary,
turn off the cutter and disconnect it from all power sources (both the
computer and the wall outlet).
• Be careful with hair, jewelry, or loose clothing near the cutter. They can
become caught in the mechanical parts.
• Never move the carriage by hand. Use the Arrow keys and let the machine do it.
• Keep hands away from the carriage when the cutter is in operation. The
carriage will automatically move to its right end position when the power
is turned on.
• Be careful when lifting the cutter. Hold the bottom surfaces of the cutter
to lift or move it.
• Keep fingers away from the drive shaft when the cutter is in operation.
• Use caution when changing a blade in the blade holder. See the Routine
Maintenance chapter of this User Guide for the recommended procedure.
• Be careful when handling the blades. They are sharp and could cause an
injury if mishandled. Although the blades are made of an extremely hard
material, they are brittle and can break if dropped or mishandled.
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INSTALLATION
Unpack the Cutter
Warning: Do not lift the cutter by the plastic end covers, the dust cover,
or the carriage rail. This may permanently damage the cutter. Use the
bottom surfaces of the cutter to lift or move it.
Carefully remove the cutter from the box and place it on a flat-stable surface.
This procedure requires two people. Save all packing materials and the box.
Check the packing list to ensure that all of the accessories are present.
Assemble the Cradle
Assembly directions and hardware for the cradle are included in the accessory
kit. Assemble the stand and attach the cutter according to the directions before attempting to cut.
Attach the Cutter
Attach the cutter to the stand (see above). The directions are included in the
accessory kit. When using a stand, make sure that the media rollers are properly installed and that the cutter is facing the correct direction.
Prepare the Area
Prepare a large clean area to work. Make sure the floor is clean and clear of any
obstacles. Pull the cutter away from the wall so the material can move freely.
Connect the Cutter to the Computer
Note: Make sure the computer and the cutter have the power turned
off. Ioline recommends using a surge protector power strip for the
design cutter and the computer.
Connect the cutter to the computer with either a parallel or a serial cable. A
parallel cable is provided in the accessory kit. Standard serial cables are
available at a computer store or from Ioline if it is necessary to connect the
cutter to a serial port on the computer. A serial connection to the cutter is
required with Windows 3.1 or DOS based software.
The parallel port receptacle on the computer is a 25 pin female receptacle.
The serial port is either a 9 pin or 25 pin male receptacle. If the computer has
a 9 pin serial port, a 9 to 25 pin adapter is necessary. Adaptors are inexpensive
and available at computer stores or can be ordered from Ioline. The cutter will
not function if a serial cable is connected to a parallel port.
Select the correct port in the design software or the Control Center after the
cables are correctly connected to the computer and cutter. Consult the design
software manual or the dealer for further information.
Important Notes:
1. Always turn off the power to both the computer and the machine
before connecting any cables. This will protect the equipment and
reset the cutter if changing between parallel and serial communication.
2. If connected to a parallel port, an LPT port designation (i.e. LPT 1,
LPT 2, etc.) must be selected. If connected to a serial port, a COM
port designation (i.e. COM 1, COM 2, etc.) must be selected. The
choice of a port for the cutter will depend on the ports being used by
other devices on the computer. Consult with the dealer if a port is
not available.
Power On
Turn on the computer and the cutter to make sure they work. The cutter power
switch is located next to the power cord on the back. The carriage will move
toward the keypad side of the machine when the power is turned on. Keep
hands and loose clothing away from all moving parts of the cutter. The red
LED on the front panel will light when the start-up process is finished.
Installing the Ioline Control Center
The Control Center is an interface for adjusting parameters to optimize cutter
performance. The cutter comes with a CD-ROM which has the Microsoft
Windows® 95, 98 and NT (3.51 or greater) version of the Ioline Control Center
program.
1. Turn on the power to the computer and start Windows®.
2. Insert the Ioline CD ROM into the CD ROM drive (usually D:)
3. Select the Start button.
4. Choose Run.
5. Type D:\SETUP (substitute the correct letter if the CD ROM drive letter is
not D:) and Click OK.
6. Follow the instructions that appear on the screen.
7. Consult the Operation chapter of this manual for details on using the
Ioline Control Center software.
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Figure 2. The Cutter Keypad.
OPERATION
KEYPAD CONTROLS
The keypad allows access to the main cutter functions.
Start/Stop
The Start/Stop key connects or disconnects communication between the computer and the cutter. If the Start/Stop key is pressed
during cutting (Stop mode) the machine will stop when the current vector is finished. The Arrow keys are active when in Stop
mode. When the Start/Stop key is pressed again, (Start mode)
cutting will resume exactly where it stopped.
START green light Arrow keys inoperable, cutter
online (ready to receive instructions).
STOP red light Arrow keys operable, cutter offline
(not ready to receive instructions).
Arrow Keys
Pressing the Arrow keys moves the material back and forth or the
carriage from side to side. The arrow keys will not work unless the
cutter is in Stop mode (see Start/Stop above).
Figure 3. Origin Point.
Note: Design software usually refers to the origin as “lower left”
because it is the lower left corner of a design. Because the cut is
usually oriented as shown, it is physically on the right side of the
cutter.
Speed
Use the Speed knob on the front panel of the cutter to adjust the
speed. Turn the knob clockwise to increase the speed, or counterclockwise to decrease the speed. Set the speed according to the
type of cutting and material being used. See the Cutting a Design
section of this manual.
Force
Adjust the force by using the Force knob on the front panel. Turn
the Force knob clockwise to increase the force exerted on the
blade. See the section on Cutting a Design for the recommended
settings. The range of force available at the knob is adjustable in
the Control Center. The available range is 1 - 400 grams.
Note: Using too much force can cause excessive drag, damage
the blade, or tear the material.
Set Origin
The Set Origin key sets the initial origin or starting position for
the design. It is best to set a new origin before cutting each design.
If a new origin is not set before sending a file to the cutter, the
cutter will begin at a point determined by the previous cut file.
The software may give the option of selecting this ending point.
The cutter will then treat the new file as a continuation of the
previous cut. This will affect the repeat function. Refer to the
Repeat section below. To set a new origin, make sure the cutter is
in Stop mode with the red light on. Use the Arrow keys to move
the pen or blade to the intended origin of the cut, then press the Set
Origin key. The cutter will then accept cut files.
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Test Cut
This button will cut a test pattern to help determine the proper
force (for knives) and blade exposure for cutting designs. The test
cut will also show the effect of the blade offset and overcut settings in the Control Center. See the section on Cutting a Design
for details on adjusting force and blade exposure. The Control
Center section has details about blade offset and overcut.
1. Make sure that material is loaded in the cutter and that the
blade holder is installed in the carriage. Position the blade over
the material near the right side of the cutter.
2. Check for the red light. Press the Start/Stop key if it is not on.
3. Press the Test Cut key for one second. The cutter will cut a
small test pattern consisting of a circle within a square.
4. Adjust the force and blade exposure up or down with the Force
knob and the blade foot. Repeat the test cut until the desired
line quality is obtained. See the section on Cutting a Design
for details on adjusting force and blade exposure.
5. Successive test cuts will be automatically aligned to the left of
the last test cut.
6. If the Test Cut key is pressed for three seconds the cutter will
cut a 1.9 in. x 7.1 in. pattern.
Repeat
Pressing the Repeat key will generate one copy of the most recently created design. The cutter must be in Stop mode (red LED)
to use the Repeat key. To start the cut in a new location, move the
blade to a new position with the Arrow keys before pressing the
Repeat key. Repeat will do the following:
1. Individual files are repeatable until the Set Origin key is pressed
and any new data is sent to the cutter. This includes updating
settings with the Update Display function.
2. If cut files are sent without setting an origin between them, they
will be stored in memory continuously as if they were one file.
This allows the user to repeat multiple files as a single group.
Pressing Repeat will cut all files sent since the last origin was
set (as long as the buffer size is not exceeded, see below).
3. If the file(s) sent exceed the capacity of the buffer (1 megabyte)
before an origin is set the repeat function is disabled. This
feature allows the cutter to handle files of limitless size. When
the buffer has overflowed it no longer holds a complete file so
repeat would produce unpredictable results.
Note: If an origin is not set between files, two possible unintended
results can occur: if the combined cuts do not exceed the buffer,
repeat will cause them all to be recut or, if the combined files
exceed the buffer size, repeat will be disabled.
THE IOLINE CONTROL CENTER
The Ioline Control Center is a utility program that does three things:
• It allows adjustment of settings to tailor output from the computer.
• It allows a completed cut file to be sent to the cutter.
• It includes several diagnostic tests for troubleshooting.
Note: To avoid communication port conflicts, do not simultaneously
run more than one application that is communicating with the cutter.
Figure 5. Control Center Main Menu.
Figure 4. Control Center Setup Screen.
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Changing System Settings
A variety of settings are adjustable to fit specific needs:
• The cutter must be in Start mode (green LED on) when changing system
settings. Press the Start/Stop key and make sure the green light is on
before changing any settings.
• The Screen Menu displays the primary settings that are adjustable. The
Menu Bar contains utilities and less common cutter settings.
• The selected changes will be in effect only after one of the Send Settings
buttons is pushed.
Note: The design software may be able to override the Control Center
settings. Check to see if it has by pressing the Update Display button
before and after a cut is completed. If the settings change, use the
design software to modify cutting parameters.
Menu Bar Features
The Ioline Control Center provides comprehensive help files to explain the
functions of the software options. Below is a brief summary Menu Bar items.
File
Send Cut File Send a cut (.plt) file to the cutter.
Open Settings File Restores saved settings files.
Save Settings As Allows user to save settings files.
Exit Exits the Control Center program.
Setup
Cutter Setup Allows user to select the correct cutter model.
Port Setup Allows user to select the communications port.
Display
Cutter Settings Allows user to view current cutter settings.
Factory Defaults
Allows user to view and restore original factory settings.
ROM Version Displays installed ROM version.
Memory Buffer Displays installed memory buffer size.
Blade Status Displays whether or not the blade holder is installed.
Options
Filtering Allows user to toggle Filtering on and off.
HPGL Setting Allows user to select HGPL language.
Install New Firmware
Installs new firmware into the cutter.
Calibrate
Calibrate Cutter Allows user to calibrate cutter.
Test
Serial Test Allows user to test serial communications.
Computer Port Test Allows user to test computer port.
Cutter Port Test Allows user to test cutter port.
Help
Contents Lists contents of help files.
About Provides Control Center version information.
Screen Menu Options
Measurement Units
English or Metric units are available when adjusting settings.
Panel Size
The Panel Size is the maximum area the cutter can use for cutting. The factory
set (and maximum) X-axis panel length is 838 inches long (2129 cm). The
maximum Y-axis panel size depends on the machine width. The material
moves along the X-axis; the carriage moves along the Y-axis. When cutting
on a Cut Sheet the panel values should be adjusted to match the sheet size.
Scale
The factory-set Scale is 100%. The cutter will produce a cut in the exact size
of any cut file that is sent. If the scale is 50%, the cutter will produce a cut that
is half the intended size. The scale of the cutter can range from 1% to 999%.
Note: Both X and Y axes are set independently.
Autoloop
Warning: Autoloop default is off. Do not allow the material to become
taut when using a roll of material with Autoloop disabled. Manually
create and maintain a service loop in the rear.
With Autoloop enabled the cutter will create a service loop of material at the
beginning of the cut and whenever necessary during the cutting process. The
factory setting is 30 inches (76.2 cm), but the loop size is adjustable. Disable
Autoloop when cutting short pieces of material.
Special Features
See the sections, How to Pounce and Stencil Cutting, for details on using
these features.
Pounce - The Pouncing feature will make a series of holes for transferring a
pattern to a flat surface. Special pounce tools are required. The hole size and
spacing is adjustable. See Cut and Blank below for more details.
Tag Board Cutout - Tag Board Cutout is for cutting stencil material (tag
board). A standard blade holder and blade is required. An intermittent cut is
created so that the stencil stays in place during cutting. See Cut and Blank
below for more details.
Cut - The Cut value is the length, in thousands of an inch (mils), that the blade
will cut when cutting the segmented line for pouncing or tag board cutout.
The default length is 40 mils (.04 inches) for pouncing and 2000 mils for tag
board. The maximum is 4000 mils for pouncing and 5000 mils for tag board.
The minimum is 40 mils for pouncing and 50 mils for tag board.
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Blank - The Blank value is the length, in thousands of an inch (mils), that the
blade will not cut when cutting the segmented line for pouncing or tag board
cutout. The default length is 600 mils (.6 inches) for pouncing and 60 mils for
tag board. The maximum is 4000 mils for pouncing and 5000 mils for tag
board. The minimum is 40 mils for pouncing and 50 mils for tag board.
Update Display
Note: The design software may override the Control Center settings.
Check to see if it has by pressing the Update Display button before and
after a cut is completed. Check the cutter setup screens in the design
software to make adjustments if necessary.
Selecting this option will update all of the screen values with the current
settings stored in the cutter. For example, using Update Display after a blade
is inserted in the carriage will update the Control Center and allow access to
the Tag Board Cutout parameters.
Send Settings to Cutter: Temporary
After changing any setting, the changes must be sent to the cutter. If Send
Settings to Cutter: Temporary is selected, all of the displayed settings will
be used for the current session. When the cutter is turned off these settings will
be lost and the previous permanent settings will be in effect when the cutter is
turned on again. If any settings are changed, repeat the Test Cut procedure to
ensure that the results are satisfactory.
Send Settings to Cutter: Permanent
If Send Settings to Cutter: Permanent is selected, all of the displayed set-
tings will be sent to the cutter and will be saved for all subsequent sessions,
even after turning off the cutter.
Acceleration
The factory set acceleration is 1.0 g. The acceleration setting determines how
quickly the pen or blade will reach full speed when starting or ending a cut
line. Use the Control Center to change the setting within a range of 0.1 to 1.0
g. For long or difficult cuts, or when trying to achieve maximum accuracy, use
lower acceleration settings.
Up/Down Delays
The factory set up and down delays are both 0 milliseconds (ms) or 0 thou-
sandths of a second. The delay setting controls the amount of time, in milliseconds, the cutter pauses after lifting or lowering the pen or blade. Under
normal circumstances this setting will not require adjustment. Thick material
may require a delay of 25 to 50 ms.
Force
The minimum and maximum force settings for the Force control knob on the
keypad is adjustable. The factory set and default minimum is 10 grams. The
maximum value is 400 grams. The default maximum force is 200 grams.
Blade Overcut
Blade overcut is the distance the blade travels beyond the end of a cut. Blade
overcut ensures that each cut actually reaches the point where one cut line
meets and slightly overlaps another cut line. This ensures that all of the pieces
of the design will be cut completely, with no undercuts. The factory set blade
overcut is 10 mils. This setting is ignored when a pen is installed in the
carriage.
Blade Steering Arc
Blade Offset
The blade offset is nominally 15 mils (or 47 mils on some blades), but specific
blades can vary within a tolerance. For close work, making some tiny test cuts
at several settings, then picking the best one, can improve accuracy. This
setting is ignored when a pen is installed in the carriage.
Minimum Angle
This is the minimum angle for which the cutter blade will perform a blade
steering arc. For a very tiny cut, a small or zero angle can be specified. For
larger cuts a greater angle of up to 45 degrees is best. The factory set value
works well with most files. Adjusting this setting for small cuts may improve
performance. This setting is ignored when a pen is installed in the carriage.
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CUTTING A DESIGN
In most cases the design files are sent directly from the design software to the
cutter. If you are cutting material such as Thermo-Flock, or Thermo-Film for
transfer to fabric, you must “Mirror” the image in your design software before
sending to the cutter. If necessary, use the Ioline Control Center software to
send design files, adjust settings and test cutter communication.
General Guidelines
1. Never let the material become suddenly taut between the cutter and a
roll of material during cutting. A service loop of unrolled material is
required for problem free operation. Ioline recommends using the Autoloop function (enabled in the Control Center). It will create the required service loop by gently pulling a set amount of material from the
roll before cutting. Autoloop default is off.
2. Use the Paneling feature in the design software for long designs. Panel-
ing will restrict the length of any X-axis move. Ioline suggests an X panel
size of 10 to 20 inches with no panels greater than 40 inches.
3. Force. Incorrect force can cause misalignment problems over the range of
a long cut. If the force is too high, the material may skew.
4. Prepare a large clean area to work.
Power On
Turn on the computer and the cutter. The cutter power switch is located next
to the power cord on the back. The carriage will move when the power comes
on. Keep hands and loose clothing away from all moving parts of the cutter.
The red light on the front panel will come on when the start up procedure is
finished.
Loading the Material
Note: If Autoloop is not enabled in the Control Center, do not allow the
material to become taut between the cutter and the material roll. Manually create and maintain a service loop in the rear. See Autoloop in the
Ioline Control Center section for more information.
If using a roll of material: Place the roll between the media rollers.
If using a roll of paper: Hang the paper roll on media roller (as an axle).
Note: Do not place a paper roll on two media rollers.
If using a cut sheet or scrap: No special instructions are necessary.
Aligning the Material and Pinchwheels on the
Optional Stand
Ioline recommends using the, “Typewriter Method,” to align the material to
the platen. The drive shaft is optimized for most common material widths as
well as scraps. Use the drive shaft markers on the carriage rail to find the drive
shaft segments when material is loaded in the cutter.
1. Lift the pinchwheels by raising the pinchwheel lever on the right side of
the cutter. Bring the material up and through the space under the pinchwheels. Pull down enough material to reach the media rollers on the
stand.
2. Roughly align the material so that the edges are overlapping the wideright-drive shaft segment and one of the smaller segments. Use the drive
shaft markers on the carriage rail to find the drive shaft segments when
they are covered by material.
3. Position the outer-pinchwheels on the material about one inch (2.5 cm)
from the edge. Make sure that the wheels are over a drive shaft segment
using the drive shaft markers on the carriage rail as a guide.
4. Slide the inner-idler wheels (when provided) so that they are as close to
evenly spaced between the outer wheels as possible while remaining
over a drive shaft segment. Use the drive shaft markers on carriage rail to
ensure that the wheels are positioned correctly.
5. With both hands, reach under the stand and clasp the front edges of the
sides of the material hanging from the front of the machine against the
edges of the material hanging from the back of the machine. Pull downward on the material and square the edges so that they are parallel front
and back. Alternatively, align the edge of the material with the edge of
the material roll.
6. While maintaining the material square and taut, clamp the pinchwheels
to the material by lowering the pinchwheel lever on the right side of the
cutter.
7. Warning: While checking alignment with the Arrow keys, make sure
that the material between the material roll and the cutter is never
pulled taut with the drive shaft. Check alignment by using the arrow
keys to move the material forward and back. Observe the material edge to
make sure it is running straight.
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Adjusting the Pinchwheels
The 100 System cutter has pinchwheels with adjustable spring force. This
allows the user to use maximum force (24 lbs.) for holding material (which
requires more force for better tracking) or less force (8 lbs.) for lightweight
materials like paper and for sandblast resists that must be tracked directly on
the rubber surface. The pinchwheels can also be set in a position that keeps
them completely off the surface so that the inner pinchwheels on larger cutters will not interfere with pen plotting.
The force adjustment is set by turning a screw on the back of the pinchwheel
assembly.
1. Move the pinchwheel to the access hole on the back of the dust cover.
2. Insert a flat screwdriver into the slot and turn the adjustment screw 90
degrees. When the slot is in the vertical position on the outer wheels the
force is 24 lbs. The horizontal position indicates 8 lbs of force. On units
equipped with inner pinchwheels, force can be set to 12 lbs. (vertical
setting) or 4 lbs. (horizontal setting). The 12 lb. inner pinchwheel setting
is useful for heavier materials such as heavy sandblast or reflective sheeting.
Low Force Position
Cam Slot Horizontal
High Force Position
Cam Slot Vertical
Figure 6. Adjusting Pinchwheel Pressure.
Cam
Slot
Locking the Pinchwheels Off of the Platen
The idler pinchwheels have a locking feature that will hold them off of the
platen during plotting. This will reduce ink smearing if plotting with a heavy
ink marker.
1. Lift the idler pinchwheels off the platen with the pinchwheel lever.
2. Press on the handles at the rear of the idler pinchwheel arm.
3. Flip the locking clip into position with both thumbs. Make sure that the
clip is under the lower tabs.
4. When the pinchwheels are lowered onto the platen the idlers will stay in
the up position.
Figure 7. Locking the Idler Pinchwheels Off of the Platen.
Lower Tab
Locking Clip
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Adjusting Blade Exposure and Force
Properly adjust blade exposure and force to achieve good cutting results.
Adjusting Blade Exposure:
1. Turn the Force knob clockwise to maximum. Set the Speed to 50% with
the keypad knob. The maximum force setting is adjustable in the Control
Center to 400 grams if required for thick materials. A maximum force of
200 grams is sufficient for most materials.
2. Check that the blade tip is barely visible when viewing the blade from the
side. This technique approaches the correct blade exposure from too
little with no chance of having too much (which could damage the blade).
3. Press the Start/Stop button on the front panel until the LED is red. Move
the carriage until the blade is near the right edge of the material.
4. Press the Test Cut key for one second. The cutter will cut a test design.
There will be no cutting if the initial foot adjustment was correct.
Figure 10. Proper blade exposure that lightly scores the backing.
Installing a Blade and the Blade Foot
Note: Using a hard surface to insert the blade may damage it.
A blade and a blade holder are included in the accessory kit. The blades are
sharp and brittle and the tips can chip or break. Be very careful when handling
the blades. To install the blade and blade foot in to the blade holder:
1. Remove the foot from the assembly by unscrewing it counterclockwise.
2. Slide the blade into the hole in the blade holder until it bottoms out. The
blade should spin freely.
3. Screw the foot onto the shank (clockwise). Stop before the blade emerges.
Installing a Blade Holder or Pen
1. Rotate the clamp screw until there is enough room to insert the blade
holder or pen. Make sure that the clamp is rotated up out of the way.
2. If using a blade holder or plot pen, slip the flange into the slot in the
carriage jaw. If using a regular pen, position the tip 1/10 inch off of the
platen when the jaw is in the up position. The cutter can hold any pen
with a maximum barrel diameter of 7/8” (22 mm).
3. Tighten the clamp screw until the blade or pen is secure.
Figure 9. Installing a Blade Holder in the Carriage Jaw.
Figures 8. Installing the Blade and the Blade Foot in the Holder.
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Sending a Cut File to the Cutter
Always load the cutter and make test cuts to determine the correct settings
before sending any files. See the Adjusting Blade Exposure and Force section for more details.
Important: Make sure that the carriage and material are in the proper
position and that an origin is set by pressing Set Origin on the keypad
(LED is green).
If you are cutting material such as Thermo-Flock for transferring to fabric,
make sure you “Mirror” the image in the design software before sending to
the cutter. Send the file directly from the design software following the directions in the documentation or;
From the Ioline Control Center:
1. From the menu bar select File, Send Cut File.
2. Either enter the path and file name of the cut or select the correct location
from the directory\file lists in the dialog box. For example, the path
might be:
C:\IOLINE\<filename>.plt.
4. Select OK.
Pausing Cutting
Warning: Do not turn the material roll or pull material tight between
the drive shaft and the material roll while cutting is paused. If the
material becomes suddenly tight, the machine will jam.
1. Press the Start/Stop key to place the cutter in Stop mode (red LED).
2. When cutting is interrupted, the carriage and material can be moved with
the keypad Arrow keys.
3. Press the Start/Stop key to resume cutting. The cutter will return to the
original cutting position and continue cutting where it stopped. The
keypad LED will change from red to green.
Canceling a Cut
1. Press the Start/Stop key to place the cutter in Stop mode (red LED).
2. Cancel the cut from the design software (refer to the design software
manual or consult software dealer) or cancel the cut in the Control Center
software by clicking on the Abort button in the Send File window. Note:
If this step is skipped the cut will continue when a new origin is set.
Figure 11. Turning the foot to add more blade exposure.
5. Turn the foot 1/8 turn upward (clockwise from below). Press the Test Cut
key. Note: Successive cuts will automatically be positioned to the left of
the previous test cut. The blade should be cutting the material.
6. Continue increasing the blade exposure and making test cuts. The test
design will completely separate from the surrounding material and lightly
score the material backing when enough blade is exposed.
Force Adjustment:
Every type of material requires different cutting force. Before adjusting force
make sure that the blade exposure is adjusted first. See instructions above.
1. Turn the force knob down slightly from maximum, about one mark, and
repeat the test cut. Use full force if the test cut is not complete.
2. If the test cut is complete, turn the force down again and repeat the test
cut. Continue until the cut is incomplete. This indicates that there is not
enough force to push the exposed blade fully into the material. At this
point turn the force knob up one mark, which should be just enough.
Verification:
1. Press the Test Cut key for 3 seconds. The cutter will cut a 1.9 inch x 7.1
inch design.
2. If the design does not separate cleanly and leave a light scoring on the
backing, try another 1/8 turn upward (counter clockwise from above) of
blade exposure and a very slight increase in force.
Page 14
14
Ioline
Material Thickness Blade Offset Force
mils mils grams
Amberlith™/Rubylith™ 1 45
o
15 30-60
Flock 15 Cobra 47 100-200
Thermo-Flock 15 45 15 200-300
Thermo-Film 3 45 15 200-300
Gorilla-Grip 4-5 45 15 200-300
Polyester, Metalized 2 45
o
15 100-140
Reflective, Engineering Grade 5 45
o
15 240-250
Sandblast Mask
2
18
1
- - -
31 Cobra 47 220-260
36 Cobra 47 220-260
40
1
- - -
Stencil, Lacquer Adhering 1 45
o
15 80-100
Stencil, Vinyl 4 45
o
15 200-220
Stencil, Water Soluble 1 45
o
15 125-135
Tag Board 10 45
o
15 300-400
Vinyl, Calendered 3 45
o
15 100-150
Vinyl, Cast2 45
o
15 100-150
1
These sandblasts typically have a backing which is designed for cutting by hand.
2
Use the low force setting on the pinchwheels if using a 80 cm or larger cutter .
Suggested Settings
There are many variables that determine cutter output quality. Ioline recommends using low force and speed settings when making the initial test cuts.
Gradually increase these settings until the best values for the material are
found. Refer to Table 1 below for settings for a variety of material types. Force
values are for starting reference only. These settings may vary due to manufacturer, color, age, and temperature of the material.
Table 1. Suggested Settings for Different Material Types.
Speed Acceleration Min. Angle Overcut Down Delay
ips g degrees mils milliseconds
med. 0.1 30
o
0-5 0-50
min. 1 15
o
10 0
min. 1 15 10 0
min. 1 15 10 0
min. 1 15 10 0
max. 1 30
o
10 0
min. 1 30
o
10 0
- - - - -
min. 1 15
o
30 0
min. 1 15
o
30 0
- - - - -
max. 1 30
o
10 0
min. 1 30
o
10 0
med. 1 30
o
10 0
min. 0.1 30
o
10 0
med.-max. 1 30
o
10 0
med.-max. 1 30
o
10 0
NOTE: Settings should be adjusted for cutting small letters or intricate detail,
refer to the Cutting Small Characters section.
Page 15
15
Ioline
Guidelines for Plotting Pens
Ioline has determined guidelines for plotting with a plot pen. Refer to the
table below for recommended settings for a variety of pen types. Use Test Cut
and gradually increase these settings until the best value is found for the pen
being used. Remember that force values are for starting reference only. These
settings may vary due to manufacturer, color, age, and temperature of the
material.
Table 2. Cutter Pen Guidelines.
Paper Pen Speed Force
grams
Comments
BMI Super Lay-
Flat™ or equivalent
high quality bond
HP-style
ballpoint
Maximum 60-80 15ms pen up/
15ms pen
down delays
" BIC® Round
Stic
ballpoint
Maximum 180-200
" Sanford
Sharpie
Maximum 70-100
" HP-style
fiber tip
Medium 70-100
___ Plastic tip ___ ___ Not
Recommended
___ Ceramic tip ___ ___ Not
Recommended
___ Liquid ink/
Metal tip
___ ___ Not
Recommended
BLANK
Page 16
16
Ioline
How to Pounce
Use the pounce feature with high quality paper. Ioline recommends 20 lb.
paper that lies flat. A pounce tool and a pounce blade (available from Ioline)
are also required.
1. Select Pounce in the Ioline Control Center. Make sure that Tag Board
Cutout is turned off. Put the cutter in Start mode (green LED on). Update
the cutter with the Send Settings (temporary or permanent) buttons.
2. Slide the paper roll onto a media roller (use the roller as an axle). Ioline
does not recommend using two media rollers to cradle paper rolls.
3. Enable Autoloop or create a service loop of material.
4. Set the Speed knob to maximum. Set the Acceleration to 0.5 g. Performance will vary with different paper types. Experiment with lower settings if required.
5. Turn the Force knob to maximum (default is 200 grams).
6. Install the pounce tool and blade like a standard blade holder. Note: there
is no foot on the pounce blade assembly.
7. With the red light ON, press the Test Cut key for 3 seconds. The cutter
will pounce a 1.9 inch x 7.1 inch design.
8. Increase or decrease the force on the Force Knob as needed for a complete
puncture through the paper. If the pounce blade picks up the paper and
jams, try setting the force and/or acceleration to lower settings.
9. The Pouncing cut is intermittent - short pounce cut followed by a longer
uncut segment. The default length is 40 mils (.04 inches) for the cut and
600 mils (.6 inches) for the blank. The lengths of the cuts and blanks are
adjustable with the Control Center. Perform test cuts to determine the
proper settings for these parameters. See the section describing the Ioline
Control Center for more details on adjusting the cut and blank settings.
Hint: Try wider blank spacing for larger images.
Stencil Cutting
Stencil material (Tag Board) is handled much the same as vinyl with the
important exception of using much higher force.
1. Select Tag Board Cutout in the Ioline Control Center. Make sure that
Pounce is turned off. Put the cutter in Start mode (green LED on). Update
the cutter with the Send Settings (temporary or permanent) buttons.
2. Slide the paper roll onto a media roller (use the roller as an axle). Ioline
does not recommend using two media rollers to cradle tag board rolls.
3. Enable Autoloop or create a service loop of material.
4. Install a blade holder in the carriage.
5. Perform test cuts to establish blade exposure and force settings. See the
section Adjusting Blade Exposure and Force for the proper procedure.
Note: Most tag board cuts are made at or near maximum force (400 grams).
Check the Control Center for the maximum force setting. Adjust as necessary. See the Suggested Settings in Table 1 for more details.
6. A Tag Board Cut is intermittent - a long cut length followed by a short
uncut segment. The default length is 2000 mils (2.0 inches) for the cut
and 60 mils (.06 inches) for the blank. The lengths of the cuts and blanks
are adjustable with the Control Center. Perform test cuts to determine the
proper settings for these parameters. See the section describing the Ioline
Control Center for more details on adjusting the cut and blank settings.
Page 17
17
Ioline
Testing the Cutter Serial Port
The diagnostic module is required for this test.
1. Connect the diagnostic module directly to the Cutter COM port.
2. From the Control Center main menu, select Test, Cutter Port Test.
3. Turn on the cutter while holding down the Test Cut key on the keypad.
Hold down the Test Cut key until the cutter beeps and the light flashes
three times. The cutter is now in Test Mode.
4. Press any Arrow key on the keypad to transmit and receive characters.
Verify that the cutter beeps.
5. Turn off the cutter at the end of the test. This will exit Test Mode. If this
test fails, the cutter port is faulty.
Testing the Computer Serial Port
The diagnostic module is required for this test.
1. Connect the diagnostic module directly to the COM port on the computer. If the computer COM port has a nine pin connector, use a 9 pin to
25 pin adapter between the COM port and diagnostic module.
2. From the Control Center main menu, select Test, Computer Port Test.
3. Verify that the COM port selected is the correct one. If it is not, select the
proper COM Port.
4. Verify the CTS handshake line is on.
5. Press any key on the computer keyboard and verify that the character
transmitted equals the character received.
6. Select the Exit button at the end of the test. This will exit Test Mode. If
this test fails, the computer port is faulty.
COMMUNICATION TESTING
There are three communication diagnostic tests available in the Control Center. These tests are designed to help determine if a communication problem
exists and to isolate where the problem is occurring.
A diagnostic module is required to run two of these tests. It will work on both
the computer and cutter serial (COM) ports. It is available from Ioline or an
authorized dealer.
Communication Test
This test will determine if communication is working between the computer
and the cutter on the parallel (LPT) or serial (COM) ports. Run this test from
the Control Center, Test menu. The diagnostic module is not required to run
this test.
1. Turn the cutter off. Connect the cutter to the computer with either a serial
or parallel port cable. See the section Connect the Cutter to the Com-
puter in the Installation chapter for more details.
2. Start the Ioline Control Center. Select Test, Communication Test from
the menu bar at the top of the window.
3. Turn on the cutter while holding down the Test Cut key on the keypad.
Hold down the Test Cut key until the cutter beeps and the light flashes
three times. The cutter is now in Test Mode.
4. If testing the serial (COM) port, press the Start/Stop key on the cutter and
verify that the handshake line (CTS) status displayed on the computer
screen toggles On/Off. Leave the handshake line On. This is not necessary for the parallel (LPT) port.
5. Press the Repeat key to switch the cutter into Echo mode. The green light
will come on.
6. Press a key on the computer and verify that the character transmitted
equals the character received. If the characters match then the connection
between the cutter and computer is working properly.
7. Select Exit after the communication test is complete.
8. Turn off the cutter at the end of the test. This will exit Test Mode.
9. The next two tests are not necessary if serial (COM) port testing is successful.
Page 18
18
Ioline
If the system is not working correctly the problem could be with the computer,
the cable, the design software, or with the cutter. Changes to the computer
operating system or the installation of new peripherals or software might
cause conflicts. If the computer or the design software cause a problem, consult the computer or software manuals or call the manufacturer or dealer.
If the problem is with the cutter, begin by making sure power is on and that the
cable between the machines is connected correctly. Test the connection with
the methods described in the Communication Testing section. Consult the
following chart for more detailed troubleshooting techniques:
Troubleshooting Chart
TROUBLESHOOTING
Table 3. Troubleshooting Chart.
Table 3-Continued. Troubleshooting Chart.
If your plot does not start at the correct point on the material:
Possible Cause Solution
1. The origin selected in your
software is different than the one
you selected on your plotter.
2. You have not set an origin.
1. Select them so they coincide; usually
lower-left (which is on the right side of
the plotter, see Figure 3).
2. Set an origin.
If pressing the Repeat key does not repeat the previous plot:
Possible Cause Solution
1. Buffer Overflow: File sizeexceeds buffer size.
1. See the Operation chapter, Repeat
section.
If you have sent a plot file, but nothing happens:
Possible Cause Solution
1. Your plotter is in Stop mode.
2. A communication problem has
occurred.
3. You have not set an origin.
1. Press the Start/Stop key to put
your plotter in Start mode
2. Perform the diagnostic tests or call
your dealer.
3. Set an origin.
If you have sent a plot file and the output is erratic:
Possible Cause Solution
1. You have sent the plot file with
the wrong plotter language.
1. Make sure the correct driver setting
is selected.
If the blade tears the material or skips when cutting:
Possible Cause Solution
1. The blade is dull or broken.
2. The blade force is too low.
3. The blade is dirty.
1. Replace the blade.
2. Increase the blade force.
3. Clean or replace the blade.
If the corners of the plots or cuts are not completely meeting:
Possible Cause Solution
1. The material is slipping.
2. The blade is dull or broken.
3. The blade overcut is too low.
4. The offset is incorrect.
1. Clean the drive shaft.
2. Replace the blade.
3. Use a higher blade overcut value.
4. Refer to the Blade Offset
section.
If you have difficulty weeding the completed pattern:
Possible Cause Solution
1. Not enough force.
2. The blade is dull or broken.
3. The blade overcut is too low.
4. The offset is incorrect.
1. Increase force setting.
2. Replace the blade.
3. Use a higher blade overcut value.
4. Refer to the Blade Offset section.
If there are tracking errors:
Possible Cause Solution
1. Pinch wheels are positioned on
a smooth section of the drive shaft.
2. Force is set too high.
3. Acceleration is set too high.
4. Speed is set too high.
5. The material is kinked as it
accumulates in the front and rear of
the plotter.
6. Dirty drive shaft.
1. Move the pinch wheels to a new
location.
2. Reduce the force.
3. Set the acceleration to .5g.
4. Reduce the speed to 50% or less.
5. Make sure the material remains
smooth, flat, and square during
loading. Clear the media path in the
front and rear of the plotter.
6. Clean the drive shaft.
Page 19
19
Ioline
Troubleshooting the Parallel Port
If the computer communicating with the cutter is on a network, it is common
for LPT 1 to be ‘captured’. If a port is captured, the data is redirected to the
network instead of flowing out of the parallel port on the back of the computer. Ending the capture will allow data to flow normally from the computer
to the cutter. Note: These instructions may vary depending on the Windows
version.
1. Click the Start button, select Settings and then click Printers to open the
Printers window.
2. Right Click the printer icon for a network printer and select Properties.
3. Click on the ‘Capture Settings’ or ‘Details’ tab.
4. Click on ‘End Capture’. Select LPT 1 and click ‘OK’.
5. Assign the network printer path to another parallel port designation like
LPT 3. Set the printer to use that port or select a network print que path.
BIOS settings can also have an effect on parallel port performance. The cutter
supports only SPP parallel port communication. ECP and EPP modes are not
supported. These instructions include editing the PC BIOS to ensure that the
port is in the proper mode prior to staring Windows.
1. Click the Start button, select Settings and then click Control Panel to
open the Control Panel window.
2 Double Click the System icon to open the System window and then click
the Device Manager tab.
3. Remove the parallel port by clicking Ports, selecting the port and clicking the Remove button.
4. Shut down Windows.
5. Restart or Reset the computer.
6. Enter the PC BIOS setup. This is usually done by hitting the DEL key or
ESC key during the boot sequence. Consult the computer manuals or
contact the manufacturer for more information about entering BIOS setup.
7. Find the parallel port setup options and set the port to be SPP (not ECP or
EPP). Also, make sure there is no DMA activity over with the port.
8. Save the BIOS settings and exit setup.
9. Restart the computer and allow Windows to start up. Windows should
find the port and install it using the new settings.
LED Codes
Note: if any yellow lights are visible on the keypad, take note of how many
times the light blinks and contact Ioline Customer Service immediately. Ioline contact information is available at the end of this manual.
If the front panel green light is blinking once:
Possible Cause Solution
The carriage is jammed. Turn off your plotter and clear away
any debris or jammed material.
If the front panel red light is blinking once:
Possible Cause Solution
The drive shaft is jammed. Turn off your plotter and clear away
any debris or jammed material
If the front panel red light is blinking twice:
Possible Cause Solution
Buffer overflow or communication
problem.
Perform the diagnostic tests or call
your dealer.
If the front panel red and green lights are blinking alternately:
Possible Cause Solution
1. Plotter language syntax error.
2. Bad or corrupted file.
1. Make sure the correct driver is
selected.
2. Recreate file.
Table 4. LED Codes.
Page 20
20
Ioline
Calibration
Over time, cutters may require calibration to account for normal wear and tear.
Typically, the accuracy of a cut is within 0.2% overall. By using the calibration feature, the variance can be adjusted to within 0.05%. Note: The Scale
command does not effect the calibration values.
Prepare the Cutter:
1. Open the Ioline Control Center program. Put the cutter in Start mode
(green LED).
2. Load the cutter with material that is greater than 22 inches wide (60 cm
model) or greater than 30 inches wide (80 cm or larger models) and a
minimum of 48 inches long. Install a blade holder (use vinyl material) or
pen (use paper material) in the carriage. Enable Autoloop or manually
create a service loop of material.
3. Move the carriage and material with the Arrow keys so that the blade or
pen is about one inch from both the right and front edge of the material.
Set an origin. See the Operation chapter for more details on preparing to
cut.
Gather the Calibration Data:
1. Select Calibrate, Calibrate Cutter from the Control Center menu bar.
2. Select Calibration Cut to cut the factory stored calibration cut. The cutter
will cut a large box (see Figure 14).
3. Precisely measure both X-axis and Y-axis lines. Better accuracy in measurement equals better calibration.
4. Measure both sides and the top and bottom of the box.
Figure 13. Cleaning the Drive Shaft.
ROUTINE MAINTENANCE
Replacing the Blade
Note: The blade tip is sharp and fragile, be careful when handling it.
If cut quality suddenly degrades the blade might be dull or broken. The tip of
the blade is very fragile and can chip or break if dropped. It is difficult to see
when the blade is damaged. A magnifying glass can be helpful. To replace the
blade:
1. Remove the adjustable blade foot by unscrewing it counterclockwise.
2. Remove the old blade with a pair of needle nose pliers and discard it.
3. Slide the new blade into the blade until it bottoms out. The blade should
spin freely.
4. Screw the foot onto the blade holder (clockwise). Stop just before the
blade tip emerges.
5. Perform test cuts as described in the Cutting a Design section before
continuing to use the cutter.
Cleaning the Drive Shaft
Warning: Do not use any cleaning agents (beside alcohol), water or
brushes with metal bristles to clean parts of the cutter. Pay special
attention to keeping the drive shaft bearings free of all liquids
Clean the drive shaft regularly to make sure the cut lines remain accurate. To
clean the drive shaft:
1. Turn off the cutter and disconnect the power cord.
2. Remove any accumulated dust and residue with a stiff bristle brush.
Figure 12. Replacing the Blade.
Page 21
21
Ioline
Figure 14. The Calibration Box and Measurements.
5. Take the average of the horizontal (Y) values by adding them together
and dividing by 2. Repeat this procedure for the vertical (X) values.
Example:
If X1 = 39.750 in. and X2 = 39.700 in.
The sum is 79.450 in. (39.750 in. + 39.700 in. = 79.450 in.).
The average is 39.725 in. (79.450 in. / 2 = 39.725 in.)
The X calibration value is the average, 39.725 in.
Enter the Calibration Data:
1. Enter the measured values in the boxes in the Calibration window. Make
sure the cutter is in Start mode (green LED). Select the Set Calibration
button.
2. The cutter will send the calibration values and the new Calibration
Setting will be displayed in the boxes in the window.
3. Click on Done when finished.
~40 in.
Y1
Y2
X1 X2
BLANK
Page 22
22
Ioline
Please gather the following information about your cutter before contacting Ioline or the dealer for technical support.
Name:
Company Name:
Phone Number: Fax:
Model:
Serial Number:
Date of Purchase:
Dealer:
Type of Material Used:
Type of Computer:
Type of design software:
New Software or Peripherals:
Service History (if any):
Note: Ioline Customer Service contact information is listed on the last
page of this section.
END NOTES
Getting Help
Ioline is committed to providing the highest quality service and support to its
customers. If you need assistance with an Ioline cutter, a number of resources
are available:
1. First, refer to this User Guide for answers to your specific questions.
2. Consult the support section of the Ioline web site: www.ioline.com.
3. For additional assistance, contact your local dealer or Ioline Customer
Service. Contact information is listed on the last page of this User Guide.
Any warranty servicing of this product not specifically described in this manual
must be authorized in writing by Ioline Customer Service. You may obtain
service by calling or faxing Ioline Customer Service. The technicians will
help you determine the nature of the problem. If factory repair is necessary,
you will receive a RMA (Return Material Authorization). Please gather the
information indicated in the next column before contacting Ioline or your
dealer.
1. Carefully package the cutter in its original container or equivalent. You
may purchase shipping containers from Ioline by contacting Ioline Customer Service. Ioline is not responsible for any damage due to inad-
equate or improper packaging.
2. Carefully wrap and secure all items in the shipping container to prevent
damage. Seal the container and note the RMA near the address block.
3. Ship the container using FED-EX or another approved carrier. COD SHIP-
MENTS ARE NOT ACCEPTED. You will be contacted prior to the start
of work with an estimate of repair cost. All repairs are warranted for 90
days.
Page 23
23
Ioline
Your Comments Are Requested
Ioline Corporation is interested in comments on our documentation and products. Please send corrections or suggestions to:
IOLINE CORPORATION
14140 NE 200th Street
Woodinville, WA 98072 USA
Voice: (425) 398-8282
Fax: (425) 398-8383
www.ioline.com
info@ioline.com
This User Guide is provided for informational purposes only. The contents are
subject to change without notice, and Ioline Corporation assumes no responsibility for any errors that may be contained herein. No part of this User Guide
may be copied, disseminated, or distributed without the express written consent of Ioline Corporation.
Customer Service
Ioline Corporation is committed to providing quality service and support to
our customers. If you need assistance with an Ioline product, contact your
local dealer or Ioline authorized service center. You may also contact the
Ioline Customer Service Department
Monday through Friday
7:00 A.M. - 5:00 P.M. U.S. Pacific Time
Voice: (425) 398-8282
Fax: (425) 398-8383
techsupport@ioline.com
www.ioline.com
Ioline has many years of experience working with design makers and designers. Feel free to contact us if you have questions or to share information.
Limit of Liability Statement
It is the responsibility of the operator of the cutter to monitor the performance
of the cutter and maintain it in proper working condition by following the
instructions in this User Guide. It is the responsibility of the operator of the
cutter to follow all safety precautions and warnings that are described in this
User Guide. Ioline is not responsible for injuries that may occur as a result of
unsafe operating procedures. Ioline is not responsible for substandard operational performance as a result of failure to maintain the cutter as described in
this User Guide.
The FCC Wants You to Know...
This equipment generates and uses radio frequency energy and, if not installed and used properly (in strict accordance with manufacturer instructions), it may cause interference to radio and television reception. Operation
is subject to the following two conditions: (1) This device may not cause
harmful interference, and (2) this device must accept any interference received, including interference that may cause undesired operation. If this
equipment does cause interference to radio or television reception - which
can be determined by turning the equipment off and on - you are encouraged
to try to correct the problem by one or more of the following measures:
• Use only shielded interface cables.
• Reorient the receiving antenna.
• Relocate the host computer with respect to the receiver.
• Move the host computer away from the receiver.
• Plug the host computer into a different outlet so that the host computer
and receiver are on different branch circuits.
If necessary, consult the dealer or an experienced radio/television technician
for additional suggestions. The following booklet, prepared by the Federal
Communications Commission, is a helpful reference:
How To Identify and Resolve Radio-TV Interference Problems:
The stock number is: 004-000-00345-4
This booklet is available from:
U.S. Government Printing Office
Washington, D.C. 20402
Page 24
24
Ioline
GLOSSARY
A
Acceleration - The rate that a cutter changes the velocity of the carriage or the
material. Acceleration is measured in units of g (1 g = 32.2 ft/s2). Higher
acceleration can increase throughput but may degrade cut quality.
Arc - A segment of a circle, also called a curve.
Axis - The geometric guidelines used to place a coordinate. Used to deter-
mine pen or blade paths for cutters.
B
Blade - Refers to the carbide steel cutting tool used by design-cutting cutters.
Blades are specified by offset (tip distance from center) and angle (relative to
the material). They are designed to work with many different materials.
Blade Bevel - Angle of the vertical cutting edge of a blade. Larger angles help
the blade travel through thicker material that produce more drag between the
blade and the medium.
Blade Offset - The distance the blade tip trails behind the center of the blade.
Blade Steering Arc - The arc followed by the center of the blade as it rotates
around the (fixed) tip. This is used to align the blade in the direction of the
next vector so no tearing occurs.
C
Calendered - Polyvinyl chloride (PVC) sheeting squeezed between a series
of heated rollers to achieve a small enough thickness for cutting with a cutter.
Calendered film is generally thicker and less expensive than cast vinyl, but it
sometimes tends to shrink or move back to its original thickness.
Cast - Polyvinyl chloride (PVC) sheeting formed by spreading a molten vinyl
mixture on a carrier sheet or web, and then baking at high temperatures to
remove solvents and fuse the remaining material into a film. Cast film is
usually thinner and more expensive than calendered vinyl.
Control Panel - Panel on the right side of the machine where primary cutter
functions are accessible. Also called the Keypad.
Coordinate - A point that can be referenced by its position on the X or Y axes
of a cutter. The use of line or arc segments to connect coordinates creates
paths for pens and knives to follow when cutting.
Cut Sheet - A single piece of material that is loaded into the cutter but is not
pulled from a roll.
D
DM/PL - Programming instructions language used to connect a cutter with a
computer. DM/PL is used in the cutter drivers of some design programs.
Drive Shaft - The motor driven shaft that moves material through a friction
feed cutter. The drive shaft has a rough surface that grips the material.
F
File Name Extensions - In MS-DOS® and Windows® based programs, the
three letters after the period in a file name. In design files the three letters
denote a file type, such as the vector and bitmap based Encapsulated Postscript (EPS) and the vector based Hewlett Packard Graphics Language (PLT).
Flange - The projecting rim around the edge that holds the pen or blade
holder to the tool carriage. The cutter automatically recognizes when a pen or
blade is installed and changes cutting parameters accordingly.
Font - Refers to the style and width of a particular design of letters, numbers,
and symbols, such as Helvetica Bold or Times Roman.
Force - In cutting, the downward pressure exerted on a pen or blade tip to ease
cutting through materials. Additional force can be added by adjusting the
Control Center Force settings and updating the cutter. Increasing the force
will darken pen lines or aid in cutting thicker materials like tag board.
Friction feed - Process where the material is fed through a cutter by placing it
between a motor-driven drive shaft and tensioned pinchwheels.
H
HPGL Setting - The cutter supports three industry standard cutter languages:
HPGL 7475, HPGL 7596, and DM/PL. Most design software uses DM/PL or
HPGL 7475 which have a lower left origin. DM/PL cannot be selected in the
Control Center because the cutter will automatically recognize it. HPGL 7596
uses a center origin so cutting begins at the center of the intended cutting
area.
I
Idler Wheel - Secondary wheels that help keep wide material flat during
cutting.
K
Keypad - Panel on the right side of the machine where primary cutter func-
tions are accessible. Also called the Control Panel.
M
Mil - Thousandths of an inch or milliinches. For example; 75 mils is the same
as .075 inches. 1 mil is equal to .025mm
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Minimum Angle - This is the minimum angle for which the machine will
perform a blade steering arc.
O
Offset - The distance the tip of the blade trails behind the center of the blade.
Origin - Place marking the zero (0) coordinate on the X or Y axes. Used as a
starting reference by cutters for pen or blade paths.
Overcut - Distance the blade travels beyond the end of each cut vector.
Overlap - Amount of material cut in one panel (or tile) that duplicates what is
done in the previous panel (or tile). The overlapped image allows for alignment when assembling and installing a large image.
P
Panel - Production area of a cutter. Cutters have a size limit along the Y axis
(a few inches less than the width of the cutter) and the X axis. If a job exceeds
the production area, consecutive panels must be set up by the design software. Also called tiling. Paneling a long cut will increase accuracy.
Parallel Communications - Method of sending information from a computer
to a cutter by sending 1 byte (8 bits) at a time through a cable. This method is
faster than serial communication. The parallel port on a PC is a female (small
holes) connector.
Pinchwheel - Wheeled roller, tensioned by springs, that clamps material between it and the drive shaft for transporting the material.
Pounce Pattern - A full sized pattern of any design to be painted. Once the
pattern is created, the outline is perforated into paper using the Pounce feature. The pattern is then held firmly against the substrate and perforations
patted with powder, charcoal or colored chalk dust, leaving an outline of the
design.
R
Resolution - The smallest distance that a cutter can move the material or the
carriage. Cutter resolution affects the accuracy that a cut file is reproduced on
the material.
Roll Feed - A method of pulling material from a roll for cutting. Works in
conjunction with panels.
S
Serial Communications - Method of sending information from a computer to
a cutter by sending 1 bit at a time through a cable. The serial port on a PC is a
male (small pins) connector.
Service Loop - Slack material between the material roll and the cutter.
Stencil - A thin sheet of material into which a design is cut. When a stencil is
placed on another substrate and paint or ink is applied, the image represented
by the cut out portion of the stencil is printed on the substrate below it.
T
Tag Board - A heavy paper (usually 150 pound) that is used in the apparel
industry for cutting patterns and stencils.
Throughput - The speed at which a cutter completes a job. Represents the
ability to process information and produce an image.
V
Vector - In computerized design making, a line segment between two coordi-
nates, on which a pen or blade path can be created for cutting.
Vinyl - Polyvinyl chloride (PVC) film that, in design making, is backed with
an adhesive that will create a strong bond to a surface when pressure is applied.
W
Weeding - Process of pulling extraneous material away from a cut design
leaving only the sections representing the intended design.
X
X - Axis - Theoretical horizontal line providing a lengthwise reference point
for cutters. Associated with material movement over the platen on the cutter.
Y
Y - Axis - Theoretical vertical line providing a longitudinal reference point
for cutters. Associated with carriage movement on the cutter.
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INDEX
Symbols
9 to 25 pin adapter 5
A
Abort 13
Acceleration 9, 14, 16, 24
Accessory kit 5, 12
Accuracy 20
Adjusting the Pinch Wheels 11
Aligning the Media 10
Amberlith™ 14
Arc 9, 24
Arrow Keys 6, 10
Autoloop 4, 8, 10, 16
Axis 24
B
BIOS 19
Blade 4, 6, 7, 8, 9, 12, 14, 16, 20, 24
Blade Exposure 7, 12
Blade Foot 12
Blade Holder 4, 7, 8, 12, 16, 20
Blade Offset 7, 9, 24
Blade Overcut 9
Blade Status 8
Blade Steering Arc 9, 24
Blank 9, 16
Box 5
Buffer 7
C
Cable 18
Calendered 14, 24
Calibrate 8
Calibrate Plotter 8
Calibration 20
Calibration Box 21
Calibration window 21
Cam 11
Canceling a Cut 13
Carriage 2, 4, 5, 12, 13, 24
Carriage Jaw 12
Carriage Rail 2, 5, 10
Cast 14, 24
CD ROM 5
Clamp 12
Clamp screw 12
Cleaning agents 20
Cleaning the Drive Shaft 20
Communication port conflicts 7
Communication Test 17
Computer 4, 5, 7, 18, 23
Computer Port Test 8
Control Center 4, 5, 6, 7, 8, 9, 10, 12, 16, 17, 20
Control Panel 6, 24
Coordinate 24
Customer Service 23
Cut 8, 16
Cut Sheet 10, 24
D
Delays 9
Design software 4, 5, 10, 13, 18
Display 8
DM/PL 24
DOS 5
Down Delay 14
Drive Shaft 4, 10, 20
Drive Shaft Marker 2, 10
Drive Shaft Segment 2
Dust Cover 2, 5
E
ECP 19
End cover 5
EPP 19
Exit 8
F
Factory Defaults 8
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File 8, 10
File Name Extensions 24
Filtering 8
Flange 24
Flock 14
Font 24
Foot 13, 20
Force 6, 9, 11, 12, 14, 15, 16, 24
Friction Feed 24
G
Getting Help 22
H
Hardware 5
Help 8
HPGL 8, 24
HPGL 7475 24
HPGL 7596, 24
HPGL Setting 8
I
Idler Pinchwheels 11
Idler Wheel 24
Idler wheels 10
Install New Firmware 8
Installing a Blade 12
Ioline Corporation 23
J
Jaw 12
K
Keypad 2, 9, 12, 19, 24
L
LED Codes 19
Limit of Liability Statement 23
Line quality 7
locking feature 11
LPT 17, 19
M
Main Menu 7
Material 10, 13, 14
Material Roll 25
Measurement Units 8
Media Roller 5, 10, 16
Memory Buffer 8
Menu Bar 8
Metric 8
Mil 24
Min. Angle 14
Minimum Angle 9, 24
O
Offset 14, 25
Open Settings File 8
Operating system 18
Options 8
Origin 6, 24, 25
Output quality 14
Overcut 9, 14, 25
Overflow 7
Overlap 25
P
Panel 25
Panel Size 8
Paneling 10
Paper 11, 16
Paper roll 10
Parallel 5
Parallel cable 5
Parallel Communications 25
Parallel Port 19
Pausing Cutting 13
PC BIOS 19
Pen 7, 9, 12
Pinchwheel 2, 11, 25
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Pinchwheel Lever 2, 10
Platen 2, 10, 12
Plot quality 20
Plotter pen 12
Plotter Port Test 8
Plotter Settings 8
Plotting Pens 15
Polyester 14
Polyvinyl chloride 24
Port Setup 8
Pounce 8, 16
Pounce Blade 16
Pounce Pattern 25
Pounce tool 16
Pouncing 8, 9
Power cord 5, 20
Power On 5
Power strip 5
Power switch 5
R
Radio frequency energy 23
Reflective 14
Repeat 6, 7
Replacing the Blade 20
Resolution 25
Return Material Authorization 22
Roll Feed 25
ROM Version 8
Rubylith™ 14
S
Sandblast 11, 14
Save Settings As 8
Scale 8
Scale command 20
Scrap 10
Screen Menu 8
Send Cut/Plot File 8
Send File 13
Send Settings to Cutter 9
Sending a Cut/Plot File 13
Serial 5
Serial Cable 5
Serial Communication 25
Serial Port 17
Serial Test 8
Service Loop 4, 16, 25
Set Origin 6, 7
Setup 7, 8
Signcutter 18, 23
Small Characters 14
Software 5, 13
Special Features 8
Speed 6, 12, 14, 16
SPP 19
Start mode 8, 16, 20, 21
Start/Stop 6, 8, 12
Steering arc 9
Stencil 14, 16, 25
Stop mode 6, 7, 13
Suggested Settings 14
Surge protector 5
T
Tag Board 8, 9, 14, 16, 25
Tag Board Cutout 8
Temperature 14, 15
Test 8
Test Cut 7, 12, 14, 15, 16
Throughput 24, 25
Troubleshooting 18
Troubleshooting the Parallel Port 19
Typewriter Method 10
U
Update Display 7, 8, 9
V
Vector 25
Vinyl 10, 11, 14, 16, 24, 25
W
Weeding 25
Windows® 3.1 5
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Windows® 95 5, 19
X
X - Axis 10, 25
Y
Y - Axis 25
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