Ioline SmarTrac I/S Using Manual
USING Y OUR
SmarTrac
Signcutter
TM
I/S
Copyright © 1999, Ioline Corporation, All Rights Reserved
Printed in the United States of America
Text Revision 1, PN 106844
All Trademarks Are The Property Of Their Respective Owners
November 1999
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Figure 1. The Ioline I/S Signcutter.
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
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TABLE OF CONTENTS
THE I/S SIGNCUTTER ............................................. 4
SAFETY AND PRECAUTIONS ................................ 4
INSTALLATION ........................................................ 5
Unpack the Signcutter ....................................... 5
Assemble the Stand or Cradle (if Included) ....... 5
Attach the Signcutter ......................................... 5
Prepare the Area ............................................... 5
Connect the Signcutter 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 Sign..................................................... 10
General Guidelines ..........................................10
Power On......................................................... 10
Loading the Material ........................................ 10
Aligning the Material and Pinchwheels ............ 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/Plot File to the Signcutter......... 13
Pausing Cutting ............................................... 13
Canceling a Cut ............................................... 13
Suggested Settings ......................................... 14
Guidelines for Plotting Pens ............................ 15
Cutting Long Signs .......................................... 15
Cutting Small Characters (Under 1/4 in.)......... 16
How to Pounce ................................................ 17
Stencil Cutting.................................................. 17
COMMUNICATION TESTING ................................ 18
Communication Test........................................ 18
Testing the Signcutter Serial Port .................... 18
Testing the Computer Serial Port .................... 18
TROUBLESHOOTING............................................ 19
Troubleshooting Chart ..................................... 19
LED Codes ...................................................... 20
Troubleshooting the Parallel Port .................... 20
ROUTINE MAINTENANCE..................................... 21
Replacing the Blade......................................... 21
Cleaning the Drive Shaft.................................. 21
Calibration........................................................ 21
END NOTES ........................................................... 23
Getting Help..................................................... 23
The FCC Wants You to Know.......................... 24
Your Comments Are Requested...................... 24
Customer Service ............................................ 24
Limit of Liability Statement............................... 24
GLOSSARY ............................................................ 25
INDEX ..................................................................... 27
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THE I/S SIGNCUTTER
Thank you for purchasing an Ioline signcutter. To make signs, you also need
a computer with design software. After you have used the design software to
create a sign, you will send it as a cut file to the Ioline signcutter . The signcutter will receive the file and cut the design. Check the following items before
you begin making signs:
• The design software, which helps you design signs, 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 signcutter to create the signs. The
computer must be assembled and installed correctly before you connect
it, by cable, to the signcutter.
• The signcutter will cut the sign exactly as you have designed it. The sign
will be cut from the material that you have loaded into the signcutter.
• There is a specialized software program that comes with the signcutter
called the Ioline Control Center. You can load this software utility into a
PC compatible computer and use it to adjust signcutter settings and perform system diagnostics. Most design software provides drivers for Ioline signcutters. Contact Ioline customer service if you need assistance
with drivers.
SAFETY AND PRECAUTIONS
Please read these safety guidelines before beginning operation of the signcutter. The signcutter 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 plotter
and a roll of material during plotting. 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 plotting 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 signcutter and disconnect it from all power sources (both the computer and the wall outlet).
• Be careful with hair, jewelry, or loose clothing near the signcutter. 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 signcutter is in operation.
The carriage will automatically move to its right end position when the
power is turned on.
• Be careful when lifting the signcutter. Hold the bottom surfaces of the
signcutter to lift or move it.
• Keep fingers away from the drive shaft when the signcutter 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 Signcutter
W arning: Do not lift the signcutter by the plastic end covers, the dust
cover, or the carriage rail. This may permanently damage the signcutter. Use the bottom surfaces of the signcutter to lift or move it.
Carefully remove the signcutter 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 Stand or Cradle (if Included)
If the signcutter was purchased with a stand or cradle, the assembly directions
and hardware are included in the accessory kit. Assemble the stand or cradle
and attach the signcutter according to the directions before attempting to plot.
Attach the Signcutter
Attach the signcutter to the stand (see above), cradle or feet depending on the
model configuration. The directions are included in the accessory kit. If using
a stand, make sure that the media rollers are properly installed and that the
signcutter is facing the correct direction.
Prepare the Area
Select the correct port in the design software or the Control Center after the
cables are correctly connected to the computer and signcutter. 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 pr otect the equipment and
reset the signcutter 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 signcutter 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 signcutter to make sure the y work. The signcutter 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 signcutter. The red LED on the front panel will light when the start-up process is
finished.
Prepare a large clean area to work. Make sure the floor is clean and clear of
any obstacles. Pull the signcutter away from the wall so the material can mo ve
freely.
Connect the Signcutter to the Computer
Note: Make sure the computer and the signcutter have the power
turned off. Ioline recommends using a surge protector power strip
for the sign cutter and the computer.
Connect the signcutter 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
signcutter to a serial port on the computer. A serial connection to the signcutter 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 ine xpensiv e
and available at computer stores or can be ordered from Ioline. The plotter
will not function if a serial cable is connected to a parallel port.
Installing the Ioline Control Center
The Control Center is an interface for adjusting parameters to optimize cutter
performance. The signcutter comes with a CD-R OM 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. T ype D:\SETUP (substitute the correct letter if the CD R OM driv e 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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OPERATION
KEYPAD CONTROLS
The keypad allows access to the main signcutter functions.
Figure 2. The Signcutter Keypad.
Start/Stop
The Start/Stop key connects or disconnects communication between the computer and the signcutter. If the Start/Stop key is
pressed during cutting or plotting (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, signcutter
online (ready to receive instructions).
STOP red light Arrow keys operable, signcutter offline
(not ready to receive instructions).
Arrow Keys
Pressing the Arrow keys moves the ma terial back and forth or the
carriage from side to side. The arrow k eys will not work unless the
signcutter is in Stop mode (see Start/Stop above).
Set Origin
The Set Origin key sets the initial origin or starting position for the sign. It is best to set a new origin before cutting each sign. If a new origin is not set before sending a file to the signcutter, the signcutter will begin at a point determined by the previous cut f ile. The software may give the option of selecting this ending point. The signcutter will then treat the new file as a continuation of the previous cut. This will affect the repeat function. Refer to the Re- peat section below . To set a new origin, make sure the signcutter 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 signcutter will then accept cut/plot files.
Figure 3. Origin Point.
Note: Design software usually refers to the origin as “lower left”
because it is the lower left corner of a sign. Because the cut is
usually oriented as shown, it is physically on the right side of the
signcutter.
Speed
Use the Speed knob on the front panel of the signcutter to adjust
the speed. T urn 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 Sign
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 pen
or blade. See the section on Cutting a Sign for the recommended
settings. The range of force available at the knob is adjusta ble in
the Control Center. The available range is 1 - 400 grams.
Note: Using too much force can cause excessive drag, damage
the pen or blade, or tear the material.
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Test Cut
This button will cut a test pattern to help determine the proper
force (for knives or pens) and blade exposure for cutting signs.
The test cut will also show the effect of the blade of fset and overcut
settings in the Control Center. See the section on Cutting a Sign
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 signcutter that the blade
holder is installed in the carriage. Position the blade over the
material near the right side of the signcutter.
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 plotter will cut a
small test pattern consisting of a circle within a square.
4. Adjust the force and blade e xposure 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 Sign 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 plotter 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 sign. The signcutter must be in Stop mode (red LED)
to use the Repeat key. To start the cut in a new location, move the
pen or blade to a new position with the Arrow ke ys before pressing the Repeat key. Repeat will do the following:
1. Individual files are repea table until the Set Origin key is pressed
and any new data is sent to the signcutter. 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 buf fer (1 meg abyte)
before an origin is set the repeat function is disabled. This feature allows the signcutter to handle files of limitless size. When
the buffer has overflowed it no longer holds a complete file so
repeat would produce unpredictable results.
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 signcutter.
• 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 plotter.
Figure 4. Control Center Setup Screen.
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.
Figure 5. Control Center Main Menu.
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Changing System Settings
A variety of settings are adjustable to fit specific needs:
• The signcutter 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 signcutter 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/Plot File Send a cut (.plt) file to the signcutter . Open Settings File Restores sav ed settings files. Save Settings As Allows user to sav e settings files. Exit Exits the Control Center program.
Setup
Plotter Setup Allows user to select the correct signcutter model. Port Setup Allows user to select the communications port.
Display
Plotter Settings Allows user to vie w current signcutter settings. Factory Defaults ROM Version Displays installed ROM v e rsion. 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
Calibrate
Calibrate Plotter Allows user to calibrate signcutter.
Test
Serial Test Allows user to test serial communications. Computer Port Test Allows user to test computer port. Plotter Port Test Allows user to test signcutter port.
Help
Contents Lists contents of help files.
About Provides Control Center version information.
Allows user to view and restore original factory settings.
Installs new firmware into the signcutter.
Screen Menu Options
Measurement Units
English or Metric units are available when adjusting settings.
Panel Size
The Panel Size is the maximum area the signcutter 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 mov es 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 signcutter will produce a cut in the exact
size of any cut file that is sent. If the scale is 50%, the signcutter will produce
a cut that is half the intended size. The scale of the signcutter 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 A utoloop disabled. Manually create and maintain a service loop in the rear.
With Autoloop enabled the signcutter will create a service loop of material at
the beginning of the plot 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 vinyl.
Special Features
See the sections, How to P ounce 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 inter mittent 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 plotting the segmented line for pouncing or tag board cutout.
The default length is 40 mils (.04 inches) for pouncing and 2000 mils
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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.
Blank - The Blank value is the length, in thousands of an inch (mils), that the blade will not cut when plotting 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 softwar e may override the Contr ol Center settings.
Check to see if it has by pressing the Update Display button before
and after a cut is completed. Check the plotter 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 signcutter. For e xample, 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 signcutter . If Send
Settings to Cutter: Temporary is selected, all of the displayed settings will
be used for the current session. When the signcutter is turned of f these settings
will be lost and the previous permanent settings will be in effect when the
signcutter 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 signcutter and will be saved for all subsequent sessions, even after turning off the signcutter.
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 sign 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 improv e accurac y. This setting is ignored when a pen is installed in the carriage.
Minimum Angle
This is the minimum angle for which the signcutter 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.
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 achie ve maximum accurac y ,
use lower acceleration settings.
Up/Down Delays
The factory set up and down delays are both 0 milliseconds (ms) or 0 thousandths of a second. The delay setting controls the amount of time, in milliseconds, the signcutter pauses after lifting or lowering the pen or blade. Under normal circumstances this setting will not require adjustment. Thick material (e.g. sandblast mask) may require a delay of 25 to 50 ms.
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