DPR GEMINI User manual
USER MANUAL
GEMINI
Digital die cutter for sheets
this product is certified:
IMPORTANT: Please keep the original packaging in
case you need to return the material. If we receive the
system in non-original packaging, the warranty will be
void.
IMPORTANT: The latest version of the Scorpio Series
software is available on our websites www.dpr-srl.it
or www.dpr-llc.com,section “Download”.
Overview
GEMINI - Digital Cutting Software
Unpacking the contents of the GEMINI
How to istall the Cutting Manager software
How to update the Cutting Manager software
Assembly of your GEMINI
Setting up the GEMINI Feeder
Cable connections and aligning the feeder
Pinch Roller Position - Paper Size/Format Adjustment
Cutting options - Blade Positions
Changing blade positions
Daily Operation Start-up
Cutting Manager software
Creating Your Cut Files
Graphics le design
Layers for printing
Layers for cutting
Printing the Artwork / Graphic le
File properties for cutting
Graphic le Compatibility
Basic operations
Startup
Sheet and camera alignment
Adjust plotter’s knife
Black-marks settings
Cutting parameters
Cut test
Copy mode
Press start to launch the cutting series
How to replace cutting mat
How to replace the knife
TroubleShooting
GEMINI USER GUIDE - TABLE OF CONTENTS
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GEMINI - DIGITAL CUTTING SOFTWARE
There are also additional functions enabling the management of die cutting sheet material, using
cross cut (Cut through) and dashed cut features, so that greeting cards, POS and packaging board
material may be also cut.
The GEMINI solution consists of 2 parts.
Hardware
An GEMINI Engine
A high resolution CCD Camera for registration and accurate positioning
An Automatic sheet feeding system for up to 150 sheets of media
A Paper exit Tray
and
Software
The cutting manager allows you to cut lines or paths of a pdf vector graphics
FOUR reference black-marks (Described later).
The high resolution CCD video camera included in your GEMINI hardware
detects the black-mark in a fraction of a second and adapts the cut
path to any variations in the origin, scale or skew distortion of the print.
The software runs with the operating systems Windows XP, 7, 8, Vista, 10.
Most of old Windows XP computers can be used, but not all of them.
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The Cutting manager software for the GEMINI needs to be downloaded from our websites
www.dpr-srl.it / www.dpr-llc.com
Execute the installation’s program Cutting manager-setup.
On some computers you could be asked the system administrator’s password to execute the
installation, in the case you do not have this information; contact the technician who administrates
the system.
After the installation you will have the software’s shortcut in your desktop, and a folder that contains
the report of all the cuts in your documents.
HOW TO INSTALL THE CUTTING MANAGER SOFTWARE
Your GEMINI is packed in 2 boxes.
The second box contains:
- The GEMINI Exit tray (ii)
- The GEMINI Feeder (iii)
- And the power adaptor, plus USB cables, manual and drivers. (iv)
The GEMINI Exit tray sits under the GEMINI cutting engine, take care to position the vertical tabs
under the recesses on the front of the cutting engine.
The GEMINI Auto-Feeder, clips on to the front of the GEMINI cutting engine, and lines up next to
paper size guides along the front left edge.
connects the USB hub integrated under the feeder to your computer.
Also in addition a USB cable to connect the GEMINI cutting Engine to the integrated USB Hub
under the feeder.
UNPACKING THE CONTENTS OF THE GEMINI
To update your cutting manager you just have to download the newest installer and accept all the
HOW TO UPDATE CUTTING MANAGER SOFTWARE
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ASSEMBLY OF YOUR GEMINI
STEP 1
Join the plotter base with the sheet tray.
STEP 2
Fix the plotter on the base.
Insert the plotter feet into the holes.
STEP 3
Unit the feeder with the plotter base.
Pay attention!
A
B
BB
A A
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SETTING UP THE GEMINI FEEDER
CABLE CONNECTIONS AND ALIGN THE FEEDER
The last item to connect is the feeder, but you need to make the USB connections before aligning
the feeder.
The GEMINI system requires 4 USB connections:
- The Plotter requires a USB cable (supplied in the box).
- The high resolution cameras used for the GEMINI vision registration system use a USB connection
(Integrated to the cameras).
- Dongle
integrated USB hub this enables you to connect all your GEMINI USB connectors.
Plug the cables as shown.
To connect the GEMINI to the pc, plug the USB cable exit on the front of the feeder
(where is the control commands) to the pc.
1 2 3 4 5
1. CAMERA
2. CAMERA
3. PLOTTER
4. DONGLE
5 . FREE USB
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After adjusting the paper guides width with the knob, you should manually advance one sheet in
order to correctly position the pinch rollers.
NOTE: The pinch rollers MUST sit over the grit rollers.
Typically the Left Pinch wheel is not moved, instead you adjust/slide the feeder to ensure the left
side of the sheet is correctly under the ‘static’ left pinch wheel.
Then adjust the right pinch rollers so that they are positioned above both the media and the grit
rollers.
MOST IMPORTANT:
If you need to move the right Pinch wheel to suit your media size, the
relocation of the pinch roller must be made only when the lever is lowered.
Once you have relocated the right pinch wheel to accommodate your
media, lift up the lever to engage the rollers.
PINCH ROLLER POSITION - PAPER SIZE/FORMAT ADJUSTMENT
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CUTTING OPTIONS - BLADE POSITIONS
The GEMINI cutting engine uses a contour cutting system.
(i) Kiss Cut (For adhesive labels)
In this mode, you cut over a cutting strip which provides a surface to cut against, and you ONLY cut
the top layer of your substrate.
You do not cut all the way through the media.
(ii) Die Cut / Cross Cut (For Packaging or Cutting all the way through substrates)
In this mode, you cut over a groove which provides a recess so the knife can cut through your
substrate and not cut into the machine.
In this mode you DO cut all the way through the media.
Left pinch roller
Right pinch roller
Button #2 for the
reading of the sheet
Power button on
the left side
Adhesive cut position
Cross cut position
Lever raised engages
the pinch rollers
Lever lowered
releases the pinch roller
In this position we cut against the cutting strip,
and do not cut all the way through the media.
In this position we cut over a groove on the cutter bed.
This enables the blade to cut all the way through the media.
(For cutting card shapes or packaging).
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Out of the box, the Blade tool has been set up to cut labels (It is in the Kiss Cut position, rear),
nearest the exit tray and the knife exposure set to the correct setting for label stocks. You need to
leave the blade in this position for making an alignment calibration on the GEMINI cutting engine
or for cutting labels.
However if you have already performed a calibration and wish to Die-cut card, you will need to
adjust the knife position to the front position (Nearest the feeder) and you will need to adjust the
blade exposure.
MOST IMPORTANT:
To save adjusting knife depth when switch between labels and card stock,
you can order a second blade holder and blade.
Then simply adjust one for labels and the other for card.
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Bracket to
hold tool Flange
1. Loosen the tool holder screw.
When removing the tool, turn it counterclockwise to remove the tool.
Removing the tool
Bracket to hold tool Tool holder
Tool holder
Bracket to hold tool
TOP
Bracket to
hold tool Flange
Tool holder
Tool holder 1
(Backward: Half cutting/
Plotting Pen)
Tool holder 2
(Forward: Using cutting)
SUPPLEMENT:
When using kiss cutting (for
labels), place the Blade
Holder in Tool Holder 1
position (backward),
and when using Die-cut
(Card cutting), set the blade
holder in Tool Holder 2
position (forward).
CHANGING BLADE POSITIONS
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DAILY OPERATION START-UP
1. Turn on the Graphtec. When the loading is completed press 2 (ROLL-2 CURRENT POSITION).
2. Turn on the Feeder.
3. Open the Cutting Manager.
4. Lower the media lever.
5. Press “Load sheet”.
6. Once the sheet is loaded, check the camera positions. The green square in the camera preview
must contain the black-mark (for label cut) or the ENTIRE sheet (for boxes). Check both cameras.
To switch from one to the other, press “Switch camera”.
7.
When you have completed the alignments, remove the sheet, raise the lever and press 2.
* The default position of the Blade holder is already in the label cutting position upon delivery.
Ready for immediately cutting sheet labels or making any alignment calibrations.
IMPORTANT:
- Left pinch wheel should always be aligned over the grit roller to avoid any error messages.
- Right pinch wheel should be adjusted accordingly with the paper width.
- Lever raised engages the pinch rollers. Lever lowered releases the pinch roller.
- Button #2 turns the plotter ‘On-Line’ and the reads the available cutting width for your sheets.
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CUTTING MANAGER SOFTWARE
OVERVIEW OF CUTTING MANAGER SOFTWARE PANEL LAYOUT
The Cutting Manager software allows you to adjust and control all the functions and parameters for
the digital cutting process.
The cutting manager allows you to cut lines or paths of a pdf vector graphics.
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1.
2.
3. “Open PDF” and “Open last job
“Open last job
4. Operation buttons to help control the cutting series
5. “Cut test” launches a single cut
6. Controls for the sheet and camera alignment
7. In this area the user chooses the number of copies per job run
8. Camera preview of the black-mark
9. Working perspective controls and preview
10. Blackmarks settings
11. Magenta lines settings (for boxes)
12. Border lines settings
13. Advanced controls
14. Label’s or Pack’s mode switch
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3
4 5
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CREATING YOUR CUT FILES
cutting manager video camera detects the black-marks in a fraction of a second and adapts the cut
path to any variations in the origin, scale or skew distortion of the print.
is positioned 23mm (0.90”) from the tail of the sheet.
Most of digital printers can print up to 5mm (0.2”) from the border of the sheet, we recommend a
minimum distance of 6mm (0.23”) between the black-mark and the bottom border of the sheet.
Each black-Mark can be 4x4mm or 2x2mm square, and should be 100% K black (Not CMYK
black) and should have no outline.
Feeding
direction
Minimum distance
25mm
0.98”
23mm
0.90”
6mm
0.23”
6mm
0.23”
140mm
5.51”
23mm
0.90”
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The minimum distance between the black-mark and the printed graphics is 5mm (0.2”).
If the graphics on your job are too close to the black-mark you can get the error: “Marker not found”
because the software won’t be able to distinguish your registration mark from the graphics content
on your print.
NOTE:
If a cutline is too close to the lead edge of the sheet then the GEMINI engine will reverse
the sheet out of the pinch rollers while trying to cut the line. When the GEMINI engine
subsequently tries to advance the sheet for the next cut line element, it may no longer
accurately feed your sheet and may skew the rest of your cutlines.
Minimum
5mm
0.2”
Align the shape to
the rst black-mark
for the quick align
between print and cut
Feeding direction
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GRAPHICS FILE DESIGN
When printing you don’t want your cut lines to appear on your printed sheet. Equally when cutting
you don’t want to confuse the cutter with lines that may be in your printed design. But, in both cases,
you need the have available the registration marks.
- One or more layers for the main graphics (the Printed artwork).
- One layer for the contour (the lines to be cut).
- One layer for the SmartMarks (the marks that are used for registration).
Graphics layer
Markers layer
Cut contour layer
NOTE:
The most common error is to print all the layers including the cutline (contour) layer that
make the prints unusable in most of cases.
Similar commands are available in Adobe Illustrator and CorelDraw to enable and disable the layers.
In the pictures shown on this page there is an
external frame to indicate the border of the
sheet making it easier for you to seet the page.
Note: That this is for illustration purposes only.
Also please note: When you open some PDF
on the graphics. You will need to delete the
correctly with
the software.
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LAYERS FOR PRINTING
In this example, the main graphics layers and the markers layer are active.
The cut contour layer is disabled.
This drawing is ready for printing.
LAYERS FOR CUTTING
In this example, the main graphics layers are disabled.
The cut contour layer and the markers layer are active.
This drawing is ready for cutting.
If you used the guidelines, remember to hide or remove them before saving.
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PRINTING THE ARTWORK / GRAPHIC FILE
(black-marks). The cutlines should not appear on your printed job - when using Adobe Illustrator, or
CorelDraw you can use layers control, for the Cutline and the Artwork, then hide the cutline before
printing.
You can use every version of both Adobe Illustrator and CorelDraw.
Remember your black-marks must be placed at least 6 mm from the printed graphics, to avoid
reading interferences.
FILE PROPERTIES FOR CUTTING
You can design jobs in every version of both Adobe Illustrator and CorelDraw.
The graphics must be saved in horizontal (landscape) view.
NOTE:
Your Cut Lines should be 100% K. You do not have to use a particular thickness for the
cut prole.
If you wish to use a second line for creasing/
scoring or for perforated lines. Use the color
100% Magenta.
Lines in magenta color are treated separately
on software, enabling to change cutting depth/
pressure for these lines, or to change the type
of cut.
GRAPHIC FILE COMPATIBILITY
Vector PDF.
Please ensure when saving your cut lines you ensure there are no guides or rulers on the
page, and that there are no boarders on the page. Then ensure you save in one of the above
formats.
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BASIC OPERATIONS
This section explains how to use the cutting manager and the plotter for a proper cut.
Turn on the plotter. Once the display brings you to the “SELECT” menu, press 2 and wait for it to
read the media and inputs width into the width settings.
Turn on the feeder and wait until the sheet loader is full lowered. Plug the Gemini’s usb cord into
your pc, then open the cutting manager.
1. STARTUP
First of all, check the green square position in camera preview. Control both the cameras by pressing
the “Switch Camera”.
advanced” >> “settings”.
Now adjust the Y and the X until the feeder’s guide is out of the green square.
2. SHEET AND CAMERA ALIGNMENT
Then press “Open” or “Open last jobOpen last job” selects the last job used
by the cutting manager).
Now, in working view select your actual perspective.
A picture under this area shows how you should watching the gemini according to this setting, and
how the sheet should be placed.
“Set then in “Working mode” if you want to cut labels or packages.
+Y
+X
Standard parameter
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WARNING “When they are loaded sheets mustn’t be bent over or damaged”.
label/tag sheets cardboard sheets
Add the sheets according to these pictures.
align the pinch rollers to the material.
For the label’s sheet, manually move the material until the blackmarks are under the feeder’s guides
holes.
Now align both the cameras. When cutting labels, move the cameras until the blackmark is directly
in the center of the green square.
When cutting boxes, move the cameras until the Entire paper is contained in the green area.
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