Ioline SmarTrac 100 Series User manual

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
EH C
F

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Ioline
TABLE OF CONTENTS
THE 100 SYSTEM CUTTER .................................... 4
SAFETY AND PRECAUTIONS ................................ 4
INSTALLATION ........................................................ 5
UnpacktheCutter...............................................5
AssembletheCradle ..........................................5
AttachtheCutter.................................................5
PreparetheArea ................................................5
Connectthe Cutter to theComputer ....................5
PowerOn ...........................................................5
InstallingtheIolineControlCenter .......................5
OPERATION ............................................................. 6
Keypad Controls .................................................. 6
The Ioline Control Center .................................... 7
ChangingSystemSettings..................................8
Menu Bar Features .............................................8
ScreenMenuOptions .........................................8
Cutting a Design................................................. 10
GeneralGuidelines...........................................10
PowerOn .........................................................10
LoadingtheMaterial.........................................10
AligningtheMaterialand PinchwheelsontheOptional
Stand ..........................................................10
AdjustingthePinchwheels ................................ 11
LockingthePinchwheels OffofthePlaten ......... 11
Installing a Blade and the Blade Foot ................12
Installing a BladeHolderorPen ........................12
AdjustingBladeExposureandForce................12
Sending a Cut File to the Cutter ........................13
PausingCutting ................................................13
Canceling a Cut ................................................13
SuggestedSettings ..........................................14
Guidelines for Plotting Pens..............................15
HowtoPounce .................................................16
StencilCutting ..................................................16
COMMUNICATION TESTING ................................. 17
CommunicationTest .........................................17
Testingthe Cutter SerialPort ............................17
TestingtheComputerSerialPort ......................17
TROUBLESHOOTING............................................ 18
TroubleshootingChart.......................................18
LED Codes ......................................................19
TroubleshootingtheParallelPort.......................19
ROUTINE MAINTENANCE .................................... 20
Replacing the Blade .........................................20
CleaningtheDriveShaft ...................................20
Calibration........................................................20
END NOTES ........................................................... 22
GettingHelp .....................................................22
TheFCCWants YoutoKnow.............................23
YourComments AreRequested........................23
CustomerService.............................................23
LimitofLiabilityStatement ................................23
GLOSSARY............................................................ 24
INDEX ..................................................................... 26

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Ioline
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 ques-
tions 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 cut-
ters. 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 (en-
abled 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 ma-
chine 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 proce-
dure.
• 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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Ioline
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 be-
fore 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 prop-
erly 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 communica-
tion.
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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Ioline
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 be-
tween the computer and the cutter. If the Start/Stop key is pressed
during cutting (Stop mode) the machine will stop when the cur-
rent 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 counter-
clockwise 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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TestCut
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 set-
tings 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 re-
cently created design. The cutter must be inStop 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 inStart 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.
UpdateDisplay
Note: The design software may override the Control Center settings.
Check to see if it has by pressing the Update Displaybutton 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, usingUpdate 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 milli-
seconds, 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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Ioline
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 Au-
toloop function (enabled in the Control Center). It will create the re-
quired 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. Manu-
ally 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 pinch-
wheels. Pull down enough material to reach the media rollers on the
stand.
2. Roughly align the material so that the edges are overlapping the wide-
right-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 down-
ward 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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Ioline
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 cut-
ters 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 sheet-
ing.
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 sec-
tion for more details.
Important: Make sure that the carriage and material are in the proper
position and that an origin is set by pressingSet 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 direc-
tions 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.

14
Ioline
Material Thickness Blade Offset Force
mils mils grams
Amberlith™/Rubylith™ 145o15 30-60
Flock 15 Cobra 47 100-200
Thermo-Flock 15 45 15 200-300
Thermo-Film 345 15 200-300
Gorilla-Grip 4-5 45 15 200-300
Polyester, Metalized 245o15 100-140
Reflective, Engineering Grade 545o15 240-250
Sandblast Mask2181- - -
31 Cobra 47 220-260
36 Cobra 47 220-260
401- - -
Stencil, Lacquer Adhering 145o15 80-100
Stencil, Vinyl 445o15 200-220
Stencil, Water Soluble 145o15 125-135
Tag Board 10 45o15 300-400
Vinyl, Calendered 345o15 100-150
Vinyl, Cast245o15 100-150
1These sandblasts typically have a backing which is designed for cutting by hand.
2Use 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 recom-
mends 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 manu-
facturer, color, age, and temperature of the material.
Table 1. Suggested Settings for Different Material Types.
Speed Acceleration Min. Angle Overcut Down Delay
ips gdegrees mils milliseconds
med. 0.1 30o0-5 0-50
min. 115o10 0
min. 115 10 0
min. 115 10 0
min. 115 10 0
max. 130o10 0
min. 130o10 0
- - - - -
min. 115o30 0
min. 115o30 0
- - - - -
max. 130o10 0
min. 130o10 0
med. 130o10 0
min. 0.1 30o10 0
med.-max. 130o10 0
med.-max. 130o10 0
NOTE: Settings should be adjusted for cutting small letters or intricate detail,
refer to the Cutting Small Characters section.

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

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 inStart 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. Perfor-
mance will vary with different paper types. Experiment with lower set-
tings 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 inStart 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 nec-
essary. 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.

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 com-
puter. 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 Cen-
ter. 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 neces-
sary for the parallel (LPT) port.
5. Press the Repeat key to switch the cutter intoEcho 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 suc-
cessful.

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, con-
sult 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 size-
exceeds 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.

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 com-
puter. 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 click-
ing 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. Io-
line 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.

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 calibra-
tion 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 mea-
surement 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.