Ioline SmarTrac I/S Installation and operating instructions

Copyright © 1999, Ioline Corporation, All Rights Reserved
Printed in the United States of America
Text Revision 1, PN 106844
November 1999
All Trademarks Are The Property Of Their Respective Owners
USINGYOUR
SmarTracTM I/S
Signcutter

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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 I/S Signcutter.
B
K
J
G
A
D
EH
C
F

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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 signcut-
ter 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 per-
form system diagnostics. Most design software provides drivers for Io-
line signcutters. Contact Ioline customer service if you need assistance
with drivers.
SAFETY AND PRECAUTIONS
Please read these safety guidelines before beginning operation of the signcut-
ter. 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 theAutoloop function (en-
abled in the Control Center) will create the required service loop by gen-
tly pulling a set amount of material from the roll before cutting. Ioline
recommends using theAutoloop function when plotting on a roll of ma-
terial.
• Do not try to repair the machine without factory authorization. Only quali-
fied service personnel should attempt any disassembly or access to inter-
nal components. If external mechanical adjustments are necessary, turn
off the signcutter and disconnect it from all power sources (both the com-
puter 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 ma-
chine 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 opera-
tion.
• 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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INSTALLATION
Unpack the Signcutter
Warning: Do not lift the signcutter by the plastic end covers, the dust
cover, or the carriage rail. This may permanently damage the sign-
cutter. 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
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 move
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 signcut-
ter 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 plotter
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 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 protect the equipment and
reset the signcutter if changing between parallel and serial com-
munication.
2.If connected to a parallelport, 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 they work. The signcut-
ter 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 signcut-
ter. 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 signcutter comes with a CD-ROM which has the Microsoft
Windows® 95, 98 and NT (3.51 or greater) version of the Ioline Control Cen-
ter program.
1. Turn on the power to the computer and start Windows®.
2. Insert the Ioline CD ROM into the CD ROM drive (usually D:)
3. Select the Start button.
4. Choose Run.
5. Type D:\SETUP (substitute the correct letter if the CD ROM drive letter is
not D:) and Click OK.
6. Follow the instructions that appear on the screen.
7. Consult the Operation chapter of this manual for details on using the
Ioline Control Center software.

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Figure 2. The Signcutter Keypad.
OPERATION
KEYPAD CONTROLS
The keypad allows access to the main signcutter functions.
Start/Stop
The Start/Stop key connects or disconnects communication be-
tween 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 ac-
tive when in Stopmode.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 material back and forth or the
carriage from side to side. The arrow keys will not work unless the
signcutter 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 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. Turn the knob clockwise to increase the speed, or coun-
terclockwise 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 adjustable 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.
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 file.
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.

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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 offset 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 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 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 re-
cently created sign. The signcutter must be in Stopmode(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 keys before press-
ing the Repeat key. Repeat will do the following:
1. Individual files are repeatable until the SetOriginkey is pressed
and any new data is sent to the signcutter. This includes updat-
ing 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 fea-
ture 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.
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 ex-
ceed 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 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 plot-
ter.
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 signcutter must be in Start mode (green LED on) when changing
system settings. Press the Start/Stopkey 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 Cen-
ter settings. Check to see if it has by pressing the Update Display but-
ton 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 saved settings files.
Save Settings As Allows user to save 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 view current signcutter 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 signcutter.
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.
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 maximumY-axis panel size depends on the machine width. The material
moves along the X-axis; the carriage moves along theY-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 andY axes are set independently.
Autoloop
Warning: Autoloop default is off. Do not allow the material to be-
cometautwhenusinga rollofmaterialwithAutoloopdisabled. Manu-
ally 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 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 - TheCut 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 software may override the Control Center settings.
Check to see if it has by pressing the Update Display button before
and after a cut is completed. Check the 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 set-
tings stored in the signcutter. For example, usingUpdate Displayafter 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 off 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 ses-
sions, even after turning off the signcutter.
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 signcutter pauses after lifting or lowering the pen or blade. Un-
der normal circumstances this setting will not require adjustment. Thick ma-
terial (e.g. sandblast mask) 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 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 car-
riage.
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 set-
ting 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.

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CUTTING A SIGN
Before cutting a sign, turn the signcutter on, load it with vinyl, install a blade
holder, and set an origin. These steps are outlined below. In most cases the
design files are sent directly from the design software to the plotter. If neces-
sary, use the Ioline Control Center software to send design files, adjust set-
tings and test signcutter communication.
General Guidelines
1. Never let the material 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. Ioline recommends using the Au-
toloop function (enabled in the Control Center). It will create the required
service loop by gently pulling a set amount of material from the roll be-
fore cutting. Autoloop default is off.
2. Use the Paneling feature in the design software for long signs. 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 signcutter. The signcutter power switch is lo-
cated 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 signcutter. 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 signcutter and the material
roll. Manually create and maintain a service loop in the rear. See
Autoloop in the Ioline Control Center section for more information.
If using a roll of vinyl: Place the roll between the media rollers (stand), on
the axle (cradle) or at the back of the machine (foot).
If using a roll of paper: Hang the paper roll on an axle if available. Use a
media roller or the cradle tube if the signcutter has them. Place the roll behind
the machine if the signcutter has only feet. 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
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 signcutter.
1. Lift the pinchwheels by raising the pinchwheel lever on the right side of
the signcutter. Bring the material up and through the space under the
pinchwheels. Pull down enough material to reach the media rollers on the
stand (I/S 80 model and larger) or about one foot (25 cm) on the tabletop
cradle mounted I/S 60 models.
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 or cradle and clasp the front edges
of the sides of the material hanging from the front of the machine against
the edges of the material hanging from the back of the machine. Pull
downward on the material and square the edges so that they are parallel
front and back.Alternatively, align the edge of the material with the edge
of the material roll.
6.While maintaining the material square and taut, clamp the pinchwheels to
the material by lowering the pinchwheel lever on the right side of the
signcutter.
7. Warning: While checking alignment with theArrow keys, make sure
thatthe material betweenthe material rollandthesigncutter is never
pulled taut with the drive shaft. Check alignment by using the arrow
keys to move the material forward and back. Observe the material edge to
make sure it is running straight.

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Adjusting the Pinchwheels
Signcutter models 80 cm and wider have pinchwheels with adjustable spring
force*. This allows the user to use maximum force (24 lbs.) for holding vinyl
(which requires more force for better tracking) or less force (8 lbs.) for light-
weight materials like paper and for sandblast resists that must be tracked di-
rectly on the rubber surface.The pinchwheels can also be set in a position that
keeps them completely off the surface so that the inner pinchwheels on larger
cutters will not interfere with pen plotting.
The force adjustment is set by turning a screw on the back of the pinchwheel
assembly.
1. Move the pinchwheel to the access hole on the back of the dust cover.
2. Insert a flat screwdriver into the slot and turn the adjustment screw 90
degrees. When the slot is in the vertical position on the outer wheels the
force is 24 lbs. The horizontal position indicates 8 lbs of force. On units
equipped with inner pinchwheels, force can be set to 12 lbs. (vertical
setting) or 4 lbs. (horizontal setting). The 12 lb. inner pinchwheel setting
is useful for heavier materials such as heavy sandblast or reflective sheet-
ing.
* This option is not available on all signcutter models.
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 cutting or 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
* This option is not available on all signcutter models.

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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 signcutter will cut a test sign.
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 plotter 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 signcutter 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.

13
Ioline
Sending a Cut/Plot File to the Signcutter
Always load the signcutter and make test cuts to determine the correct set-
tings before sending any files. See the Adjusting Blade Exposure and Force
section for more details.
Important:Makesurethatthecarriage and materialareintheproper
position and that an origin is set by pressing Set Origin on the keypad
(LED is green).
Send the file directly from the design software following the directions in the
documentation or;
From the Ioline Control Center:
1. From the menu bar select File, Send Cut/Plot 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 notturnthe material rollorpull 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 signcutter 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 signcutter will return to
the original cutting position and continue plotting where it stopped. The
keypad LED will change from red to green.
Canceling a Cut
1. Press the Start/Stop key to place the signcutter 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.
3. Press the Set Origin key to make the signcutter delete the cut data it has
already received but has not yet plotted.
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 material should have a light pattern.
6. Continue increasing the blade exposure and making test cuts. The test
sign 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 signcutter will cut a 1.9 inch x
7.1 inch design.
2. If the sign does not separate cleanly and leave a light scoring on the back-
ing, try another 1/8 turn upward (counter clockwise from above) of blade
exposure and a very slight increase in force.

14
Ioline
Suggested Settings
There are many variables that determine signcutter output quality. Ioline rec-
ommends using low force and speed settings when making the initial test
cuts. Gradually increase these settings until the best values for the material are
found. Refer to Table 1 below for settings for a variety of material types.
Force values are for starting reference only. These settings may vary due to
manufacturer, color, age, and temperature of the material.
Table 1. Suggested Settings for Different Material Types.
Speed Acceleration Min. Angle Overcut Down Delay
ips g degrees mils milliseconds
med. 0.1 30o0-5 0-50
min. 1 15o10 0
max. 1 30o10 0
min. 1 30o10 0
-----
min. 1 15o30 0
min. 1 15o30 0
-----
max. 1 30o10 0
min. 1 30o10 0
med. 1 30o10 0
min. 0.1 30o10 0
med.-max. 1 30o10 0
med.-max. 1 30o10 0
Material Thickness Blade Offset Force
mils mils grams
Amberlith™/Rubylith™ 1 45o15 30-60
Flock 15 Cobra 47 100-200
Polyester, Metalized 2 45o15 100-140
Reflective, Engineering Grade 5 45o15 240-250
Sandblast Mask2181-- -
31 Cobra 47 220-260
36 Cobra 47 220-260
401-- -
Stencil, Lacquer Adhering 1 45o15 80-100
Stencil, Vinyl 4 45o15 200-220
Stencil, Water Soluble 1 45o15 125-135
Tag Board 10 45o15 300-400
Vinyl, Calendered 3 45o15 100-150
Vinyl, Cast 2 45o15 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 plotter .
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 plotter 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. Plotter Pen Guidelines.
repaP neP deepS ecroF smarg stnemmoC
-yaLrepuSIMB tnelaviuqero™talF dnobytilauqhgih
elyts-PH tniopllab mumixaM08-06/punepsm51 nepsm51 syalednwod
"dnuoR®CIB citS tniopllab
mumixaM002-081
"drofnaS eiprahS mumixaM001-07
"elyts-PH pitrebif muideM001-07
___pitcitsalP______toN dednemmoceR
___pitcimareC______toN dednemmoceR
___/knidiuqiL pitlateM ______toN dednemmoceR
Cutting Long Signs
To cut long signs it is necessary for the signcutter to be properly calibrated
and to make sure the pinchwheels are correctly spaced. Additionally, some
system settings must be adjusted to achieve the best results. Use the Ioline
Control Center to make system changes.When cutting long signs, it becomes
increasingly important for the material to be aligned properly and for the set-
tings to be properly adjusted. These suggestions can help produce fine quality
long signs.
1. Use a stand or cradle. The use of a stand or cradle takes advantage of the
signcutter platen design. When the material is draped over the platen it
can benefit from its natural tendency to curl downward.
2. Build a material slide. Cut two cardboard pieces the width of the stand
large enough to lean against the signcutter stand legs. This prevents the
material from going under the machine and getting buckled with material
from the other side.
3. Check the material roll. Place the roll of material to the right of the
material cradle or media rollers. Make sure the roll is tightly wrapped and
even along the sides.
4. Load the material straight. See the previous sections Loading the Ma-
terial and Aligning the Material and Pinchwheels to properly load the
signcutter.
5. Lower Acceleration. Using the Ioline Control Center program, set the
acceleration to 0.5 g or less. Lower acceleration will help with overall
accuracy, especially in the transition between frames.
6. Use Autoloop. Autoloop will gently pull a set amount of material from
the roll. This helps the material feed into the signcutter more accurately
and keeps it from “jerking”from the roll. Autoloop also helps to set up
the drive track in the backing of the material which helps keep the mate-
rial aligned. Autoloop is enabled in the Control Center. Set Autoloop to
ON and set the Loop Size to the default of 30 inches. Setting the panel
size in the sign making software to the same length as the Loop Size
might help tracking accuracy. IfAutoloop is OFF, maintain a service loop
of material behind the signcutter to prevent, “jerking,”material from the
roll.
7. Speed. Set the Speed knob to 50 percent or less. Moving the material at a
slower speed helps to keep it more stable and prevents it from kinking or
buckling.

16
Ioline
8. Force and Blade Depth. Incorrect cutting force and blade depth can
cause misalignment problems over the range of a long plot. If the force is
too high, the material may skew. If the blade depth is set too deep, it
could cut all the way through the material and/or cause the material to
become jammed under the blade.
9. Let the software help. Use the automatic sorting, ordering or contour
ordering feature in the design software (some software programs auto-
matically handle this process). This will reduce the number of time con-
suming back and forth and side to side movements.Wear on the material
backing (as well as the vinyl) is also decreased which will improve track-
ing. The more complex the file, the more difficult the problem.
10. Use the Paneling feature in the design software. Paneling will restrict
the length of any x-axis move. Ioline suggests a panel size of 10 to 20
inches. With most sign making software, the paneling feature allows the
placement of a panel between characters.
Cutting Small Characters (Under 1/4 in.)
For cutting small characters or intricate detail in various material, it is neces-
sary for the signcutter to be calibrated properly and to make sure the pinch-
wheels are spaced correctly. Also, some of the system settings should be ad-
justed to achieve more accurate detailed cutting. This is done by making
changes in the Ioline Control Center and by adjusting the dial controls on the
front panel. The following is a list of adjustments that should be made:
1. Lower Force. The lowest blade force possible is the best for small, de-
tailed cutting. Start by making test cuts with one quarter force. Gradually
increase the force until the vinyl is completely cut.
2. Slower Speed. The speed knob should be set halfway or less.
3. Foot Adjustment. After setting the lowest cutting force, adjust the foot
downward until the cut is not complete, then back it up just enough to get
a complete cut. Since some force is applied to the foot, a slight increase in
cutting force might be necessary. When the foot is adjusted properly, the
blade tip should just cut through the material.
4. LowerAcceleration.When cutting Rubylith orAmberlith, set the Accel-
erationto 0.1 g in the Control Center. Set the Acceleration to 0.5g for all
other material.
5. Minimum Angle. This is listed in the Control Center under the
Blade SteeringArc heading. The minimum angle should be set at 0 de-
grees.
6. Overcut. Set this between 0-5 mils. If weeding becomes difficult at cor-
ners, increase overcut by one mil at a time until weeding is easier.A little
more force might help if the material has incomplete cutting not at the
corners.
7. Offset. Usually the offset listed for the blade is used as the offset in the
Control Center. For very small characters, tiny manufacturing variances
among blades can make a difference. Check this by cutting small charac-
ters with sharp turns, i.e. the letter “N”.With the standard 45 degree, .015
inch offset blade try several tests using different offset values, i.e. 13, 14,
15, 16, and 17 mils, then pick the value with the best result.
8. Position the Wheels. Place the pinchwheels near the cutting area to as-
sure that the vinyl stays flat.

17
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 signcutter in Start mode (green LED on).
Update the signcutter 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 signcut-
ter 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 com-
plete 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 signcutter in Start mode (green LED on).
Update the signcutter 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:Mosttagboardcutsaremadeatornear 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.

18
Ioline
Testing the Signcutter Serial Port
The diagnostic module is required for this test.
1. Connect the diagnostic module directly to the signcutter COM port.
2. From the Control Center main menu, select Test, Plotter Port Test.
3. Turn on the signcutter while holding down the Test Cut key on the key-
pad. Hold down the Test Cut key until the signcutter beeps and the light
flashes three times. The signcutter is now in Test Mode.
4. Press any Arrow key on the keypad to transmit and receive characters.
Verify that the signcutter beeps.
5. Turn off the signcutter at the end of the test. This will exit Test Mode. If
this test fails, the signcutter port is faulty.
Testing the Computer Serial Port
The diagnostic module is required for this test.
1. Connect the diagnostic module directly to the COM port on the computer.
If the computer COM port has a nine pin connector, use a 9 pin to 25 pin
adapter between the COM port and diagnostic module.
2. From the Control Center main menu, select Test, Computer Port Test.
3.Verify that the COM port selected is the correct one. If it is not, select the
proper COM Port.
4. Verify the CTS handshake line is on.
5. Press any key on the computer keyboard and verify that the character
transmitted equals the character received.
6. Select the Exit button at the end of the test. This will exit Test Mode. If
this test fails, the computer port is faulty.
COMMUNICATION TESTING
There are three communication diagnostic tests available in the Control 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 signcutter 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 plotter 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 plotter off. Connect the plotter to the computer with either a
serial or parallel port cable. See the section Connect the Signcutter to the
Computer 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 signcutter while holding down the Test Cut key on the key-
pad. Hold down the Test Cut key until the signcutter beeps and the light
flashes three times. The signcutter is now in Test Mode.
4. If testing the serial (COM) port, press the Start/Stop key on the signcut-
ter and verify that the handshake line (CTS) status displayed on the com-
puter screen toggles On/Off. Leave the handshake line On. This is not
necessary for the parallel (LPT) port.
5. Press the Repeat key to switch the signcutter into Echo mode. The green
light will come on.
6. Press a key on the computer and verify that the character transmitted
equals the character received. If the characters match then the connection
between the signcutter and computer is working properly.
7. Select Exit after the communication test is complete.
8. Turn off the signcutter 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.

19
Ioline
If the system is not working correctly the problem could be with the com-
puter, the cable, the design software, or with the signcutter. Changes to the
computer operating system or the installation of new peripherals or software
might cause conflicts. If the computer or the design software cause a problem,
consult the computer or software manuals or call the manufacturer or dealer.
If the problem is with the signcutter, begin by making sure power is on and
that the cable between the machines is connected correctly. Test the connec-
tion with the methods described in the Communication Testing section. Con-
sult the following chart for more detailed troubleshooting techniques:
Troubleshooting Chart
TROUBLESHOOTING
Table 3. Troubleshooting Chart.
Table 3-Continued. Troubleshooting Chart.
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ehtgnisserpfI taepeR :tolpsuoiverpehttaepertonseodyek
esuaCelbissoPnoituloS
-eziseliF:wolfrevOreffuB.1 .ezisreffubsdeecxe ehteeS.1 noitarepO ,retpahc taepeR
.noitces
:sneppahgnihtontub,eliftolpatnesevahuoyfI
esuaCelbissoPnoituloS
nisirettolpruoY.1 potS .edom
sahmelborpnoitacinummocA.2 .derrucco .nigironatestonevahuoY.3
ehtsserP.1 potS/tratS tupotyek
nirettolpruoy tratS edom llacrostsetcitsongaidehtmrofreP.2 .relaedruoy .nigironateS.3
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:srorregnikcarteraerehtfI
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.tfahsevirdytriD.6
wenaotsleehwhcnipehtevoM.1 .noitacol .ecrofehtecudeR.2 .g5.otnoitareleccaehtteS.3 .sselro%05otdeepsehtecudeR.4 sniamerlairetamehterusekaM.5 gniruderauqsdna,talf,htooms ehtnihtapaidemehtraelC.gnidaol .rettolpehtforaerdnatnorf .tfahsevirdehtnaelC.6

20
Ioline
Troubleshooting the Parallel Port
If the computer communicating with the signcutter is on a network, it is com-
mon for LPT 1 to be ‘captured’. If a port is captured, the data is redirected to
the network instead of flowing out of the parallel port on the back of the
computer. Ending the capture will allow data to flow normally from the com-
puter to the plotter. Note: These instructions may vary depending on the Win-
dows 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
signcutter 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
contactthemanufacturerformore information aboutenteringBIOS 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.
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.demmajsiegairracehTyawaraelcdnarettolpruoyffonruT .lairetamdemmajrosirbedyna
:ecnogniknilbsithgilderlenaptnorfehtfI
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.demmajsitfahsevirdehTyawaraelcdnarettolpruoyffonruT lairetamdemmajrosirbedyna
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Table 4. LED Codes.
Table of contents
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