Ioline FlexJet E User manual

User Guide
Ioline FlexJet E & StudioJet Printers

Trademarks
Ioline, StudioJet and FlexJet E printers are trademarks of Ioline Corporation. HP is a trademark of the
Hewlett-Packard Company. Other product names, logos, designs, titles, words or phrases mentioned
within this publication may be trademarks, service marks, or trade names of Ioline Corporation or other
entities and may be registered in certain jurisdictions including internationally.
Ioline Disclaimer
IOLINE CORPORATION PROVIDES THIS MANUAL “AS IS” WITHOUT WARRANTY OF ANY KIND,
EITHER EXPRESS OR IMPLIED, INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES
OR CONDITIONS OR MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. IN NO
EVENT SHALL IOLINE, ITS DIRECTORS, OFFICERS, EMPLOYEES OR AGENTS BE LIABLE FOR ANY
INDIRECT, SPECIAL, INCIDENTAL, OR CONSEQUENTIAL DAMAGES (INCLUDING DAMAGES
FOR LOSS OF PROFITS, LOSS OF BUSINESS, LOSS OF USE OR DATA, INTERRUPTION OF BUSINESS
AND THE LIKE), EVEN IF IOLINE HAS BEEN ADVISED OF THE POSSIBILITY OF SUCH DAMAGES
ARISING FROM ANY DEFECT OR ERROR IN THIS MANUAL OR PRODUCT.
Limit of Liability Statement
It is the responsibility of the operator of the printer to monitor the performance of the printer and main-
tain it in proper working condition by following the instructions in this User Guide. It is the responsibility
of the operator of the printer to follow all safety precautions and warnings that are described in this User
Guide. Ioline Corporation is not responsible for injuries that may occur as a result of unsafe use. Ioline
Corporation is not responsible for substandard operational performance as a result of failure to maintain
the printer as described in this User Guide.
© 2003-2008 Ioline Corporation. All rights reserved. This manual may not be copied, photocopied, repro-
duced, translated, transmitted or converted to any electronic or machine-readable form in whole or in
part without prior written approval of Ioline Corporation.
Service and Support
If you require assistance with an Ioline product, your local Ioline dealer or authorized service center is
ready to help. Support information is also available 24/7 on the Ioline Web site—or you may contact Ioline
directly:
Ioline Corporation
14140 NE 200th Street
Woodinville,Washington 98072 U.S.A.
Ioline Customer Service Department
Monday through Friday
7:00 A.M. - 5:00 P.M. U.S. Pacic Time
Voice: 1.425.398.8282
Fax: [phone]
[e-mail]
www.ioline.com
User Notice
Part Number 109619 Rev. 1

User Guide
Ioline FlexJet E
Printers

Table of Contents
Safety & Cautions
Visual Reference Guide
Chapter 1 Overview
Getting Started ................................................................................................. 15
How The Ioline FlexJet E and StudioJet printers Work ................................ 16
Chapter 2 Installation
Printer Assembly .............................................................................................. 17
Unpacking the Printer ......................................................................................................... 17
Assembling the Stand .......................................................................................................... 17
Attaching the Printer to the Stand ................................................................................... 17
Connect the printer to the Computer: Overview ....................................................... 17
Cable Connections .............................................................................................................. 18
Serial Conguration ............................................................................................................. 18
COM Port .............................................................................................................................. 18
Baud Rate ............................................................................................................................... 19
Other Serial Port Settings .................................................................................................. 19
Software Setup Options ..................................................................................................... 19
Power On ........................................................................................................... 21
Installing FlexPlot and the Control Center ................................................... 21
Chapter 3 Operation
Keypad Controls ............................................................................................... 23
Start/Stop ............................................................................................................................... 23
Clean ....................................................................................................................................... 24
Quality .................................................................................................................................... 24
Set Origin ............................................................................................................................... 24
Arrow Keys ............................................................................................................................ 25
Page Advance ......................................................................................................................... 25
Unroll (FlexJet E Only) ........................................................................................................ 25
Special Key Combinations .............................................................................. 25
Roll Up (FlexJet E Only) ..................................................................................................... 25
Reset Serial Port Baud Rate ............................................................................................... 25
Restore Factory Default Settings ...................................................................................... 25
The Control Center ......................................................................................... 26
Overview ................................................................................................................................ 26
Changing System Settings ................................................................................................... 26

Control Center Menu Bar Features ............................................................... 27
File ........................................................................................................................................... 27
Communications .................................................................................................................. 27
Tools ........................................................................................................................................ 27
Help ......................................................................................................................................... 27
Control Center Menu Options ........................................................................ 28
Software Version ................................................................................................................... 28
Cartridge Count ................................................................................................................... 28
Get Plotter Data .................................................................................................................. 28
Plotter Data (check box) .................................................................................................... 28
Line Width .............................................................................................................................. 28
Scale ......................................................................................................................................... 28
Frame Size .............................................................................................................................. 28
Quality Setting ...................................................................................................................... 29
Measurement Units .............................................................................................................. 29
Consumables ..................................................................................................... 29
Paper ....................................................................................................................................... 29
Ink ............................................................................................................................................ 29
Guidelines for Installing a Cartridge* ............................................................................................................................................... 29
Printing a Marker ............................................................................................. 30
Overview ................................................................................................................................ 30
General Guidelines .............................................................................................................. 30
Loading Paper on the StudioJet ...................................................................... 31
Loading Paper on the FlexJet E Printer ......................................................... 31
Installing the Take-up Shaft (FlexJet E Models only)............................................ 32
Feeding Paper (FlexJet E Models only) ................................................................ 33
Tape Paper to the Take-up Shaft (FlexJet E Models only) .................................. 34
Positioning the Pinchwheels ............................................................................ 34
Insert Front Dancer Bar (FlexJet E Models only) ............................................... 35
Insert Read Dancer Bar (FlexJet E 2H+ Models only) ........................................ 36
Set an Origin ..................................................................................................... 36
Sending Plot Files ............................................................................................. 36
Pausing a Marker Plot ...................................................................................... 36
Canceling a Marker Plot .................................................................................. 37
Removing Markers from the Take-up Shaft (FlexJet E Models only) ................. 37
Manually Freeing theTake-up Shaft (FlexJet E Models only) ............................ 38
Automatically Freeing the Take-Up Shaft (FlexJet E Models only) .................. 39
Reattach Paper to the Take-up Shaft (FlexJet E Models only) .......................... 39
Printing to the Floor ........................................................................................ 40
Chapter 4 Routine Maintenance
Cleaning the Drive Shaft ................................................................................. 41
Cleaning the Platen and Traverse ................................................................... 41
Cleaning the Support Blocks (FlexJet E Models only) ....................................... 42
Size Calibration ................................................................................................ 42
Prepare the Printer (See the Operation chapter) ............................................................... 42
Use the Control Center to Gather the Calibration Data .......................................... 43
Enter the Calibration Data: ................................................................................................ 43
Cartridge Calibration ....................................................................................... 44
Prepare the Printer .............................................................................................................. 44
Motion Adjust (Carriage Scan Alignment) ..................................................................... 45
Frame Gap (Paper Scan Alignment) ................................................................................. 45

Cartridge Maintenance and Handling ............................................................ 46
Check Cartridges ................................................................................................................. 46
Automatic Cleaning Procedure ......................................................................................... 46
Manual Cleaning Procedure ............................................................................................... 47
Print Cartridge Storage ................................................................................... 48
Short-term Storage (7 days or less) ................................................................................. 48
Long-term Storage (greater than 7 days) ........................................................................ 48
Updating Firmware using the Control Center .............................................. 48
Summary ................................................................................................................................. 48
Prepare the printer for a Firmware Update ................................................................... 48
Check the Current Firmware Version ............................................................................. 48
Update the Firmware .......................................................................................................... 49
Reset Calibration Values ..................................................................................................... 50
Chapter 5 Troubleshooting
General Troubleshooting .................................................................................. 51
Media Tracking .................................................................................................. 51
Printing Quality ................................................................................................ 52
Line Quality ....................................................................................................... 52
Serial Communication ..................................................................................... 52
Keypad Error Codes ......................................................................................... 53
Legend ..................................................................................................................................... 53
Common Issues ................................................................................................ 54
Common Issues (FlexJet E Models only) ............................................................. 57
Chapter 6 End Notes
Service & Support ............................................................................................ 59
Getting Help ..................................................................................................... 59
Customer Service ............................................................................................. 60
Your Comments Are Requested ..................................................................... 60
Before you contact Support… ........................................................................ 61
The FCC WantsYou to Know... ........................................................................ 62
Glossary
Index

NOTES

NOTES

The Ioline FlexJet E and StudioJet printers have many fast moving
components. Please read and follow these safety guidelines before
beginning operation of the printer:
nDo not try to repair the machine without factory authoriza-
tion. Only qualied service personnel should attempt any
disassembly or access to internal components. If external
mechanical adjustments are necessary, turn off the printer and
disconnect it from all power sources (both the computer and
the wall outlet).
nBe careful with hair, jewelry, or loose clothing near the printer.
They can become caught in the mechanical parts.
nNever attempt to move the carriage by hand when the power is
on. Always use the Arrow keys to move the carriage. To park
the carriage safely in
the Service Station
and protect the print
cartridges, press the
Clean button.
nKeep hands away
from the carriage
when the printer is in
operation. The car-
riage will automati-
cally move to touch
the left end plate then
back to the right end
(the Service Station
position) when the
power is turned on.
nNever insert hands or other objects into the Service Station
area on the right side of the printer. The carriage occasionally
enters this area without warning and could collide with an
obstruction, potentially causing and injury.
nBe careful when moving or lifting the printer. Moving the
FlexJet E printer requires at least 2 people. To avoid injury to
your ngers, do not lift either model by the end plates. Hold
the bottom surfaces of the end covers to lift or move them. See
Figure 1.
nKeep ngers away from the drive shaft when the printer is in
Figure 1. Hold the bottom surfaces of the
end covers to avoid injury to your ngers.
Safety &
Cautions
ix

The Ioline FlexJet E Printer Front View.
x
A. Left End Cover
B. Right End Cover
C. Take-up Motor
D. Stand Leveling Foot
E. Feed Roll
F. Take-up Shaft
G. Feed Shaft
H. Dancer Bar
I. Stand
AA. Power Switch
BB. Serial Port
CC. USB Port
KEY
D
AB
E
I
C
G
H
F
AA BB CC
Rear Panel Behind Right End Cover
Visual Reference Guide

Visual Reference Guide
The Ioline FlexJet E Printer Front View Close-up
J. Drive Shaft Marker
K. Pinchwheel
L. Traverse or Carriage Rail
M. Carriage Assembly
N. Platen
P. Ink Cartridge Latch
Q. Ink Cartridge Stall
R. Pinchwheel Lever
S. Keypad
T. Service Station
U.Take Up Sensors
KEY
KM
T
N
J
R
U
S
L
P
Q

Visual Reference Guide
Figure 5. The Ioline StudioJet Front View.
ABC
H
G
M
L
N
K
D E
E
F
O
I
J
A. Left End Cover
B. Drive Shaft Marker
C. Pinchwheel Lever
D. Pinchwheel
E. Drive Shaft
F. Right End Cover
G. Keypad
H. Stand Leg
I. Inkjet Cartridge
J. Carriage
K. Stand Leveling Foot
L. Feed Shaft
M. Cross-member
N. Platen
O. Traverse
KEY

Getting Started
Thank you for purchasing the Ioline FlexJet E or StudioJet printer.
This manual contains instructions and guidelines for setting up,
operating and maintaining your Ioline printer. The following compo-
nents are needed to create markers:
nA FlexJet E printer assembled according to the directions out-
lined in the FlexJet E Printer or StudioJet Quick Start Guide.
nA computer system that is properly installed and has a func-
tioning serial or USB port.
nApparel design software loaded into the computer according to
the installation instructions.
nPrinting media and ink cartridges that are within the guidelines
stated under the Operation chapter.
nDepending on the communications setup, Ioline FlexPlot soft-
ware is required if your CAD software does not create compat-
ible les.
In order to output to the FlexJet
E or StudioJet printer, your
apparel design software must
create plot les in HPGL 7475
or DM/PL format.Alternatively,
you can output markers using the
FlexPlot software, included with
the printer. FlexPlot imports and
converts a variety of le formats
for output to your Ioline printer.
Note
i
The Ioline Control Center
and FlexPlot will only run on
the Windows® 2000/XP/Vista
operating systems. Most design
software provides drivers for
Ioline printers. Contact Ioline
customer service if you need as-
sistance with drivers.
Note
i
Overview
Chapter 1
Unless otherwise noted, diagrams and descriptions de-
picting Ioline FlexJet E printer models also apply to the
Ioline StudioJet in this manual.

16 Ioline FlexJet E User Guide
LEFT EDGE OF PLOT
LOWER EDGE OF PLOT
Y
HowThe Ioline FlexJet E and
StudioJet printers Work
The FlexJet E and StudioJet printers create printed images through
synchronized media and carriage motion. Files are sent to the printer
from a computer or le server via a serial or USB*connection.
When the printer receives a le, the electronic logic system translates
the vector image into X-axis (paper motion) and Y-axis (carriage mo-
tion) instructions and uses digital feedback to ensure plot accuracy.
The FlexJet E and StudioJet printers break the plot le into frame
segments in order to plot long markers. The FlexJet E printer then
rolls the frame segments onto a take-up shaft. The FlexJet E printer
can roll up to 600 yards onto the take-up shaft at a time. The Studio-
Jet plots to the oor.
Origin at right side of printer
and lower left on plot
Left side of FlexJet E printer Right side of FlexJet E printer
Figure 7. The X- and Y-axes and origin (top view).
* Note: The StudioJet has a serial
port. The FlexJet E has both a se-
rial port and a USB port.
In this manual the right and left
side refers to the right and left
side of the front of the printers.
Design software usually refers
to the Origin (or Start Point)
as “lower left” because it is the
lower left corner of a plot. The
plot is usually oriented in the
printer rotated 90 degrees coun-
ter clockwise as shown in Figure
5. The lower left corner of the
plot is physically on the right side
of the printer.
Note
i

Printer Assembly
Unpacking the Printer
Carefully remove the printer from the box and place it on a at,
stable surface. This procedure requires two people. Check the pack-
ing list to ensure that all of the accessories are present. (See the FlexJet
E printer or StudioJet Quick Start Guide for more information.) Save all
packing materials and the box.
Assembling the Stand
Assemble and level the stand using the hardware included in the Ac-
cessory Kit and directions outlined in the See the FlexJet E printer or
StudioJet Quick Start Guide.
Attaching the Printer to the Stand
Attach the printer to the stand with the top bars resting in the
notches in the stand legs. Use the hardware as indicated in the See the
FlexJet E or StudioJet Quick Start Guide.
Connect the printer to the Computer: Overview
Connect the printer to your computer via serial cable (provided in the
Accessory Kit). The corresponding serial port on your computer may
be either a 9-pin or 25-pin male receptacle. If the computer has 25-pin
serial ports, a 25- to 9-pin adapter is necessary.
Once connected, select the correct port and data rate in your apparel
design software, FlexPlot and/or the Control Center. Consult the
design software manual or the dealer for further information. Infor-
mation on conguring FlexPlot and the Control Center follows in
the Operation chapter.
An overview of the complete setup procedure is described
in detail in the FlexJet E Printer and StudioJet Quick
Start Guides (provided in the Accessory Kit).
Do not hold the printer
head by the bottom edge
of the end plates when
attaching it to the stand. Fingers
and hands might get pinched
between the end plates and stand
legs. Hold the bottom of the end
covers when handling the printer.
(See Figure 1.)
Caution
Before connecting the
printer to your PC, make
sure the computer and
the printer both have the power
turned off. Ioline recommends
using a surge protector power
strip for both the printer and the
computer.
Caution
Installation
Chapter 2

18 Ioline FlexJet E User Guide
Cable Connections
When connecting the printer to the computer by serial cable:
1. Make sure that power to the printer is off. Power is off when
the switch is in the “0” position, and is turned on when placed
in the “1” position.
2. Connect the supplied serial cable and power cord to the panel
on the back right end cover of the printer. Lock the serial cable
to the port on the printer with the thumb screws.
Figure 8. The serial cable and power
cord plug into the sockets in the back
of the right end cover.
Figure 9. PCs typically have two 9-pin
serial ports, COM 1 and COM 2.
3. Plug the printer power cable into a wall socket or a surge pro-
tector.
4. Make sure that power is off to the computer.
5. Connect the serial cable to a 9-pin male serial port on the back
of the computer. (If your computer has a 25-pin connector,
acquire a 25-pin to 9-pin serial adapter to make the connection.)
Tighten the thumbscrews.
Serial Conguration
It is critical that the Control Center, FlexPlot software, and any other
software that send data to the printer use the same COM port and
baud rate that the printer is using.
COM Port
A PC typically has two external 9-pin male serial connections.
These ports are often listed in the system settings as COM 1 and
COM 2. Determine which port is connected to the printer, then
select that port in all the software as instructed in the respective
software user guides. (See Figure 10.)
COM
Ports

19
Chapter 2: Installation
Figure 10. FlexPlot Serial Port set-up window.
Baud Rate
The serial port on the printer has an adjustable baud rate. Available
speeds are 9600, 19200, 38400, 57600, and 115200. The default is set
at the factory to 38,400. The baud rate is adjustable in the Control
Center in the Communications>Settings window.
Other Serial Port Settings
You may also need to set additional serial port settings, for instance,
when you use a terminal program. The recommended conguration
settings are:
Data Bits: 8
Parity: None
Stop Bits: 1
Flow Control: Software or Xon/Xoff
Software Setup Options
Ioline recommends using FlexPlot for marker making on the print-
er. FlexPlot offers the most robust and exible workow available
for creating output. It’s especially useful when many le formats are
used, a common situation for service bureaus. To set-up and learn
how to use the software, see the FlexPlot User Guide.
The printer is designed to work in many different production envi-
ronments. The type of marker printing you do will often determine
your preferred communication method. Two typical methods for
sending markers are:
1. Plot directly from the marker or design software to the
printer. (See Figure 11.)
Unlike other marker printers, the FlexJet E and StudioJet print-
ers are capable of operating as stand-alone devices with no extra
software running on the computer. This method works if your
CAD software includes a driver for any Ioline product, such as
the Ioline 600Ae or the Summit 2200. It will also work if the CAD
software can create a compatible HPGL- or DM/PL-formatted le.

20 Ioline FlexJet E User Guide
Figure 11. Workow: output direct from CAD software (without FlexPlot).
2. Use FlexPlot software to convert les before sending them
to the printer for output.
The printer includes the FlexPlot software which will convert
many different les into a format that is compatible with the
printer. It also provides an advanced marker queue manage-
ment system and other tools to optimize the performance of the
printer.
Figure 12. Workow using FlexPlot for le conversion and output.
FlexJet E printer
FlexJet E printer
CAD
Software FlexPlot
[Network]
HPGL
DM/PL
DXF
ASTM 6959
STD
CAD
Software HPGL
DM/PL
(Alternate Conguration)
CAD
Software
+
FlexPlot

21
Chapter 2: Installation
Power On
Turn on the computer and the printer to make sure they both work.
The printer power switch is located next to the power cord on the
back of the machine, behind the keypad. When the paper is properly
loaded and the printer is powered up, the carriage will move toward
the left side of the machine, then return to the opposite side to park
in the Service Station. The OK light will turn red and the Square
light will turn green on the front panel after the start-up process has
nished.
If no paper is loaded when the printer is powered up, the printer
displays an error message. The OK light will turn red and the Circle
light will turn orange. This combination of lights indicates a paper
out error. The keypad buttons do not work unless paper is properly
loaded—or a small piece of masking tape is placed over the Paper
Out sensor on the back of the printer. Once paper is loaded or the
sensor is taped over, press the Start/Stop button to clear the orange
circle and regain use of the keypad.
Installing FlexPlot and
the Control Center
The printer includes two software interfaces: FlexPlot and the
Control Center. FlexPlot will import and queue plot les from
many design programs to optimize production operations. The
Control Center is an interface for adjusting parameters to optimize
printer performance. The printer comes with a CD-ROM which has
Microsoft Windows®2000/XP/Vista versions of the programs as
well as PDF user guides and the required Adobe®Acrobat®reader.
1. Power on the computer and Windows®.
2. Insert the Ioline CD-ROM into the CD-ROM drive (usually D:).
3. The installation program should start automatically. If it does
not:
a. Select the Start button.
b. Choose Run.
c. Type D:\IOSETUP (substitute the correct letter if the CD-
ROM drive letter is not D:) and Click OK.
4. Follow the instructions that appear on the screen.
5. The FlexPlot User Guide has details on using the FlexPlot
software. In this manual, see the section The Control Center for
more details about the Control Center software.
Keep hands and loose
clothing away from all
moving parts of the
printer. Make sure the Service
Station opening in the right end
plate is not obstructed and that
the stall latches are lowered.
Caution
In this manual the right and left
side refers to the right and left
side of the front of the printer.
Design software usually refers
to the Origin (or Start Point)
as “lower left” because it is the
lower left corner of a plot. The
plot is usually oriented in the
printer rotated 90 degrees coun-
ter clockwise as shown in Figure
5. The lower left corner of the
plot is physically on the right side
of the printer.
Note
i

22 Ioline FlexJet E User Guide
This page intentionally left blank