Ioline FlexJet User manual

User Guide
Ioline FlexJet™

Trademarks
Ioline and FlexJet are trademarks of Ioline Corporation. HP is a trademark of the Hewlett-Packard Com-
pany. 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.
© 2003-2005 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 108186 Rev. 3

User Guide
Ioline FlexJet™

Images & Illustrations
Figure 1. FlexJet: Lifting procedure ........................................................................................ ix
Figure 2. The Ioline FlexJet printer front view .................................................................... x
Figure 3. The Ioline FlexJet printer rear view...................................................................... xi
Figure 4. The Ioline FlexJet Printer front view close-up ................................................. xii
Figure 5. The X- and Y-axes and origin ................................................................................ 14
Figure 6. The serial cable and power cord sockets .......................................................... 16
Figure 7. PC serial ports, COM 1 and COM 2 ................................................................ 16
Figure 8. FlexPlot serial port set-up window .................................................................. 17
Figure 9. Workow: using FlexPlot for output ................................................................. 18
Figure 10. Workow using FlexPlot for le conversion and output ............................ 18
Figure 11. The FlexJet Keypad ................................................................................................. 21
Figure 12. Plot origin point location on paper ..................................................................... 22
Figure 13. FlexJet Control Center Main Menu .............................................................. 24
Figure 14. The Hewlett-Packard 51645A (‘45’ cartridges) ................................................ 27
Figure 15. Ink cartridge installation ........................................................................................ 28
Figure 16. Installing the feed shaft ........................................................................................... 29
Figure 17. Installing the take-up shaft ..................................................................................... 30
Figure 18. The correct paper feeding path on the Ioline FlexJet printer ....................... 31
Figure 19. Taping the paper to the take-up shaft ................................................................. 32
Figure 20. Positioning the pinchwheels for 72-in (183-cm) paper ................................... 33
Figure 21. Inserting the dancer bars ....................................................................................... 33
Figure 22. Location of dancer bar channels .......................................................................... 34
Figure 23. Manually freeing the take-up shaft ....................................................................... 36
Figure 24. Taping over the front take-up bar sensor .......................................................... 38
Figure 25. Paper path for printing to the oor .................................................................... 38
Figure 26. Cleaning the Drive Shaft ........................................................................................ 39
Figure 27. Calibration screen in Control Center ............................................................ 40
Figure 28. The Calibration box and measurements ............................................................ 41
Figure 29. Cartridge calibration window ............................................................................... 42
Figure 30. The Cartridge Alignment Box .............................................................................. 43
Figure 31. The Motion Adjust Box .......................................................................................... 43
Figure 32. The Frame Gap Box ..........................................................................................................44
Figure 33. Ink cartridge storage .............................................................................................. 46
Figure 34. Factory calibration sticker inside the Service Station ................................ 50
Figure 35. HP cartridges ink level indicator ................................................................................................ 52
Figure 36. Keypad LED lights ......................................................................................................... 53

Table of Contents
Safety & Cautions
Visual Reference Guide
Chapter 1 Overview
Getting Started ................................................................................................. 13
How The Ioline FlexJet Works ........................................................................................... 14
Chapter 2 Installation
FlexJet Assembly ...................................................................................................................... 15
Unpacking the Printer ......................................................................................................... 15
Assembling the Stand .......................................................................................................... 15
Attaching the Printer to the Stand ................................................................................... 15
Connect the FlexJet to the Computer: Overview ........................................................ 15
Cable Connections .............................................................................................................. 16
Serial Conguration ............................................................................................................. 16
COM Port .............................................................................................................................. 16
Baud Rate ............................................................................................................................... 17
Other Serial Port Settings .................................................................................................. 17
Software Setup Options ..................................................................................................... 17
Power On ..................................................................................................................................... 19
Installing FlexPlot and the Control Center ................................................................ 19
Chapter 3 Operation
Keypad Controls ....................................................................................................................... 21
Start/Stop ............................................................................................................................... 21
Clean ....................................................................................................................................... 22
Quality .................................................................................................................................... 22
Set Origin ............................................................................................................................... 22
Arrow Keys ............................................................................................................................ 23
Page Advance ......................................................................................................................... 23
Unroll ...................................................................................................................................... 23
Special Key Combinations ................................................................................................. 23
Roll Up .................................................................................................................................... 23
Reset Serial Port Baud Rate ............................................................................................... 23
Restore Factory Default Settings ...................................................................................... 23
The FlexJet Control Center ............................................................................................... 24
Overview ................................................................................................................................ 24
Changing System Settings ................................................................................................... 24

Control Center Menu Bar Features ............................................................................... 25
File ........................................................................................................................................... 25
Communications .................................................................................................................. 25
Tools ........................................................................................................................................ 25
Help ......................................................................................................................................... 25
Control Center Menu Options .......................................................................................... 26
Software Version ................................................................................................................... 26
Cartridge Count ................................................................................................................... 26
Get Plotter Data .................................................................................................................. 26
Plotter Data (check box) .................................................................................................... 26
Scale ......................................................................................................................................... 26
Frame Size .............................................................................................................................. 26
Loop Length ........................................................................................................................... 26
Line Width .............................................................................................................................. 26
Quality Setting ...................................................................................................................... 27
Measurement Units .............................................................................................................. 27
Consumables ............................................................................................................................. 27
Paper ....................................................................................................................................... 27
Ink ............................................................................................................................................ 27
Guidelines for Installing a Cartridge ................................................................................ 27
Printing a Marker .................................................................................................................... 28
Overview ................................................................................................................................ 28
General Guidelines .............................................................................................................. 28
Power On ............................................................................................................................... 29
Loading Paper ........................................................................................................................... 29
Installing the Take-up Shaft ................................................................................................. 30
Feeding Paper ............................................................................................................................ 31
Tape Paper to theTake-up Shaft ...................................................................................... 32
Positioning the Pinchwheels ............................................................................................... 32
Insert the Dancer Bars ......................................................................................................... 33
Set an Origin .............................................................................................................................. 34
Sending Plot Files .................................................................................................................... 34
Pausing a Marker Plot ........................................................................................................... 34
Canceling a Marker Plot ....................................................................................................... 35
Removing Markers from theTake-up Shaft ................................................................ 35
Manually Freeing the Take-up Shaft ................................................................................ 36
Automatically Freeing theTake-Up Shaft .................................................................... 37
Reattach Paper to theTake-up Shaft ............................................................................. 37
Printing to the Floor .............................................................................................................. 38
Chapter 4 Routine Maintenance
Cleaning the Drive Shaft .................................................................................................... 39
Cleaning the Platenand Traverse ..................................................................................... 39
Cleaning the Support Blocks ............................................................................................. 40
Size Calibration ........................................................................................................................ 40
Prepare the Printer (See the Operation chapter) ............................................................... 40
Use the Control Center to Gather the Calibration Data .......................................... 41
Enter the Calibration Data: ................................................................................................ 41
Cartridge Calibration ............................................................................................................ 42
Prepare the Printer .............................................................................................................. 42
Cartridge Alignment ............................................................................................................ 43
Motion Adjust (Carriage Scan Alignment) ..................................................................... 43
Frame Gap (Paper ScanAlignment) .................................................................................. 44
Cartridge Maintenance and Handling ........................................................................... 44

Check Cartridges ................................................................................................................. 44
Automatic Cleaning Procedure ......................................................................................... 45
Manual Cleaning Procedure ............................................................................................... 45
Print Cartridge Storage ....................................................................................................... 46
Short-term Storage (7 days or less) ................................................................................. 46
Long-term Storage (greater than 7 days) ........................................................................ 46
Updating Firmware using the Control Center ......................................................... 46
Summary ................................................................................................................................. 46
Prepare the FlexJet for a Firmware Update ................................................................... 46
Check the Current Firmware Version ............................................................................. 46
Update the Firmware .......................................................................................................... 47
Manually Updating Firmware usingTeraTerm™........................................................ 48
Summary ................................................................................................................................. 48
Prepare to Update the Firmware ..................................................................................... 48
Setup TeraTerm ..................................................................................................................... 48
Update Firmware ................................................................................................................. 49
Reset Calibration Values ..................................................................................................... 49
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
Chapter 6 End Notes
Service & Support ................................................................................................................... 57
Getting Help .............................................................................................................................. 57
Customer Service ................................................................................................................... 58
Your Comments Are Requested ...................................................................................... 58
Before you contact Support ............................................................................................... 59
The FCC Wants You to Know ............................................................................................ 60
This booklet is available from: .......................................................................................... 60
Glossary
Index

The Ioline FlexJet has 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 print-
er requires at least 2 people. To avoid injury to your ngers, do
not lift the printer by the end covers. Hold the gray bars on the
printer to lift or move it. See Figure 1.
nKeep ngers away from the drive shaft when the printer is in
operation. Serious injury could result.
Figure 1. Lift the printer head using the gray
bars to avoid injury to your ngers.
Safety &
Cautions
ix

A. Left End Cover
B. Safety Cover
C. Right End Cover
D. Take-up Motor
E. Stand Leveling Foot
F. Feed Roll
G. Take-up Shaft
H. Feed Shaft
I. Stand
KEY
Figure 2. The Ioline FlexJet Printer Front View.
E
A
B
C
F
H
I
D
G
x

Visual Reference Guide
Figure 3. The Ioline FlexJet Printer Rear View (head tilted in maintenance position.)
J. Take-up Motor Cable
K. Take-up Motor Outlet
L. Serial & USB Ports
M. Power Switch
N. Platen Leveling Foot
O. Cross-member
P. Paper Out Sensors
(hidden)
KEY
J
K
L M N
xi
OP

Figure 4. The Ioline FlexJet Printer Front View Close-up (safety cover lifted for clarity.)
Q. Ink Cartridge Stall
R. Cartridge Stall Latch
S. Pinchwheel Lever
T. Keypad
U. Service Station
(Beneath Cover)
V. Take-up Sensor
W. Platen
X. Pinchwheel
Y. Drive Shaft Marker
Z. Traverse
AA.Carriage Assembly
KEY
Q
T
V
W
AA Z
R
U
S
X
Y
xii

In order to output to the FlexJet,
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 FlexJet. FlexPlot imports and
converts a variety of le formats
for output to the FlexJet.
Getting Started
Thank you for purchasing the Ioline FlexJet.
This manual contains instructions and guidelines for setting up,
operating and maintaining the Ioline FlexJet printer. The following
components are needed to create markers:
nA FlexJet assembled according to the directions outlined in the
FlexJet 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. Note
i
The Ioline Control Center
and FlexPlot will only run on
the Windows® 98/NT/2000/XP
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

14 Ioline FlexJet User Guide
How The Ioline FlexJet Works
The FlexJet creates 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 breaks the plot le into frame segments in order to plot
long markers. The printer then rolls the frame segments onto a take-
up shaft. The FlexJet can roll up to 600 yards onto the take-up shaft
at a time.
Origin at right side of FlexJet
and lower left on plot
Left side of FlexJet Right side of FlexJet
Figure 5. The X- and Y-axes and origin (top view, safety cover removed for clarity).
,%&4%$'%/&0,/4
,/7%2%$'%/&0,/4
9
8
In this manual the right and left
side refers to the right and left
side of the front of the FlexJet.
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

FlexJet Assembly
Unpacking the Printer
Carefully remove the printer from the box and place it on a at, sta-
ble surface. This procedure requires two people. Check the packing
list to ensure that all of the accessories are present. (See the FlexJet
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 FlexJet Quick Start Guide.
Attaching the Printer to the Stand
Attach the printer to the stand with the top bars resting in the notch-
es in the stand legs. Use the hardware as indicated in the FlexJet
Quick Start Guide.
Connect the FlexJet 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 Quick Start Guide. The FlexJet
Set-up, Operating and Maintenance Video, provided on
CD-ROM, also provides a helpful visual overview. Both
materials are provided in the Accessory Kit.
Do not hold the printer
chassis 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 gray
metal top bars a few inches from
the end plates when handling the
head. (See Figure 1.)
Caution
Before connecting the
FlexJet 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

16 Ioline FlexJet User Guide
Cable Connections
When connecting the FlexJet 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 6. The serial cable and power
cord plug into the sockets in the back
of the right end cover.
Figure 7. A PC typically has 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 FlexJet Control Center, FlexPlot software, and
any other software that send data to the printer use the same COM
port and baud rate that the FlexJet 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 FlexJet, then
select that port in all the software as instructed in the respective
software user guides. (See Figure 8.)
COM
Ports

17
Chapter 2: Installation
Figure 8. FlexPlot Serial Port set-up window.
Baud Rate
The serial port on the FlexJet 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
FlexJet. 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 FlexJet 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
FlexJet. (See Figure 9.)
Unlike other marker printers, the FlexJet is capable of operating
as a stand-alone device 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.

18 Ioline FlexJet User Guide
Figure 10. Workow using FlexPlot for le conversion and output.
2. Use FlexPlot software to convert les before sending them
to the FlexJet for output.
The FlexJet includes the FlexPlot software which will convert
many different les into a format that is compatible with the
FlexJet. It also provides an advanced marker queue manage-
ment system and other tools to optimize the performance of the
printer.
Figure 9. Workow: output direct from CAD software (without FlexPlot).
FlexJet
FlexJet
CAD
Software FlexPlot
[Network]
HPGL
DM/PL
DXF
ASTM 6959
STD
CAD
Software HPGL
DM/PL
(Alternate Conguration)
CAD
Software
+
FlexPlot

19
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 FlexJet is pow-
ered 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.
Installing FlexPlot and
the Control Center
The FlexJet 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®98/NT/2000/XP 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 soft-
ware. In this manual, see the section The FlexJet 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

20 Ioline FlexJet User Guide
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