MUTOH kona Series User manual

User’s Guide

User’s Guide Kona / Kona apparel cutting plotter
AP-75370 - Revision 1.1 3
Copyright notice
COPYRIGHT © 16/6/11 Mutoh Belgium nv All rights reserved.
Mutoh Belgium nv reserves the right to modify the information contained in this manual at any
time without prior notice.
This document may not be reproduced by any means, in whole or in part, without written
permission of the copyright owner.
Mutoh furnished this document to support the Kona / Kona apparel cutting plotter series. In
consideration of the furnishing of the information contained in this document, the party to
whom it is given, assumes its custody and control and agrees to the following:
The information herein contained is given in confidence, and any part thereof shall not be
copied or reproduced without written consent of Mutoh Belgium nv.
This document or the contents herein under no circumstances shall be used in the
manufacture or reproduction of the article shown and the delivery of this document shall not
constitute any right or license to do so.

User’s Guide Kona / Kona apparel cutting plotter
4AP-75370 - Revision 1.1

User’s Guide Kona / Kona apparel cutting plotter
AP-75370 - Revision 1.1 5
Table of contents
Chapter 1 Regulations and safety information . . . . . . . . . . . . 11
1.1 Warnings, cautions and notes. . . . . . . . . . . . . . . . . . . . . . . . . 12
1.2 Compliance with the following regulations . . . . . . . . . . . . . . 12
1.3 Important notes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.4 Safety labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Chapter 2 Product overview . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.1 Dimensions machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2.2 Installation environment requirements. . . . . . . . . . . . . . . . . . 18
Power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Ambient conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Room conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2.3 Part names and functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Chapter 3 Basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
3.1 (Un)Install USB drivers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Install USB drivers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Check COM port used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Uninstall/update USB drivers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
3.2 Power ON / OFF the cutter . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Powering ON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Powering OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
3.3 Installing firmware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Normal procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Recovery procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

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3.4 Installing and replacing tools . . . . . . . . . . . . . . . . . . . . . . . . . 40
Installing tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Replace cutter blade. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Replace sheet-off blade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Replace cutting mat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
3.5 Setting the correct knife depth . . . . . . . . . . . . . . . . . . . . . . . . 46
Contour cutting knife depth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Cut through depth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Adjusting the knife depth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Features of knife holder with nonius. . . . . . . . . . . . . . . . . . . . . . . . . 49
3.6 Handling and storing media. . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Handling media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Precautions on storing media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
3.7 Loading media. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Media width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Pressure roller positioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Loading sheet media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Loading a roll of media using the media support rollers . . . . . . . . 59
Loading a roll of pre-printed media using the roll-off system . . . . 64
3.8 Loading curled media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
3.9 Pausing the current job . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
3.10 Remaining time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Chapter 4 Operation panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
4.1 Explaining the different buttons . . . . . . . . . . . . . . . . . . . . . . . 77
Main menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Settings or actions menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Adjust value menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
4.2 Menu overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Settings 1/3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

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Settings 2/3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Settings 3/3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Actions 1/2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
Actions 2/2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
Chapter 5 Finetuning your cutter . . . . . . . . . . . . . . . . . . . . . . 139
5.1 Knife types. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
5.2 Kona / Kona apparel calibration . . . . . . . . . . . . . . . . . . . . . . 141
Knife settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
EPOS test cuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
XY-distance accuracy. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
Chapter 6 Contour cutting. . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
6.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
6.2 Different alignment methods . . . . . . . . . . . . . . . . . . . . . . . . . 147
6.3 Which alignment method to use? . . . . . . . . . . . . . . . . . . . . . 148
Automatic alignment method. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
Manual alignment method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
6.4 Bounding box details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
Hints, tips and recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . 152
Bounding box specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
6.5 Scanning routing of bounding box . . . . . . . . . . . . . . . . . . . . 158
Chapter 7 Through cutting . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
7.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
7.2 Setting up your Kona / Kona apparel cutting plotter. . . . . . 163
Tools necessary on a Kona . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
Tools necessary on a Kona apparel. . . . . . . . . . . . . . . . . . . . . . . . 163
Toolswap settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164

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Through cut settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
7.3 Through cutting workflow . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
Basically, 4 cut through parameters are required. . . . . . . . . . . . . 167
Cut the vectors in following order . . . . . . . . . . . . . . . . . . . . . . . . . . 167
Cut through specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
7.4 Poster trimming workflow . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
Chapter 8 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
8.1 Cleaning and daily maintenance . . . . . . . . . . . . . . . . . . . . . . 172
Cleaning the grit roll . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
Cleaning the cutting plotter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
Cleaning the cutter blade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
Cleaning the touch screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
Chapter 9 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
9.1 Day-to-day use issues . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
Warning messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
Beeping codes: My Kona / Kona apparel is making a beeping sound
once in a while. 189
The USB connection disappears. . . . . . . . . . . . . . . . . . . . . . . . . . . 189
The power ON, but the cutter does not operate. . . . . . . . . . . . . . 190
Media is loaded, but the cutter does not operate. . . . . . . . . . . . . 190
Data is sent from the computer, but the cutter does not react. . 190
Data is sent from the computer, but errors occur on the cutter’s side.
190
Some parts of the design are not well cut. . . . . . . . . . . . . . . . . . . 191
The output is 2,5 x too large or 2,5 x too small. . . . . . . . . . . . . . . 191
9.2 Error messages. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
Recoverable error messages with no error ID number . . . . . . . . 192
Errors with error number (ID 1009-6115). . . . . . . . . . . . . . . . . . . . 194
Contourcutting errors and warnings (ID 6201-6271) . . . . . . . . . . 197
MGL errors (ID 4000-5000) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206

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Chapter 10 Consumables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
10.1 Knife holder and blades . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
Knife Holder without Depth Change Indication . . . . . . . . . . . . . . . 209
Knife Holder with Depth Change Indication. . . . . . . . . . . . . . . . . . 210
10.2 Pens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
10.3 Sheet off blades . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
10.4 Cutting mat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211

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1
User’s Guide Kona / Kona apparel cutting plotter
Regulations and safety information
AP-75370 - Revision 1.1 11
Chapter 1 Regulations and
safety information
Warnings, cautions and notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Compliance with the following regulations . . . . . . . . . . . . . . . . . . . . . . . 12
Important notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Safety labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

User’s Guide Kona / Kona apparel cutting plotter
Regulations and safety information
12 AP-75370 - Revision 1.1
1.1 Warnings, cautions and notes
Safety terms in this manual and the contents of warning labels attached to the cutter are
categorized into the following three types, depending on the degree of risk (or the scale of
accident).
Read the following explanations carefully and follow the instructions in this manual.
1.2 Compliance with the following regulations
Safety terms Details
Important Must be followed carefully to avoid death or serious bodily injury.
Caution Must be observed to avoid bodily injury (moderate or light) or damage to
your equipment.
Notes Contains important information and useful tips on the operation of your
cutter.
The CE marking is a mandatory European marking for certain
product groups to indicate conformity with the essential health and
safety requirements set out in European Directives.
By affixing the CE marking, the manufacturer, his authorized
representative, or the person placing the product on the market or
putting it into service ensures that the item meets all the essential
requirements of all applicable EU directives and that the applicable
conformity assessment procedures have been applied.
Your product is designed and manufactured with high-quality
materials and components, which can be recycled and reused.
When this crossed-out wheeled bin submenu is attached to a
product, it means the product is covered by the European Directive
2002/96/EC - WEEE regulation.
Please inform yourself about the local separate collection system for
electrical and electronic products.
Please act according to local rules and do not dispose of your old
products with your normal household waste. The correct disposal of
your old product will help prevent potential negative consequences
for the environment and human health.

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Regulations and safety information
AP-75370 - Revision 1.1 13
1
1.3 Important notes
Technical problems and maintenance, which require the cutter to be opened, can only be
done by qualified personnel who were trained to repair this type of machine.
Unauthorized removing of covers and/or overruling safety locks can be dangerous and will
result in your guarantee becoming void.
After powering OFF the machine, wait at least 10 seconds before powering ON again. Not
respecting this time interval could damage the machine.
The cutter must be connected to an earthed mains socket-outlet.
This product is tested and approved by the Canadian Standards
Association (CSA), this to provide increased assurance of quality and
safety.
The product is tested according to IEC60950.
This standard tries to cover all safety aspects.
Mechanical, electrical
Choice of components
Choice of materials: flammability!
Connectors, cables
Fire enclosure
This means the product is safe for users, service personnel and
production personnel.
CSA International certification is not a legal commitment but it
assures the quality and safety of the machine.
FCC
This equipment has been tested and found to comply with the limits
for a Class A digital device, pursuant to Part 15 of the FCC Rules.
These limits are designed to provide reasonable protection against
harmful interference when the equipment is operated in a commercial
environment. This equipment generates, uses, and can radiate radio
frequency energy and, if not installed and used in accordance with
the instruction manual, may cause harmful interference to radio
communications. Operation of this equipment in a residential area is
likely to cause harmful interference in which case the user will be
required to correct the interference at his own expense.
ICES This Class A digital apparatus complies with Canadian ICES-003.

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Regulations and safety information
14 AP-75370 - Revision 1.1
1.4 Safety labels
Label Description
Be careful not to pinch your fingers
between the pressure rollers and grit rollers
when loading media for example.
Be careful not to get stuck between the
following moving parts:
Cutting head
Grit rollers
This label only appears on the Kona
Apparel.
It indicates the position of the pressure
rollers at the back side of the cutter.
In some cases it might be necessary to
have a little bit less or more pressure on
your media. Set the pressure rollers as
needed.

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Regulations and safety information
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1
This label only appears on the Kona
Apparel.
Label indicating how to insert the tool
correctly in the second location.
Refer to On the second location (Kona
apparel only) on page41
Be sure not to stare in the laser mounted
on the cutting head.
Label Description

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Regulations and safety information
16 AP-75370 - Revision 1.1
Kona
Kona apparel
Serial number label providing you the
following information:
Serial number
Unit name
Power supply requirements
Regularisations
Class A product
Address Mutoh Belgium nv
Label Description

2
User’s Guide Kona / Kona apparel cutting plotter
Product overview
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Chapter 2 Product overview
Dimensions machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Installation environment requirements . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Ambient conditions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Operation environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Recommended environment (dark area) . . . . . . . . . . . . . . . . . . . . . . . . . 18
Variation rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Storage environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Room conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Part names and functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

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Product overview
18 AP-75370 - Revision 1.1
2.1 Dimensions machine
2.2 Installation environment requirements
2.2.1 Power supply
Voltage 100-240 V AC
Current 1.5 A
Frequency 50-60 Hz
2.2.2 Ambient conditions
Operation environment
Temperature:10°C - 35°C
Humidity:35% - 75% non-condensing
Recommended environment (dark area)
Temperature:16°C - 32°C
Humidity:35% - 70% non-condensing
Variation rate
Temperature:2°C per hour
Humidity:5% per hour
Storage environment
Temperature: 0°C - 50°C
Kona 760 Kona 1400
or
Kona apparel 1400
Kona 1650
or
Kona apparel 1650
Width 1200 mm / 47,2” 1850 mm / 72,8” 2090 mm / 82.3”
Depth 260 mm / 10,2” 490 mm / 19,3” 490 mm / 19,3”
Height 275 mm / 10,8” 1150 mm / 45,3” 1150 mm / 45,3”
Weight (options excl.) 21 kg / 46,3 lb 48 kg / 105,8 lb 52 kg / 114,6 lb
Weight (options incl.)
Media support rolls
Media basket
Roll off system
40 kg / 88,9 lb 56 kg / 123,5 lb 63 kg / 138,9 lb
T(°C)
Humidity (%)
10 16 32 35
35
70
75

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Product overview
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2
2.2.3 Room conditions
Please protect your cutter from moisture, dust, draught and direct sunlight (to prevent
possible media detection and epos readout issues). It is best to keep your machine away
from open windows and air-conditioners.
See to it that there is an adequate space around the cutter so that ventilation is not
obstructed.
Avoid unnecessary vibrations and set up your cutter on a level surface.
Be sure to have some free space on each side of the Kona / Kona apparel to ease the
operating of it.
a= at least 1 meter
b= at least 1 meter
c= at least 1 meter
d= at least 0,2 meter
a
b
c
d

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Product overview
20 AP-75370 - Revision 1.1
2.3 Part names and functions
N° Description Extended description
1Pressure rollers To push the media against the grit rollers
2Media guide A guiding platform with vacuum fans to transport
the media as flat as possible during cutting
3Cutting mat Provides a reliable cutting surface and minimizes
damage to the knife tip
4Grit rollers Rollers with a granular surface to move the media
front and backwards
5Control panel touch screen To make various settings before and during cutting
6Cutting head
Assembly of cutting knife, sheet-off knife and EPOS
sensor.
On the Kona apparel an extra tool mounting
position is fixed against the right inner side of the
cutter.
7USB inlet To connect the USB cable
8Power inlet and power switch To connect the power cable and power on the unit
9Roll conveyor To support and roll-off the media
(Optional on Kona 760)
10 Stand and wheels To move the cutter easily
(Optional on Kona 760)
11 Media bag To collect the media when sheeting off
(Optional on Kona 760)
12 Roll-off system To roll-off pre printed media
(Optional on Kona 760)
13 Pressure roller lever To lower and raise the pressure rollers