Ioline FlexJet Operation & User’s Manual

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. Pacific Time Voice: 1.425.398.8282 Fax: 1.425.398.8383 [email protected] www.ioline.com User Notice Part Number 108186 Rev. 3

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. Workflow: using FlexPlot for output .................................................................. 18 Figure 10. Workflow using FlexPlot for file 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 floor ..................................................................... 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

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 Configuration  ..............................................................................................................   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

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 the Take-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 the Take-up Shaft  .................................................................   35 Manually Freeing the Take-up Shaft  .................................................................................   36 Automatically Freeing the Take-Up Shaft  ....................................................................   37 Reattach Paper to the Take-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

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 using TeraTerm™  ........................................................  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

and follow these safety guidelines before beginning operation of the printer: n Do not try to repair the machine without factory authoriza- tion. Only qualified 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). n Be careful with hair, jewelry, or loose clothing near the printer. They can become caught in the mechanical parts. n Never 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. n Keep 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. n Never 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. n Be careful when moving or lifting the printer. Moving the print- er requires at least 2 people. To avoid injury to your fingers, do not lift the printer by the end covers. Hold the gray bars on the printer to lift or move it. See Figure 1. n Keep fingers 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 fingers. Safety & Cautions ix

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 

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 O P

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

your apparel design software must create plot files 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 file 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: n A FlexJet assembled according to the directions outlined in the FlexJet Quick Start Guide. n A computer system that is properly installed and has a func- tioning serial or USB port. n Apparel design software loaded into the computer according to the installation instructions. n Printing media and ink cartridges that are within the guidelines stated under the Operation chapter. n Depending on the communications setup, Ioline FlexPlot soft- ware is required if your CAD software does not create compat- ible files. 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

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 file server via a serial or USB connection. When the printer receives a file, 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 file 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

Carefully remove the printer from the box and place it on a flat, 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 configuring 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

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 Configuration 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

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 configuration 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 flexible workflow available for creating output. It’s especially useful when many file 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 file.

Figure 10. Workflow using FlexPlot for file conversion and output. 2. Use FlexPlot software to convert files before sending them to the FlexJet for output. The FlexJet includes the FlexPlot software which will convert many different files 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. Workflow: 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 Configuration) CAD Software + FlexPlot

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 finished. Installing FlexPlot and the Control Center The FlexJet includes two software interfaces: FlexPlot and the Control Center. FlexPlot will import and queue plot files 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

Figure 11. The Printer Keypad. Start/Stop The Start/Stop key toggles the FlexJet online and offline. If the Start/Stop key is pressed during printing, the OK light turns red and the machine will stop after it finishes printing the current scan. The Arrow, Unroll and Paper Advance keys are active when in STOP mode. When the Start/Stop key is pressed again, the printer enters START mode, the OK light turns green and printing resumes exactly where it stopped. START mode OK = green Arrow keys inoperable, printer online (ready to re- ceive instructions). STOP mode OK = red Arrow keys operable, printer offline (not ready to receive instructions). Chapter 3 Operation

Clean Runs the print heads through a cleaning cycle in the Service Station. Put the FlexJet in STOP mode and wait until the OK light turns red. Then press the Clean button. If the carriage is not already parked, it will return to the Service Station. After auto cleaning, the FlexJet will react differently when you put it in green light (START) mode, depending on what it was doing just prior to the cleaning: FlexJet state before auto cleaning—e.g. what the printer is doing just before before it is put in STOP (red light) mode FlexJet reaction when put in START mode after auto cleaning Printing in START mode (OK light is green) Resumes printing Idle in START mode (OK light is green) Stays parked and capped. Idle, in STOP mode (OK light is red) Stays parked and capped. Quality Switches between the Best—or dark (600 dpi)—line mode and Draft mode (300 dpi), which prints lighter and consumes less ink. You can change line quality while the FlexJet is printing. Set Origin The Set Origin key sets the initial origin or starting position for the marker. It’s best to always set a new origin point after cycling power. To set a new origin, press Start/Stop until the OK light turns red (STOP mode). Use the Arrow keys to move the carriage so that the ‘V’ notch and red LED light are positioned over the desired starting point. Press the Set Origin key. The OK light will turn green, indi- cating the printer is ready to accept plot files. (See Figure 12.) Figure 12. The Set Origin key sets the marker origin point directly below the top of the notched ‘V’ on the carriage base—located on the right side, near the red LED light. ‘V’ Notch Apparel design software usually refers to the origin as “lower left” because it is the lower left corner of a marker. Because the plot is usually oriented as shown in Figure 5, it is physically on the right side of the printer. Note i

Arrow Keys Pressing the Arrow keys moves the carriage left or right. The Arrow keys are only active in STOP mode (see Start/Stop), when the OK light is red. Page Advance Pressing this button advances the paper in small increments. This is useful if a plot was removed from the printer and you need a paper leader to tape to the take-up shaft. The Page Advance key is only ac- tive in STOP mode (when the OK light is red). Unroll Unroll Material – Press the Start/Stop button until the OK light turns red. Press and release the Unroll button. The printer will unroll a short segment of paper from the take-up shaft. Automatic Unroll – Press the Start/Stop button until the keypad light turns red. Press and hold the Unroll button. The printer will automatically unroll paper. To cancel Automatic mode, press the Start/Stop key again. Special Key Combinations Roll Up Use this function to roll material back onto the take-up shaft. Press and hold the Unroll and Right Arrow buttons at the same time. The rolling will continue until the dancer bar reaches the optical sensor. The Roll Up key is only active in STOP mode (when the OK light is red). Reset Serial Port Baud Rate This key combination will restore the serial port baud rate to the default speed of 38,400. This is useful for diagnostic testing of the communication system. Turn power off. Press and hold the Page Advance key as you turn power on again. Continue holding the key down until the OK light turns red and the Square light turns green. Restore Factory Default Settings This function replaces settings that are not working properly and can be used when manual calibration is unsuccessful. This key combina- tion will restore all calibration values to the factory defaults. Turn power off. Press and hold the Unroll key as you power up again. Continue holding the key down until the OK light turns red and the Square light turns green. + 1 0 + + 1 0 For more details on removing plotted markers from the take-up shaft see Removing Markers from the Take-Up Shaft later in this chapter. Note i

The FlexJet Control Center Overview The FlexJet Control Center is a utility program that does two things: n Allows you to adjust settings to tailor output (e.g. scale, line width) from the computer. n Provides an interface to send completed files to the printer. Figure 13. FlexJet Control Center Main Menu. Changing System Settings A variety of settings are adjustable to fit specific needs: n Make sure the printer power is on and that the initialization process is complete. The carriage will park, the keypad OK light will turn red and the Square light will turn green. n The Screen Menu displays the primary settings that are adjust- able. The Menu Bar contains utilities for setting up the Control Center and calibrating the FlexJet. n Changes only take effect after one of the Send buttons is pushed. To avoid communication port conflicts, do not simultaneously run more than one application that communicates with the printer. Note i

Control Center Menu Bar Features File Download Firmware Allows the user to download the lat- est firmware version for the FlexJet. See the section Downloading Firm- ware in the Routine Maintenance chapter for more information. Send Plot File Print a PLT or PLX file. Exit Exit the Control Center. Communications Settings Select the COM port and baud rate to match the printer. Send Command Permits advanced users to manually enter commands. Automatic Buffer Disables Buffer Close Timer. Improves Closing communications on some systems. Tools Aux Sensor Controls the bottom Paper Out sensor on new FlexJets or the Cover Sensor on old FlexJets. Cartridge Calibration Displays tools to adjust print cartridge alignment. See Routine Maintenance for more details. Size Calibration Allows adjustment of the size cali- bration settings. See Routine Main- tenance for more details. About Your FlexJet Displays license information for ma- chines with upgraded print heads. FlexJet Licensing Sets the license key code to enable inactive print heads in machines pre-wired for expansion. Requires firmware version 368.x or greater. Help About Displays Control Center version information.

Control Center Menu Options Software Version Displays the current installed firmware and boot loader version. Cartridge Count Displays how many cartridges are in active use by the printer. Get Plotter Data Reads and displays the current input box settings stored in the FlexJet. Plotter Data (check box) Indicates when the displayed settings were successfully downloaded from the printer. If this box is unchecked, the Control Center was unable to connect with the FlexJet and cannot display current settings. Check the connections, baud rate and COM port. Press the Get Plotter Data button to attempt to download settings if the process failed during startup. Scale The printer scale ranges from 1% to 999%. The factory default Scale is 100%. A scale set to 50% prints at half size. Changes do not take effect until the Set Scale button is pressed. Note: Both X- and Y-axes are set independently. Frame Size Most design software sends long plots to printers by breaking them into smaller pieces called frames. In general, design software does this automatically and adjusts the Frame Size in the printer to match. The Frame Size setting establishes clipping limits for each data frame. If the printed size of a plot frame exceeds the frame size set in the FlexJet, the excess is clipped or thrown away. (If the plot is clipped, try increasing the Frame Size manually.) The factory-set X-axis (paper direction) frame size is 46-in (116.8-cm), maximum is 21600-in (54,864-cm). Default and maximum Y-axis (carriage direc- tion) frame size is 72-in (182.9-cm). Loop Length Controls the length of the take-up loop. Shortening the loop may reduce paper tearing but runs the take-up motor more often. Line Width Controls the weight of the plotted line using line width. Three levels are available; Thin, Normal, and Thick. Thin lines use less ink and make fine details like Asian text and small pieces easier to see. Thick lines use more ink to produce higher contrast lines. Used in conjunction with the Quality Setting (see below), the FlexJet provides six options for output quality, to enable you to produce clearly visible lines using the least possible amount of ink.

Quality Setting Choose Draft or Best to control line density. Draft mode uses 300 DPI. Best mode uses 600 DPI. A lower DPI setting uses less ink by creating a fainter line. Higher DPI uses more ink but makes a darker line. Use this setting in conjunction with the Line Width (see above) to find a bal- ance between saving ink and making clearly visible lines. Measurement Units Choose between English or Metric units for settings display. Consumables Paper Ioline recommends 27 to 35 pound recycled or bond paper, 36- to 74-in (91- to 188-cm) wide. The feed system supports rolls up to 600 yds long. Ink The Ioline FlexJet requires Hewlett-Packard 51645A or ‘45’ cartridges. Guidelines for Installing a Cartridge 1. With the printer in STOP mode (red OK light), press the left arrow key to move the carriage out onto the platen until all cartridge stalls are exposed. 2. Raise the safety cover. Open the blue stall latch and remove the old cartridge if one is present. Squeeze the handle between your fingers and pull forward, then up. Repeat for each cartridge. 3. Insert the new cartridge with the print head pointing down toward the rear of stall and at a slight outward angle. Press firmly while rotating the top of cartridge toward the back of the stall until it stops in an upright position. (See Figure 15.) Figure 14. The Hewlett-Packard 51645A (‘45’ cartridges) are widely available.

4. Close the stall latch. If the cartridge is inserted properly, the latch will snap shut and securely hold the cartridge. Do not force the latch. If the latch does not close properly, remove and reinsert the cartridge. Printing a Marker Overview The basic steps required to print a marker on the FlexJet are: 1. Turn the printer and computer power on. 2. Load paper. 3. Install cartridges in the stalls. 4. Set an origin. 5. Start FlexPlot or your design application.* 6. Send marker/plot files. These steps are outlined in the next several sections. In most cases the design files are sent to the printer from FlexPlot or the design ap- plication. If necessary, use the Ioline Control Center to send design files or adjust settings. General Guidelines 1. Good paper loading makes good plots. Follow loading instruc- tions carefully. 2. Ensure that the paper roll is centered on the feed shaft by align- ing the paper hub with the guideline marks. 3. Keep the plastic feed shaft block clean and well lubricated. 4. Use the FlexPlot software for optimal file management and printing throughput. Figure 15. Insert ink cartridges at an angle into the cartridge bay. Lock in place with the stall latch. * Refer to the FlexPlot User Guide for information on set-up and configuration.

Power On Turn on power to the computer and to the printer. The printer power switch is located next to the power cord on the back. When the power comes on, the carriage will move left across the platen then return and stop on the right side. The front panel OK light will turn red and the Square light will turn green when the printer is ready. Loading Paper 1. Before loading a new paper roll always make sure the drive shaft is clean. See the Routine Maintenance section for more de- tails. 2. Place a paper hub in each end of the paper roll using a rubber mallet. 3. Slide the feed shaft through the paper hubs and the paper roll. If a paper hub falls out, press it firmly back into the end of the paper roll and reseat it with a rubber mallet. 4. This step is very important. Center the paper roll on the feed shaft by aligning the hubs with the black markings on the feed shaft. Make sure the hubs remain securely in place. Figure 16. Installing the feed shaft. Support Block (apply grease supplied in the Accessory Kit) Support Block w/ Bearings Feed Shaft Paper Roll (unrolls from behind) Paper Hubs Flanged Coupling Keep hands and loose clothing away from all moving parts. Caution The FlexJet Set-up, Operating and Maintenance Video, provided on CD-ROM in the Accessory Kit, provides a helpful visual overview. Hint Make sure the paper unrolls from behind and towards the printer. Note i

5. Use the supplied hex wrench to tighten both screws on each paper hub. 6. Check that the right support block is clear of debris and apply a light coating of white lithium grease (supplied in the Accessory Kit.) 7. Lift the feed shaft ends, one at a time, into the support blocks. Installing the Take-up Shaft 1. If the take-up shaft has plotted markers on it, remove them. See Removing Markers from the Take-up Shaft later in this chapter. 2. Turn the FlexJet on (the switch is on the back of the left cover.) 3. Use the keypad Unroll key to rotate the take-up key until it is oriented perpendicular to the support block opening as shown in Figure 17. 4. Put the take-up shaft into the front support blocks with the flanged coupling at the right (keypad) end. Rotate the shaft until the slot in the flanged coupling is aligned with the take- up key. When the shaft slot and the key are aligned, push the take-up shaft into place until it is seated in the support block. Figure 17. Installing the take-up shaft in the support blocks. Take-Up Shaft Use the keypad to position Take- Up Key as Shown Support Block Rectangular Slot Flanged Coupling Never touch the take-up key or flanged coupling while they are rotating. Serious personal injury could re- sult. Turn power off first. Caution

Feeding Paper Figure 18 represents the proper paper path. The diagram on the left shows the paper after it is inserted properly and taped to the take-up shaft. The figure on the right shows the result after the dancer bars are inserted. 1. Remove any printed markers from the take-up shaft and make sure the carriage is parked in the Service Station before feeding the paper. (To park the carriage, press Start/Stop. Wait for the OK light to turn red and press the Clean button.) 2. If the pinchwheels are lowered, raise them by pushing the pinchwheel lever away from the machine. 3. Pull a long leader of paper off of the paper roll and insert it through the stand, behind the plotting head, over the rear top bar, and between the platen and pinchwheels. 4. Temporarily lock the paper in place by pulling the pinchwheel lever toward the machine to lower the pinchwheels. Rear Top Bar Figure 18. The correct paper feeding path on the Ioline FlexJet Printer. Platen Take-up Shaft Feed Roll Proper Paper Path After Loading Front Top Bar Pinchwheel Lever Paper Path when Ready to Plot and Dancer Bars installed Front Dancer Bar Rear (Heavy) Dancer Bar

Tape Paper to the Take-up Shaft 1. Stand in front of the machine. 2. Place 3 short pieces of masking tape within easy reach on the safety cover. (See Figure 19.) 3. Holding the edge of the paper with one hand, use your free hand to lower the pinchwheel lever to raise the pinchwheels. 4. Grasp the front edge of the paper with both hands and pull 20- in (51-cm) of paper over the platen and gray top bar and under the take-up shaft. (See Figure 18 for the proper paper path.) 5. Add tension to the feed roll by applying gentle pressure using the bottom of your foot. 6. To align the paper, gently pull it forward and side to side until the tension feels even. 7. Press and hold the paper on the center of the platen with your left hand, then lower the pinchwheels to lock the paper in place. 8. Attach the paper to the take-up shaft in the center and 2-in (5-cm) from each end with the tape. Figure 19. Taping the paper to the take-up shaft. Tape the paper in 3 places Positioning the Pinchwheels Pinchwheel position should correspond to paper size. Always place two pinchwheels at the outside edges and evenly distribute the others. 1. Ensure that the paper is loaded as described in the previous steps. 2. Press and hold the paper on the center of the platen with your left hand, then raise the pinchwheels by pushing the pinchwheel lever away from the machine with your right hand. When installing or retaping paper, remove the rear and front dancer bars and set them aside. Note i

3. Make sure that the paper roll is centered on the feed shaft. 4. Move the pinchwheels into their proper positions over a tread and under the white markers on the traverse rail. (See Figure 20.) Do not place pinchwheels over drive shaft bearings.) 5. Lower the pinchwheels. Insert the Dancer Bars 1. Lower the pinchwheels by pulling the lever toward the machine. 2. Hold the paper in place over the rear top bar and insert the rear (heavy, gray) dancer bar into the rear dancer bar channel. Apply gentle pressure to control the paper feed as gravity pulls the heavy bar into the channel. See Figure 21. 3. Insert the front dancer bar into the front dancer bar channels. Inner Pinchwheel Figure 20. Positioning the pinchwheels for 72-in (183-cm) paper. 72 Inch Paper Outer Pinchwheels White Driveshaft Markers Figure 21. Inserting the dancer bars. Rear Dancer Bar (Gray heavy rod) Front Dancer Bar (Silver light rod) Drive Shaft Bearings Ensure that the paper roll is cen- tered on the feed shaft. Note i

Set an Origin 1. Ensure that cartridges are installed in the carriage stall(s). (See Guidelines for Installing a Cartridge earlier in this chapter.) 2. Close the cover and turn on the power. After a brief pause, the carriage will glide to the left end plate, then return for a clean- ing in the Service Station. When the initial start-up pro- cess completes, the OK light will turn red and the Square light will turn green. 3. Press the Left Arrow key to position the carriage so that the tip of the small ‘V’ notch in the base is over the desired starting point of the plot. Close the safety cover. 4. Press the Set Origin key. The OK light will turn green. The printer is ready to plot. Sending Plot Files Send plot files to the printer using FlexPlot or design software. Make sure the power is on and that the paper is loaded as previously described. Also, be sure that a new origin is set with the Set Origin keypad button and that the printer is in Start mode (green light). From FlexPlot:* 1. Choose input file type and location then double click on the file. 2. Conversion will occur and the Send to Queue button is acti- vated. Press this button to add the file to the queue. 3. Repeat steps 1 to 2 until the Queue contains all files you wish to print. 4. Press the Send button. Pausing a Marker Plot 1. Pause a plot by pressing the Start/Stop key. 2. The OK light will change from green to red. The FlexJet will finish printing the current scan, then pause. 3. Once the printing has paused, you may use the keypad keys to move the carriage, paper, and take-up shaft. When the Start/Stop key is pressed again (OK light changes from red to green) the printer will begin printing again where it left off. Figure 22. Front Dancer Bar Channel. Front Dancer Bar Channel Sensor Window Do not pull paper tight between the drive shaft and the take-up shaft while printing is paused. Do not turn the feed roll or take-up roll by hand while printing is paused. Caution * See the FlexPlot User Guide or your design application user guide for information on how to send files to the printer.

Canceling a Marker Plot 1. Press the Start/Stop key to place the printer in STOP mode (red light). The FlexJet will finish printing the current scan and pause. 2. To stop the computer from sending plot files to the printer, click the Abort button in FlexPlot. 3. Use the keypad Arrow keys to position the carriage for the start of a new plot file as described earlier. 4. Press the Set Origin key to ready the printer for the next plot file. Removing Markers from the Take-up Shaft 1. Press Start/Stop until the OK light changes to red (STOP mode). 2. Wait for the plotting to halt, then open the safety cover. 3. Remove the front dancer bar. Place it in the small notches in the brackets in the front cover hinges for storage. 4. Cut the paper with the supplied cutting tool, using the groove in the front of the platen as a guide. 5. Use one of the following methods to remove completed markers: Method 1: Unroll with the take-up shaft in place a. With the power off, rotate the take-up shaft by hand until the rectangular opening in the flanged coupling is perpen- dicular to the opening in the support block (see Figure 17). b. Remove the shaft from the support blocks. c. When unwound, the plotted image faces up, permitting markers to be unrolled onto the cutting table with the take-up shaft in place. Method 2: Manual unroll with the Unroll key a. Press the Unroll key to unroll full markers in short steps. b. Cut the marker free from the take-up shaft. Reattach the paper to the take-up shaft with masking tape following the steps outlined under the section Reattach Paper to the Take- up Shaft later in this chapter before continuing printing. Method 3: Automatic Unroll with the Unroll Key a. Press and hold the Unroll key for 3 seconds; The take-up shaft will automatically unroll. b. Cancel automatic unroll at any time by pressing Start/Stop. Method 4: Remove the shaft and unroll away from the machine a. Cut the marker free, wind it manually or automatically with the take-up motor, and remove the take-up shaft from the support blocks. Except when the feed roll is changed, it is best to leave the pinchwheels down when removing completed markers from the take- up roll. Leaving the pinchwheels down will help keep the paper aligned with the feed roll and reduce the time between printing operations. Note i The take-up shaft is very heavy when many plots have been rolled up. It is recommended that two or more people remove a full take-up roll from the machine. Caution An alternate method to ease removal of markers is to slide a 3-in cardboard core over the take-up shaft then tape paper to it. The cardboard core will rotate slowly at first—and may not raise the front dancer bar—but will still roll up completed markers. Simply slide the core off the take up shaft when plotting is complete. Hint

Manually Freeing the Take-up Shaft Use this method to remove the take-up shaft from the completed roll without having to unroll the markers. 1. Tape the loose end of the roll down so that it cannot flap freely. 2. Rotate the take-up shaft by hand until the rectangular opening in the flanged coupling is perpendicular to the opening in the sup- port block (see Figure 17). Remove the shaft. 3. Stand the roll on end with the flanged coupling pointing up. Ro- tate the take-up shaft counter clockwise (opposite to the direction that the paper was rolled on the machine. (See Figure 23.) 4. The larger the roll, the more rotations are required to free the shaft. When the shaft freely rotates, lay the roll on the ground. 5. Continue to twist the shaft counter clockwise while pulling it out of the paper roll until it is free. Figure 23. Manually freeing the take-up shaft.

Automatically Freeing the Take-Up Shaft Like the manual method, this method removes the take-up shaft from the completed roll without having to unroll the markers. The only difference is the use of the take-up motor. 1. Tape the loose end of the roll down so that it cannot flap free. 2. While one person lifts from the bottom and holds the paper roll still, press the Unroll key to rotate the take-up shaft opposite to the direction that the paper was rolled on the machine. 3. The larger the roll, the more rotations are required to free the shaft. When the shaft freely rotates in the roll, stop turning the take-up shaft. If the printer jams and the motor does not turn then do not unwind the roll with the motor. (See Manually Freeing the Take-Up Shaft above.) 4. Rotate the take-up shaft by hand until the rectangular opening in the flanged coupling is perpendicular to the opening in the support block (see Figure 17). Remove the shaft and lay it on the ground. 5. Continue to twist the shaft counter clockwise while pulling it out of the paper roll until it is free. Reattach Paper to the Take-up Shaft 1. Use the Page Advance key to drive enough paper forward to drape over the gray top bar and wrap under and around the take-up shaft. 2. Guide the paper over the gray top bar as it is pulled forward. 3. Make sure the paper wraps under the take-up shaft. 4. Follow the guidelines described in Taping Paper to the Take- Up Shaft. 5. Make sure the silver front dancer bar is below the sensor shown in Figure 22. The take-up shaft is very heavy when many plots have been rolled up. It is recommended that two or more people remove the plotted paper roll from the machine. Caution Except when the feed roll is changed, it is best to leave the pinchwheels down when removing completed markers from the take- up roll. Leaving the pinchwheels down will help keep the paper aligned with the feed roll and reduce the time between printing operations. Note i

Printing to the Floor With careful setup and constant supervision, the FlexJet will print markers directly onto the floor. This method is NOT intended for printing long markers or unattended printing. Ioline recommends that only markers 10 yards and shorter are printed with this method. Figure 24. Before printing to the floor, place tape over the front take-up bar sensor. 1. With FlexJet power off, place a piece of tape over the front take-up bar sensor as shown in Figure 24. 2. Use the paper path diagram to thread the paper on the front of the machine. It should drape over the front top bar AND the empty take-up shaft. 3. Set an origin normally and begin plotting. Make sure that the paper piles smoothly onto the floor. If it bunches up, it may catch on the moving carriage and tear. Figure 25. Paper path for printing to the floor. If the paper bubbles or wrinkles while it flows over the platen surface, the carriage might catch the edge of the paper and tear it, causing a paper jam. Make sure that the paper is smoothly collecting on the floor to avoid paper jams. Caution The front dancer bar is not needed when plotting to the floor. Note i

Clean the drive shaft regularly to assure accurate plotting: 1. Turn off the printer and disconnect the power cord. 2. Gently remove any accumulated dust and residue with the stiff non-metal bristle brush provided in the Accessory Kit. Figure 26. Cleaning the Drive Shaft. Cleaning the Platen and Traverse Dust and paper residue accumulate on the platen and traverse. Un- der regular use, clean every two weeks: 1. Turn off power to the printer. 2. Dampen a lint-free cloth with isopropyl (pharmacy) alcohol and gently wipe the platen and traverse rails until accumulated residue is removed. Warning: Do not use water, brushes with metal bristles or solvents (ex- cept isopropyl—pharmacy—al- cohol) to clean the printer. Keep the drive shaft bearings free of all liquids. Caution Use antistatic spray instead of isopropyl alcohol to clean platen and traverse, if desired. Hint Chapter 4 Routine Maintenance

Figure 27. Calibration screen in Control Center. Cleaning the Support Blocks When dust and paper residue will accumulate on the take-up and feed shaft support blocks, frequent feed shaft jams can occur. Per- form this procedure when debris inhibits easy rotation of the shaft. 1. Turn off power to the printer. 2. Remove the feed shaft and the take-up shaft. 3. Dampen a lint-free cloth with isopropyl (pharmacy) alcohol and gently wipe the plastic support blocks until accumulated residue is removed. 4. Apply a light coating of grease to the plastic feed shaft support block. White Lithium grease is supplied with the printer. 3-in- 1™ brand oil is also a very good lubricant for the feed block. 5. Wipe down both ends of the feed and take-up shafts before reinstalling them. Size Calibration Over time, the printer may require calibration to account for normal wear. Calibration adjusts the output to match design intent. Prepare the Printer (See the Operation chapter) 1. Load the printer with, at minimum, 46-in wide paper. 2. Install ink cartridges. 3. Using the Arrow keys, move the carriage so that the carriage notch is positioned about 1 inch from the right edge of the paper. 4. Press the Set Origin key to put the printer in START (green light) mode. Never touch the take-up key or flanged coupling while they are rotating. Serious personal injury could result. Turn power off first. Caution The Scale command does not effect calibration values. Note i

Use the Control Center to Gather the Calibration Data 1. Open the FlexJet Control Center program. 2. Select Tools>Size Calibration from the Menu Bar. The win- dow in Figure 27 will appear: 3. Press the Send Size Plot button to print the factory stored calibration box. The printer will print a box that is 40” (102-cm) long on the X-axis and 30-in (76-cm) wide on the Y-axis. 4. Precisely measure both sides (X) and the top and bottom (Y) of the box and record the results. Better accuracy in measurement equals better calibration. 5. Take the average of the horizontal (Y) values by adding them together and dividing by 2. Repeat this procedure for the verti- cal (X) values. Example: If X1 = 39.750-in and X2 = 39.700-in The sum is 79.450-in (39.750-in + 39.700-in = 79.450-in) The average is 39.725-in (79.450-in / 2 = 39.725-in) The X calibration value is the average, 39.725-in Enter the Calibration Data: 1. Enter the measured values in the boxes in the Calibration win- dow. Make sure the printer is in START (green light) mode. Select the Set Calibration button. 2. The Control Center will send the calibration values to the printer and the new Calibration Setting will be displayed in the boxes in the window pictured in Figure 27. 3. Click on Done when finished. Figure 28. The Calibration box and measurements. Y1 Y2 X1 X2 ~40 in. Only use Reset Calibration to restore original factory calibration settings. Note i The factory-set calibration values are written on a small sticker inside the Service Station (See Figure 34). To view them, turn off the power, manually pull the carriage out over the platen and peer through the opening in the right end cover. You’ll see a white sticker in the back. Hint The Get Plotter Data button will read the stored calibration settings from the printer and dis- play them in the Factor windows. Hint

Prepare the Printer 1. Load the printer with paper that is a minimum of 46-in wide. (Follow the loading instructions under the Operation chapter.) Install cartridges. 2. Move the carriage using the Arrow keys so that the carriage notch is over the paper and roughly one inch from the right paper edge. 3. Put the printer in START (green light) mode by pressing the Set Origin key. (See the Operation chapter for more details on preparing to plot.) 4. Start the FlexJet Control Center software. Ensure that there are no errors when the program tries to communicate with the printer. If errors occur, check the cables and ensure that the cor- rect port number and baud rate are selected. (See Connect the FlexJet to the Computer: Overview in the Installation chapter for information on serial port connections.) Figure 29. Cartridge calibration window. Cartridge Calibration There are three types of adjustments associated with the ink cartridges. Most line quality issues are resolved by adjusting these values. n Cartridge Alignment aligns each individual ink cartridge rela- tive to one another. n Motion Adjustment aligns scans in the direction of carriage travel. n Frame Gap aligns scans in the direction of paper movement. Cartridge alignment is not neces- sary for FlexJets with a single activated cartridge stall. Note i

Cartridge Alignment 1. Enter -50 in the Frame Gap Window to add a 0.05-in gap after each scan. 2. Press Select Alignment Plot. 3. Browse to the c:\Ioline\Calibration folder. Select the 40X8.plt test file. 4. The boxes in the Cartridge Align- ment window correspond to the print cartridges. The cartridge on the side closest to the keypad is Car- tridge 1. This cartridge also prints closest to the front of the machine. The first 0.5-in of each scan is from the first cartridge; the second 0.5-in is from the second cartridge. 5. Changing the values will move the line closer or further from the line made by the previous cartridge. Adding 1 to the adjustment moves the cartridge alignment about ½ line width either direction. 6. Adjust the values, then press the Set Alignment button. Example (using the first cartridge as reference): a. Lines from the second cartridge must shift one line width (2 units) left to align with the first cartridge. b. Subtract 2 from the number displayed in the box (negative numbers are okay) and enter it in the Cartridge 2 window. c. Press the Set Alignment button. d. Resend the 40X8.plt test file to ensure the results are satisfactory. Repeat until the results are correct. 7. Perform the Frame Gap adjustment detailed later in this chap- ter to reset the Frame Gap. Motion Adjust (Carriage Scan Alignment) 1. Press Select Alignment Plot. 2. Browse to the c:\Ioline\Calibration folder. Select the 40X8.plt test file. 3. The Motion Adjust box has one number for adjustment. The default value is 0. 4. Changing the values affects the next scan, created when moving from left to right. 5. Press the Set Motion button after making adjustments to the values. Example: a. Lines from the second scan shift left to align with the first scan. b. Decrease the Motion Adjust value by 1. c. Press the Set Motion button. d. Repeat the test until alignment is correct. 6. Click on Done when finished. Figure 31. The Motion Adjust Box. Figure 30. The Cartridge Alignment Box. Adding (+) numbers moves the lines right. Subtracting (-) numbers moves the lines left. Note i Adding (+) numbers moves the second scan left. Subtracting (-) moves the second scan right. Note i

Frame Gap (Paper Scan Alignment) 1. Press Select Alignment Plot. 2. Browse to the c:\Ioline\Calibration folder. Select the 40X8.plt test file. 3. The Frame Gap box has one number for adjustment. The default value is 0. 4. Changing the values affects the next scan, created when moving paper forward through the printer. 5. Press the Set Gap button after mak- ing adjustments to the values. Example: a. Lines from the next scan have a small space gap between the previous scan. b. Decrease the Frame Gap value by 1. c. Press the Set Gap button. d. Repeat the test until alignment is correct. 6. Click on Done when finished. Figure 32. The Frame Gap Box. Cartridge Maintenance and Handling A key to maintaining good print quality is proper print cartridge maintenance. During printing, ink-spray, paper fibers and dust can build up on the print cartridge and eventually will degrade plot quality. In addition, when print cartridges sit inactive for a period of time, ink may dry in the nozzles and create an ink plug. This results in the appearance of white streaks in the printed text or graphic. Check Cartridges If you experience print quality problems, first verify that the ink cartridge(s) is undamaged and is not out of ink: 1. Press the Start/Stop key. 2. If the carriage is parked in the Service Station, use the Left Ar- row key to move it out over the platen. 3. Open a blue stall latch and remove the first cartridge. 4. Inspect the cartridge for damage and check the ink level indica- tor. If it is green, the cartridge still contains ink. If it is black, the cartridge is empty and needs replacing. 5. Repeat Steps 1–4 for each cartridge stall. Adding (+) numbers moves the scans further apart. Subtracting (-) moves the scans closer together. Note i Use Best Mode when testing print quality as the higher resolution (600 dpi) setting exercises more nozzles and pushes more ink out of the cartridge. Hint

6. If the cartridge(s) is undamaged and still contains ink, move on to the Automatic Cleaning Procedure. Automatic Cleaning Procedure 1. Press the Start/Stop key and wait until the OK light turns red. 2. Press the Clean key; The carriage will park in the Service Sta- tion and automatically clean the print heads. 3. When the cleaning process finishes, test the print quality again in Best Mode (activiated with the Quality key.) Press the Start/ Stop key. The OK light will turn green. If the FlexJet was active when you initiated Step 1, it will resume printing. If it was idle, send a marker to the print queue. 4. If print quality remains poor, the paper fiber build-up may be such that auto cleaning alone is insufficient for removing ink plugs from the nozzles. You may need to manually clean the print head. Manual Cleaning Procedure To maintain optimal print quality, manually clean cartridges after they sit idle for longer than two days—or are placed in storage. Wip- ing the print head will clean out the nozzles and firing chambers. A Cloth Should Be: n Soft, fiberless, and moistened with deionized water. Should NOT Be: n Abrasive, made of small fibers, dry nor contain chemical additives. 1. Press the Start/Stop key. 2. Using the Left Arrow key, reposition the carriage over the platen. 3. Open the latch for the first cartridge and remove it. 4. Inspect the ink level indicator on the cartridge to verify the cartridge is not empty. 5. Dampen the cloth with de-ionized water. 6. Drag the surface of the cartridge print head over the surface of the cloth. Wipe slowly across the long-axis with the print car- tridge facing down. Do not apply excessive force, as this could scratch the nozzle area. 7. Repeat until the print head leaves an evenly dark line of ink on the cloth. 8. When the cleaning process finishes, test the print quality again in Best Mode (activated with the Quality key.) Press the Start/ Stop key. The OK light will turn green. If the FlexJet was active when you initiated Step 1, it will resume printing. If it was idle, send another marker to the print queue. Use only fiberless cloth as fibers will block the nozzles of the print cartridge. The cloth must be moistened with deionized water so it does not scratch the print cartridge. Scratches can blur line quality. Note i

Print Cartridge Storage Short-term Storage (7 days or less) n Simply leave the print cartridge in the machine, capped in the Service Station. n If the cartridge was not in the Ser- vice Station, it may require manual cleaning. Long-term Storage (greater than 7 days) n lace the print cartridge upside- down in an air-tight container. Lay a sponge or cloth dampened with de-ionized water next to it to help prevent the cartridge from drying out. n To return the cartridge to service, follow the manual cleaning procedure above. Updating Firmware using the Control Center Summary 1. Prepare the FlexJet. 2. Check the Current Version. 3. Update the firmware. Prepare the FlexJet for a Firmware Update 1. Power on the PC and FlexJet. 2. Ensure that the serial cable is connected between the PC and the FlexJet. 3. Copy the firmware file to the folder c:\Ioline\Firmware (or another location that is easy to remember.) Check the Current Firmware Version 1. Start the FlexJet Control Center. 2. The main screen shows the current firmware version in the upper right corner. If the version is less than 253.2 then please follow the directions under the section labeled Manually Updating Firmware using a Terminal Program like TeraTerm. Figure 33. Ink cartridges should be stored in an air- tight container.. If the firmware file is a ZIP archive, make sure it is decom- pressed before sending it to the FlexJet. You can download a ZIP decompression utility at http://www.winzip.com if necessary. Note i If you are using firmware version 247.x or older, you will need to update the firmware manually. The Control Center will not upgrade the older firmware. Note i

3. If you do not see a firmware version displayed, please check connections to the printer. Call Ioline Customer Service for help resolving communication issues. Update the Firmware 1. Choose File>Download Firmware from the menu bar. 2. Press the Select Firmware button. 3. Follow the on-screen directions for restarting the printer so that it will accept new firmware. Press OK when the printer is ready (three yellow lights on the keypad.) 4. Use the file window to browse to the location where you stored the firmware file (e.g. c:\Ioline\Firmware.) 5. A download progress window will appear. 6. When the download finishes, the printer will go through the initialization process. When the FlexJet is finished, the OK light will turn red and the Square light will turn green. 7. Press the Done button. 8. The FlexJet is ready for normal use. Perform test plots and verify that the calibration values are correct. If anything is not performing correctly, reset calibration values as described un- der the Reset Calibration Values section in this chapter. The firmware filename usually looks like ‘xxxxx.mot’, where xxxxx is the unique version number for your printer. Note i

Manually Updating Firmware using a Terminal Program like TeraTerm™ (For firmware versions 247.x and older) Summary 1. Prepare the FlexJet. 2. Set up TeraTerm™. 3. Update the firmware. Prepare to Update the Firmware 1. Power on the PC and FlexJet. 2. Ensure that the serial cable is connected between the PC and the FlexJet. 3. Copy the firmware file to a folder like c:\Ioline\Firmware or another location that is easy to remember. Setup TeraTerm 1. Start TeraTerm™. (Please contact Ioline if you need a copy.) It is included on the FlexJet CDROM in the X:\tools (where X is the CDROM drive letter) folder. 2. When the New Connection window appears, click on the circle next to Serial then select the COM port that connects the printer to the PC. 3. In the main TeraTerm™ window menu, click on Setup>Serial Port. 4. Make sure the settings match the following: a. Data: 8 bit b. Parity: None c. Stop: 1 bit d. Flow Control: Xon/Xoff e. Transmit Delay: 0/0 5. Press OK. If the firmware file is a ZIP archive, make sure it is decom- pressed before sending it to the FlexJet. You can download a ZIP decompression utility at http://www.winzip.com if necessary. Note i

Update Firmware 1. Press the CAPS LOCK key on the keyboard so that the CAPS LOCK light is lit. 2. With TeraTerm™ open, turn FlexJet power off then back on. A message should appear in the TeraTerm™ window. 3. Within 8 seconds of turning on power, press the Y key on the keypad. This prepares the FlexJet to accept new software. The carriage should NOT move after pressing the Y key. 4. In TeraTerm, choose File>Send File. 5. Use the window to browse to c:\Ioline\Firmware and double click on the firmware file (usually xxxxx.mot, where xxxxx is the version number). A window will appear that shows the transfer progress. 6. When the transfer window closes, press the Z key. The FlexJet will finish updating the firmware for approximately 2 minutes. A few messages will appear indicating progress. 7. When the download process is complete, the carriage will go through the Power On sequence and park the Service Station. TeraTerm™ will show that the new software is installed by displaying the version number. The keypad OK light turns red and the Square light turns green. 8. The FlexJet is ready for normal use. Perform test plots and verify that the calibration values are correct. If anything is not performing correctly, reset calibration values as described un- der the Reset Calibration Values section in this chapter. Reset Calibration Values Perform the steps below if calibration values have been altered: 1. With the FlexJet in STOP mode, use the arrow keys to move the carriage to the center of the traverse. 2. Turn power off on the FlexJet. 3. Copy the factory calibration values from the white sticker inside the service station (see Figure 34.) If no sticker is present, recalibrate the machine using the procedure available in the FlexJet User Guide. 4. Press and hold the Unroll key on the keypad then turn FlexJet power on. 5. When the OK light turns red, release the key. 6. Use the FlexJet Control Center software to re-enter the calibra- tion values copied from the sticker OR perform the calibration using the directions in this chapter. 7. Turn power off then back on to ensure the new calibration val- ues take affect. Perform test plots to verify proper calibration and operation. 8. If you have any difficulties, please contact Ioline Customer Service.

Figure 34. Factory calibration values on the sticker inside the Service Station.

the computer, the cable, the design software or the printer. Changes to the computer operating system or the installation of new peripherals or software might cause conflicts. If the computer or the design software are causing a problem, consult your computer and/ or software manuals, or call your manufacturer or dealer. If the problem is with the printer, begin by making sure power is on and that the cable between the machines is connected correctly. Consult the chart at the end of this chapter for more detailed trouble- shooting techniques. Media Tracking Tracking is the process that controls media motion over the platen and assures accurate lines. If the paper slips under the pinchwheels or is out of alignment, printing quality will degrade. To resolve tracking difficulties try the following suggestions: n Install paper correctly. See the Operation chapter for more details. n Make sure the paper path and dancer bars are set correctly (as shown in Figures 18 and 25.) n Inspect the paper for wrinkles or folds. Never use paper that is folded, wrinkled, or torn in any way. It may cause paper jams. n Make sure the pinchwheels are spaced across the paper as outlined under the Operation chapter. n The pinchwheels should never be positioned over bearings on the drive shaft as paper tearing and bunching will occur. Verify that the pinchwheels are positioned over treads (e.g. under the white markers affixed to the traverse.) n Check to make sure that the printer is level. See the FlexJet Quick Start Guide for more information. n The paper may slip when debris accumulates on the drive shaft. Inspect and clean the drive shaft. Refer to the Routine Maintenance chapter for further information. n Contact an Ioline distributor or Ioline Customer Service if you are unable to resolve the problem or if the FlexJet is damaged. Chapter 5 Troubleshooting The FlexJet Service Manual, available on request from Ioline Customer Service, provides ex- panded troubleshooting informa- tion. Note i

Printing Quality Good printing quality is dependent upon a number of different fac- tors. The type of paper, environmental conditions, and operator hab- its are only a few of the variables that can affect the quality of a plot. It is important that the printer is loaded and maintained according to the guidelines under the Operation chapter. If the scans (printing from a single pass) do not line up, see the sec- tions on calibrating the printer in the Routine Maintenance chapter. Line Quality If the line quality is uneven try the follow- ing, in the order listed below: 1. Press Start/Stop then the Clean keys on the keypad to automatically clean the cartridges. 2. Inspect the ink level window on cartridge. If it is black, then the cartridge is empty. Replace it with a new one. 3. Remove the cartridge(s) and manu- ally clean the print head with a (de- ionized) water-moistened, lint-free cloth. (See Cartridge Maintenance and Handling under the Routine Maintenance chapter for more information.) 4. Plot on undamaged or higher quality paper that is free of wrinkles and bubbles. 5. Use genuine HP 45 cartridges as recommended by Ioline. 6. Contact an Ioline distributor or Ioline Customer Service if you need further help. Serial Communication The serial port on the FlexJet has an adjustable baud rate. Available speeds are 9600, 19200, 38400, 57600, and 115200. It is critical that the FlexJet Control Center, FlexPlot or design software use the same baud rate that the FlexJet is using. If there is ever any doubt about what baud rate the printer is using, Ioline recommends resetting it to the default of 38400. To reset the baud rate: 1. Turn off the power to the FlexJet. Figure 35. HP cartridges have an ink level indicator. Black means empty Use the FlexJet Control Center to change the baud rate to match the design software. Hint Use the Page Advance and Power Switch key combination to reset baud rate: Note i 1 0 +

OK n l p Problem/Status G OFF OFF OFF Ready to Print, Origin Set R OFF OFF OFF Paused / Offline, Keypad Active R G OFF OFF Power on reset finished. R Y-Blink OFF OFF Cover open (obsolete) R OFF Y-Blink OFF Paper Feed Out / Jammed Y-Blink R R OFF X- (paper) axis jam Y-Blink G R OFF Y- (carriage) axis jam Y-Blink G G OFF TU (take-up) jam Y-Blink R G OFF SS (Service Station) jam OFF R Y-Blink OFF Buffer Overflow Y-Blink OFF R OFF Init from EPROM failed OFF R R OFF File syntax error Y-Blink Y-Blink Y-Blink OFF Printer ready to receive firmware Y-Blink OFF OFF OFF Motors off / System Stop 2. Press and hold the Page Advance key while turning power on. 3. Continue holding the Page Advance key until the OK light turns red and the Square light turns green. 4. Cycle power again (do not touch any keys this time) to ensure communications are reset. If using a terminal program like TeraTerm™ to communicate with the FlexJet, make sure to use 8 Data Bits, No Parity, 1 Stop Bit, and Xon/Xoff Flow Control. Keypad Error Codes Legend G = Green light R = Red light Y = Yellow light Y-Blink = Blinking yellow light* OFF = Unlit If keypad errors are not shown on the chart to the left, update the firmware. Downloads are available on Ioline’s FlexJet Web site or by contacting Ioline Customer Service. Note i Figure 36. LED lights on the keypad. * First generation FlexJet keypad lights do not blink.

Common Issues A marker plot doesn’t start at the correct point on the paper Cause: The origin is not set. Solution: Position the pen where the plot should start. Press the Set Origin key. The printer does not complete the marker. Cause: 1. Outdated software. 2. The frame/panel size is mis- matched between the printer and the design software. Solution: 1. Visit the Ioline FlexJet Web site to download upgrades. Or, contact Ioline Customer Service. 2. Check the panel size in the software. It should be equal to or lower than the default printer panel size of 46-in (116.8-cm).. When a marker plot file is sent, nothing happens. Cause: A communication problem has oc- curred or the printer is in STOP (red light) mode. Solution: Make certain the communication port is connected and configured properly. Position the pen where the plot should start and press the Set Origin key to put the printer in START (green light) mode. No power when printer is turned on; keypad lights stay dark. Cause: 1. The power cord is damaged or disconnected. 2. The printer is damaged and needs professional service. Solution: 1. Check the power connection. 2. Contact an Ioline distributor or Ioline Customer Service. Poor line quality. Cause: 1. Ink cartridge is improperly installed. 2. Frame Gap setting is incorrect. 3. Carriage electronics or cables are damaged. Solution: 1. Remove and reinstall ink car- tridge. 2. Use the Control Center to adjust frame gap as shown in the Routine Maintenance chapter. 3. Contact Ioline customer service.

Jagged scan alignment. Cause: 1. Cartridge alignment is incorrect. 2. Motion alignment is incorrect. 3. Platen or stand is not level. 4. Loose carriage pulley causing ran- dom/uneven gaps between scans. Solution: 1. Use the Control Center to adjust cartridge alignment as shown in the Routine Mainte- nance chapter. 2. Use the Control Center to adjust motion alignment as shown in the Routine Maintenance chapter. 3. Follow the directions in the FlexJet Quick Start Guide to level the stand and platen. 4. Contact Ioline customer service. Rear heavy bar goes to the top of the channel and the keypad shows and error. Cause: 1. Out of paper. 2. Paper path is obstructed. 3. Dirty feed roll support blocks. 4. Paper is not aligned properly. 5. Paper runs under rear cross- member. Solution: 1. Change the paper roll. 4. Make sure nothing is touching the feed roll and that the rear top bar rotates freely. 5. Clean then lubricate the feed shaft block. Use the included white lithium grease. 6. Load paper straight as described in the Operation chapter. 7. Adjust paper to go between the front and rear cross-members. Gap between each scan. Cause: 1. Frame Gap setting is incorrect. 2. Ink cartridge is out of ink, dirty or the print head is plugged. Solution: 1. Use the Control Center to adjust frame gap as shown in the Routine Maintenance chapter. 2. Check ink level indicator. Replace cartridge if indicator is black. If cartridge is not empty, see Cartridge Maintenance and Handling under the Rou- tine Maintenance chapter. Pauses during printing. Cause: 1. Vector density is very high due to fine detail or the design soft- ware is not using fonts embed- ded in the printer. 2. Communication baud rate is set very low. Solution: 1. Reduce vector density, use em- bedded printer fonts, or increase communication baud rate. 2. Increase baud rate from the minimum of 9600 baud to the default of 38,400 or higher.

Regular or intermittent paper tearing. Cause: 1. Front or rear dancer bar is not installed. 2. Paper gets “yanked” by the machine during take up. 3. Paper is improperly loaded. 4. Paper buckles plotting to floor. 5. Paper roll damaged. 6. Paper not loaded correctly. 7. Platen not level. 8. Outdated firmware does not advance paper at startup. 9. Pinchwheels press on a drive shaft bearing. 10. Take-up loop too long. Solution: 1. Install front or rear dancer bar. 2. Remove slack from paper roll before pressing Set Origin. 3. Reload paper and verify that it is in alignment. 4. Clear paper path. 5. Inspect the feed paper roll. Drop- ping the paper roll on an end can wrinkle the edge which can catch the carriage and cause a tear. 6. Correct paper loading is vital. Fol- low the steps in the Operation chapter to reset paper alignment. Make sure the front silver dancer bar is BELOW the front optical sensor before plotting. 7. Make sure the distance between the print heads and platen sur- face is the same at both the right and left side of the printer. Adjust the platen levelers as described in the FlexJet Quick Start Guide. 8. Use the Control Center to check the firmware version and ensure it is 324 or greater. 9. With power off, raise the pinchwheels and align them with the white driveshaft markers on the traverse. 10. Use the Control Center to decrease loop length. Requires Control Center version 6 or later and firmware version 324. Poor paper tracking. Cause: 1. Paper is improperly loaded. 2. Bad paper roll or paper quality. 3. Pinchwheels not in correct location. 4 Feed paper roll is centered on feed shaft. 5. Paper roll not centered on feed shaft. 6. Loose paper hubs. Solution: 1. Reload and align paper. 2. Replace the paper roll. 3. Reposition the pinchwheels as indicated in the Operation chapter. 4. Center the paper roll on feed shaft (see Figure 16). Make sure screws are tight on both paper hubs. 5. Ensure the feed roll is centered on the feed shaft. 6. Tighten screws on the paper hubs.

Ioline has many years of experience working with designers, graders and marker makers. Feel free to contact us if you have questions—or to share information. Getting Help Ioline is committed to providing the highest quality service and sup- port to its customers. If you need assistance with an Ioline FlexJet, a number of resources are available: 1. First, refer to this FlexJet User Guide for answers to your specific questions. 2. Many detailed troubleshooting and repair issues are listed in the FlexJet Service Manual, available upon request from Ioline Customer Service. 3. Consult the support section of the Ioline Web site: www.ioline. com. FlexJet users must have a User Name and Password to log into the site. Please contact Ioline customer service to set up your free account. 4. For additional assistance, contact your local dealer or Ioline Customer Service. Contact information is listed under Customer Service in this chapter. Any warranty servicing of this product not specifically described in this manual must be authorized in writing by Ioline Customer Service. You may obtain service by calling or faxing Ioline Customer Service. The technicians will help you determine the nature of the problem. If factory repair is necessary, you will receive a RMA (Re- turn Material Authorization). Please gather the information indicat- ed on the next page before contacting Ioline or your dealer. 1. When returning a machine, carefully package the equipment in its original container or packaging equivalent. You may purchase shipping containers from Ioline by contacting Ioline Customer Service. Ioline is not responsible for any damage due to inadequate or improper packaging. 2. Carefully wrap and secure all items in the shipping container to FlexJet service manuals, technical bulletins, software updates and other information is available to FlexJet owners on www.ioline. com. Access is free. Just contact Ioline Customer Service at [email protected] to set up a User Name and Password. Hint Chapter 6 End Notes

prevent damage. Seal the container and note the RMA number near the address block. 3. Ship the container using FED-EX or another approved carrier. COD shipments ARE NOT ACCEPTED. An Ioline representa- tive will contact you prior to the start of work with an estimate of repair cost. All repairs are warranted for 90 days. Customer Service Ioline Corporation is committed to providing quality service and support to our customers. If you need assistance with an Ioline prod- uct, contact your local dealer or Ioline authorized service center. You may also contact: Ioline Customer Service Department Monday through Friday 7:00 A.M. - 5:00 P.M. U.S. Pacific Time Voice: 1.425.398.8282 Fax: 1.425.398.8383 [email protected] www.ioline.com Your Comments Are Requested Ioline Corporation is interested in comments on our documentation and products. Please send corrections or suggestions to: Ioline Corporation 14140 NE 200th Street Woodinville, WA 98072 USA Voice: 1.425.398.8282 Fax: 1.425.398.8383 [email protected] www.ioline.com This User Guide is provided for informational purposes only. The contents are subject to change without notice, and Ioline Corpora- tion assumes no responsibility for any errors that are contained herein. No part of the FlexJet User Guide may be copied, dissemi- nated, or distributed without the express written consent of Ioline Corporation.

Name: Company Name: Phone Number: Fax: E-mail: Model: Serial Number*: Date of purchase: Dealer: Type of media & ink used: Type of Computer: Type of design software: New software or peripherals: Service history: Before you contact Support… Please gather the following information about your printer before contacting Ioline or your dealer for technical support: * You’ll find the serial number above the power switch on the back side of the right cover.

The FCC Wants You to Know... This equipment generates and uses radio frequency energy and, if not installed and used properly (in strict accordance with manufac- turer instructions), it may cause interference to radio and television reception. Operation is subject to the following two conditions: (1) This device may not cause harmful interference, and (2) this device must accept any interference received, including interference that may cause undesired operation. If this equipment does cause inter- ference to radio or television reception - which can be determined by turning the equipment off and on - you are encouraged to try to correct the problem by one or more of the following measures: n Use only shielded interface cables. n Reorient the receiving antenna. n Relocate the host computer with respect to the receiver. n Move the host computer away from the receiver. n Plug the host computer into a different outlet so that the host computer and receiver are on different branch circuits. If necessary, consult the dealer or an experienced radio/television technician for additional suggestions. How To Identify and Resolve Radio-TV Interference Problems, a booklet published by the Federal Communications Commission, is a helpful reference. Please contact the FCC to request a copy: www.fcc.gov Document stock number: 004-000-00345-4 This booklet is available from: U.S. Government Printing Office Washington, D.C. 20402 This equipment was 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 en- ergy and, if not installed and used in accordance with the instruction manual, may cause harmful inter- ference 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 or her own expense. Note i

velocity of the carriage or the paper. Acceleration is measured in units of g (1 g = 32.2 ft/s2). Arc – A segment of a circle, also called a curve. Axis – A geometric guideline used to place a coordinate. B Bottom Cover – Metal housing that protects the underside of the printer. C Control Panel – See Keypad. Coordinate – A point that is referenced by its position on the X- or Y-axes of a printer. Vector or arc seg- ments connect coordinates to create printing paths. Carriage – The component that holds the ink cartridge(s). It travels along the Y-axis on the traverse. D Dancer Bar – Rod that holds the feed loop and take- up loop taut during printing. DM/PL – Digital Microprocessor/Plotting Lan- guage. An instruction set used to send vector information to a machine that can represent the data as an image. DM/PL is used in software drivers for some design programs. DPI – Dots Per Inch. Refers to the dot density or print resolution on paper. Drive Shaft – The motor driven shaft that moves ma- terial through a friction feed printer. The FlexJet drive shaft has a rough surface that grips the material.  Glossary F Feed Loop – Slack material between the feed roll and the printer. The rear dancer bar holds the feed loop taut during printing. Feed Shaft – Metal rod that holds the paper roll parallel to the printer and allows it to turn during feeding. File Name Extensions – In DOS and Windows based programs, the three letters after the period in a file name. With graphics files the three letters de- note a file type such as the vector and bit map based Encapsulated Postscript (EPS) and the vector based Hewlett-Packard Graphics Language (PLT). Font – Refers to the style and width of letters, num- bers, and symbols. Examples are Helvetica Bold or Times Roman. Frame – Segment of a plot established by the design software. Frames can be any size up to 21600-in (X axis) by 72-in (Y axis). Markers are generally plotted as a series of frames. Frame Size – The X axis length of each part of the plot as established by the design software. Frame size is also called tile size, page size, etc. Friction Feed – Process where the material is fed through a printer by placing it between a motor- driven drive shaft and tensioned pinchwheels. Front Dancer Bar – Light-weight rod that holds the take-up loop taught. G Green Light Mode – See START Mode. H HPGL – Hewlett-Packard Graphics Language. Instruction set used to send vector information to a

62 Ioline FlexJet User Guide machine that can represent data as an image. HPGL 7475 is the most common plot language used for com- munication between a printer and design software. K Keypad – Panel on the right side of the printer where the user controls simple printer functions. Carriage and paper motion is accessible from here during Stop mode. Also called the Control Panel. M Mil – Thousandths of an inch or milli-inches. For example; 75 mils is the same as .075 inches. 1 mil is equal to .025-mm. O Origin – Point marking the zero (0) coordinate on the X and Y axes. Used as a starting reference by the printer. On an Ioline printer, the origin is set with the Set Origin key on the keypad. P Panel – See Frame. Paper Hub – Device that holds the feed paper roll in position on the feed shaft. Pinchwheel – Roller wheels that push the paper against the drive shaft when lowered into position by the square shaft. Pinchwheel Lever – Lever connected to the square shaft that, when actuated, raises and lowers the pinchwheels. Platen – Curved surface that houses the drive shaft and supports the material during printing. Printer – A device that uses image data to produce output, usually on paper. In electronic marker mak- ing, printers create sewn good outlines on paper from a set of coordinates stored in a computer file. R Rear Dancer Bar – Heavy rod that holds the paper feed loop taught. Red Light Mode – See STOP Mode. Resolution – The smallest distance that a printer can move the material or the carriage. Printer resolution affects the accuracy of plot file reproduction on the material. Roll Feed – A method of pulling material from a roll for printing. Works in conjunction with the rear dancer bar and drive shaft. S Scan – A single pass of the carriage over the platen. The FlexJet may or may not print during a scan. Sensor – The electronic eye that reads paper position by monitoring the dancer bars. Serial Communications – Method of sending infor- mation from a computer to a printer by sending 1 bit at a time through a cable. The serial port on a PC is a male (9- or 25-pin) connector. Service Loop – See Feed Loop. Service Station – Located underneath the right end cover (behind the keypad). When the carriage is parked, the Service Station caps the inkjet cartridges for short-term storage of 2 days or less. Square Shaft – Shaft that raises and lowers the pinchwheels when rotated. Located behind the tra- verse assembly. START Mode – OK light on the keypad is green. Printer is ready to print. See Set Origin or Start/Stop under Keypad Controls in the Operation chapter. STOP Mode – OK light on the keypad is red. Printer is paused and offline (e.g. not ready to print). See Set Origin or Start/Stop under Keypad Controls in the Operation chapter. Support Blocks – Plastic parts that hold the feed shaft and take-up shaft. T Take-up Loop – Slack material between the printer

take-up loop taut during printing. Take-up Motor – The motor that rotates the take-up shaft on the FlexJet. Take-up Shaft – Metal rod that the plotted markers are rolled onto. The take-up shaft is driven by the take-up motor. Throughput – The speed at which a printer com- pletes a job. Represents the ability to process infor- mation and produce an image. Top Bar – Metal bars in the front and rear of the printer that hold the feed loop and take-up loop vertical. Traverse – Structure that supports and guides the carriage and holds the pinchwheel assemblies. U USB – Universal Serial Bus. High speed method for transferring information from a PC to a peripheral like a printer. V Vector – A line segment between two coordinates. X X-Axis – Theoretical horizontal line providing a length reference point for the printer. Associated with paper movement over the platen. Y Y–Axis – Theoretical vertical line providing a width reference point for the printer. Associated with car- riage movement across the traverse.

Acceleration 61 Accessory Kit 15, 29, 30, 39 Active print cartridges 25 Alignment—See Calibration; See Troubleshooting Arc 61 Arrow keys ix, 21, 22, 23, 35, 40, 42 Buttons 23 Assembly 15 Lifting technique ix ASTM 6959 18 Automatic Buffer Closing 25 Automatic mode 23 Automatic unroll 23 Aux Sensor 25 Axis 61 B Baud rate 16, 17, 23, 25, 26, 42, 52, 55—See also Serial port Adjusting 17 Reset 23 Speed 17, 23 Bottom cover 61 C Cables Power cord 16, 19, 29, 39, 54 Serial 15, 16, 46, 48—See also Serial port Socket and port locations on FlexJet 16 CAD software—See Design software Calibration 25, 40–44, 47, 49 Cartridge alignment box 43 Cartridge calibration window in Control Center 42 Control Center calibration screen 40 Factory default settings 41, 50 Calibration sticker 50 Ink cartridges 42 Measuring the calibration box 41 Motion adjust box 43 Plot size 40 Calibration box 43, 44 Calibration folder 43, 44 Calibration sticker 50 Cancel a print job 35 Carriage ix, xii, 14, 19, 22, 23, 24, 26, 27, 29, 31, 34, 35, 38, 40, 41, 42, 44, 45, 49, 53, 55, 56, 61, 62, 63 Close-up view xii Notched ‘V’—See Set origin Parked, cartridges capped 22 Parking 31 Positioning with Arrow Keys 23 Stall xii Carriage motion—See Plot Carriage rail—See Traverse Carriage scan alignment 43 Cartridge alignment 43 Cartridge alignment box 43 Frame gap box 44 Cartridges—See Ink cartridges CDROM—See FlexJet Set-up, Operating and Maintenance Video; See Control Center; See FlexPlot Changing system settings—See Control Center Clean ix, 22, 31, 39, 45, 52, 55 Button 22 Cleaning agents 39

66 Ioline FlexJet User Guide Cleaning the drive shaft 39 Using the brush 39 Clipping 26 Communications 62 Baud rate 16, 17, 23, 25, 26, 42, 52, 55 Data bits 17, 53 Flow control 17, 48, 53 Parity 17, 48, 53 Stop bits 17 Conflicts 24—See also Troubleshooting Get plotter data 26 Ports—See Serial port, USB Settings 25 COM ports—See Serial port, USB Computer 15, 59 Consumables 27 Ink 27—See also Ink cartridges Paper 27 Hubs 28, 29, 30 Installing feed shaft 29 Installing take-up shaft 30 Loading 28–32 Minimum width 40 Proper paper path 31 Reattaching after marker removal 37 Taping 32 Taping paper to take-up shaft 32 Consummables Paper Loop Length 26 Control Center 13, 15, 16, 17, 19, 24, 25, 26, 28, 41, 42, 46, 49, 52, 54, 55, 56 Cartridge calibration 25 Cartridge count 26 Download firmware 25 Exit 25 Frame size 26 Get plotter data 26 Help about 25 Installation 19 Line width 26 Main Menu 24 Measurement units 27 Menu Bar 25 Menu options 26 Quality setting 27 Scale 26 Screen Menu 24 Send command 25 Send plot file 25 Set key code 25 Set machine ID 25 Settings 25 Size calibration 25 Software version 26 Control panel 21, 61—See also Keypad Conversion 13, 18 Coordinate 61 Cross-member xi Customer service x, 47, 49, 51, 52, 53, 54, 57, 58 Contact information 58 D Dancer bar 61 Channels 33 Front dancer bar 31 Front dancer bar channel 34 Insertion 33 Installation 33 Rear dancer bar 31, 33, 62 Data bits 17, 53 Data rate—See Baud rate Design software 13, 15, 17, 22, 26, 34, 51, 52, 54, 55, 59, 61, 62 Installation 13 DM/PL 13, 17, 18, 61 DPI 61—See also Printing Resolution Drivers 13, 61 Drive shaft ix, 29, 33, 34, 39, 51, 56, 61, 62 Maintenance 39 Using the brush 39 Drive shaft marker xii, 33 Location xii E Error codes Keypad errors 53 F Factory default settings Restoring 23 FCC 60 Feed loop 61

Feed shaft x, 28, 29, 30, 33, 40, 55, 56, 61, 62 Flanged coupling 29 Installing feed shaft 29 Support block 29, 30 File conversion 13 File formats 13, 17, 18, 61, 62 File import 13 Files Download firmware 25, 47 File name extensions 61 EPS 25, 61 PLT 25, 61 PLX 25, 61 Plot file adjustments—See Control Center Send plot file 25 Firmware Software version 26 TeraTerm 48–49 Updating 25, 46–50 Updating manually with terminal program 48 Flanged coupling 29, 30 FlexJet Assembly 15–20 Connections 13, 15, 16, 17, 23, 52, 62 Front close-up xii Front View x Maintenance 39–50 Operation 21–38 Pre-wiring for expansion 25 Rear view xi Set-up, Operating and Maintenance Video 15, 29 Settings 26 Start-up process 19 FlexJet Control Center—See Control Center FlexJet Quick Start Guide 13, 15, 51 FlexJet Service Manual 51 FlexJet Set-up, Operating and Maintenance Video 15 FlexPlot 13, 15, 16, 17, 18, 19, 28, 34, 35, 52—See also the FlexPlot User Guide Abort button 35 Installation 19 Send to queue 34 Set-up window 17 Workflow using CAD software 18 Workflow with FlexPlot 18 Flow control 17, 48, 53 Font 61 Foot Platen leveling foot close-up xi Stand leveling foot close-up x Frame 61—See also Plot Frame gap 42 Eliminating or adjusting 44 Frame gap box 44 Frame gap box 44 Frame size 26, 61 Friction feed 61 Front dancer bar 31 Front top bar 31 G Get plotter data 26 Getting started 13 Assembly 15 Connecting to computer 15 Unpacking the FlexJet 15 Gray bars ix Lifting by gray bars ix Grease 29, 30, 40, 55 Green light mode 61—See also START Mode H Hardware—See FlexJet Assembly Help 57–59—See also FlexPlot and Control Center Hex wrench 30 HPGL 13, 17, 18, 61, 62 Hubs 28, 29, 30 I Import 13 Ink 27 Ink cartridges 13, 28, 40, 42 Auto cleaning 22, 45 Calibration & alignment 25, 40, 41, 42, 43, 44, 47, 49 Cartridge alignment box 43 Control Center cartridge calibration window 42

68 Ioline FlexJet User Guide Motion adjust box 43 Cartridge count 26 Cartridges in stalls xii Cartridge stall latch xii Cleaning 45 Guidelines for installing 27–28 Install and lock in place 28 HP 51645A 27 Ink 27 Ink level indicator 44, 45, 52, 55 Empty cartridge 52 Maintenance and handling 44–46 Requirements 27 Stalls xii, 27, 28, 44 Storage 46 Air-tight container 46 Upgrading number of stalls 25 Installation 15–20 Ioline Corporation 58 J K Keypad 19, 21, 23, 24, 30, 34, 35, 43, 47, 49, 52, 53, 55, 61, 62 Arrow keys ix, 21, 22, 23, 35, 40, 42 Clean ix, 22, 31, 39, 45, 52, 55 Close-up view of 21 Lights—See Troubleshooting LED lights 53 OK light 19, 21, 22, 23, 24, 27, 29, 31, 34, 35, 45, 47, 49, 53, 62 Page advance 23, 37, 52, 53 Quality 22 Reset serial port baud rate 23 Restore factory default settings 23 Roll Up 23 Set origin 22, 34, 35, 40, 42, 54, 56, 62 Special key combinations 23 Square light 19, 23, 24, 29, 34, 53 Start/Stop 21, 22, 23, 31, 34, 35, 44, 45, 52, 62 Unroll 21, 23, 30, 35, 37, 49 Keypad error codes 53 L Left end cover x License key code 25 Limit of liability statement x Line quality—See Printing Quality; See also Troubleshooting Line width 24, 26, 27, 43—See also Printing Quality Loop Length 26 Loss of registration between frames 54 Lower left plot origin 14 M Maintenance 39–50 Lubricants 40 Manual unroll 23 Marker removal Manually freeing take-up shaft 36 Markers—See also Plot Removal 35–37—See also Unroll Using cardboard tube 35 Starting position—See Plot Set origin Measurement Units 27 Media 13, 14, 51, 59 Media tracking 51, 56 Menu Control Center 25 FlexPlot—See the FlexPlot User Guide Mil 62 Motion adjust 43 Motion adjust box 43 N Notched ‘V’ 22 Images Location on carriage 22 O Offline 21, 62 OK light 19, 21, 22, 23, 24, 27, 29, 31, 34, 35, 45, 47, 49, 53, 62 Operating system 19, 61

‘V’ notch on carriage 22 Location on plot 14 Output—See Printing P Page advance 23, 37, 52, 53 Button 23 Panel—See Frame Paper—See Consumables Paper Hub 62—See also Consumables Paper Hubs Paper jams—See Troubleshooting Paper motion—See Plot Paper Out sensor 25 Paper path 31, 32, 38, 56 Correct feeding path 31 Feed loop 61 Printing to floor 38 Paper path diagram 38 Sensor 62 Taping sensor 38 Reattaching paper after marker removal 37 Take-up Loop 62 Taping paper to take-up shaft 23, 32, 35, 38 Paper scan alignment 44—See also Frame gap Paper sensor 23, 37, 38, 56—See also Paper path Printing to floor Parity 17, 48, 53 Pause a print job 34 Pinchwheel 62 Location of xii Position 32, 33 Outer and inner pinchwheel locations 33 Pinchwheel lever xii, 31, 62 View from front xii Platen xi, xii, 31, 39, 55, 56, 62 Cleaning 39 Platen leveling foot xi Plot 13, 14, 17, 23, 27, 30, 31, 33, 35, 36, 37, 38, 51, 56, 63 Accuracy 14 Adjustments with Control Center 24–26 Carriage motion 14 Frame 14, 26, 54, 55 Alignment 42 Frame size 26, 61 Scan gaps—See Troubleshooting Layout 14 Line width 24, 26, 27, 43 Paper motion 14, 62 Quality—See Printing Quality Removal—See Unroll Scale 24, 26 Scan 62 Alignment 44 Sending to printer 24, 34 Set origin 22 X-axis 14, 26, 41 Y-axis 14, 26, 41, 61 Plotter settings 13, 15, 16, 17, 19, 24, 25, 26, 28, 40, 41, 42, 46, 49, 52, 54, 55, 56 Plotting pens—See Ink cartridges Plotting quality—See Printing quality Poor line quality—See Printing Quality; See Troubleshooting Port setup 16–17 Power cord 16, 19, 29, 39, 54 Socket location 16 Power on 29 Power switch xi, 19, 29, 59 Pre-wiring for expansion 25 Printer 62 Printing Cancel a print job 35 File conversion—See Conversion General guidelines 28 Overview 28 Page advance 23, 37, 52, 53 Pause print job 34 Printing to floor—See Paper path Paper path diagram 38 Taping sensor 38 Quality 22, 27—See also Troubleshooting Queue management 18 Recommended software 17 Resolution 22 Roll feed method 62 Send plot files to printer 25, 34 Speed 63 Workflow 17–18 Using CAD software 18 Using FlexPlot 18 Problems—See Troubleshooting

70 Ioline FlexJet User Guide Q Quality 22—See Printing quality LED Lights on keypad 22 Queue management 18 R Radio frequency 60 Rear dancer bar 31, 62 Red light mode 62—See also STOP mode Removing markers—See Markers Removal Repair ix, 57, 58 Factory authorization ix Reset Serial Port Baud Rate Button combination 23 Reset serial port baud rate 23 Resolution 62—See also Printing resolution Restore Factory Default Settings Button combination 23 Restore factory default settings 23 Right end cover x Roll feed 62 Roll Up 23 Button combination 23 S Safety Lifting printer by gray bars ix Removing markers 35 Safety precautions ix Take-up key 30 Safety cover x Scale 26 Scan 62 Scan alignment—See Frame gap Screen menu options—See Control Center Segments (of a plot or marker)—See Plot Select alignment plot 43 Send Command 25 Sending plot files 34 Send plot file 25 Send size plot 41 Send to queue 34 Sensor xii, 23, 62 Serial communication 62—See also Communications Serial port xi, 13, 15, 16, 17, 23, 52, 62 Configuration 16 Data bits 17 FlexPlot set-up window 17 Flow control 17 Location on computer 16 Location on FlexJet 16 Parity 17 Setup 16–17 Stop bits 17 Service loop 62—See also Feed loop Service Station ix, xii, 19, 22, 31, 34, 41, 44, 45, 46, 49, 50, 53, 62 Set alignment 43 Set calibration 41 Set gap 44 Set motion 43 Set origin 22, 34, 35, 40, 42, 54, 56, 62 ‘V’ notch on carriage 22 Button 22 Size calibration 25, 40, 41 Software—See also Firmware Apparel design software 13, 15, 17, 22, 26, 34, 51, 52, 54, 55, 59, 61, 62 Control Center 13, 15, 16, 17, 19, 24, 25, 26, 28, 41, 42, 46, 49, 52, 54, 55, 56 FlexPlot 13, 15, 16, 17, 18, 19, 28, 34, 35, 52 Setup 17 Software version 26—See also Firmware Special keycombinations 23 Square light 19, 23, 24, 29, 34, 53 Square Shaft 62 Stall xii, 27, 28, 44 Stand x, 15, 32, 36 Assembly & Leveling 15 Cross-member xi Stand leveling foot x Start/Stop 21, 22, 23, 31, 34, 35, 44, 45, 52, 62 Button 21

Start point—See Origin STD 18 Stop bits 17 STOP mode 21, 22, 23, 27, 35, 49, 62 Support 57–60 Contact information 57, 58 Ioline Web site 57 Warranty 57 Support block 29, 30, 62 Surge protector 15, 16 System settings—See See Control Center T Take-up key 30, 40 Take-up loop 62 Take-up motor x, xi, 63 Take-up motor cable xi Take-up motor outlet xi Take-up sensor xii—See also Sensor Take-up shaft x, 14, 23, 30, 31, 32, 34, 35, 36, 37, 38, 40, 62, 63 Installation 30 Installing take-up shaft 30 Manually freeing take-up shaft 36 Maximum paper roll length 14 Taping paper to take-up shaft 32 Tape positions 32 Tech Support 58 TeraTerm 48–49 Terminal program 17, 53 Throughput 63 Top bar 63 Tracking 51, 56 Traverse xii, 39, 63 Cleaning 39 Troubleshooting 51–56—See also FlexJet Service Manual Alignment issues 55 Common issues 54–56 Communications 52 General troubleshooting 51 Keypad error codes 53, 55 Loss of registration between frames 54 Media tracking 51, 56 Paper jams 38, 40 Paper tears 56 Power 54 Printing quality 44–46, 52, 54–55 Radio-TV interference 60 Scan gaps 55 Speed 55 U Unroll 21, 23, 30, 35, 37, 49 Automatic unroll 23, 35 Button 23 USB xi, 63 V Vector 63 W Windows 19, 61 Wrench 30 X X-Axis 63—See also Plot Y Y-Axis 63—See also Plot Z