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Ioline FlexJet User Manual

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Ioline FlexJet™

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  • Page 1 Us er G u i de Ioline FlexJet™...
  • Page 2 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.
  • Page 3 Ioline FlexJet™ User G u i d e...
  • Page 4 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.

  • Page 5: Table Of Contents

    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 ..........................
  • Page 6 Control Center Menu Bar Features ................25 File ............................25 Communications ........................25 Tools ............................25 Help ............................25 Control Center Menu Options ..................26 Software Version ........................26 Cartridge Count ........................26 Get Plotter Data ........................26 Plotter Data (check box) ....................26 Scale ............................
  • Page 7 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 ............

  • Page 9: Safety & Cautions

    Safety & Cautions The Ioline FlexJet has many fast moving components. Please read and follow these safety guidelines before beginning operation of the printer: Do not try to repair the machine without factory authoriza- tion. Only qualified service personnel should attempt any disassembly or access to internal components.
  • Page 10 A. Left End Cover Feed Roll B. Safety Cover G. Take-up Shaft C. Right End Cover H. Feed Shaft D. Take-up Motor Stand E. Stand Leveling Foot Figure 2. The Ioline FlexJet Printer Front View.

  • Page 11: Visual Reference Guide

    Visual Reference Guide Take-up Motor Cable N. Platen Leveling Foot K. Take-up Motor Outlet O. Cross-member L. Serial & USB Ports Paper Out Sensors M. Power Switch (hidden) Figure 3. The Ioline FlexJet Printer Rear View (head tilted in maintenance position.)
  • Page 12 R. Cartridge Stall Latch W. Platen S. Pinchwheel Lever X. Pinchwheel T. Keypad Y. Drive Shaft Marker U. Service Station Z. Traverse . Carriage Assembly (Beneath Cover) Figure 4. The Ioline FlexJet Printer Front View Close-up (safety cover lifted for clarity.)

  • Page 13: Chapter 1 Overview

    Ioline FlexJet printer. The following components are needed to create markers: A FlexJet assembled according to the directions outlined in the FlexJet Quick Start Guide. A computer system that is properly installed and has a func- tioning serial or USB port.

  • Page 14: Figure 5. The X- And Y-Axes And Origin

    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.

  • Page 15: Chapter 2 Installation

    This procedure requires two people. Check the packing pinched between the end plates list to ensure that all of the accessories are present. (See the FlexJet and stand legs. Hold the gray Quick Start Guide for more information.) Save all packing materials metal top bars a few inches from and the box.

  • Page 16: Cable Connections

    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.

  • Page 17: Figure 8. Flexplot Serial Port Set-Up Window

    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.

  • Page 18: Figure 10. Workflow Using Flexplot For File Conversion And Output

    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.

  • Page 19: Power On

    The printer power switch is located next to the power cord on the moving parts of the back of the machine, behind the keypad. When the FlexJet is pow- printer. Make sure the Service ered up, the carriage will move toward the left side of the machine, Station opening in the right end then return to the opposite side to park in the Service Station.
  • Page 20 Ioline FlexJet User Guide This page intentionally left blank...

  • Page 21: Chapter 3 Operation

    Chapter 3 Operation Keypad Controls The keypad provides access to the main functions of the FlexJet. 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.

  • Page 22: Clean

    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...

  • Page 23: Arrow Keys

    Chapter 3: Operation 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.

  • Page 24: Figure 13. Flexjet Control Center Main Menu

    Overview run more than one application that communicates with the The FlexJet Control Center is a utility program that does two things: printer. Allows you to adjust settings to tailor output (e.g. scale, line width) from the computer.

  • Page 25: Control Center Menu Bar Features

    Chapter 3: Operation 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.

  • Page 26: Control Center Menu Options

    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...

  • Page 27: Figure 14. The Hewlett-Packard 51645A ('45' Cartridges)

    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. Figure 14. The Hewlett-Packard 51645A (‘45’ cartridges) are widely available.

  • Page 28: Printing A Marker

    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: Turn the printer and computer power on. Load paper. Install cartridges in the stalls.

  • Page 29: Power On

    Support Block w/ Bearings Feed Shaft Paper Roll (unrolls from behind) Hint The FlexJet Set-up, Operating and Maintenance Video, provided on CD-ROM in the Accessory Kit, provides a helpful visual overview. Paper Hubs Support Block Flanged Coupling (apply grease supplied in...

  • Page 30: Installing The Take-Up Shaft

    If the take-up shaft has plotted markers on it, remove them. See Removing Markers from the Take-up Shaft later in this chapter. Turn the FlexJet on (the switch is on the back of the left cover.) 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.

  • Page 31: Figure 18. The Correct Paper Feeding Path On The Ioline Flexjet Printer

    Front Shaft Dancer Bar Front Top Bar Rear (Heavy) Dancer Bar Feed Roll Proper Paper Path Paper Path when Ready to Plot After Loading and Dancer Bars installed Figure 18. The correct paper feeding path on the Ioline FlexJet Printer.

  • Page 32: Figure 19. Taping The Paper To The Take-Up Shaft

    Ioline FlexJet User Guide Tape Paper to the Take-up Shaft Note When installing or retaping paper, Stand in front of the machine. remove the rear and front dancer Place 3 short pieces of masking tape within easy reach on the bars and set them aside.

  • Page 33: Figure 20. Positioning The Pinchwheels For 72-In (183-Cm) Paper

    Chapter 3: Operation White Driveshaft Markers Note Ensure that the paper roll is cen- 72 Inch Paper tered on the feed shaft. Outer Pinchwheels Inner Pinchwheel Drive Shaft Bearings Figure 20. Positioning the pinchwheels for 72-in (183-cm) paper. Make sure that the paper roll is centered on the feed shaft. Move the pinchwheels into their proper positions over a tread and under the white markers on the traverse rail.

  • Page 34: Set An Origin

    Pausing a Marker Plot Caution Pause a plot by pressing the Start/Stop key. The OK light will change from green to red. The FlexJet will finish Do not pull paper tight printing the current scan, then pause. between the drive shaft...

  • Page 35: Canceling A Marker Plot

    Canceling a Marker Plot Press the Start/Stop key to place the printer in STOP mode (red light). The FlexJet will finish printing the current scan and pause. To stop the computer from sending plot files to the printer, click the Abort button in FlexPlot.

  • Page 36: Manually Freeing The Take-Up Shaft

    Ioline FlexJet User Guide 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. Tape the loose end of the roll down so that it cannot flap freely.

  • Page 37: Automatically Freeing The Take-Up Shaft

    Chapter 3: Operation Automatically Freeing Caution the Take-Up Shaft The take-up shaft is very heavy when many plots have been rolled up. It is Like the manual method, this method removes the take-up shaft recommended that two or more from the completed roll without having to unroll the markers. The people remove the plotted paper roll from the machine.

  • Page 38: Figure 25. Paper Path For Printing To The Floor

    Figure 24. Before printing to the floor, place tape over the front take-up bar sensor. With FlexJet power off, place a piece of tape over the front take-up bar sensor as shown in Figure 24.

  • Page 39: Chapter 4 Routine Maintenance

    Chapter 4 Routine Maintenance Cleaning the Drive Shaft Caution Warning: Do not use Clean the drive shaft regularly to assure accurate plotting: water, brushes with metal Turn off the printer and disconnect the power cord. bristles or solvents (ex- cept isopropyl—pharmacy—al- Gently remove any accumulated dust and residue with the stiff cohol) to clean the printer.

  • Page 40: Figure 27. Calibration Screen In Control Center

    Ioline FlexJet User Guide Cleaning the Support Blocks Caution Never touch the take-up When dust and paper residue will accumulate on the take-up and key or flanged coupling feed shaft support blocks, frequent feed shaft jams can occur. Per- while they are rotating.

  • Page 41: Figure 28. The Calibration Box And Measurements

    Chapter 4: Routine Maintenance Use the Control Center to Gather the Calibration Data Note Open the FlexJet Control Center program. Only use Reset Calibration to Select Tools>Size Calibration from the Menu Bar. The win- restore original factory calibration dow in Figure 27 will appear: settings.

  • Page 42: Figure 29. Cartridge Calibration Window

    Cartridge alignment is not neces- rect port number and baud rate are selected. (See Connect the sary for FlexJets with a single FlexJet to the Computer: Overview in the Installation chapter for activated cartridge stall. information on serial port connections.)

  • Page 43: Figure 30. The Cartridge Alignment Box

    Frame Gap. Motion Adjust (Carriage Scan Alignment) Press Select Alignment Plot. Browse to the c:\Ioline\Calibration folder. Select the 40X8.plt test file. The Motion Adjust box has one number for adjustment. The default value is 0. Changing the values affects the next scan, created when moving from left to right.

  • Page 44: Frame Gap (Paper Scanalignment)

    Ioline FlexJet User Guide Frame Gap (Paper Scan Note Alignment) Adding (+) numbers moves the Press Select Alignment Plot. scans further apart. Browse to the c:\Ioline\Calibration Subtracting (-) moves the scans closer together. folder. Select the 40X8.plt test file. The Frame Gap box has one number for adjustment.

  • Page 45: Automatic Cleaning Procedure

    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.

  • Page 46: Print Cartridge Storage

    Power on the PC and FlexJet. Ensure that the serial cable is connected between the PC and the FlexJet. Copy the firmware file to the folder c:\Ioline\Firmware (or another location that is easy to remember.) Note If the firmware file is a ZIP...

  • Page 47: Update The Firmware

    Square light will turn green. Press the Done button. 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-...

  • Page 48: Manually Updating Firmware Using Teraterm

    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. 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.

  • Page 49: Update Firmware

    Reset Calibration Values section in this chapter. Reset Calibration Values Perform the steps below if calibration values have been altered: With the FlexJet in STOP mode, use the arrow keys to move the carriage to the center of the traverse. Turn power off on the FlexJet.
  • Page 50 Ioline FlexJet User Guide Figure 34. Factory calibration values on the sticker inside the Service Station.

  • Page 51: Chapter 5 Troubleshooting

    Chapter 5 Troubleshooting General Troubleshooting If the FlexJet is not working correctly the problem could arise from 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.

  • Page 52: Printing Quality

    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 Hint baud rate that the FlexJet is using.

  • Page 53: Keypad Error Codes

    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...

  • Page 54: Common Issues

    Press the Set Origin key. The printer does not complete the marker. Cause: Solution: Outdated software. Visit the Ioline FlexJet Web site to download upgrades. Or, contact Ioline Customer Service. The frame/panel size is mis- Check the panel size in the matched between the printer software.
  • Page 55 Routine Maintenance chapter. Platen or stand is not level. Follow the directions in the FlexJet Quick Start Guide to level the stand and platen. Loose carriage pulley causing ran- Contact Ioline customer service. dom/uneven gaps between scans.
  • Page 56 Adjust the platen levelers as described in the FlexJet Quick Start Guide. Outdated firmware does not Use the Control Center to advance paper at startup.

  • Page 57: Chapter 6 End Notes

    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: First, refer to this FlexJet User Guide for answers to your specific questions.

  • Page 58: Customer Service

    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...

  • Page 59: Before You Contact Support

    Chapter 6: End Notes Before you contact Support… Please gather the following information about your printer before contacting Ioline or your dealer for technical support: Name: Company Name: Phone Number: Fax: E-mail: Model: Serial Number*: Date of purchase: Dealer: Type of media &...

  • Page 60: The Fcc Wants You To Know

    Ioline FlexJet User Guide 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.

  • Page 61: Glossary

    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 HPGL – Hewlett-Packard Graphics Language. shaft has a rough surface that grips the material.
  • Page 62 75 mils is the same as .075 inches. 1 mil is Scan – A single pass of the carriage over the platen. equal to .025-mm. The FlexJet may or may not print during a scan. Sensor – The electronic eye that reads paper position by monitoring the dancer bars.
  • Page 63 The front dancer bar holds the 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.
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  • Page 65: Index

    Index Symbols 16, 19, 29, 39, 54 Power cord 15, 16, 46, 48— Serial See also Serial port Socket and port locations on FlexJet 16 51645A — CAD software See Design software Calibration 25, 40–44, 47, 49 Cartridge alignment box 43...
  • Page 66 Ioline FlexJet User Guide Ioline FlexJet User Guide Cleaning the drive shaft Software version Using the brush 39 Control panel 21, 61— See also Keypad Clipping Conversion 13, 18 Communications Coordinate Baud rate 16, 17, 23, 25, 26, 42, 52, 55...
  • Page 67 13, 15, 51 HPGL 13, 17, 18, 61, 62 FlexJet Service Manual Hubs 28, 29, 30 FlexJet Set-up, Operating and Maintenance Video 13, 15, 16, 17, 18, 19, 28, 34, 35, 52— FlexPlot See also the FlexPlot User Guide Abort button...
  • Page 68 Ioline FlexJet User Guide Ioline FlexJet User Guide Motion adjust box 43 License key code Cartridge count Limit of liability statement Cartridges in stalls xii Cartridge stall latch Line quality — See Printing Quality See also Troubleshooting Cleaning Line width 24, 26, 27, 43—...
  • Page 69 Index Index Optical sensor — Frame 14, 26, 54, 55 See Sensor Alignment Origin 14, 22, 34, 35, 40, 42, 53, 54, 56, 62 26, 61 Frame size ‘V’ notch on carriage 22 — Scan gaps See Troubleshooting Location on plot 14 Layout Output —...
  • Page 70 Ioline FlexJet User Guide Ioline FlexJet User Guide Sending plot files Send plot file Quality 22— See Printing quality Send size plot LED Lights on keypad 22 Send to queue Queue management Sensor xii, 23, 62 Serial communication 62— See also Communications...
  • Page 71 Terminal program 17, 53 Throughput Y-Axis 63— See also Plot Top bar 51, 56 Tracking Traverse xii, 39, 63 Cleaning Troubleshooting 51–56— See also FlexJet Service Manual Alignment issues 54–56 Common issues Communications General troubleshooting Keypad error codes 53, 55...

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