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Intec ColorCut CC500 User Manual

Digital die-cutting for sheet labels and packaging
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Digital die-cutting for sheet labels and packaging
User Guide - English

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  • Page 1 Digital die-cutting for sheet labels and packaging User Guide - English...

  • Page 3: Table Of Contents

    Intec ColorCut User Guide - Table of Contents OVERVIEW ........................ 5 Intec ColorCut CC500 - Digital Cutting Solution ............... 5 Unpacking the contents of the ColorCut ..............6 Installation of the ColorCut Vision Control software ........... 7 Assembly of your ColorCut CC500................10 Setting up the ColorCut Feeder ................
  • Page 4 Graphics file design ....................33 Layers for printing ......................34 Layers for cutting ......................34 Printing the Artwork / Graphic file ................35 file PROPERTIES for cutting ..................35 Graphic file Compatibility ....................36 Adobe illustrator export ....................36 Corel Draw Export ....................36 Cutting Cardboard or heavy paper (DIE-cutting ) .............

  • Page 5: Overview

    OVERVIEW Intec ColorCut CC500 - Digital Cutting Solution The Intec ColorCut CC500 has been designed primarily to cut sheet labels effectively. There are also additional functions enabling the management of die cutting sheet material, using cross cut (Cut through) and dashed cut features, so that greeting cards, POS and packaging board material may be also cut.

  • Page 6: Unpacking The Contents Of The Colorcut

    UNPACKING THE CONTENTS OF THE COLORCUT Your Intec ColorCut is packed in 2 boxes. The first box contains the Intec ColorCut Cutting engine. (Item (i)) The second box contains: The ColorCut Exit tray (ii) The ColorCut Feeder (iii) And the power adaptor, plus USB cables, manual and drivers.

  • Page 7: Installation Of The Colorcut Vision Control Software

    INSTALLATION OF THE COLORCUT VISION CONTROL SOFTWARE The ColorCut Vision control software for the Intec ColorCut is supplied on the included CD, however it may also be downloaded from our website http://www.intecprinters.com/support/downloads/colorcut-cc500 Please run the installation program: Setup for Colour Cut Vision Control.exe The setup’s program requires various...
  • Page 8 INSTALLATION OF THE SOFTWARE (CONT) The software will install into the C:\Script folder on the root of your hard-disk. Please change installation folder. Simply click the [ NEXT> ] button. Then click [Start ] to start the installation. At the end of the installation, the installer will prompt you to install the Microsoft Visual C++ re-distributable libraries (if they are not already installed).
  • Page 9 INSTALLATION OF THE SOFTWARE (CONT) When the installation has finished. Click the [ CLOSE ] button. Click the the [ EXIT ] but. The ColorCut’s program icon - “Colour Cut Vision Control” will be created on the desktop and a short-cut in the Windows Start Menu.

  • Page 10: Assembly Of Your Colorcut Cc500

    The ColorCut Exit tray sits under the ColorCut engine, gently lower the Intec ColorCut Digital cutting engine onto the end of the Output feed table. Note, the weight of the Intec ColorCut digital cutting engine, will hold the output tray in place. Intec ColorCut Cutting Engine is...

  • Page 11: Setting Up The Colorcut Feeder

    (2) The Intec Digital Cutter engine requires a USB cable (supplied in the box). (3) The high resolution i-Vision CCD camera used for the Intec vision registration system utilises a USB connection (Integrated to the camera). To avoid requiring 3 USB ports, and to simplify connection, on the underside of the feeder you will find an integrated USB hub this enables you to connect all your Intec ColorCut USB connectors into one unified cable to connect to your Computer.

  • Page 12: Aligning The Feeder

    SETTING UP THE COLORCUT FEEDER ALIGNING THE FEEDER Place the Intec ColorCut Feeder in-front of the Digital Cutting engine. The lead edge of the Intec Feeder has a lip. On the edge of this, there is an alignment arrow. On the intec ColorCut Digital cutter you will find a slot, that the lip from the feeder will clip into.

  • Page 13: Air Separation System And Adjustment

    SETTING UP THE COLORCUT FEEDER AIR SEPARATION SYSTEM AND ADJUSTMENT The Intec ColorCut feeder has a capacity of approx 100 sheets of media depending upon your substrate thickness. To reduce the risk of multiple sheets being fed, the ColorCut feeder includes an air separation system (using dual side mounted fan blowers) to help start to separate your media.

  • Page 14: Vacuum Feed Air Adjustment

    VACUUM FEED AIR ADJUSTMENT In addition the the air separation, and similar to a lithographic printing press. The Intec ColorCut uses a pneumatic style feed system. (using vacuum force through suction cups). For thin or porous papers, it may be necessary to decrease the aspiration pressure for the vacuum feed by rotating the control knob counter clockwise (See below).

  • Page 15: Paper Size/Format Adjustment

    SETTING UP THE COLORCUT FEEDER PAPER SIZE/FORMAT ADJUSTMENT When loading paper or label stocks. Place the sheets in the feeder, and adjust the back stop by turning the knob for paper length (a). (Do not restrict the paper, leave it slightly loose).

  • Page 16: Pinch Roller Position - Paper Size/Format Adjustment

    SETTING UP THE COLORCUT FEEDER PINCH ROLLER POSITION - PAPER SIZE/FORMAT ADJUSTMENT After adjusting the paper guides width with the knob, you should advance manually one sheet in order to verify the position under the pinch rollers. NOTE: The pinch rollers MUST sit over the grit rollers. Typically the Left Pinch wheel is not moved, instead you adjust/slide the feeder to ensure the left side of the sheet is correctly under the ‘static’...

  • Page 17: Cutting Options - Blade Positions

    CUTTING OPTIONS - BLADE POSITIONS The Intec ColorCut Digital Cutting engine uses a contour cutting system. The cutter has a dual position blade holder enabling two different types of cutting. (i) Kiss Cut (For adhesive labels) In this mode, you cut over a cutting strip which provides a surface to cut against, and you ONLY cut the top layer of your substrate.

  • Page 18: Changing Blade Positions

    CHANGING BLADE POSITIONS 1. Loosen the tool holder screw. Bracket to hold tool Tool holder Tool holder Bracket to hold tool 2. While pushing up the holder, push until its flange completely touches the upper part of the holder. Bracket to Tool holder hold Blade Holder Flange...

  • Page 19: Daily Operation Start-Up

    7. Press Button #2 on the cutting engine’s control panel to activate the Intec Digital Cutting engine and place it ‘On-Line’ and ready to cut.. Button #2 Turns the ColorCut ‘On-Line’...

  • Page 20: Colorcut I-Vision Software

    COLORCUT I-VISION SOFTWARE OVERVIEW OF COLORCUT I-VISION SOFTWARE PANEL LAYOUT The ColorCut i-Vision software handles all the functions for the automation of the digital cutting process. It can import files saved in either AI format from Adobe Illustrator or EPS format from CorelDraw.

  • Page 21: Basic Operations And Settings Explained

    The value depends on the position of the pinch rollers on the Intec Digital cutting engine (Do not set the rollers too wide, when they are right on the edge of your media thinner paper stocks may ‘buckle’...
  • Page 22 Intec Digital Cut engine for the changed knife position. Failure to use this before executing a job with the START button can cause TAGs used during Die-Cutting to then be placed on labels so they don’t peel out easily, or may cause the cut to be...

  • Page 23: Opening A File

    (0.2”), if the value is completely wrong the first marker does not stop in a central position under the camera. If the Intec i-Vision Registration can not see the marker with 5mm of the centre of the window then you will get the error: “Marker not found”...

  • Page 24: Status And Error Messages

    “Load media” on the display of the Intec ColorCut Digital cutting engine.. You have to raise the media lever and press button #2 on the cutting plotter panel.

  • Page 25: Calibrating Your Colorcut For Accurate Cutting

    CALIBRATING YOUR COLORCUT FOR ACCURATE CUTTING. PRINT AND CUT ALIGNMENT METHODS At installation of your Intec ColorCut* it is necessary to calibrate the i-Vision CCD registration system for the print and cut alignment. This corrects the cutting position in relation to the printed sheet.

  • Page 26: Performing An Interactive Alignment Calibration

    If the [CUT TEST] button is greyed out and the CUTTER WIDTH Value shows 0 or if there is a RED X in the lower section of the screen under the preview window, then your Intec Digital Cutter is Not Connected or Not Ready.
  • Page 27 INTERACTIVE ALIGNMENT CALIBRATION (CONT) In the Video camera preview window you will see the first marker appear. It should be almost central. If it is slightly out then the system will compensate for any origin error up to 5mm. If you receive an error, ‘Timeout’ marker could not be read.

  • Page 28: Performing An Automatic Alignment Calibration

    [SET] button. Press the “Cut Marker” button. The Intec ColorCut digital cutter will cut a small square on the black sheet you loaded manually. NOTE: DO NOT MOVE OR REMOVE THE SHEET AFTER IT IS CUT.
  • Page 29 AUTOMATIC ALIGNMENT CALIBRATION (CONT) Using a craft knife, remove the small square adhesive that was cut to expose the white liner Next Press the ”Read Marker” button to read the calibration values. ColorCut engine will then automatically read the values that are specific for the camera installed on your cutting engine and enter them for you.

  • Page 30: Advanced Cutting Adjustments

    COMPENSATION FOR PRINTER OR MEDIA DISTORTION ADVANCED CUTTING ADJUSTMENTS The i-Vision registration system on the Intec ColorCut uses two SMARTmarks providing data points for Origin, Scale and Skew. This delivers high precision near the SMARTmarks. With the X & Y adjustment within the calibration settings, you can reach the maximum precision along the bottom part of the print.

  • Page 31: Creating Your Cut Files

    CREATING YOUR CUT FILES EXPLANATION OF THE SMARTMARKS Your files must contain two reference marks, known as SMARTmarks, the ColorCut’s high resolution i-Vision video camera detects the SMARTmarks in a fraction of a second and adapts the cut path to any variations in the origin, scale or skew distortion of the print.

  • Page 32: Smartmarks - Minimum Distance To Graphic Elements

    CREATING YOUR CUT FILES SMARTMARKS - MINIMUM DISTANCE TO GRAPHIC ELEMENTS The minimum distance between the SMARTmark and the printed graphics is 5mm (0.2”). If the graphics on your job are too close to the SMARTmark you can get the error: “Marker not found”...

  • Page 33: Graphics File Design

    GRAPHICS FILE DESIGN When printing you don’t want your cut lines to appear on your printed sheet Equally when cutting you don’t want to confuse the cutter with lines that may be in your printed design. But, in both cases, you need the have available the registration marks. Therefore it is advisable to organize the graphic design in different layers: - One or more layers for the main graphics (The Printed artwork).

  • Page 34: Layers For Printing

    LAYERS FOR PRINTING In this example, the main graphics layers and the markers layer are active. The cut contour layer is disabled. This drawing is ready for printing. LAYERS FOR CUTTING In this example, the main graphics layers are disabled. The cut contour layer and the markers layer are active.

  • Page 35: Printing The Artwork / Graphic File

    PRINTING THE ARTWORK / GRAPHIC FILE The printed file for use with ColorCut i-Vision Control Software must contain two square registration marks of 4mm size (SMARTmarks) and your artwork, (The cutlines should not appear on your printed job - when using Adobe Illustrator, or CorelDraw you can use layers control, for the Cutline and the Artwork, then hide the cutline before printing.

  • Page 36: Graphic File Compatibility

    GRAPHIC FILE COMPATIBILITY The Intec ColorCut i-Vision Control software can open files in the following formats: EPS exported from CorelDraw. AI saved from Adobe Illustrator (in v.8 Format). Please ensure when saving your cut lines you ensure there are no guides or rulers on the page, and that there are no boarders on the page.

  • Page 37: Cutting Cardboard Or Heavy Paper (Die-Cutting )

    CUTTING CARDBOARD OR HEAVY PAPER (DIE-CUTTING ) In addition to cutting labels, The Intec ColorCut has a dual knife/blade position. The standard position of the blade holder, places your knife over the cutting strip, this is used for kiss cutting labels. However, moving the...
  • Page 38 CUTTING CARDBOARD OR HEAVY PAPER (CONTINUED) The speed should be set on a low value range from 5 to 15. This way, you do not stress the blade too much and will not affect the cutting speed. It is preferable to use two passes, it allows you to use a lower cut force (below 20);...

  • Page 39: Special Color Panel

    SPECIAL COLOR PANEL The “Special Color” panel allows a separate cutting control for lines designed using the color magenta in your graphics file. When you design your jobs including a 100% magenta line in your graphic, it is recognised by the ColorCut i-Vision software and the “Special color”...

  • Page 40: Using The Dashed Line Feature

    USING THE DASHED LINE FEATURE If you select Dashed line in the drop down options under the Special Color settings. Then the ColorCut will treat all 100% magenta Colored lines separately from the black lines. Even though the line is drawn a a solid 100% magenta line, the controls for Cut length and Gap enable you to alter the cutting properties from a solid line to a perforated line.

  • Page 41: Creating Perforated Lines On Card With The Dashed Line Function

    CREATING PERFORATED LINES ON CARD WITH THE DASHED LINE FUNCTION The Dashed line function creates added capabilities when you are using the Die-Cutting mode with the Knife in the Front position (Nearest to the feeder). If you select Dashed line in the drop down options under the Special Color settings.

  • Page 42: Using The Plain Cut Feature - Special Color Panel

    USING THE PLAIN CUT FEATURE - SPECIAL COLOR PANEL Selecting “Plain Cut” under the “Special color” section is used to KissCut labels (cutting through only the top sheet of a label) and then applies additional pressure/cut force to cut through the sheet completely (using the die-cut parameters). This mode should ONLY be used with the optional Cutting Mat as in this mode, the positioning of the cut knife is over the cutting strip (the blade in KissCut position - the Rear position).

  • Page 43: Using The Blade Creasing Feature - Special Color Panel

    1mm (0.04”) so ensure the graphics are designed accordingly to mask/eliminate any movement. In addition as you will place the sheet in the feeder upside down, the Intec ColorCut software will flip your image for you to reflect the cutline required upside down. It does using your Smartmark as the origin point.
  • Page 44 Having measured the position of the SMARTmarks relative ot the sheet edge, ensure you load the sheet with the print face down and ensure you place the side with the black-marks on the camera side. Since the sheets are loaded upside-down the specifications regarding the maximum cutting area and black-marks are different to those used on the front-side mode.

  • Page 45: Feeder Arm Adjustments

    FEEDER ARM ADJUSTMENTS On the right bottom corner of the software window there are two settings for controlling the movement of the insertion arm. Uplift controls the height of the arm when inserting the sheet. Insertion control how much the suction cups have to push the sheet into the plotter. If the insertion is too short the sheet is not pinched by the rollers.

  • Page 46: Setting The Blade Depth (Exposure)

    SETTING THE BLADE DEPTH (EXPOSURE) THE BLADE HOLDER The ColorCut cuts using a cutter blade mounted in a Blade Holder. There are two different Blade Holders to suit the diameter of the cutter blade to be mounted (the 0.9 mm cutter Blade Holder (is BLUE) and is provided as a standard accessory). Ensure you mount the cutter blade in the corresponding cutter Blade Holder.

  • Page 47: How To Replace Cutting Strip

    HOW TO REPLACE CUTTING STRIP CAUTION: Please turn off the power when replacing the cutting strip. Please move the tool carriage to “A” position allowing for ease of work. 1. Remove the cutting strip. -The cutting strip is attached to the cutting base (fig.1) -Please remove only the cutting strip from the cutting strip base from the location shown by the highlighted selection (A) (fig.1) Tool Carriage...

  • Page 48: Trouble Shooting

    TROUBLE SHOOTING Issue Possible cause(s) Remedy No connection to the ColorCut Check USB and Power connections [CUT TEST] or Media Lever is not raised Raise Media Lever [START] buttons not available No #2 button has not been Ensure media lever is raised and press pressed.

  • Page 49: Trouble Shooting

    TROUBLE SHOOTING Issue Possible cause(s) Remedy Click the ‘EYE’ icon top corner of the screen, and Click ‘COLORCUT VISION CONTROL’ at the bottom of the menu. Set the above values: Marker: 50 Delta X: 95 Delta Y: 109 Click SET button and close this window Load into the feeder the sample test sheets included with the unit.

  • Page 50: Trouble Shooting

    TROUBLE SHOOTING Issue Possible cause(s) Remedy Check your artwork, and measure the position of the second Mark on the sheet, then check your Cutting line artwork, is the distance the same? Normally this happens Marker Not Found. The 1st Smart Mark on the if the PRINT has been printed with FIT to Time Out sheet is read but then second...

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