MUTOH Kona User Manual
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MUTOH Kona User Manual

Cutting plotter
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  • Page 1 User’s Guide Kona cutting plotter...
  • Page 3 Copyright notice COPYRIGHT © 3/6/10 Mutoh Belgium nv All rights reserved. Mutoh Belgium nv reserves the right to modify the information contained in this manual at any time without prior notice. This document may not be reproduced by any means, in whole or in part, without written permission of the copyright owner.
  • Page 4 User’s Guide Kona cutting plotter AP-75380 - Revision 1.2...

  • Page 5: Table Of Contents

    User’s Guide Kona cutting plotter Table of contents Chapter 1 Regulations and safety information ... . 11 Warnings, cautions and notes ......12 Compliance with the following regulations .
  • Page 6 User’s Guide Kona cutting plotter Replace sheet-off blade ........40 ...

  • Page 7: Chapter 7 Through Cutting

    Knife types........124 Kona calibration ........125 Knife settings .
  • Page 8 ........155  Beeping codes: My Kona is making a beeping sound once in a while. ...
  • Page 9 User’s Guide Kona cutting plotter Knife Holder without Depth Change Indication ....179  Knife Holder with Depth Change Indication ....180 ...
  • Page 10 User’s Guide Kona cutting plotter AP-75380 - Revision 1.2...

  • Page 11: Chapter 1  Regulations And Safety Information

    User’s Guide Kona cutting plotter Regulations and safety information Chapter 1  Regulations and  safety information Warnings, cautions and notes ....... . . 12 Compliance with the following regulations .

  • Page 12: Warnings, Cautions And Notes

    User’s Guide Kona cutting plotter Regulations and safety information Warnings, cautions and notes Safety terms in this manual and the contents of warning labels attached to the cutter are categorized into the following three types, depending on the degree of risk (or the scale of accident).

  • Page 13: Important Notes

    User’s Guide Kona cutting plotter Regulations and safety information This product is tested and approved by the Canadian Standards Association (CSA), this to provide increased assurance of quality and safety. The product is tested according to IEC60950. This standard tries to cover all safety aspects.

  • Page 14: Safety Labels

    User’s Guide Kona cutting plotter Regulations and safety information Safety labels Label Description Be careful not to pinch your fingers between the pressure rollers and grit rollers when loading media for example. Be careful not to get stuck between the...

  • Page 15: Chapter 2 Product Overview

    User’s Guide Kona cutting plotter Product overview Chapter 2 Product overview Dimensions machine ......... 16 Installation environment requirements .

  • Page 16: Dimensions Machine

    User’s Guide Kona cutting plotter Product overview Dimensions machine Kona 760 Kona 1400 Kona 1650 Width 1200 mm / 47,2” 1850 mm / 72,8” 2090 mm / 82.3” Depth 260 mm / 10,2” 490 mm / 19,3” 490 mm / 19,3”...

  • Page 17: Room Conditions

    Avoid unnecessary vibrations and set up your cutter on a level surface.  Be sure to have some free space on each side of the Kona to ease the operating of it.  a = at least 1 meter ...

  • Page 18: Part Names And Functions

    User’s Guide Kona cutting plotter Product overview Part names and functions N° Description Extended description Pressure rollers To push the media against the grit rollers A guiding platform with vacuum fans to transport Media guide the media as flat as possible during cutting...

  • Page 19: Chapter 3 Basics

    User’s Guide Kona cutting plotter Basics Chapter 3 Basics (Un)Install USB drivers ........21 Install USB drivers .
  • Page 20 User’s Guide Kona cutting plotter Basics Loading media ..........47 Media width .

  • Page 21: Un)Install Usb Drivers

    Basics (Un)Install USB drivers Before you will be able to work with Mutoh’s Kona cutting plotter compatible software, a connection between your workstation and the Kona cutting plotter should be made. In case your computer already has an earlier USB driver installed, please uninstall it and reinstall the driver.
  • Page 22 User’s Guide Kona cutting plotter Basics In the control panel’s device manager select ‘Other devices - Kona’. Step 6: AP-75380 - Revision 1.2...
  • Page 23 User’s Guide Kona cutting plotter Basics Right click and choose ‘Update Driver Software ...’ Step 7: When prompted, choose ‘Install this driver software anyway’. Step 8: AP-75380 - Revision 1.2...
  • Page 24 User’s Guide Kona cutting plotter Basics The USB driver is now installed. Step 9: A new error will be shown briefly about the virtual comport. Step 10: AP-75380 - Revision 1.2...
  • Page 25 User’s Guide Kona cutting plotter Basics In the control panel’s device manager select ‘Other devices - USB Serial Port’. Step 11: AP-75380 - Revision 1.2...
  • Page 26 User’s Guide Kona cutting plotter Basics Right click and choose ‘Update Driver Software...’ Step 12: When prompted, choose ‘Install this driver software anyway’. Step 13: AP-75380 - Revision 1.2...

  • Page 27: Check Com Port Used

    User’s Guide Kona cutting plotter Basics USB Serial Port driver is now installed. Step 14: 3.1.2 Check COM port used For Windows XP users Open the windows control panel. Step 1: Double click on the system icon Step 2: Click on the hardware tab...

  • Page 28: For Windows Vista And 7 Users

    User’s Guide Kona cutting plotter Basics For Windows Vista and 7 users Click on the start button Step 1: Type device manager in the search window Step 2: Click on device manager Step 3: Unfold the Ports (COM & LPT) menu and check which COM port is written next to Step 4: the Kona cutting plotter.

  • Page 29: Uninstall/Update Usb Drivers

    User’s Guide Kona cutting plotter Basics 3.1.3 Uninstall/update USB drivers Please follow the instructions below to know how to uninstall the USB drivers. Make sure your cutter is powered ON and connected to the PC. Step 1: In the Device manager you will find your device...

  • Page 30: Installing Firmware

    User’s Guide Kona cutting plotter Basics Installing firmware 3.2.1 Normal procedure Make a connection between the Kona cutting plotter and your computer using a Step 1: USB cable (standard in-the-box item). Be sure that the USB driver is already installed! Step 2: Refer to Uninstall/update USB drivers on page 29...
  • Page 31 Check COM port used on page 27 The PC will send and program the new firmware to the cutter. Step 12: The Kona cutting plotter will restart automatically as soon as the firmware has been Step 13: installed. The new firmware has been installed properly when you hear a beep.

  • Page 32: Recovery Procedure

    User’s Guide Kona cutting plotter Basics 3.2.2 Recovery procedure In case the Kona fails to update the firmware, there is a recovery procedure available. If the firmware upgrade has failed, the cutter will: not light its display  not make any sounds when powering on ...
  • Page 33 Check COM port used on page 27 The PC will send and program the new firmware to the cutter. Step 8: The Kona cutting plotter will restart automatically as soon as the firmware has been Step 9: installed. The new firmware has been installed properly when you hear a beep.

  • Page 34: Recovery Procedure Via The Cutserver

    User’s Guide Kona cutting plotter Basics Recovery procedure via the CutServer Start the CutServer. Step 1: In the CutServer, click the Extra tab and select Activate Firmware Recovery Mode. Step 2: A new screen appears asking if you are sure. Select Yes.
  • Page 35 User’s Guide Kona cutting plotter Basics In the status bar, a recover connection will become available. Step 4: Select this recover connection. Step 5: The recovery button appears next to the checkbox. As soon as selecting this button, Step 6: a confirmation window appears asking if you are sure you want to proceed.
  • Page 36 User’s Guide Kona cutting plotter Basics The firmware is being recovered. Step 7: After the recovery, restart the CutServer or restart the cutter. Step 8: AP-75380 - Revision 1.2...

  • Page 37: Installing And Replacing Tools

    User’s Guide Kona cutting plotter Basics Installing and replacing tools 3.3.1 Installing tools At the right-hand side of the cutter head, you will find a pivoting mounting bracket. Opening this bracket will enable you to install a full range of cutting and drawing tools.

  • Page 38: Replace Cutter Blade

    User’s Guide Kona cutting plotter Basics 3.3.2 Replace cutter blade To replace a blade, please follow the procedure below: Standard knife holder Hold the body (2) into one hand and unscrew the base part (1) Step 1: Remove the spring (3) and the cutting blade (4).

  • Page 39: Knife Holder With Nonius

    User’s Guide Kona cutting plotter Basics Knife holder with nonius Take the body into one hand and remove the base part. Step 1: Pull the old blade out of the holder and insert a new one. Step 2: Place the base part on top of the holder assembly and twist it tightly.

  • Page 40: Replace Sheet-Off Blade

    User’s Guide Kona cutting plotter Basics 3.3.3 Replace sheet-off blade Caution Be careful not to cut your fingers when replacing the sheet-off blade!  Please follow the procedure below to replace the sheet-off blade: Loosen the screw fixing the sheet-off blade and protection plate with a hexagon key Step 1: of 2,5 mm.

  • Page 41: Replace Cutting Mat

    Install the new cutting mat in the same position as the old one. Step 3: If you notice some cutting errors after replacing the cutting mat, it might be Step 4: necessary to contact an authorized Mutoh technician to perform a Y-Z profile measurement. AP-75380 - Revision 1.2...

  • Page 42: Setting The Correct Knife Depth

    User’s Guide Kona cutting plotter Basics Setting the correct knife depth Adjusting the knife depth is a very important parameter when it comes to making high quality outputs. First of all you will need to decide whether to cut your job in single or multi tool mode before you are able to set the knife depth correctly.

  • Page 43: Cut Through Depth

    User’s Guide Kona cutting plotter Basics 3.4.2 Cut through depth Always make sure that the knife blade protrudes enough out of the knife holder, but not too much. The knife top should come through the backing. N° Description Knife holder...

  • Page 44: Adjusting The Knife Depth

    User’s Guide Kona cutting plotter Basics 3.4.3 Adjusting the knife depth Standard knife holder Knife holder with nonius Hold the body (2) as shown below in one Loosen the base part of the cutting knife. To hand and adjust the depth by using the set do this, take the base part in your left hand screw (3).

  • Page 45: Features Of Knife Holder With Nonius

    For some applications it might be convenient to be able to very accurately change the depth of the cutting blade. For those applications, Mutoh can provide you with a knife holder, featuring a nonius (vernier) with which it is possible to adjust the depth of the knife in increments of 0.01 millimetre (0.0004”) The upper scale lines make it possible to change the...

  • Page 46: Handling And Storing Media

    User’s Guide Kona cutting plotter Basics Handling and storing media Before you will be able to cut a job, it is necessary to know which media to use. 3.5.1 Handling media When you handle media, please pay attention to the following: Use recommended media in an appropriate environment.

  • Page 47: Loading Media

    3.6.2 Pressure roller positioning As you notice, there are 2 pressure rollers on a Kona 760 and 3 pressure rollers on a Kona 1400 or on a Kona 1650. Positioning the pressure rollers on a Kona 760 is fairly easy. But on a Kona 1400 or Kona 1650 there are more possibilities.

  • Page 48: Possibility 1

    User’s Guide Kona cutting plotter Basics Possibility 1 Loading small sized media Schematic overview Kona 1650 When the media does not reach the second sensor, the second pressure roller will determine the width of the media. Position the pressure rollers as follows:...

  • Page 49: Possibility 3

    Possibility 3 Loading sensitive medium sized media Note When working on a Kona 1400 or Kona 1650 with sensitive media files where it  is not wanted to leave any pressure roller marks, it is possible to disable the middle grit roller. To do so, move it to the docking station. The pressure roller will be disabled as soon as you lower them.

  • Page 50: Possibility 4

    User’s Guide Kona cutting plotter Basics Both sensor 1 and sensor 2 are covered. The media width is determined by pressure roller 3. Position the pressure rollers as follows: Position pressure roller 2 Position pressure roller 3 Kona 1400 Disabled...

  • Page 51: Loading Sheet Media

    User’s Guide Kona cutting plotter Basics 3.6.3 Loading sheet media Configuration to start from The pressure rollers are raised.  The rear media collection bag is open and empty.  Open the front media collection bag when the cutting job is smaller than 4m.
  • Page 52 Refer to Pressure roller positioning on page 47 Note When working on a Kona 1400 or Kona 1650 with sensitive media files where it  is not wanted to leave any pressure roller marks, it is possible to disable the middle grit roller. To do so, move it to the docking station. The pressure roller will be disabled as soon as you lower them.
  • Page 53 User’s Guide Kona cutting plotter Basics Make sure that about half of the sheet hangs in front of the machine and half hangs Step 4: at the back. This will make it easier to align the media correctly. Load the media straight. To help you, rulers are drilled in the front platen.
  • Page 54 User’s Guide Kona cutting plotter Basics When no problems occur, the main screen will appear. The usable width of media Step 9: will be displayed in the home window: Note In some cases, the cutter gives a warning screen for example if there is no tool ...

  • Page 55: Loading A Roll Of Vinyl Using The Media Support Rollers

    Basics 3.6.4 Loading a roll of vinyl using the media support rollers Note The media support rollers are not standard on a Kona 760. This procedure is  only possible when you have this option installed. Configuration to start from The pressure rollers are raised.

  • Page 56: Media Loading Procedure

    User’s Guide Kona cutting plotter Basics Media loading procedure Place the vinyl on the media support rolls. Be sure that the space between the rolls Step 1: is smaller than the diameter of the core. Otherwise, the core will fall through the rolls when the roll is (almost) empty.
  • Page 57 User’s Guide Kona cutting plotter Basics Note When working on a Kona 1400 or Kona 1650 with sensitive media files where it  is not wanted to leave any pressure roller marks, it is possible to disable the middle grit roller. To do so, move it to the docking station. The pressure roller will be disabled as soon as you lower them.
  • Page 58 User’s Guide Kona cutting plotter Basics Be sure that the media is cut off straight at the front to avoid media initialization Step 5: mismatches. Select the media measure method. Step 6: Refer to Load mode on page 85 Note Make sure not to get stuck on the pressure roller lever, this could damage your ...
  • Page 59 User’s Guide Kona cutting plotter Basics When no problems occur, the main screen will appear. The usable width of media Step 9: will be displayed: Note In case there is no tool installed, the cutter gives a warning screen. ...

  • Page 60: Loading A Roll Of Pre-Printed Vinyl Using The Roll-Off System

    Be aware that the media roll-off system is not standard on a Kona 760, 1400  and 1650. This procedure is only possible when you have this option installed.

  • Page 61: Media Loading Procedure

    User’s Guide Kona cutting plotter Basics Media loading procedure Install the pre-printed media roll between the media holders. Position the roll and Step 1: tighten the media holders by fixing the thumb screws. Guide the media as shown below: Step 2:...
  • Page 62 Refer to Pressure roller positioning on page 47 Note When working on a Kona 1400 or Kona 1650 with sensitive media files where it  is not wanted to leave any pressure roller marks, it is possible to disable the middle grit roller. To do so, move it to the docking station. The pressure roller will be disabled as soon as you lower them.
  • Page 63 User’s Guide Kona cutting plotter Basics Load the media properly: Step 5: It is best that you hold the front edge of the media in the middle with one hand  and with the other hand the roll itself. As you are holding the roll firmly into position, pull the front edge of the media ...
  • Page 64 User’s Guide Kona cutting plotter Basics When no problems occur, the main screen will appear. The usable width of media Step 9: will be displayed: Note In case there is no tool installed, the cutter gives a warning screen. ...

  • Page 65: Loading Curled Media

    Basics Loading curled media Next to multiple kinds of media, the Kona is also able to cut curled media. However, to perform this action, there are some extra items you need to keep in mind. Please follow the procedure below to load curled media properly.
  • Page 66 User’s Guide Kona cutting plotter Basics Note When working on a Kona 1400 or Kona 1650 with sensitive media files where it  is not wanted to leave any pressure roller marks, it is possible to disable the middle grit roller. To do so, move it to the docking station. The pressure roller will be disabled as soon as you lower them.
  • Page 67 User’s Guide Kona cutting plotter Basics Lower the pressure rollers. Step 7: Note Make sure not to get stuck on the pressure roller lever, this could damage your  clothes. Note The head will move fast over the media. Be careful not to pinch your fingers ...
  • Page 68 User’s Guide Kona cutting plotter Basics AP-75380 - Revision 1.2...

  • Page 69: Operation Panel

    User’s Guide Kona cutting plotter Operation panel Chapter 4 Operation panel Explaining the different buttons ....... . 71 Main menu .
  • Page 70 User’s Guide Kona cutting plotter Operation panel Information ..........106 ...

  • Page 71: Explaining The Different Buttons

    Settings button Open the settings menu 1/4 Actions button Open the actions menu 1/2 This icon will appear if the Kona is connected via the USB indication USB and the driver is correctly installed. Play / pause button Pause or resume a job In case there is no cutting job active, the Kona ...

  • Page 72: Settings Or Actions Menu

    User’s Guide Kona cutting plotter Operation panel 4.1.2 Settings or actions menu N° Description Extended description Home button Go back to the home menu (the menu shown above) Settings button Open the settings menu 1/4 Actions button Open the actions menu 1/2...

  • Page 73: Adjust Value Menu

    User’s Guide Kona cutting plotter Operation panel 4.1.3 Adjust value menu N° Description Extended description Home button Go back to the home menu (the menu shown above) Settings button Open the settings menu 1/4 Actions button Open the actions menu 1/2...

  • Page 74: Menu Overview

    User’s Guide Kona cutting plotter Operation panel Menu overview 4.2.1 Tree diagram Main menu Sub menus BOLD = default value More info Tool down 1 - 60 -100 cm/s Velocity page 77 Tool up 1 - 100 cm/s Offset 0.1 - 0.5 - 1 mm...

  • Page 75: Settings 3/4

    User’s Guide Kona cutting plotter Operation panel Main menu Sub menus BOLD = default value More info Automatic Epos align Manual color page 93 Manual XY Epos Distance X Optimize page 96 Distance Y Color page 97 Language English Nederlands...

  • Page 76: Settings 4/4

    User’s Guide Kona cutting plotter Operation panel Main menu Sub menus BOLD = default value More info Diagnostics page 104 Beep On/Off 15%< 25% > Contrast Screen page 104 Brightness 0 < 50 > 100 Settings 4/4 Wait time off <3 Animation min >...

  • Page 77: Settings 1/4

    User’s Guide Kona cutting plotter Operation panel 4.2.2 Settings 1/4 Velocity Set the cutting speed according to the application (cut through, contour cutting). The following speeds can be set: Tool up speed the speed of the cutting head when the tool is up ...
  • Page 78 User’s Guide Kona cutting plotter Operation panel Set the velocity as follows: Press the following buttons in order: Step 1: Settings  Velocity  Select which speed you want to change Step 2: Tool Down  Tool Up  Change the value(s) to the desired speed and confirm with...

  • Page 79: Offset

    Accurate measurement of the offset to be used is very difficult and requires specialized equipment. You should therefore adjust the offset (1) by checking real cutting results on the media you will use. Mutoh helps you doing this by way of a semi-automatic offset adjustment routine, which is integrated into your cutter.
  • Page 80 User’s Guide Kona cutting plotter Operation panel Select Yes to perform the test. Step 2: The machine cuts a series of squares, each with a different offset. Step 3: 0,45 0,46 0,47 0,48 0,49 0,50 0,51 0,52 0,53 0,54 AP-75380 - Revision 1.2...
  • Page 81 User’s Guide Kona cutting plotter Operation panel Weed out the boxes as shown below, check the patterns and determine which of Step 4: them gives best quality. Especially look for good quality of the corners and easy weeding. The offset value is smaller than the op-...

  • Page 82: Force

    User’s Guide Kona cutting plotter Operation panel Force Tool force (cutting pressure) is the amount of downward pressure that the cutter applies on the knife / pen. We merely want to point out that you have to try to cut your design with the lowest possible pressure that gives no trouble to weed.
  • Page 83 User’s Guide Kona cutting plotter Operation panel Follow the procedure below to test the actual settings: Press the following buttons in order: Step 1: Settings  Force  Test  When performing the test, a pattern will be cut using the current force value.

  • Page 84: Tool

    User’s Guide Kona cutting plotter Operation panel Tool Depending on the installed tool, an offset needs to be taken into account.  When a pen is loaded, no offset is necessary as the pen point is in the centre of the pen head.

  • Page 85: Load Mode

    User’s Guide Kona cutting plotter Operation panel Load mode It is necessary to pre-define the method of media measurement before lowering the pressure rolls. Follow the procedure below to set the media measurement method: Press the following buttons in order:...
  • Page 86 User’s Guide Kona cutting plotter Operation panel Media measure Media measurement method When lowering the pressure rollers, the cutter determines the left, right and front side of the media. Next to this, the cutter feeds the media forward. With front In case the rear sensor does not longer detect media, the cutter ...

  • Page 87: Load Length

    Your Kona cutter is equipped with Mutoh’s unique auto sheet-off feature. If the autoshuffle  is on, the Kona automatically cuts off media at the end of a cutting sequence. Following an automatic PAGE command or a manual PAGE command initiated via the control panel, the cutter will shuffle through the pre-set load length of media, to ensure that there is enough media left for a possible replot.

  • Page 88: Settings 2/4

    User’s Guide Kona cutting plotter Operation panel 4.2.3 Settings 2/4 Smoothing Smoothing can be enabled or disabled. Depending on your choice, cutting of obtuse angles will be dealt with differently by the cutter. If the complementary angle between two consecutive vectors A & B is larger than the smoothing angle, the cutter will slow down and cut a sharp corner (1).

  • Page 89: Sheet Off

    User’s Guide Kona cutting plotter Operation panel Sheet off The auto-sheet-off mechanism can be very easily used to cut the front edge of a new roll of vinyl straight as well as to cut off a sheet of vinyl from a roll.

  • Page 90: Job Focus

    User’s Guide Kona cutting plotter Operation panel Job focus A lot of advanced cutting settings will be made in the background without any need of intervention by the end-user. Select by means of the table below the correct job focus.

  • Page 91: Origin

    User’s Guide Kona cutting plotter Operation panel Origin Note Be aware that this is the standard Origin setting. There is also the possibility to  customize the origin. For more information concerning the customized origin refer to Origin on page 110 Set the cutting starting position (origin) as follows: Please make sure media is loaded.

  • Page 92: Page Mode 0

    The PAGE command is used to relocate the origin after a job is finished and can take control remotely of the cutter’s automatic sheet-off feature. Sheeting-off automatically, without user intervention, is a feature which is unique to Mutoh cutting-plotters and which enhances the cutter’s versatility and overall performance enormously.

  • Page 93: Settings 3/4

    Epos Epos Alignment This test will fine-tune the position of the cutting knife compared to the EPOS laser. This test can be done manually and automatically. It is recommended however, to let the Kona adjust the values automatically. Note It is advised to perform this test for each completely new cutting knife.
  • Page 94 User’s Guide Kona cutting plotter Operation panel Press the following buttons in order: Step 3: Settings  2x next page  Epos  Epos Align  You now have 3 options  Automatic Manual Position Manual color (Recommended) Select automatic...
  • Page 95 User’s Guide Kona cutting plotter Operation panel Automatic Manual Position Manual color (Recommended) The machine will The machine will The Kona displays Step 7: present the test pattern present the test pattern following screen: by feeding the vinyl by feeding the vinyl Pull the media manually ...
  • Page 96 User’s Guide Kona cutting plotter Operation panel Optimize When calibrating the EPOS, the X and Y distance is measured between the pen and the laser. These values are being used when contour cutting. Normally, these values are correct, but in rare cases a shift could happen. To delete this shift, you can optimize the offset distances between the pen and the laser.

  • Page 97: Language

    User’s Guide Kona cutting plotter Operation panel Color When performing a manual EPOS color calibration, it is not longer necessary that the machine performs an automatic color detection. Therefore, you can switch this setting off. Note When performing a new automatic EPOS calibration, the setting is switched ...

  • Page 98: Protocol

    User’s Guide Kona cutting plotter Operation panel Protocol This menu incorporates Emulation and VS/ZF/AS. To set these parameters press the following buttons in order: Step 1: Emulation Settings  2x next page  Protocol  Emulation  VS/ZF/AS VS/ZF/AS ...

  • Page 99: Resolution

    User’s Guide Kona cutting plotter Operation panel Resolution Please note that some software packages use the “step per mm” terminology, in which case a program step of 0.025 mm corresponds with 40 steps per mm and a program step of 0.010 mm with 100 steps per mm.

  • Page 100: Swap Alert

    Refer to for the other cut through settings. Cut through on page 102 Refer to the Application Guide of the Kona to know how to initiate a cut through routine flawless. Press the following buttons in order: Step 1: Settings ...
  • Page 101 When a change tool command is requested and the mode is set to single tool,  the Kona displays a message asking if you are sure to continue in single tool mode. When continuing, this message is not displayed again when receiving a new change tool command.

  • Page 102: Cut Through

    Refer to the Application Guide of the Kona to know how to initiate a cut through routine flawless. It is however not easy to match an ideal tool configuration setup in which the media weakness suffers not radically from the multiple cut through samples accomplished.
  • Page 103 User’s Guide Kona cutting plotter Operation panel Follow the procedure below to the velocity and force: Press the following buttons in order: Step 1: Settings  2x next page  Cut through  Set the values for the velocity and force.

  • Page 104: Settings 4/4

    User’s Guide Kona cutting plotter Operation panel 4.2.5 Settings 4/4 Diagnostics This section is intended for service technicians only! Note In case of entering the diagnostics mode and changing settings, the cutter may  become disordered if you are not sure what you are doing.
  • Page 105  After changing it, confirm with Animation:  Wait time: Set the time the Kona has to wait before starting the screensaver.  After changing it, confirm with Play: Select this button to start an example of the screensaver. ...

  • Page 106: Information

    User’s Guide Kona cutting plotter Operation panel Information As well for yourself as for the communication with a CutServer, it is handy to know which firmware, serial number, revision... the machine has. Open the information screen as follows: Press the following buttons in order:...

  • Page 107: User

     User It is possible to reset the user settings of the Kona. We do advise to make a backup of all settings before performing this action. For more information on how to make a backup, refer to the User’s Guide of the CutServer.

  • Page 108: Actions 1/2

    User’s Guide Kona cutting plotter Operation panel 4.2.6 Actions 1/2 Jogging With this function your are able to move the head from left to right or the media forward or backwards as follows: Press the following buttons in order: Step 1: Actions ...
  • Page 109 User’s Guide Kona cutting plotter Operation panel The cutter displays following screen: Step 2: Item Information Move the head to the left Move the head to the right Feed the media forwards Feed the media backwards Position of the knife top.

  • Page 110: Origin

    User’s Guide Kona cutting plotter Operation panel Origin Note Be aware that this is the customized Origin setting. There is also a standard  origin. For more information concerning the standard origin refer to Origin on page 91 Follow the procedure below to change/control the origin:...
  • Page 111 User’s Guide Kona cutting plotter Operation panel Note It is possible to move both the head as media at the same time when touching  the jog screen in diagonal direction. Navigate the head and/or media using the arrows until you reached the desired Step 3: origin.

  • Page 112: Cut Through - Trim Poster

    User’s Guide Kona cutting plotter Operation panel Cut Through - Trim Poster After printing some posters, it is possible to use the Kona to trim the posters afterwards. Do this as follows: Load the poster in the cutter. Step 1: Install a knife at through cut depth.
  • Page 113 User’s Guide Kona cutting plotter Operation panel Move the penhead using the jog keys until the knife point is positioned above P1 Step 7: and press OK when done. X Length Y Width The cutter will automatically feed the media the length set previously. Use the jog Step 8: keys to set the second corner more precisely if necessary.
  • Page 114 User’s Guide Kona cutting plotter Operation panel After finalizing the trimming of the poster, insert the standard tool again and press Step 12: Note This message will only be displayed when the swap alert setting is set to  multi-tool.

  • Page 115: Contour Cut

    When performing a single or multi-frame contour cut job, the job can be started via the Go button on Mutoh’s CutServer. It is also possible to launch the job directly from the cutter itself, only on the condition that the cutter is connected with Mutoh’s CutServer. In fact, this function replaces the Go button.
  • Page 116 User’s Guide Kona cutting plotter Operation panel Set the number of jobs to perform Step 3: Press Jobs  Fill in the number of jobs.  Press Step 4: Press the Sheet off between button. Step 5: Decide if you want to perform a sheet off action between two jobs or not.
  • Page 117 User’s Guide Kona cutting plotter Operation panel Manual When you want to start a contour cutting job without using the automatic alignment option, the manual mode needs to be chosen. This could be useful when you have loaded very reflective media which cannot be detected by the cutter.
  • Page 118  Position the laser at the left side of the bar code and press OK.  The Kona will scan the bar code and display one of these two messages.  Not mirrored means the cut job is inserted normally....
  • Page 119 User’s Guide Kona cutting plotter Operation panel Mirrored means the cut job is inserted upside down.  The bar code looks as follows: In case the bar code is not read out properly, following message appears. Step 2: Press OK and retry.

  • Page 120: Epos Read

    User’s Guide Kona cutting plotter Operation panel EPOS read To be able to perform a contour job, the EPOS sensor needs to see the difference between the media and the printed bounding box. When loading a media and the measurement of the bounding box fails, it is interesting to perform the EPOS read test.

  • Page 121: Sheet Off

    User’s Guide Kona cutting plotter Operation panel Sheet off Via this menu you can sheet-off the media. Perform a sheet-off as follows: Press the following buttons in order: Step 1: Actions  Sheet off  Depending on the settings made in the sheet-off parameter menu, one of the Step 2: following screens will be displayed.

  • Page 122: Actions 2/2

    User’s Guide Kona cutting plotter Operation panel 4.2.7 Actions 2/2 Copies In case multiple outputs of a specific design are needed, use the copies function. This function will replot the last set of data, which was sent to the cutting plotter. That is, all data that was sent since the last INITIALISATION command (“IN”).

  • Page 123: Chapter 5 Finetuning Your Cutter

    Kona calibration ........

  • Page 124: Knife Types

    User’s Guide Kona cutting plotter Finetuning your cutter Knife types There are several knife types available, each of them meant for specific cutting media. Cutting blade 1 Cutting blade 2 Cutting blade 3 Standard type Used for thick Used for thin media media e.g.

  • Page 125: Kona Calibration

    User’s Guide Kona cutting plotter Finetuning your cutter Kona calibration 5.2.1 Knife settings There are three factors that have to be taken into account when setting up your cutter to execute a demanding cutting job: The knife depth for as well kiss cutting, contour cutting as through cutting.

  • Page 126: Epos Test Cuts

    Mutoh CutServer can be found on the getting started CD of the Kona. This sheet will enable you to calibrate your Kona Epos® Electronic Positioning System for full automatic contour cutting. Verify the EPOS alignment as...

  • Page 127: Epos Alignment Test

    EPOS alignment test This test will fine-tune the position of the cutting knife compared to the EPOS laser. This test can be done manually and automatically. It is recommended however, to let the Kona adjust the values automatically. Refer to to know how to perform the test.
  • Page 128 User’s Guide Kona cutting plotter Finetuning your cutter A box will be cut. Step 7: Peel out the box. Step 8: Measure the X length and Y width and enter them. Be sure to enter the values in Step 9:...

  • Page 129: Chapter 6 Contour Cutting

    User’s Guide Kona cutting plotter Contour cutting Chapter 6 Contour cutting Introduction..........130 Different alignment methods .

  • Page 130: Introduction

    User’s Guide Kona cutting plotter Contour cutting Introduction Contour cutting is a very popular feature of the Mutoh cutters. This feature is made to cut pre-printed signs on vinyl for sticker production as shown on this picture: Please read this chapter carefully.

  • Page 131: Different Alignment Methods

    User’s Guide Kona cutting plotter Contour cutting Different alignment methods There are some different approaches to cut your signs which also implicate a different alignment method. N° Description Info Manual alignment method Manual Manually set the size of the paper and 4 corners of the box ...

  • Page 132: Which Alignment Method To Use

    Kona. If each sign on the roll has a barcode and if all plot files are in the Mutoh CutServer, just click on Go in the Mutoh CutServer and every sign on the roll will be cut, without the need for user intervention (make sure you’ve enabled auto-sheet-off in EasySIGN for each contour-sign).

  • Page 133: Multi Frame Alignment Method

    Mutoh’s CutServer. With this method, it is possible to make signs of 10m or longer, and the Kona will measure segment per segment, and cut segment per segment. This method gives you more accuracy than the previous method.

  • Page 134: Bounding Box Details

    “magenta hairline” or “spotcolor” with <CutContour> swatch name (in the CMYK pallet). Thickness line = hairline (or 0.25)  Colour = 100% magenta  For more details, please refer to the Kona Application Guide.  AP-75380 - Revision 1.2...

  • Page 135: Bounding Box Specifications

    User’s Guide Kona cutting plotter Contour cutting 6.4.2 Bounding box specifications The frame reference box printed or generated around the contour cut data should respect the following guidelines: Sheet Bounding box Pressure roller N° Description Minimum Maximum White edge at the right side...

  • Page 136: Scanning Routing Of Bounding Box

    User’s Guide Kona cutting plotter Contour cutting Scanning routing of bounding box The bounding box will be measured by the Epos sensor during a fast scan routine. It is interesting to know the principle behind this innovative scanning method. The scanning routine will go through the following steps: The laser will be activated to detect the background colour.
  • Page 137 User’s Guide Kona cutting plotter Contour cutting Situation 2 = Both sides detected (4 points) scan 1 Situation 3 1st scan > both sides detected (2 points) feed of media to start second fast scan 2nd scan > bottom and side of frame detected (4 points) 4’...
  • Page 138 User’s Guide Kona cutting plotter Contour cutting AP-75380 - Revision 1.2...

  • Page 139: Introduction

    Introduction..........139 Setting up your Kona cutting plotter ......140 Tools necessary.

  • Page 140: Setting Up Your Kona Cutting Plotter

    Cutter firmware 1.00 service pack v 5.12 There is a special driver update required when working with EasySIGN the Kona cutting plotter series cutters. This file (Mutoh.drv) can be found on and should be copied over the Mutoh’s FTP existing Mutoh.drv Mutoh Grip (+) 8.00...
  • Page 141 User’s Guide Kona cutting plotter Through cutting Press the following buttons in order: Step 1: Settings  2 x next page  Swap alert  Make your preferred choice: Step 2: Multi-tool configuration. You will be asked to switch tools ...

  • Page 142: Through Cut Settings

    User’s Guide Kona cutting plotter Through cutting 7.2.3 Through cut settings It is however not easy to match an ideal tool configuration setup in which the media weakness suffers not radically from the multiple cut through samples accomplished. Therefore a perfect harmony between your tool down force and tool up distance needs to be synchronised.
  • Page 143 User’s Guide Kona cutting plotter Through cutting Press the test key to verify the quality of the through cutting settings. Step 6: The following pattern will be cut. Step 7: Check if it is easy to push out the cut patterns.

  • Page 144: Through Cutting Workflow

     On a Kona 760 ==> 2 pressure rollers  On a Kona 1400 and Kona 1650 ==> 3 pressure rollers  lower your cut through media width dimension  choose your in between margins for cut through stickers sufficient enough ...

  • Page 145: Poster Trimming Workflow

    User’s Guide Kona cutting plotter Through cutting Poster trimming workflow After printing some posters, it is possible to use the Kona cutting plotter to trim the posters afterwards. Do this as follows: Load the poster in the cutter. Step 1: Install a knife at through cut depth.
  • Page 146 User’s Guide Kona cutting plotter Through cutting The cutter will automatically feed the media the length set previously. Use the jog Step 8: keys to set the second corner more precisely if necessary. Do this until you have selected all 4 corners in correct order (P1 – P2 – P3 – P4).
  • Page 147 User’s Guide Kona cutting plotter Through cutting After finalizing the trimming of the poster, insert the standard tool again and press Step 12: Note This message will only be displayed when the swap alert setting is set to  multi-tool.
  • Page 148 User’s Guide Kona cutting plotter Through cutting AP-75380 - Revision 1.2...

  • Page 149: Chapter 8 Maintenance

    User’s Guide Kona cutting plotter Maintenance Chapter 8 Maintenance Cleaning and daily maintenance ....... 150 Cleaning the grit rolls .

  • Page 150: Cleaning And Daily Maintenance

    User’s Guide Kona cutting plotter Maintenance Cleaning and daily maintenance Your cutting plotter, knives and pens will work better and last longer if you keep them clean and perform a few simple daily maintenance tasks. Note Before performing cleaning and daily maintenance, please power OFF the unit ...

  • Page 151: Cleaning The Cutter Blade

    User’s Guide Kona cutting plotter Maintenance 8.1.3 Cleaning the cutter blade Use following procedure to remove small vinyl particles in the base part of the cutting blade holder. Standard knife holder Hold the body (2) into one hand and unscrew the base part (1) Step 1: Remove the spring (3) and the cutting blade (4).

  • Page 152: Cleaning The Touch Screen

    User’s Guide Kona cutting plotter Maintenance Place the base part on top of the holder assembly and twist it tightly. Step 4: 8.1.4 Cleaning the touch screen After a while, fingerprints or dust will make the touch screen dirty. Clean the touch screen as follows: Power off the cutter.

  • Page 153: Chapter 9 Troubleshooting

    Pressure roller positioning warning ......158  Beeping codes: My Kona is making a beeping sound once in a while..161 ...
  • Page 154 User’s Guide Kona cutting plotter Troubleshooting Error messages ..........164 Recoverable error messages with no error ID number .

  • Page 155: Day-To-Day Use Issues

    9.1.1 Warning messages Calibration warning When starting up the Kona, the machine is verifying the YZ profile and the EPOS calibration. If one of these two is not calibrated, a message appears warning the user to perform these calibrations. Note Select the checkbox in case you do not want to see these messages when starting up.

  • Page 156: Media Loaded Warning

    Media loaded warning When starting up the Kona it is advised there is no media loaded. If there is media loaded, the Kona will show below warning message. If the sheet off knife is in the down position, the loaded media will be sheeted off while the Kona is initializing.

  • Page 157: Epos Warning

    User’s Guide Kona cutting plotter Troubleshooting EPOS warning When performing an EPOS contour cutting operation, and a warning appears, an extra option is added to ignore similar warnings for this job. For example: A Multi- Frame job is done and in the first segment a warning is encountered. If you choose not to ignore similar warnings, the warning message will keep appearing if the warning situation is encountered in another segment.

  • Page 158: Pressure Roller Positioning Warning

    Troubleshooting Pressure roller positioning warning If a pressure roller is wrongly positioned, the Kona will show a warning message during the media measurement. There are 3 types of warning messages. Move pressure roller. (Can appear on Kona 760 - 1400 - 1650) ...
  • Page 159 User’s Guide Kona cutting plotter Troubleshooting No pressure rollers on centre grit roller  There must always be 1 pressure roller on the centre grit roller. Position one of the suggested pressure rollers on the centre grit roller.  Kona 1400...
  • Page 160 User’s Guide Kona cutting plotter Troubleshooting There are too many pressure rollers positioned in the middle of the grit roller. Reposition the pressure rollers on the grit roller.  Kona 1400 Kona 1650 Refer to for more information. Pressure roller positioning on page 47...

  • Page 161: Beeping Codes: My Kona Is Making A Beeping Sound Once In A While

    The USB connection disappears. In case the Kona is subject to static electricity, the USB connection can be abrupted. To make a new connection, pull out the USB cable and reinsert it. It is very important to install the anti static brushes to avoid these kind of problems.

  • Page 162: The Power On, But The Cutter Does Not Operate

    User’s Guide Kona cutting plotter Troubleshooting 9.1.4 The power ON, but the cutter does not operate. Is the power cable connected to the cutter?  9.1.5 Media is loaded, but the cutter does not operate. Is the pressure roller lever lowered? ...

  • Page 163: Some Parts Of The Design Are Not Well Cut

    User’s Guide Kona cutting plotter Troubleshooting 9.1.8 Some parts of the design are not well cut. Check whether the knife tip is not clogged with material residues.  Examine the knife blade with a magnifier to see if the tip is not damaged or broken.

  • Page 164: Error Messages

    During a cutting, measuring or other sequence, it might be possible that one of the below errors occur. Please find a list below with all the possible errors which can be solved yourself, without any need of an intervention by an authorized Mutoh technician.
  • Page 165  point a paper during the switch, this error can occur also. It might be possible that the reference box Select the correct file in the Mutoh Refer to Application Guide   cannot be found. CutServer and start the job manually...

  • Page 166: Errors With Error Number (Id 1009-6115)

    User’s Guide Kona cutting plotter Troubleshooting 9.2.2 Errors with error number (ID 1009-6115) Error Message Description Solution Category The head is obstructed and cannot move anymore. Remove the media or object Fatal 1009 Y position error Because of a media crash or mechanical obstruction for...
  • Page 167 User’s Guide Kona cutting plotter Troubleshooting Error Message Description Solution Category Make sure that the difference  between white and colour can be recognized by the EPOS sensor Refer to EPOS read on page 120 6098 EPOS calibration error Could not calibrate the pen to laser distance...

  • Page 168: Contourcutting Errors And Warnings (Id 6201-6271)

    User’s Guide Kona cutting plotter Troubleshooting 9.2.3 Contourcutting errors and warnings (ID 6201-6271) When a specific contour cutting warning or error occurs, an error number will be displayed and a cross will be cut in the lower right corner. All codes are unique and the cross has a predefined angle and size to know of which nature the error is.
  • Page 169 User’s Guide Kona cutting plotter Troubleshooting Please find below an overview of the codes and category of problem A warning means that you will have the choice to continue cutting the current segment, all segments or to cancel the job.
  • Page 170 User’s Guide Kona cutting plotter Troubleshooting Error Message Description Solution Category Did you sent the correct file  Media size Check if the margins left, right, top and bottom are within the specifications. 6218 Error Refer to Bounding box details on...
  • Page 171 User’s Guide Kona cutting plotter Troubleshooting Error Message Description Solution Category Stretch detected on bottom of frame. P1 & P4 have identical thickness. P2 & P3 Print distortion 6227 have identical thickness. But thickness of P1-P4 and P2-P3 differ too much from print stretch each other.
  • Page 172 User’s Guide Kona cutting plotter Troubleshooting Error Message Description Solution Category Thickness All measured points of frame bottom vary too much from each other! This will 6231 problem influence the accuracy of the cutting. frame bottom Thickness Invalid thickness of P1 (right side of frame bottom). Thickness varies too much 6232 problem...
  • Page 173 User’s Guide Kona cutting plotter Troubleshooting Error Message Description Solution Category Thickness All measured points of frame top vary too much from each other! This will 6241 problem influence the accuracy of the cutting. frame top Thickness Invalid thickness of P5 (right side of frame top). Thickness varies too much from 6242 problem...
  • Page 174 User’s Guide Kona cutting plotter Troubleshooting Error Message Description Solution Category Thickness Thickness of centre points (P9 & P10) differs too much from each other AND 6251 problem differs also from bottom points P1 and P4. frame centre Thickness Invalid thickness of P9 (right centre point). Thickness varies too much from P10! 6252 problem...
  • Page 175 User’s Guide Kona cutting plotter Troubleshooting Error Message Description Solution Category No valid frame No valid frame found during fast scan routine (after several retries). Make sure all 6261 found frame specifications are applied. No valid frame 6262 Only 1 frame point found during diagonal scan.

  • Page 176: Mgl Errors (Id 4000-5000)

    9.2.4 MGL errors (ID 4000-5000) As from the moment data is sent to the Kona which is not correct, an error and sub error number will be displayed. Please find below a list with explanations of these sub numbers. Sub number...
  • Page 177 User’s Guide Kona cutting plotter Troubleshooting Sub number Description Error in MGL command definition Label out of limit error other Unknown MGL error Note Be aware that when one of the above errors occurs, no beeping sound will be ...
  • Page 178 User’s Guide Kona cutting plotter Troubleshooting AP-75380 - Revision 1.2...

  • Page 179: Knife Holder And Blades

    Cutting mat ..........181 Refer to the Mutoh Kona cutting plotter’s unit or spare part price list for the most recent prices of these consumables.

  • Page 180: Knife Holder With Depth Change Indication

    User’s Guide Kona cutting plotter Consumables 10.1.2 Knife Holder with Depth Change Indication Picture part number Description Knife Holder with Depth Change Indication ZMY-10034B Including one blade, 45° angle, 0.5 mm offset Blades for Knife Holder with Depth Change Indication - 0.5 mm...

  • Page 181: Sheet Off Blades

    User’s Guide Kona cutting plotter Consumables 10.3 Sheet off blades Picture part number Description KY-15134 Set of Sheet Off Blades (10 pieces) 10.4 Cutting mat Picture part number Description Cutting mat (5 pieces) KY-15305 (The colour of the cutting mat could be white or black, both have the same quality) AP-75380 - Revision 1.2...
  • Page 182 User’s Guide Kona cutting plotter Consumables AP-75380 - Revision 1.2...
  • Page 183 User’s Guide Kona cutting plotter Index Actions Daily maintenance ....150 ......108 Day-to-day use issues .
  • Page 184 User’s Guide Kona cutting plotter Job focus ......90 Normal procedure ..... . 30 Jogging .
  • Page 185 User’s Guide Kona cutting plotter Safety labels ......14 Warnings, cautions and notes ... . 12 Scanning routing of bounding box .
  • Page 186 User’s Guide Kona cutting plotter AP-75380 - Revision 1.2...
  • Page 188 MUTOH INDUSTRIES LTD. MUTOH AMERICA INC. EMEA Headquarters Regional Sales office Tel.:81-(0)3-5740-4020 Tel.:1-480-968-7772 MUTOH BELGIUM nv MUTOH DEUTSCHLAND GmbH. Fax:81-(0)3-5740-4030 Fax:1-480-968-7990 Tel.:32-(0)59-561400 Tel.:49-(0)221-385474-0 E-mail:ibd@mutoh.co.jp E-mail:sales@mutoh.com Fax:32-(0)59-807117 Fax:49-(0)211-385474-74 http://www.mutoh.co.jp http://www.mutoh.com E-mail:mutoh@mutoh.be E-mail:Vertrieb@mutoh-gmbh.de http://www.mutoh.eu http://www.mutoh-gmbh.de http://www.mutoh.de...

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