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plotter needs rehab

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I have a APD plotter and i use precision cut  . When i use flexicut to cut signs then i go back to cutting precisioncut the sizes are off . Like it will cut a 4" sq  only 1 1/2 "sq  . I have to go into precision cut and adjust the units per inch . ITs suppose to cut at 1016 and i have to adjust it to 2550 to cut an accurate size . Any suggestions what it could be ? Llumar has never heard of this problem .

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