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P-600 service manual

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1. 14VHS JHL NI JAOO9 JHL NI 39NY 14 dWV19 3915 lt S 3111001H LIM 3HO03S lt T HOSN3S HJAOO SAOWSY lt 1 6 OL M3389S 3090801 lt Scy 9111907 340938 lt L SALON Carriage Assembly Bill of Materials 600Ae amp P 600H only N u E C oeer CARRIAGE S 00728 31 x 106864 BRACKET SENSOR CARRIAGE 175 600 2 x 106464 BLOCK SPACER FLEXURE 3 AW x 107208 BRACKET CALIBCARRIAGEI SS x 106523 PEN RNIFE CARRIAGE 5 156945 DOWEL PIN 062501 Xen 7 106954 FILTER SENSOR ENS L ms pos assy CARRIAGE 9 106236 7 PCBASSY CARRIAGE P600 9 iosas far CARRIAGE seo 10 x 06460 MOUNT VC CARRIAGE SCHE f 106255 WHEEL CARRIXGE 595 17 L ws ir i861 3120D DezTH NYLON 22 x 106073 SCREW SHOULDER 187 DIA 37516 23 156162 SPRING EXTENSION 25 0D 337 DIA 2 106130 10 32 ROUND THUNB 26 x 103720 IYRAPIINXSINBIACK 29 Bea 1 106115 SPACER 188 ID 313 OD 188 LG 100705 PAD PEN CAP 1 4 DIA PAD PENCAP I ADIA I 106750
2. 145 Pinch Wheel Assembly 600Ae amp P 600H only Bill of Materials 146 Chassis Assembly Sheet 1 a ea 147 Chassis Assembly Sheet 2 4 22 22 re 148 Chassis Assembly Bill of Materials P 600 only 149 Y Axis Transmission Assembly 600 only 151 Y Axis Transmission Assembly Bill of Materials P 600 only 152 Keypad Assembly P 600 amp M 28 only 153 Keypad Assembly Bill of Materials P 600 amp M 28 only 154 Rear Panel As embly sc bafi fbr m acie tor isi 155 Rear Panel Assembly Bill of Materials estet la 156 Carriage Assembly P 600 only nee nene canne naar inn 157 Carriage Assembly Bill of Materials P 600 only 156 Carriage Assembly M 28 only iiid aieo aii er 159 Carriage Assembly Bill of Materials M 28 only 160 Carriage PCB Assembly s s icut En 161 Carriage PCB Assembly Bill of Materials aaa 162 PCB Assembly P 600 only eu 163 PCB Assembly Bill of Material
3. 63 Front Roller Motor Key 64 Carriage Y Axis Transmission Tee 64 Internal Cabling and Connection Inspection 64 Tools Reguired us usus as u Renee 65 Initial Internal Inspection en 65 Testing Power Supplies 66 Tools Required Herne 66 Inspect the Fuse and Output Terminals 66 Test the Power Supply Output Voltage 66 Swap Power Supply Connections 1 1 1 nennen nnne nnne nnn nnn 67 Reference Information for the Power Supply Test Fixture 67 Testing the Logic Board 68 Tools Required 20er 68 Testing the FETsS TransistorS sense ent 68 Testing and Replacing the Other Logic Components Including the RS 232 69 Testing the Motors 69 Tols Required zu u E 69 Initial Motor Inspections iei e an 69 Likely Modes of Motor Failure eere nn enne nnn 69 Grit Shaft X Axis Motor Replacement 1 1 70 Carriage Y Axis Motor
4. 32 Preparing to Send a File eee ev e eremo 33 Software Installation aan 34 Installing the Ioline Control Center Software 34 Microsoft Windows 3 1 Installation 2 2 34 Windows 95 98 installation Edu nob zu va 36 Macititosh TostallatigIisa side 36 Chapter 3 uu a ES CEA OF Keypad Controls 38 AFTOW KGy 38 ee En 39 ROl SWINE S 39 Pen Lc 39 Sensor E RETE Urea Gara NEN E DERE 39 DE 40 Power ey 40 Rear Panel ON OFF Control asua a Coena e rct c inicr ra n Rai E PUn a rit d e 40 Control Center Software 40 eeclesie 40 Measurement e rk ER RE xia e ci ra 41 S Fa Bata 41 Speed M T 41 UB Bown Delays u 42 Sensor Enabled 42 Frame ne a RR 42
5. 2 11 2 1 1 1 12 4 4 nnn nn 70 Roll Feed Motor Replacement nnne nenne nnn nnns 70 Testing the New Motor u 70 Contacting Ioline Customer Service 71 DiagrigsucRecoldlo u ae 71 Re Packing the 600 72 Chapter 5 Repair and 73 List Of Recommended Tools And Equipment 74 Cleaning And Regular Maintenance 75 Cleaning The Grit BR 75 Cleahing The Patel qasawan RAE A 76 Cleaning The Support Blocks mais era 77 Cleaning the Traverse Extrusion and Carriage V Wheels 77 General Disassembly Procedures 78 Removing the End Covers and Dust Cover 78 Removing the Bottom Cover for Internal Access 80 Tools Required te e ER utes e a vate us 80 Y Axis Subsystem 81 CARRIAGE ee 81 Car
6. OL X T31Vvd3s 39vxovd SILON N Gaius ro IHM O 161 Carriage PCB Assembly Bill of Materials DMPONEN STE ON DRAWIN NUMBER LA CB CARRIAGE 28 600 BEE GEBE CB CARRIAGE ONN FLEX CABLE 12 PIN R ANGLE TYRAP 1 IN X 3 IN BLACK DICE COIL ONN TERMINAL RING 4 22 18 GA ABLE ASSY ITH LU WIRE ST GN X 3 IN UL1007 10 HEATSHRINK 250 DIA BLK HEATSHRINK 125 DIA BLK s E ee WAND FRAME SENSOR W A UNE MEE EE mS NEN EE 7 7 162 OVE OILVLS 9 X L NI Q3 18 3SSV 3OV d SNOILNVOSYd OLIVLS LINV ISN SLIN3NOdWOO AAILSNAS 2115150419919 OL 39VIAVGO LNFAFUg OL NOILNYO 91514 3ALLOVOIOVH OLL3NO VIA OLL3NO VAOHLO3T3 DIIVLSOHLO3 T3 SNOMLS YVAN 3301 dIHS LON Od S3OIA A3G DINOYLOATS 3ALLISN3S NOILNVO 163 PCB Assembly P 600 only Part Number 106238 PCB Assembly Bill of Materials P 600 only en ete ee 106240 IC ROM P600 PROG 0 105418 IC ROM DSP 2200 PROG U U PGA PRO 0106 00 910 U 105413 PCB ASSY LOGIC 2200 p 164 Take up Shaft Assembly Part Number 106263 1 39 79 62 76 67 2X
7. 123 600Ae Part Number Equivalents 124 LED Code Differences kasa 124 Bill of Materials for Unique 600Ae 125 Accessory Kit 600AE 125 Carriage Assembly Bill of Materials 600Ae 126 Carriage PCB Assembly 600Ae nennen nnn nnn nin 127 PCB Assembly 600Ae sive koI ePi Uo cA Y Osa E ERA RR ua 127 FGI Level 600A6 128 Appendix of Drawings For the P 600 600H amp 600Ae 134 Fan ASSOMDIY fee E 135 Fan Assembly Bill of Materials 136 Cable Assembly 137 Cable Assembly Bill of Materials 138 Pinch Wheel Assembly P 600 only 139 Pinch Wheel Assembly Bill of Materials P 600 only 140 Cable Assembly 141 Cable Assembly Bill of Materials URGE en da 142 Pinch Wheel Assembly P 600 only nennen nnn nnn 143 Pinch Wheel Assembly Bill of Materials P 600 only 144 Pinch Wheel Assembly 600Ae amp P 600H only
8. PEN PRESSURIZED BALL POINT PEN PILOT V BALL HUBFEEDASSY BELT UNWINDING 60 23 STATIC GARLAND 77 56IN CABLE SERIAL 9F 25MPIN USER GUIDE 601 SOFTWARE SCREW 1 4 20 1 00 LG BTN HDSOCK SCREW 1 4 20 2 LG 7 SCREW 1 4 20 625 LG BTN HD SOCK IBOX SHIPPING 9X7X5 7 125 Addendum 600Ae Carriage Assembly Bill of Materials 600Ae 107367 600Ae Carriage Assembl Ioline part Description Number of Number Parts used 106863 BASE CARRIAGE 1 S 600 28 106864 BRACKET SENSOR CARRIAGE I S 600 106464 BLOCK SPACER FLEXURE _ 106622 JAW CARRIAGE SC98 107208 BRACKET CALIB CARRIAGE I S CLAMP PEN KNIFE CARRIAGE 106523 CLAMP PEN KNIFE MOLDED 106455 MOUNT VC SC98 T 7 106226 PCBASSY CARRIAGE P600 106230 WHEEL CARRIAGE 598 106254 FLEXURE CARRIAGE Z AXIS PRING EXTENSION 25 OD 037 DIA 107178 PRING EXT 25 OD 04 ID 75 LG PRING COMP 24 OD 1 25 LG UT ROUND THUMB nin zn R O v Carriage Assembly Bill of Materials 600Ae Cont n 106532 NUT 6 32 HEX NYLOCK 106358 DOUBLECOATED SINWIDE 1 10708 SCREW 46 32 6251GFHP 2 O a 0625 107381 SCREW 6 32 1 0 LG FHP 107018 SCREW 6 32 625 LG FHP Carriage PCB Assembly 600Ae 106236 600Ae Cariage PCB ass Ioline part Description Number of Num
9. rss ae 43 Send Settings to P 600 2a 43 FORCE 222 43 Panel nn a Pw br ire Ferias d 43 aA eae 44 Menu Bar Items oco iin ano OE ROS OR DER as 44 44 Open Settings File aa anna ana ar able 44 SAVE SEINES AS 44 Set D as das isq E 45 Plotter Setup iar e e Re nk 45 Com Port 45 DISD AY PME pP 45 PlotiepiSetfineS P 45 Factory Defaulis E 45 ROM Version hiuc ated uuu uni e 45 Memory eo RD Rakes 45 Cdl Dra O Xa eA FAR cx UAR E Dad 46 CalibratePlotteE tiet 46 T9 calibrate the P 600 anne 46 U a TN PN EM 47 Serial Testis nah um akuy vea ye HEN Dresd p Tante 47 Computer Port Lest EEES 47 Plotter Port Test iiis t etit 47 eeepc E 48 COMETS 2 ss s 48 48 Chapter 4 Troubleshooting and Testing 4
10. L iussss BRACKET RER TJO PANEL 600728 1 x 100121 JACK SOCKET KIT 44 40 104756 CABLE ASSY KEYPRD RS 232 1 105479 CABLE ASSY AC POWER 2200 5 nor 6 156 SV 6 1109 LN3IHO lt 3111907 341935 lt SSVE NI ITOH H3AO Vd N3JN3O AIILYNWIXOYddY lt 6 WALI asva lt CC 3111907 3193 lt SILON er gt R S lt I gt amp 40 SIHL NO 3111901 AlddV LON wo aa Ns 5 e om 5 E 2 8 q 33s J Carriage Assembly Bill of Materials P 600 only L ier CARRIAGE PSO 1 155435 WHEEL CARRIAGE BEARING FLANGE 2501D 50000 U 0000 0589 W DU I05891 SCREW SHOULDER 750 DIA 62516 106245 JAW CARRIAGE F 106215 BLOCK BASE CARRIAGE ZAXIS 106250 MOUNT VOICE COIL BOBBIN CARRIAGE 9 0293 CLAMP PEN CARRIAGE ft x 106754 CARRIAGE Z AXIS 11 106310 SHAFT SPRING RETAINER CARRIAGE 12 NYLOCK SPRIN I6 EXTENSION 00 OD 049 D BUNBER UP LIMIT C
11. 5 The fixture provides labeled test points for all output voltages Turn the power on and measure the voltages All of them should be tested relative to the associated ground pin the 5 V shares a common ground and should read as labeled 1096 Repeat this procedure for the other power supply If any voltage fluctuates wildly or is not within 1046 of the specified value then replace the power supply If the voltages are within the tolerances continue to the next step Swap Power Supply Connections 1 Turn the power off 2 Swap the power supply connectors J3 and J7 so that the plug that was connected at J3 1s now connected and J7 and the connector at J7 is connected at J3 Turn on the power and determine if the problem is gone i e the carriage resets and gives a steady red LED on the keypad If there was a jam and it seems to have been cleared test all motions with the arrow keys letting the motors run for ten seconds or so If the problem is resolved then the power supplies were starting in the wrong sequence and should now work correctly If these procedures are not effective in solving the problem read Testing the Logic Board for the next step in the diagnostic process Reference Information for the Power Supply Test Fixture The information below describes the resistive loads imposed on the power supply when the Ioline Power Supply Test Fixture is used While not as effective a 20w
12. NOTES gt SECURE WITH LOCTITE 222 gt CLEAN MATING SURFACES WITH ALCOHOL AND APPLY TWO PART EPOXY ADHESIVE CLEAN AWAY ANY EXCESS ADHESIVE AFTER ASSEMBLY Take up Shaft Assembly Bill of Materials COMPONENT PART NUMBER COMPONENT DESCRIPTION DRAWING NUMBER i 1 a 105967 END TAKE UP SHAFT 600 28 130455 TAKEUP HUB 0 D H DN 106180 SHAFT TAKEUP SUMMIT 97 106181 SHAFT FEED SUMMIT 97 166 Feed Shaft Assembly Part Number 106264 NOTES CLEAN MATING SURFACES WITH ALCOHOL AND APPLY TWO PART EPOXY ADHESIVE CLEAN AWAY ANY EXCESS ADHESIVE AFTER ASSEMBLY 167 Feed Shaft Assembly Bill of Materials OMPONENT PART NUMBER OMPONENT DESCRIPTION DRAWING NUMBER Fe _ END TEEDSHArI 600728 106181 SHAFT FEED SUMMIT 97 168 Cable Assembly Power Motors Part Number 106290 e vlad OL 6 L y14 8 2 A 9 S e NAD N S v aaa v IHM L 9 z T nTa 1 NId NId D c IHM L E r aaa Cx s 1d Cc 9 L aga cx 21 NId NOLLVOO 31VIAIXOSddV NI MNINHSLWSH 3 18VO S33IM ALVINSNI lt OL NOLLVINSNI SIM MNIUHS 1 lt H3AO 3019 ASN lt SIHL SV T3
13. 95 Rear Panel Replacement rre c Ero cene ione oen 96 Electronic Subsystems nennen 97 Logic Board Replacement a 97 Resetting the Factory Defaults 98 Keypad Replacement Hate 98 Inetalling a ROM Upgrade a 99 Installing DSP ROM Upgrade etes neant iore 100 Addendum M 28 102 Product Overview LOS Specifications are rier esos ene 104 How The M28 Works ana 104 P 600 M 28 Operation Maintenance and Repair Distinctions 105 Operation DIfTererices ha 105 M 28 Part Number Equivalents eniin aenean enano aa nean 106 LED Code Differences sen to o TED 106 Bill of Materials for Unique M 28 Components 107 Accessory Kit Bill of materials M 28 esses 107 Carriage Assy Bill of Materials M 28 108 Carriage PCB Assembly Bill of Materials M 28 109 PCB Assemb
14. MOTOR SERVO a0 5 107347 MOTOR SMMSHAFT SERVO 24V 5 100317 BEARING BALL 251D 6250D 1900 6 PINYDRIVE 7 1 104736 PULLEY 080X3 8X25T 8 100080 IWSHR 6 LOCKEXTSTAR 9 100111 SPACER 25410 37500 030LG GOL 10 104975 7 1 178 Take up Transmission Assembly 600Ae amp P 600H only Part Number 107233 DETAIL A SEE DETAIL A NOTES gt ALIGN MOTOR AND SUPPORT BLOCK TO ENSURE THE ASSEMBLY DOES NOT KNOCK 179 Take up Transmission Assembly Bill of Materials 600Ae amp P 600H only OMPONENT PART NUMBER OMPONENT DESCRIPTION DRAWING NUMBER s n 106277 SUPPORT BLOCK 600A 105932 LABEL WARNING PINCH HAZARD 104717 NUT 10 32 HEX NYLOCK 4 WSHR 10 FLAT STEEL 103380 WSR 10 FLAT STEEL x 106340 SCREW 1 4 20 375 LG SHCS 105969 600 28 7 SCREW 1 4 20 375 LG SET CUP 8 105 ee 106952 MOTOR GEAR PLANETARY 24V LATCH 9 06 500 U 106274 SCREW 6 32 X 375 LG FHCS 106434 CABLE ASSY TAKE UP EXT LATCH 12 10401 52 i 180 Carriage Assembly 600Ae amp P 600H only Part Number 107367 LIMOVUA JAIS WOLLOS qa18WN3ssv V lIVL3d
15. Cassis Assembly Bill of Materials Cont TRAVERSE SUMMIT 97 1061722 406147 _ BOTTOM COVER SUMMIT 97 i 80 89 U TENNIS 7 26 wo 36 150 Axis Transmission Assembly P 600 only Part Number 105954 gt G NOTES 291 4 1 gt SECURE ALL PULLEY SET SCREWS WITH LOCTITE 222 BE SURE ONE SET SCREW IS AGAINST FLAT ON SHAFT 3 REF REF Se CLEAN MATING SURFACES OF BEARINGS ITEM 6 AND BRACKET ITEM 1 WITH LOCTITE PRIMER N SECURE BEARINGS TO PLATES WITH LOCTITE 609 2 ADD A SMALL4 ADD A AMOUNT OF LOCTITE THREAD LOCKER 290 TO INNER RACE M ID OF BEARINGS ITEM 6 CAUTION ID OF BEARINGS ITEM 6 WIPE OFF ALL EXCESS LOCTITE DO NOT ALLOW ANY TO GET INSIDE BEARING 5 gt INSTALL PULLEY SO THAT THE GAP BETWEEN THE PULLEY FLANGE CAUTI O N AND BRACKET IS 100 010 SENSITIVE ELECTRONIC DEVICES DO NOT SHIP OR STORE NEAR STRONG MOTOR ITEM 5 IS STATIC SENSITIVE COVER MOTOR AND CONNECTOR ELECTROSTATIC ELECTROMAGNETIC WITH 3 X 5 STATIC BAG AND SECURE WITH A RUBBER BAND 151 MAGNETIC OR RADIOACTIVE FIELDS Axis Transmission Assembly Bill of Materials P 600 only DMPONENT PART NUMBER OMPONENT DESCRIPTION BRACKET Y TRANS SUMMIT 97 BELT 080 X
16. amp 3 CORPORATION SERVICE MANUAL APPAREL MARKER SYSTEM P 600 M 28 JOLINE Editon Noies This is the first edition of the P 600 M 28 Service Manual Subsequent updates or revisions will be announced on this page Copyright Notice Copyright c 2000 Ioline Corporation All Rights Reserved Printed in the United States of America PN 107359 REV 0 December 2000 Trademarks Ioline P 600 600H 600A 600Ae M 28 28H 28A 28Ae and StylistAe are trademarks of the Ioline Corporation All registered and unregistered trademarks mentioned in this publication are the sole property of their respective owners Your Comments Are Requested This manual is provided for informational purposes only Ioline has made every effort to make the P 600 M 28 easy to operate maintain and repair The contents are subject to change without notice and the Ioline Corporation assumes no responsibility for any errors that may be contained herein No part of this manual may be copied disseminated or distributed without the express written consent of the Ioline Corporation Ioline Corporation values your comments on our equipment and documentation Please send your corrections or suggestions to Ioline Corporation 14140 NE 200th St Woodinville WA 98072 USA ATTENTION CUSTOMER SERVICE MANAGER Or contact us by phone Phone 425 398 8282 FAX 425 398 8383 Or by Email at techsupport ioline com Contents Chapte
17. ar of Manufacture Joline Model Number Figure 1 2 Ioline Serial Number Indications Glossary 1 BOM Bills of materials for an assembly 2 BOTTOM PAN 4 CHART TAPE 6 FRAME SENSOR 7 GRIT SHAFT Metal housing protecting the underside of the plotter The component that holds the pen and frame sensor It travels along the Y Axis on the traverse assembly Slick white tape located under the pen to cushion and protect the platen and pen if it runs off the paper Roller wheels that push the paper against the grit shaft The electronic eye that reads frame position and adjusts plotting perameters so that the frames are aligned properly A traction roller bar designed to grip and move material under the chart wheels 15 3L INE Chapter I Indtroduction and Overview v Where the user controls simple plotter 8 KEYPAD functions Carriage and media motion is accessible from here during stop mode 9 PLATEN Curved surface that houses the grit shaft and supports the material during plotting Shaft that raises and lowers the chartwheels 10 SQUARE SHAFT when rotated Provides proper traction on the material during operation Located below the traverse assembly 11 TRAVERSE ASSEMBLY 59 that supports and guides the carriage Direction of paper moving over the platen ma Usually associated with the grit shaft 13 Y AXIS Direction of pen motion Usually associated with the carriage 1
18. LA 01934 R 4 D DC BIN HD SOCK 04180 REW 8 104713 SCREW 6 32 375 PHP SEMS 59 100026 SCREW 26 32 5 LG PHP SEMS 258 106176 SCREW 1 4 20 1 LONG THP 860 U e t W H H U 102726 SETSCREW 10 32 75 LG STEEL 6 175 Chassis Assembly 600Ae amp P 600H Bill of Materials Cont NUT 98 32 KEP BE NUT 10 32 HEX NYLOCK 65 103027 JTYRAP 1INXS 3 416 104726 GROMMET STRIP CONTINUOUS 7 64 69 106667 DOUBLE COATED 30 WIDE 70 106756 TRAVERSE NS0028 2 D6 D 600 107180 E00 PHASEZ 5 106857 Y BELTASSY 175 600 106654 LEVER ASSY PINCHWHEEL REAR 13 315 71 w 106928 PCB ASSY 68331 600AE PROG L 106928 pos AsV 68331 PROG 107386 PCB ASSY 68331 V REG PROG 600 16 106758 END PLATE RIGHT A S 600725 17 600 06848 OV BO OM 500 104753 POWER SUPPLY 106816 MOTOR SERVO 24V MOTOR SERVO 2 107347 MOTOR 5MM SHAFT SERVO 24V D 09 CA X OND 00 06 D B 080 X DC n 0 107346 PULLEY 5MM 16TX 080X1 4 43 1070404 5 MEDIA CUTTER GREY 44 A 1070431 feme CUTTING WHHE L io6951 PRING TORSION 5315 45 WIRE 77 10529 _ TOPBARASSY 600 78 107233 TAKE UPASSY R
19. l Shut off the plotter and remove the power and serial cables Remove the right 4 screws and left end covers 4 screws See Removing the End Covers and Dust Cover above To remove the chartwheel lever loosen and remove the allen screw with a 5 32 hex wrench the nylock nuts with a 3 8 nut driver and the set screw in the lever body with a 5 64 hex wrench Then remove the spring Pull the lever off the end plate and set it aside Make sure that the metal spacer under chartwheel lever is retained for re assembly Loosen and remove the allen screw on the left end plate with a 5 32 hex wrench Loosen the set screws in the square shaft support bushings with a 1 16 hex wrench Gently pull the square shaft out of the support brackets toward the left end plate The chart wheels and support bushings will probably fall out If a chart wheel needs to be replaced remove the defective unit and install a new part Insert the old square shaft as outlined below for a new square shaft Gently slide in new square shaft As the shaft is inserted the chart wheels and 90 FOL INE Chapter 5 Repair and Maintenance v support bushings will have to be placed on the shaft Use the assembly diagrams in 11 the Appendix section to get the correct order and orientation Make sure that the support bushings are inserted into the square shaft supports and that the set screw is facing toward the front of the plotter so that they can be tightened after t
20. v wa s ss Cleaning The Platen During use the P 600 will accumulate dust and paper residue on the platen This debris may have to be removed as often as every two weeks Clean the platen by wiping with an isopropyl pharmacy alcohol dampened lint free cloth Commer cially available antistatic spray instead may be used instead of isopropyl alcohol 1 Turn off the P 600 2 Dampen a lint free cloth with isopropyl pharmacy alcohol and gently wipe the platen until any accumulated residue has been removed Antistatic spray may be used instead of isopropyl alcohol Platen Figure 5 2 Cleaning the Platen 76 FOL Chapter 5 Repair and Maintenance v x 7 Cleaning The Support Blocks Dust and paper residue will accumulate on the support blocks Clean the support blocks by wiping them off with an isopropyl pharmacy alcohol dampened lint free cloth 1 Turn off the P 600 2 Remove the feed shaft and the take up shaft 3 Dampen a lint free cloth with isopropyl pharmacy alcohol and gently wipe the support blocks until any accumulated residue has been removed 4 Wipe down the ends of the feed shaft and the take up shaft before reinstalling them Note The remaining preventive maintenance procedures require the removal of the dust cover Use the Removing the Dust Cover procedure in the General Disassembly section that follows Cleaning the Traverse Extrusion and Carriage V Wheels As dust and debris accumulate
21. 600Ae amp P 600H only 182 P 600 Interconnect Diagram 184 JOLINE CORPORATION Chapter 1 Introduction and Overview FOL INE Chapter I Introduction and Overview Chapter One provides an overview of the Service Manual and important background information about the P 600 Marker Plotter The following information is covered here How to Use This Manual Safety Product Overview Limit of Liability Statement Ioline Warranty Policy Serial Number Identification Glossary How To Use This Manual This Service Manual explains most aspects of the Ioline P 600 Marker Plotter includ ing product specifications installation directions and testing and repair procedures Chapter 1 of the manual provides introductory information and general specifica tions Chapter 2 describes the basic setup procedures for the P 600 and the Control Center software This section is intended to supplement the P 600 User s Guide Selected portions of the setup procedure such as paper loading have been added to empha size their importance Chapter 3 familiarizes the user with how the P 600 operates and how to use the software to maximum benefit This section also supplements the P 600 User s Guide Chapter 4 is a troubleshooting and testing guide Chapter 5 provides details for repair and maintenance of the P 600 Illustrations is an index of illustrat
22. M 28 only OMPONENT PART NUMBER COMPONENT DESCRIPTION DRAWING NUMBER ERSTER o 102655 BERRIN FLANGE 250ID 5000D 894 REW HOU R D DIA 6 deg K SPACER CARRIAGE Z AXI 06248 BLOCK BASE CARRIAGE TANIS an PEN CARRIA a LE LEVER CARRIAGE EST EXTEN ION 300 OD oe V WHEEL UPPER toro wr sem EE 109908 SCREW 78 32 5015 PHP SEM p OUND THUMB R PAD PEN CAP 1 4 DIA R EW 10 75 LG BIN HD COCK TOP CARRIAGE asini FRONT CARRIAGE MPR 022D rare DOUSLECORTED S TN REW 6 32 1 5 LG BH REW 6 iosmes screw F637 2505 ETW WD 56 LG PHP 54ID 750D OLG REW 6 TOL B 160 Carriage PCB Assembly Part Number 106236 0 Sl SLIS GSHOLVW SV NIVW3H LSNW L3NSVN 39IOA NOLLOVO lt HLSN31 031312395 OL SAYIM HOSN3S WIL lt dVHAL GN3LXS AINOHS XNIHHSIV3H 5301 89d HO S3HIM 9NLLOVLNOO WO 7104 G II3HS 1 OL NOLLVINSNI HOSN3S 3A33 18 lt S Y Y NOLLO3S NI NMOHS SV dVYAL S33IM HOSN3S 1109 39NVHUV Y PINIHHS 1V3H OV 18 O3MUVWN 1109 GV31 JAIM lt 3A331S 3901 6 GT3IHS LSIML lt 135 V SV H3H13901 LANOVW 109 d33 LNG
23. gt lt gt T oma 2 gt 2 5 2 o FEE i 8 gt 2 g ojl v Pie gt uz 5 un gt x LE LEVER CARRIAGE 106309 PRING EXTENSION 300 OD 049 D ASE CARRIAGE z gt gt 53 255 AlZ z m 2 lt 5 wh zr z 5 9 o mos a z l 3 Ww 9 4 I v T T T r r T 103896 T T r T Q N m 79 r T 100705 103447 1 1 2 3 1 3 3 1 I CREW 10 32 1 75 LG BTN HD SOCKE LOCK TOP CARRIAGE 1 EVER FRONT CARRIAGE _ 1 106217 LEVER REAR CARRIAGE 1 ISPACER SHAFT 1 1 2 5 2 2 5 2 3 1 9 9 m 2 a gt 9 A gt PRING COMPRESSION 300 OD 022D CREW 8 32 375 LG PHP BLK OXI APE DOUBLE COATED 5 IN WIDE CREW 6 32 1 5 LG BHCS CREW 6 32 1 25 LG BHCS CREW 6 32 25 LG BTN HD 104337 101860 PACER 254ID 3750D 030LG GOL CREW 6 32 1 0 LG BHCS 100067 106358 HvV 106307 mio eoo x o 106366 105435 102655 105894 106246 106247 106248 106250 106253 106254 106256 106309 10616 106311 103390 103896 106130 104012 NUT 6 100705 103447 10621
24. lt ONIMVSO SIHL dO T3A371 A38 Lad 138V1 lt SALON xe s e 0 97 G a M 08 141 Cable Assembly Bill of Materials OMPONENT PART NUMBER OMPONENT DESCRIPTION BENEFIT 10025 CONN RSG 3 PIN 1 X 3 FEMALE 0024 ONN RMTNA STN 104343 WIRE 18 GA ST GRN YEL 100242 ONN TERMINAL 187 18 22GA INSU 4 100243 CONN TERMINAL 250 18 22GA INSU WIRE 18 GA ST BRN 142 DRAWING NUMBER Pinch Wheel Assembly P 600 only Part Number 105568 143 NOTES TO READ 8 LB TEXT 1 Pinch Wheel Assembly Bill of Materials P 600 only 144 HOVASIDS SIHL OL HSV33 ID ISOAIANALLINN lt ALA TANOD SI ATHINHSSV NHHA V TVLIA NI NMOHS SV LSNW lt WALI WYO lt 6 SWALI JHL WAHLAOOL TAV XIGWASSV WALI NIOTA LqOdd4nS ANV WALI Wav SI lt WALI NVO lt SALON 600H only Pinch Wheel Assembly 600Ae amp P Part Number 107215 Pinch Wheel Assembly 600Ae amp P 600H only Bill of Materials 146 Chassis Assembly Sheet 1 Part Number 105952 s DETAIL A BEN
25. 5W resistor between 5V red and ground black or brown will also work for test ing R jong 20 W 3 watt 250 ma 200 w 1 2 watt use 2 X 1Kw res for I 24 ma R jus 500 w 1 2 watt use 2 X IK w for I 24 ma R 1 K w 1 2 watt use 2 X 2Kw 1 4 watt resistor for I 24vload All load resistors should be within a 20 tolerance 24 ma 24vload 67 FOL INE Chapter 4 Troubleshooting and Testing Testing the Logic Board Use this procedure if The procedures in Testing the Power Supplies did not resolve the difficulty The carriage was difficult to move during external inspection Tools Required Phillips head screw driver Multimeter capable of reading resistance in Ohms Soldering apparatus and grounding strap both optional Testing the FETs Transistors 1 Turn the power off Discharge any static electricity as described above 2 Find the motor power transistors FETs on the logic board They are located near the power input plugs 73 and J7 and are labeled Q1 Q8 Q10 Q11 If any of FETs have melted smell acrid or burnt or have discolored the logic board they should be replaced Using a multimeter test the resistance between the source S and drain D leads and between the gate G and drain D leads on each of the transistors If any of the resistance measurements are less than 500 kw the part is suspect If any readings are below 1
26. Arrow key Release the Up Arrow key when the carriage starts moving Installing DSP ROM Upgrade Electrostatic discharge preventative measures must be adhered to during all assembly replacement procedures Nuta to follow these directions explicitly may cause permanent damage to the DSP ROM and may cause the plotter to malfunction Leave the DSP ROM in its protective case until it is ready to be installed Shut off the plotter and remove the power cable Perform the procedures in Removing the Bottom Cover for Internal Access above Ensure that the same static potential is achieved by attaching a grounding wrist strap to a non painted surface on the inside of the plotter and then attaching the strip to the technician Carefully remove the old DSP ROM in the U2 socket on the logic board using a small flat tool under one end between the DSP ROM and its socket and then the other end gently rocking the DSP ROM out of its socket Remove the new DSP ROM from its protective case Ensure the pins are straight and evenly spaced Install the new DSP ROM Make sure that the notch in the ROM is pointed the same way as the other components on the logic board In this case the notch must be away from the keypad When inserting the DSP ROM be careful not to bend any of the pins also be sure that all the pins are inserted in the socket 100 FOL Chapter 5 Repair and Maintenance 9 Ensure the DSP ROM is firmly seated
27. CAP 0931D BIK f 327 x PLATE 36 j 106826 SCREW SHOULDER 187 DIA 562516 37 107085 SENSOR 33 L menos isse SPRING T 37000 35 107014 SHAFT CLAMP STOP CARRIAGE 40 107774 WSR 14510 0107 PTFE A 1055 E 107331 CARRIAGE MOLDED CLAMP 175 44 x O72065 PLATE CALIBRATION CARRIAGE I S 1072 8 SCREW 4 40 1 2516 5 O 106528 TAPE DOUBLE COATED 128 W 47 1073322 SCREW 6 32 FLATHEAD SOCKET BLK 48 101866 SCREW 2 56 31216 PHP 14 106530 WSHR 1951b 2450D 03THK 16 SERE 05220015 R 8 10637 SCREW 76 32 LOSTGER Is CREW 4 30 ST PHP SENS 19 106527 SCREW 6 32 31216 FHP 20 105625 NUT 56 32 HEX SMALL PATTERN 27 182 Carriage Assembly Bill of Materials 600Ae amp P 600H only Cont 153 WULSe3LHEKWWORK x TAPEUHMW 43WIDE 32 L mess mre DOUBLE conven 2s 5 DOUBLE COATED SINWIDE 34 P E REW 6 32 625 LG FHP pz REW 36 32 1 0 LG FHP REW 6 32 625 LG FHP 183 P 600 Interconnect Diagram All Models
28. Chapter 2 Setting up the P 600 M 28 Leveling the Stand When the P 600 Marker Plotter is attached to the stand the entire unit must be level The feed shaft take up shaft and platen must all be aligned and parallel to ensure proper operation 1 Make sure the stand is on a flat level surface Place a level on the horizontal surface in the center of either the stand or crossmember See figure 2 8 2 Use an adjustable wrench to loosen the lock nut of one of the leg levelers 3 Turn the leg leveler to raise or lower one end of the leg assembly until it is level 9 x e Na Figure 2 8 Leveling the Legs 22 JOLINE Chapter 2 Setting up the P 600 M 28 x TTT Attach Plotter To The Stand Attaching the P 600 to the stand requires two people Make sure the stand is fully assembled and completely stable before beginning One person should be positioned at each end of the plotter Grasp the front and back bars where they attach to the end plates and gently lift the Plotter onto the stand See figure 2 5 cover the motor the keypad the pen carriage or the middle of the Do not lift the P 600 Marker Plotter by the traverse extrusion the left front and back bars This may permanently damage the plotter Figure 2 5 Place the plotter on the stand make sure the front and back bars fit into the their slots 23 JOLINE Chapter 2 Setting up the P 600 M 28 vv I
29. Options Calibrate Test Help Acceleration lt E Serial Test Computer Port Test Ix Plotter Port Test ws Je Measurement Units r Panel Size J Figure 3 8 Test Menu Serial Test Tests the serial connection between the plotter and the computer See Chapter 4 Communications Problems for further information Computer Port Test Tests the serial port on the computer with a special tool available from Ioline See Chapter 4 Communications Problems for further information Plotter Port Test Tests the serial port on the plotter with a special tool available from Ioline See Chapter 4 Communications Problems for further information 47 FOLI NE Chapter 3 Operation x nm Help Plotter 600 Control Center Fa fal Help g x 10 Figure 3 9 Help Menu Contents Lists the contents of the help screen About Provides revision information about the Ioline Control Center software 48 JOLINE JOLINE v Chapter 4 Troubleshooting and Testing 49 FOL INE Chapter 4 Troubleshooting and Testing This section contains guidelines and testing procedures for resolving most plotting difficulties Some of this information coincides with repair procedures located in Chapter 5 The following primary topics are explained and illustrated Basic Operational Difficulties Mechanical Electrical and Electronic Diagnostic Processes
30. SS RS e ODO Number 2 Phillips magnetic head screwdriver Precision Pull Scale 1 kg x 20 g 36 oz x 1 2 oz 9 64 5 64 5 32 supplied 1 16 and 1 8 Hex Wrenches Socket Wrench Driver 9 Socket Wrench Extension 3 8 Socket or Nut Driver 11 32 Socket 11 32 1 2 and 9 16 Open End Wrenches Torque Driver w in Ibs inch pound Scale Exacto knife Double back tape Needle nose pliers Volt Ohm Meter Static Grounding Strap supplied on request Ioline Power Supply Test Fixture available from Ioline Ioline Serial Port Test Fixture available from Ioline Plastic Cable Ties 74 FOL Chapter 5 Repair and Maintenance v as Cleaning And Regular Maintenance The following preventive maintenance procedures should be performed as required The dust cover may have to be removed before some of these procedures can be accomplished Cleaning The Grit Shaft Note Any dust and paper residue that accumulates on the grit shaft or under the chartwheels can cause the grit shaft to lose contact with the paper which may result in a loss of registration or poor tracking Clean the grit shaft regularly to make sure the P 600 continues to draw accurate marker plots 1 Turn off the P 600 2 Remove the paper from the platen 3 Using the grit shaft cleaning brush remove any accumulated dust and paper resi due from the grit shaft Grit shaft 75 FOL Chapter 5 Repair and Maintenance
31. The rest of the differences relate to the visual differences where the 600H is an entirely new design of plotter There are too many visual differ ences to mention Plotter 600 A Control Center ICE x File Setup Display Options Calibrate Test Help Sensor Options Sensor Enable Frame Gap AN e mils Measurement Units m A Panel Size APIS 4680 in sr e Delays Up ms Down ms Send Temporary vi Settings to grams Plotter Permanent AES grams Figure A 2 Ioline Control Center Screen for the 600H 114 POL INE Addendum 600 H 600H Part Number Equivalents Part numbers for major assemblies that are different in the 600H are listed below The component numbers within each assembly are listed in the bills of material BOM provided in the following section P 600 Part Number M 28 Part Number Top Internal Assembly 105952 106362 Top External Assembly 106175 106350 Carriage Assembly 106235 106365 Logic Board 106238 106368 LED Code Differences There are no LED code differences between the P 600 and the 600H See L E D codes for the P 600 in chapter 4 115 Addendum 600 H Bill of Materials for Unique 600H Components This section contains bills of materials assembly diagrams and circuit schematics for all of the major components that are unique to the 600H The following subsystem details are available 6
32. assures accurate lines and frame matching If the paper is slipping under the chartwheels or is misaligned plotting quality and frame registration are degraded To resolve track ing difficulties try the following suggestions The paper must be installed correctly see Chapter 2 so that it is taut and square Check the take up shaft to see if the roll of completed marker plots exceeds the height of the paper guide flanges If the paper roll diameter is greater than the paper guide flanges the roll will have to be unwound before sending the next plot file If the allen screws that hold the P 600 on the stand legs are over tightened the end plates can be bowed and binding can occur Look for gaps between the end plates and the stand legs Loosen the stand screws and tighten them until just before gap occurs 57 FOL INE Chapter 4 Troubleshooting and Testing Tracking Cont The paper may be sticking to a dirty platen Inspect the platen and refer to the Cleaning section of Chapter 5 for further instructions Make sure both pairs of the outermost chartwheels are at least six inches in from the edge of the paper If the square shaft supports interfere with chartwheel align ment reposition the paper roll near the center of the feed shaft If the inner chartwheels are positioned over the bearings in the grit shaft paper tearing and bunching will occur Check to ensure that this is not happening Check to make sure that the P 600 i
33. at tached at 2 Thread the Y Axis belt through the access slots in the end plate and around the empty pulley in the transmission It is very important to make sure that there are no twists in the belt and that the belt teeth properly engage the pulley Insert one of the metal T connectors into the grooves on the back of the car riage body With a pair of needle nosed pliers grasp the other and slip into the grooves This operation may require a strong pulling force Align the tensioner assembly with the indentations on the end plate and apply light tension to the belt by tightening the allen screw Move the carriage to the far right Adjust the belt tension by tightening the belt tensioner until the spring scale measurement at the center with the belt pulled 1 out from the normal position is 320 20 grams Plug the power cord into the P 600 and into a wall outlet Move the carriage back and forth across the traverse extrusion with the keypad keys while watching the Y Axis belt If there is excessive noise or if the belt is badly misaligned the 11 32 nuts can be loosened and the transmission can be adjusted slightly to achieve proper alignment Cable tie the wire bundles together to ensure that they do not interfere with mov ing parts and end cover replacement Reconnect the serial cable and perform test plots Reassemble the P 600 in the reverse order that it was disassembled See General Disassembly Proced
34. defective motor 1 Xxx e 62 Blinking GREEN Light Emitting Diode LED on the keypad Blinking RED Light Emitting Diode LED on the keypad FOL INE Chapter 4 Troubleshooting and Testing External Inspection Use these procedures if The P 600 did not initialize dark LED fan not running carriage did not move or made small jerking movements at power on after it was unpacked from the box and setup following the procedure outlined in the P 600 User s Guide or in Chap ter 2 The P 600 has been working but did not initialize after being reset by turning the power off then on Jam messages occur without media or other objects obstructing normal operation The carriage is making loud or unusual sounds Tools Multimeter capable of reading AC voltage Phillips head screw driver Allen wrenches 1 16 and 5 64 Nut driver or socket wrench with extension 11 32 Inspect the Outside of the Unit 1 Inspect the unit for damage or obvious signs of mechanical malfunction Measure the voltage at the wall outlet to verify that it is between 100 and 250 Turn the plotter off VAC Clear all media paths and ensure that nothing is obstructing the movement of the front take up roller Move the carriage from side to side by hand If the carriage resists easy move ment then a short is probably present on the logic board or in the motor Follow the disassembly procedures in Chapter 5 Gen
35. determine the neces sary frame gap use the following procedure Turn off the frame sensor refer to the Sensor Enable description above Send two consecutive marker plots to the P 600 Measure the frame separation or overlap For a separation enter the measurement as a positive number in the frame gap field For overlapping enter the measurement as a negative number in the frame gap field 5 With the plotter in Start mode green LED send the settings to the plotter with the Temporary or Permanent screen options BR U Ne 42 FOLI NE Chapter 3 Operation HPGL Default Your P 600 plotter supports three industry standard plotter languages HPGL 7475 HPGL 7596 and DMPL Your P 600 will automatically switch between DMPL and HPGL The plotter cannot distinguish between HPGL 7475 and HPGL 7596 so the version number must be set in Control Center before a plot file is sent HPGL stands for Hewlett Packard Graphics Language and DMPL stand for Digital Microprocessor Plotter Language HPGL 7475 is the default plotting language and is most common in the industry It has a lower left origin which means the P 600 be gins plotting from the lower left keypad side and measures everything from this location HPGL 7596 uses a center origin and is much less common A center origin means the P 600 begins plotting from the center of the panel and measures every thing from this location Send Settings to P 600 When changes are made in
36. foam tape on the channel bottom Connect the ribbon cable to the carriage by inserting the cable into the rectangu lar connector until it stops the locking collar must be pulled out Make sure that the exposed metal leads face down toward the bottom of the channel Slide the locking collar toward the socket until it snaps shut The collar is fragile so be very careful when closing it Plug the power cord into the P 600 and into a wall outlet Move the carriage back and forth with the keypad keys while watching the ribbon cable in the track If the cable snags in the channel check for proper alignment where the cable is stuck to the foam tape Reconnect the serial cable and perform test plots If the carriage does not func tion check that the cable is oriented correctly in the rectangular connectors Re assemble the P 600 in the reverse order that it was disassembled See General Disassembly Procedures above If problems arise contact Ioline customer service Frame Sensor Adjustment The frame sensor does not typically require any adjustment once it is set at the fac tory If the sensor does not read the mark or the sensor looks to be too high or too low then slight adjustment may be required 1 The bottom of the wand should be approximately 2 8mm 017 from the bot tom of the sensor to the paper This is the thickness of two pennies If this mea sure 83 FOL Chapter 5 Repair and Maintenance gt ment is
37. nothing happens 50 to match the setting of the apparel design software or lower the apparel design software s frame size setting if it is larger than 46 Make sure the serial ports on the computer and the P 600 are configured properly Press the Start Stop key to put the P 600 in Start mode green LED on Error Messages Chapter 4 Troubleshooting and Testing Error messages that are specific to the P 600 are divided into two categories software errors and LED codes Software errors present themselves on the computer screen and usually indicate a communication problem LED codes are visible below the keypad on the front panel of the P 600 and can be green red or a combination of both The LED code table in this section is for finding the cause of obvious external or communication problems Later in the chapter a more comprehensive LED index is available for complex mechanical and electronic difficulties Other errors can occur with the operating system or the plotting software and should be resolved with the software vendor Software Errors Could not open COMx Green LED Not ON or Plotter Not Connected to COMx Setup Com Port and Check Plotter Present The plotter you have selected is not the same as that connected to your computer This version of Control Center needs a ROM version of X X or later The Control Center couldn t open the COM port for use A serial port that is not ava
38. of the end plates for lifting and moving the plotter Tools Required Phillips head screw driver 5 32 allen wrench supplied Two people capable of lifting 100 pounds each Grounding strap optional Perform the Following Disassembly 1 Remove the two allen head screws 5 32 allen wrench holding the rear of the P 600 on the stand 80 FOL Chapter 5 Repair and Maintenance v C 2 Lift the plotter forward rotating it from the back until it rests on the front resting screws Remove the six phillips screws that retain the bottom cover including the ones in the center of the covers Open the bottom cover a few centimeters and carefully unplug the fans from the logic board Do not touch any of the logic components Remove the bottom cover Y Axis Subsystem CARRIAGE Carriage Replacement 1 10 11 Shut off the plotter and remove the power and serial cables Remove the right 4 screws and left 4 screws end covers and dust cover 1 screw on each side See Removing the End Covers and Dust Cover above Remove the carriage cover by loosening the three HEX head screws There are two on the left side and one on the right side Once the screws are loose pull the cover towards you Loosen the allen screw on the belt tensioner left side of the machine until the screw is not exposed Do not remove the screw With a pair of needle nosed pliers grasp one of the metal T connectors o
39. on the traverse extrusion it will have to be wiped off with an isopropyl pharmacy alcohol dampened lint free cloth 1 Remove the dust cover if it is still installed refer to Removing The Dust Cover procedure above 2 Dampena lint free cloth with isopropyl pharmacy alcohol and gently wipe the top and bottom rails of the traverse extrusion until any accumulated dust and debris has been removed 3 Carefully lift the ribbon cable from the groove Do not unplug the ribbon cable Gently wipe the ribbon cable groove and remove any accumulated dust and debris 4 Clean the carriage v wheels by holding an isopropyl alcohol dampened lint free cloth against a v wheel while gently sliding the carriage back and forth Repeat this procedure for each of the v wheels 5 Reinstall the dust cover 77 FOL Chapter 5 Repair and Maintenance gt Figure 5 3 Cleaning the Traverse Extrusion and Carriage V Wheels General Disassembly Procedures The following procedures describe the basic disassembly of the P 600 to gain access to the carriage logic power and drive components Please pay close attention to the Warning and Caution notes Removing the End Covers and Dust Cover 1 Turn off the P 600 and unplug the serial and power cables 2 If the take up shaft is loaded on the support blocks remove them and set them aside Remove the two black phillips head screws and the two silver phillips head screws on the bottom
40. test Normal communications will be re stored when the power is turned back on If this test is successful the next two tests are not necessary Testing the P 600 Plotter Port Run this test from the P 600 Control Center The diagnostic module WILL be needed to run this test l Connect the diagnostic module directly to the P 600 serial port 2 Turn on the P 600 while holding down the Sensor Test key on the keypad Hold down the Sensor Test key until the P 600 beeps and LEDs flash three times Press any arrow key to transmit and receive characters Verify the P 600 beeps and the green LED flashes Turn off the P 600 at the end of the test Normal communications will be restored when the power is turned back on Testing the Computer Port Run this test from the P 600 Control Center The diagnostic module WILL be needed to run this test 54 J Chapter 4 Troubleshooting and Testing 1 Connect the diagnostic module directly to the serial port on the computer 2 From the P 600 Control Center select Test 3 Select Computer Port Test 4 Verify that the COM port displayed is the correct one If it is not press the ESC key twice and select the correct COM port from the Setup COM Port Setup menu If any key other than ESC is pressed the computer serial test screen will be displayed 5 Press any key on the computer keyboard and verify that the character transmitted is the same as the characte
41. the Diagnostic Record at the end of the chapter T Computer Communication Software Problem Computer Software Resolution Resolution Begin Recording Diagnostic Information p 60 Logic Problem Examine the External Components p 52 Disassemble Check Cabling and Connections p 54 Examine Power Supplies p 55 Examine Logic Board p 57 Examine Motors p 58 Disassemble Chapter 5 Replace RS 232 p 58 Power On Test Power On Test Power On Test Contact loline Customer Support If Required Figure 4 1 Mechanical Electrical and Electronic Diagnostic Flow Chart 61 Chapter 4 Troubleshooting and Testing Expanded LED Codes LED Sequence Probable Causes P 600 not plugged in Cycling power supply due to Incorrect power supply sequence or defective power supply Defective transistor s on logic board Short or other problem with motor Defective power supply Defective transistor s on logic board Defective keypad Dark or erratic flashing LED Carriage Y axis or roll feed jam due to Media or mechanical jam Transmission failure Defective power supply Defective transistor s on logic board Defective motor encoder Short or other problem with motor 3 Second pause then repeat Grit Shaft X axis jam due to Media or mechanical jam Defective tra
42. the other end of the crossmember to the second stand leg Note the position of the crossmember and the screws in Figure 2 3 Stand Leg Medium length screw a Long Rx Crossmember Figure 2 3 Attaching the Bottom Crossmember to the other Stand Leg 19 AOLINE Chapter 2 Setting up the P 600 M 28 Installing the top crossmember To attach the top crossmember have the second person hold one end while screwing the crossmember to the leg Use 4 of the medium length screws See figure 2 4 lt Medium length screws 2 Sy ey l gt 4 Crossmember Medium length screws 2 Gj Figure 2 4 Attaching the Top Crossmember to the Stand Legs 20 AOLINE Chapter 2 Setting up the P 600 M 28 Attaching the static Dissipaters A large amount of static can build up from paper feeding off a large roll The machines ability to track correctly can be greatly affected by static build up Not to mention electronic parts DO NOT LIKE STATIC To help keep this problem to a minimum using the static dissipaters is recommended Attach the two static dissipaters to the stand by placing the hooks through the holes in the stand legs Refer to Figure 2 7 the P 600 is not shown lt Garland static dissipators Figure 2 7 Attaching the Static Dissipaters 21 JOLINE
43. the screen dialog boxes the plotter logic has to be updated via the serial link Two options exist to make the changes take effect Sending the settings with the Temporary button will replace the current plotter parameters until the power is turned off or new settings are sent from the control center If the Perma nent button is used to send the settings they remain in the plotter even after the power is turned off until they are changed from the Control Center Force The Force settings control the maximum and minimum pen force that can be applied with the Force knob on the keypad You can select a force setting range from 1 to 300 grams The factory defaults are 50 grams minimum and 200 grams maximum A narrow range of values allows fine adjustments to the pen force setting A wide range of values allows coarse adjustments to the pen force Panel Size The P 600 works with the apparel design software to create long markers by dividing them into smaller more manageable frames The P 600 s default maximum frame size is 46 inches long by 72 inches wide 43 FOL INE Chapter 3 Operation nm 191 Scale By default the P 600 will produce a marker at 100 the size of the specified in the plot file no scaling Ifthe X and Y scale is set to 50 the Summit will produce a marker that is half the specified size You can set either or both the X and Y scaling of the plot from 1 to 999 Menu Bar Items The menu items along the top of the s
44. to be used to assure frame to frame accuracy Every other system on the plotter is the same as that on the P 600 with respect to maintenance and repair The following information and tables are a complete summary of the variation in operation part numbers and trouble shooting procedures Operation Differences The primary operating difference is in the Ioline Control Center software The Frame Gap settings will always be adjustable and the Sensor Enable option will be unavailable Figure A 2 Ioline Control Center Screen for the M 28 105 Addendum M 28 M 28 Part Number Equivalents Part numbers for major assemblies that are different in the M 28 and P 600 are listed below The component numbers within each assembly are listed in the bills of mate rial BOM provided in the following section LED Code Differences LED Sequence Probable Causes Solution P 600 ONLY This LED is only present on the P Continuous Not Avallabl 600 and has to do with the frame Oksava sensor and registration Remove the completed markers Reload the paper Press start point and continue plotting 3 Second pause then M 28 ONLY repeat The maximum marker length for the continuous beeping M 28 9 1 meters has been exceeded 106 SLINE Addendum M28 ww Bill of Materials for Unique M 28 Components This section contains bills of materials BOMs assembly diagrams and ci
45. w there is an internal short and a definite FET failure If the FETs are defective and the logic board is revision 0 the entire board should be replaced with the newest version If the logic board is revision 1 the defective FETs can be replaced with exact duplicates The transistors at locations Q1 Q3 Q5 Q7 and Q10 are p channel FETs and can be replaced with Ioline part number 105858 The transistors Q2 Q4 Q6 Q8 and Q11 are n channel FETs and require Ioline part number 102807 for replacement If replacing a FET is not possible remove and replace the entire logic board Before the plotter is re tested with a new logic board and or new transistors make sure that any media or mechanical jams have been cleared so that the FETs are not damaged in the same manner that might have caused their original failure Also ensure that the ROM version is 1 05 or greater 68 FOL INE Chapter 4 Troubleshooting and Testing C HhH hme Testing and Replacing the Other Logic Components Including the RS 232 1 If all of the other diagnostic procedures have been exhausted and the FETs are testing good change the logic board Communications problems may indicate that the RS 232 chip may need to be replaced This socketed component is lo cated at U25 No other logic board components can be field tested If these procedures are not effective in solving the problem read Testing the Motors for the next step in the diagnostic process
46. 0 Marker Plotter 2 If the chartwheels are lowered raise them by lifting the chartwheel lever on the keypad side of the machine 3 Pull some paper off the paper roll and feed it over the back bar the platen and under the raised chartwheels Make sure the paper is even taut and square as it is pulled off the paper roll Attaching Paper to the Take Up Shaft Be sure the paper goes over the front and back bars of the machine and around the underside of the take up shaft See figure 2 13 Pinch Wheels Front Bar Take up shaft Paper path Paper feed roll Figure 2 13 Paper path through the P 600 side view 29 JOLINE Chapter 2 Setting up the P 600 M 28 Tape here first Takeup shaft Figure 2 14 Taping the Paper to the Take Up Shaft The paper must be taut and square from the feed shaft paper roll over the platen to the take up shaft Press the roll feed key down arrow to pull some paper off the feed roll until the paper wraps around the take up shaft 2 or 3 times 30 Chapter 2 Setting up the P 600 M 28 Positioning Chartwheels There are six chartwheels mounted on the square chartwheel shaft Position both outermost pairs of chartwheels six inches 15 cm in from the outer edges of the Pees 72 PAPER 63 PAPER 36 PAPER Figure 2 15
47. 00H Chassis Internal Assembly 600H Chassis External Assembly and Accessory Kit Carriage Assembly and Logic Main Logic Board Assembly Accessory Kit Bill of materials P 600H 106287 P 600H Accessory Kit Ioline part Description Number of Number Parts used 104357 104366 105997 106394 106760 104444 105968 106185 107032 106269 100059 103764 104473 106283 USER GUIDE 600 28 HUB FEED ASSY r r r 1 T y T y DISK CONTROL CENTER 32 BIT 3 5 STATIC GARLAND 77 56 IN ORM ADDENDUM UG 600A 28A SCREW 1 4 20 1 00 LG BTN HD SOCK SCREW 1 4 20 2 LG SCREW 1 4 20 625 LG BTN HD SOCK BOX SHIPPING 9 X 7 X 5 FORM WARRANTY PACKING LIST ACC KIT 600 28 UNWINDING B 500 B T CABLE SERIAL 9F 25M PIN 7 EEE GE S 1 C 1 GE 42 2 2 PEN PILOT V BALL i O BELT UNWINDING 600 28 O C 1 EEE 7 1 4 2 6 1 1 FC 1 Carriage Assembly Bill of Materials P 600H 107020 P 600H Carriage Assembl Number Parts used 106863 BASE CARRIAGE 1 5 600 28 7 1 106864 BRACKET SENSOR CARRIAGE I S 6000 1 10644 BLOCK SPACER FLEXURE 1 106622 JAW CARRIAGE SCOS 1 107209 JAW CARRIAGE MOLDED CLAMP 698 1 10623 PEN KNIFE CARRIAGE 1 1067722 MOLDED 1 106455
48. 1 4 X 110T PULLEY 16T X 080 X 1 4 PULLEY 60T X 080 X 1 4 E a ed 3042 2771 MOTOR SERVO LAY 1 MENGE Aras PRENNE 1 00317 L 7 PACER 2541D 3750D 030LG GOL_ 10 REW 6 32 375 LG BIN HD al 152 m Keypad Assembly P 600 amp M 28 only Part Number 106170 43 Xc 439 x 2 E IC 7 E MANOS LAS GNOOAS JHL ASIMMOOTOYS LNNOD ATINA GANYNL SI H31L3 AOLLN3LOd AHL NMOA LHOIVALS SI MYYN AHL IVH L OS LAVHS NO 1 14 LSNIVOV 5 LAS 15414 N3 LH9IL ALILOOT SMAUIS LAS AYNOAS lt WALI 340 V88 JO s3904 HOLIMS 3NVHSINHIN dO S3903 33HHL NOI TV lt WALI HOLIMS INVYANEN SNIATddV 330438 1OHOO IV SOWSAYNS SIH L NV31O lt SALON 153 Keypad Assembly Bill of Materials P 600 amp M 28 only E ME SENI 104014 KNOB BLACK 35 SHAFT KNOB BLACK 6X 770D 25SHAFT 2 05428 MEMBRANE SWITCH 2200 i 106182 MEMBRANE SWITCH SUMMIT 97 SCREW 4 40 375 S 0 105427 PCB ASSY KEYPAD 2200 rs 154 Rear a an Part Number Rear Panel Assembly Bill of Materials OMPONENT PART DESCRIPTION DRAWIN
49. 107020 CARRIAGE ASSY I S 600 METAL 7 ADD A A V DN DR NI 500 7 DUU 106867 REAR 1 0 PANEL ASSY 1 5 600 107046 REAR 1 0 PANEL ASSY 600H 28H 106817 TRANS ASSY Y DRIVE 24V rds IRANS Ree T DRIVE EATE DIET SOON 22242 CHANNEL RIGHT FRONT SUMMIT 97 105964 106853 COVER DRIVESHAFT 23 6516 28 107411 SPACER DRIVESHAFT 23 6116 28 106958 SPACER DRIVESHAFT PL 6 0516 eio eic 6 CO 00 N N e g D 6 ve g YDAD A V A 7 7 T A DRIV LA DU 500 BRA DOW IJPDI Y 500 T T 7 7 7 T L HT P i pow 1 400 DA D DRIV LEA OVER DRIV COVER DRIVESHAFT OZ EG 107410 SPACER DRIVESHAFT PL 6 75 LG 106628 SPACER BEARING DRIVESHAFT LONG 106854 SPACER BEARING DRIVESHAFT 61 LG N LJ 9 4 MOTOR AR ARY LA H MOTOR AV LA Li AR D AN ADY 106300 PLATE ADJ PLANETARY MOTOR 37 106290 CABLE ASSY TU amp POWER INT 106434 CABLE ASSY TAKE UP EXT LATCH N ADAP V 105538 89121 fe pou mU NEN l A UMM 106967 STRIP MEDIA CUTTER 1 5 600 28 106081 LABEL WARNING HAZARD VOLTAGE 106649 LABEL DRIVE AREA RAD REN GAP DAT PEN AD A DIA D LA D Y 59 OD BUSHIN NYLON D 620D STANDOFF M F 10 32 1 125LG S97 WSHR 8 32 190 ID 416 OD 080THK 106186 WASHER 265 ID 625 OD 7 P WSHR D DOOD 06261
50. 6 JOLINE v Chapter 2 Setting up the P 600 M 28 JOLINE Chapter 2 Setting up the P 600 M 28 v This chapter outlines the procedures required to properly setup and configure the P 600 plotter and the control center software The following subsystems and procedures are explained and illustrated Assembling The P 600 Loading Paper Software Installation Assembling The P 600 The first step in setting up the Machine is to remove the plotter from the box and place it on a flat surface until it is ready to be attached to the stand Check the pack ing list carefully to make sure that all of the accessories and parts are present Save all of the packing materials and the box so that the Machine can be returned to Ioline for service if necessary Assembling The Stand Assembling the stand requires two people One person should hold the parts in place while the other person uses the supplied hex wrench and screws to fasten everything together You must assemble the stand on a flat level surface 1 Locate the two crossmembers and each stand leg 2 Attach the bottom crossmember to the stand leg As shown in Fig 2 2 Use one medium length screw and one long screw for the bottom crossmember Crossmember Stand Leg Medium Length screw 4 Long screw Figure 2 2 Attaching the Bottom Crossmember to a Stand Leg 18 JOLINE Chapter 2 Setting up the P 600 M 28 Repeat procedure 2 to attach
51. 8 LED Code Differences There is one LED code difference between the P 600 and the 600Ae If you should see a blinking Yellow light on the keypad of the plotter call customer service ASAP For a list of all other L E D codes see L E D codes for the P 600 in chapter 4 124 SLINE Addendum 600 ww Bill of Materials for Unique 600Ae Components This section contains bills of materials assembly diagrams and circuit schematics for all of the major components that are unique to the 600Ae The following subsystem details are available 600Ae Chassis Internal Assembly 600Ae Chassis External Assembly and Accessory Kit Carriage Assembly and Logic Main Logic Board Assembly Accessory Kit 600Ae 106874 600Ae Accessory kit Ioline part Description Number of Number Parts used 106885 UIDE QUICK START AE PLOTTERS 106884 D ROM INSTALL AE PLOTTERS 104366 RENCH ALLEN 156 TEE ABLE PARALLEL 10 FT IEEE 1284B 104921 CABLE RS 232 15 FT __ 100150 CUTTER PAPER 104352 BRUSH GRIT SHAFT PEN PRESSURIZED BALL POINT PEN PILOT V BALL HUB FEED ASSY BELT UNWINDING 600 28 104362 STATIC GARLAND 77 56 IN 105118 SERIAL 9F 25M PIN USER GUIDE 601 SOFTWARE 101934 SCREW 1 4 20 1 00 LG BTN HD SOCK SCREW 1 4 20 2 LG SCREW 1 4 20 625 LG BTN HD SOCK 103764 BOX SHIPPING 9 X 7 X 5 106966 ACKING LIST ACCY KIT 600AE 28AE BRUSH GRIT SHAFT
52. 81 SCREW 8 32 375FHP BLACK 6 106018 LABELFRONT P6OO0 1 106243 COVERASSY TAKEUP P600 7 1 106229 COVER CARRIAGE P28 1 105065 _ SCREW 6 32 25LG BTNHD 3 _ 105969 600 28 1 106334 5 1 4 20 37516 SET 1 1063398 STRAINRELIEF PLASTIC 30 35 ID 1 100133 8 32 KEP 4 106355 GUIDE UNPACKING THE 600 28 1 110 JOLINE Addendum P 600H FOL INE Addendum 600 H This addendum covers the major maintenance and repair differences between the 600H and the P 600 The following information is covered here Product Overview 600H Operation Maintenance and Repair Distinctions Technical Drawings and BOMs for Unique 600H Components Product Overview The Ioline 600H Marker Plotter can handle any large format plotting operation up to 72 inches 1 8 meters wide and 600 yards meters long Three industry standard plotter languages HPGL 7475 HPGL 7596 and DMPL are supported It is most commonly used in conjunction with apparel design software for plotting large marker plot patterns The 600H also comes with Control Center software that allows adjust ment of a variety of system settings from the computer Figure A 1 Ioline 600H Marker Plotter 112 POL INE Addendum 600 H Specifications Plotting Acceleration max Maximum Frame Size Length 1 17 m 46 0 in Wid
53. 9 106216 106217 103825 1062200 100067 10638 106305 106307 105065 104337 101860 10011 108 SLINE Addendum M28 ww Carriage PCB Assembly Bill of Materials M 28 Carriage PCB M 28 Ioline Part Part Description 1 Partsused 106385 PCB CARRIAGE 102624 CONN FLEX CABLE 12 PIN R ANGLE 103726 TYRAP 1 IN X 3 IN BLACK 104646 VOICE COIL 101369 HEATSHRINK 125 DIA BLK PCB Assembly Bill of Materials M 28 106368 PCB Assembly M 28 Ioline Part Part Description 1 Parts used 106360 IC ROM P28 PROG 104527 IC ROM UNPROG 27020 1 _ 105510 FPGA PROG 1010B 2200 910 1 105419 ASSY LOGIC 2200 109 lt Addendum M 28 x FGI Level Bill of Materials M 28 106350 FGI M 28 Ioline Part parts used 106258 100278 105167 106174 CROSSMEMBER 600 28 1 106264 SHAFTASSY FEED 600 1 106263 SHAFT ASSY TAKEUP 600 1 _ 106244 DANCERBARASSY FRONTP600 1 106245 DANCERBARASSY REARPP600 1 1035660 LABEL SHIPPING CARTON IOLINE 22 2 106284 2 BOX SHIP 600 28 1 106285 PACKINGLIST 600 28 7 1 106286 LABEL CARTON END APPAREL 2 106287 ACCESSORYKIT 600 28 1 105762 LABEL REARPANEL FCC CE 1 106241 WSHR 8 32 190 1D 4160D 080THK 8 104926 STANDOFF 8 32 5 2556 2 104725 STANDOFF 8 32 1 75LG 2 1015
54. 9 Basic Operational Difficulties 50 Common zu u ioa Fl erp aea nm HE E 50 Error Messages nn P En 51 u uuu ua um p ag bib 51 ESE DEC OCS ee ep tet ta dee oes eit acte 52 No Power When The P 600 is Turned 1 1 11 53 P 600 Won t Respond to the Computer 53 Communications Problems 53 Serial Gommiunicatlon Test 2 555 eios aeu a ee 54 Testing the P0600 54 Testing Ihe Computer Port oue lin u 54 Plotting Quality Problem s 55 Regular or intermittent tearing a 56 Paper Tearing Under the Chartwheels 56 Loss of Registration Between 1101 57 eem 57 60 58 Paper Alignment Proced re ic nee 59 Mechanical Electrical and Electronic Diagnostic Process 61 ExDalided LED COdSS 2 einer 62 External Inspection anas a Ka ERR arg E ER 63 Required Tools 63 Inspect the Outside of the Unit
55. A31 A33 ON L3Vd 3IAVS T38V1 lt 4 SIHONI SLSIML Z OL SL SHHIM LSIML lt TIVL3G SALON V d lt lt D Re OSE 0 01 44S aT v aa gas F TVLAG Aas 7 7 De b Mes s Heg Ds Ds s ds Se Iy Ju Ju Ju J Ju fbr flu fbr JJ MV m T TI TI TI TI u TIVL3G qas 9 7 Oo Cp OU 0 837 05 lt 169 Cable Assembly Bill of Materials L conn IDPINIOCKINGEMMEE 3104345 WIRETSGASTWAT 2 10434 WIREISGASTRD 3 104339 WIRES GASTBIR 4 1043733 24 GA 4 COND SHED DRN j 5 100246 CONN TERMINAL 110 18 22GA INSU 6 105457 CONN HSG 1X6 156 SP FEMALE 7 EEE r 102974 HEAT SHRINK DTA LEAR 100284 CONN CRIMP INSERT 16 74 GA 156 11 1 101370 HEATSHRINK 250 DIA BLK x 107183 HEATSHRINK3 32TNCH f 170 Take up Transmission Assembly Part Number 106538 DETAIL A SEE DETAIL A NOTES gt ALIGN MOTOR AN
56. ARRIR E 90 40D U WA D D 102027 S ur 49 ou LG PHP CLAMP SENSOR 106 17 LAMP SENSOR P600 SPACER SENSOR CLAMP SCREW 8 32 50 LG PHP SEMS COVER CARRIAGE P600 SCREW 26 52 375 LG BINHD WSHR 25 ID 375 OD 03 THK WSHR 2 FLAT STEEL NU 710 ROUND NUT 6 32 KEP 100705 PAD PEN CAP 1 4 DIA BLOCK TOP CARRIAGE 2 7 106216 LEVER FRONT CARRIAGE 106217 LEVER REAR CARRIAGE ORATE E SPRING COMPRESSION 300 OD 022D 100067 SCREW 8 2 375 L BLK OXI SCREW 96 32 15 LG BHCS 106307 SCREW 46 22 125 LG BHCS 106312 NUT 6 32 HEX 3 7 a C 10929301 15 104012 10219 1055 7 2 SCREW 74 40 375 PHP SEMS OZ Aa bani ns URL a e 106320 SCREW 6 7516 SLF TAP 7 106371 96321018 BHS 59 158 NMOHS SV S3MIM 1109 LN3ISO lt S A ALILOOT 341935 ASV NI 31OH S3 LN3O 6L WALI asva J VIXYY9 OL ONIHOVLLY 390439 SLYVd GALVOIGNI 31TgW3SSV lt 2 AAA 3111901 386238S lt L 159 MAYOS dO SIHL 9527 N 3111901 AlddY LON 33s oS Nos NS E Carriage Assembly M 28 only Part Number 106365 Carriage Assembly Bill of Materials
57. Ae have two wheels for better tracking The pinch wheel lever is located on the back of the plotter instead of the front and finally the 600Ae allows you to adjust the frame gap right on the key pad with the Set Gap button This button allows you to close the gap between frames while you re plotting For a more detailed explanation of these fuctions see the 600Ae user guide available on our web site at www ioline com The rest of the differences relate to the visual differences where the 600Ae is an entirely new design of plotter There are too many visual differences to mention E Plotter 600 Ae Control Center CE XI File Setup Display Options Calibrate Test Help Sensor Options Check Every Frame Measurement Units Every 4th Frame Disable Sensor Frame Gap P mils Panel Size X Axis in Y Axis 72 0 in SENG Temporary Settings to grams Plotter Permanent ME grams Figure A 2 Ioline Control Center Screen for the 600Ae 123 JOLINE Addendum 600Ae 600Ae Part Number Equivalents Part numbers for major assemblies that are different in the 600Ae are listed below The component numbers within each assembly are listed in the bills of material BOM provided in the following section P 600 Part Number M 28 Part Number Top Internal Assembly 105952 106362 Top External Assembly 106175 106350 Carriage Assembly 106235 106365 Logic Board 106238 10636
58. Contacting Ioline Customer Service Basic Operational Difficulties If the system isn t working correctly it is very important to determine which compo nent is causing the problem Likely difficulties may involve the computer the power cord or serial cable the apparel plot design software or the P 600 If the problem appears to be with the computer or apparel design software consult the appropriate documentation or an Ioline dealer first The information in the following sections has been organized to eliminate minor problems with easy solutions first If these remedies do not fix the problem more complex and invasive resolutions are provided If a solution cannot be found in this manual or by changing the software and computer setup fill out the Diagnostic Record at the end of this chapter and contact Ioline customer service Common Problems A marker plot doesn t The starting point has not Press the Start Point Key with start at the correct the pen positioned where the plot point on the paper should start The P 600 does not complete the marker Increase the P 600 s frame size setting from the Control Center The apparel design software frame size is set plot and leaves large gap between frames larger than the P 600 s frame size setting the factory set and maximum frame size is 46 inches A communication problem has occurred or the P 600 is in Stop Red LED mode If a marker plot file has been sent but
59. D SUPPORT BLOCK TO ENSURE THE ASSEMBLY DOES NOT KNOCK 171 Take up Transmission Assembly Bill of Materials DRAW dris mida en TAKE e EXTERNAL COVER ASSY TARE UP PRU 1059 STRAIN RELIEF PLASTIC 30 35 ID 15973 106274 SCREW F6 37X 3 5 LG FHCS OE As 201 04 NU NYLOCK p AUS M e 103389 WSHR 10 FLAT STEEL REW 1 4 20 375 LG SHCS NUT 1 4 20 HEX NYLO 172 Chassis Assembly 600Ae amp P 600H only Sheet 1 9 Part Number 106852 Oe 2 H 88 8 g2 aw Oo a 2 173 A A AAA Chassis Assembly 600Ae amp P 600H only Sheet 2 Part Number 106852 3 W130 a18v9 8 8 MIIA T3NVd a18 vo 3182 2 e a18v9 TaNWd anavo 174 YOLOW X 1 43 anavo 555 54 YOLOW A Chassis Assembly 600Ae amp P 600H Bill of Materials COMPONENT DESCRIPTION DRAWING NUMBER wai DON D D ON 106868 PINCH WHEEL ASSY 12 LB PLASTIC 107215 PINCHWHEEL ASSY 6 LB 1 1 PLASTIC
60. D VOICE COIL SIDE ONLY 30 30 1030 Chassis Assembly Sheet 2 Part Number 105952 FAN CABLE L D VIEW B B MOTOR POWER A C CABLE FLEX CABLE FAN CABLE FLEX CABLE FROM KEYPAD FLEX CABLE FROM REAR PANEL 148 A C CABLE FROM REAR PANEL X MOTOR FLEX CABLE FROM REAR PANEL ROLL FEED ENCODER CABLE TRANSMISSION WIRES VIEW D D Y MOTOR VIEW C C ENCODER CABLE Chassis Assembly Bill of Materials P 600 only DRAWTN ONER A Y 600 REAR PANEL ASSY 600 lL AB I i uf 2 FAN ADAPT SUMMIT 97 SQUARE SHAFT A m lt g gt lt a e N Y DUND v O b b O DR POW POWER N RON JMM RON UMM O O Gv b POUU IMM 106753 JBRACKET i HINGE SUMMIT 97 CO C ST 97 105587 STANDOFF M F 32 3 28316 I 185 104203 5 10 312 50055 16 106239 STANDOFF M F 10 32 1 12516 597 38 100059 SCREW 1 4 20 62516 BTNHD SOCK 41 lt LC x 100031 SCREW 6 32 187 16 SHSETCUPPO 13 De
61. Follow the instructions that appear on the screen When the Windows installation is complete a Control Center Setup screen similar to figure 2 18 will appear N O 34 FOLI NE Chapter 2 Setting up the P 600 M 28 3 Control Center Setup loline Plotter 600 loline Plotter 28 x Figure 2 18 The Control Center Setup Screen 8 Select P 600 and the communication port that will be used to send plot files to the plotter COM2 is the default communication port selection 9 Select Plotter Present then Click on 10 You will see a P 600 Control Center screen similar to figure 2 19 Plotter 600 Control Center Figure 2 19 The Control Center Main Screen 35 JOLINE Chapter 2 Setting up the P 600 M 28 Windows 95 98 installation 1 Place the disk in drive A or B 2 Click on the Start button then click on Run 3 Select the Browse button and switch to the drive where the disk is installed 4 Click on Setup exe and click OK 5 In the Run box click The install wizard will now start the installation process Follow the prompts until the installation of the Ioline Control center 1s finished Macintosh Installation m Turn on the computer and the P 600 plotter Insert the Macintosh version of the Control Center diskette into the disk drive of the computer Drag the entire contents of the diskette to
62. IGHT S0UAE 8i 60 176 Axis Transmission Assembly 600Ae amp P 600H only Part Number 106974 REF I TAA T po HII CJ NOTES 291 j T gt SECURE ALL PULLEY SET SCREWS WITH LOCTITE 222 BE SURE ONE SET SCREW IS AGAINST FLAT ON SHAFT p 37 CLEAN MATING SURFACES OF BEARINGS ITEM 6 AND BRACKET ITEM 1 WITH gt LOCTITE PRIMER N SECURE BEARINGS TO PLATES WITH LOCTITE 609 2 ADD A SMALL4 ADD A AMOUNT OF LOCTITE THREAD LOCKER 290 TO INNER RACE ID OF BEARINGS ITEM 6 CAUTION ID OF BEARINGS ITEM 6 WIPE OFF ALL EXCESS LOCTITE DO NOT ALLOW ANY TO GET INSIDE BEARING CAUTION 5 gt INSTALL PULLEY SO THAT THE GAP BETWEEN THE PULLEY FLANGE AND BRACKET IS 100 010 SENSITIVE ELECTRONIC DEVICES gt MOTOR ITEM 5 IS STATIC SENSITIVE COVER MOTOR AND CONNECTOR IELCTROSTATIG ELECTROMAGNETIC ELECTROSTATIC ELECTROMAGNETIC WITH 3 X 5 STATIC BAG AND SECURE WITH A RUBBER BAND 177 MAGNETIC OR RADIOACTIVE FIELDS Axis Transmission Assembly Bill of Materials 600Ae amp P 600H only COMPONENT PART NUMBER 105535 BRACKET YTRANSSUMMIT7 1 106975 BELT 2 104636 PULLEY 24TX 080X14 3 107326 PULLEY SMM BORE 247 X 080X14 3 PULLEY GOTX 080X14
63. Inspect the Fuse and Output Terminals Turn the power off 2 Inspect the onboard power supply fuse If it is defective it can be replaced with a 3 4 x 3 16 3 AMP GFE fast blow fuse or equivalent 3 Examine the metal terminals at the 24 V 5 V and ground output wires The insulation for these wires is colored red for 5 V yellow for 24 V and black or brown for ground They should be flush against the board and unable to touch each other 4 If it looks like they could short or if arcing has occurred re solder as necessary and or insulate the wires so that they can no longer contact each other 5 The power supply may also be returned to Ioline for a replacement If this does not isolate a power supply problem continue to the next step Test the Power Supply Output Voltage 1 Turn the power off 2 Mark the power supply connectors with their associated socket number J3 or J7 3 Unplug both power supplies from the logic board It is very important that they be disconnected from the logic board for correct voltage readings 4 Connect one of the power supplies to the Ioline Power Supply Test Fixture The plug will only fit on one way f the Ioline test fixture is not available insert a 20w 5W resistor into the plug between one of the red 5V wires and one of the black or brown ground wires The voltages are labeled on the logic board at the J3 and J7 connectors 66 FOL INE Chapter 4 Troubleshooting and Testing
64. MBER Pi 104744 FAN 24 VDC 050 SONNE IN TA 22 00284 CONN CRIME INSER I 20 28 GA doo 3 i 136 ONIMV G SIH L SV 13441 A38 H38lIATN LYYd IWYS 3 18VO 138V 1340 LNIAd lt a 9 amp e c N x co N orn NIN Sc m 09 19 69 N N eo N x N N N o SHOLOnQNOO I CE o 0 LTO wjr 5569550050 0050000000 P en X f SHOLONANOD 61 96 901 i L Nid ps OSL Cable Assembly Part Number 104756 Cable Assembly Bill of Materials OMPONENT PART NUMBER OMPONENT DESCRIPTION DRAWING NUMBER ONN RIBBON CABLE 34 PIN FEMALE B L B ONN RIBBON CABLE 20 PIN ONN RIBBON CABLE DB25 SK 138 Pinch Wheel Assembly Bill of Materials P 600 only ws LEVER PINCH WHEEL D D M V NCH WH VED DINTH UH MACHINED MO D ND D NI LI HAND PINCH WH MOLDED g 7 D HEX NYLO 140 Cable Assembly Part Number 105479 xe SNIA331S SNILLIJ 575 3 18VOINVdX3 00LSX X313 3100
65. OL Chapter 5 Repair and Maintenance v belt tension 22 23 24 25 Attach the Y Axis transmission and install the belt as outlined above in Y Axis Transmission Assembly Replacement Cable tie the wire bundles together to ensure that they do not interfere with mov ing parts and end cover replacement Attach the chartwheel lever and make sure that the chartwheels are oriented properly with respect the lever position and that the set screw in the lever body is tightened Reconnect the serial cable and perform test plots Reassemble the P 600 in the reverse order that it was disassembled See General Disassembly Procedures above If problems arise contact Ioline customer service Chart Tape Replacement 1 6 Turn off the P 600 and disconnect the power cord Use an exacto knife to pull up one corner of the old chart tape Firmly grip the pulled up corner and remove the old chart tape by peeling it out of the molded groove on the front of the platen Clean the surface of excess glue Pull a strip of new chart tape off of the roll Make sure that the new strip of tape is slightly longer than the length of the platen Carefully press the new chart tape into the molded groove in the platen Make sure that the air holes are not covered Trim excess tape from the end of the platen Reconnect the power cord and interface cable to the P 600 Take Up Shaft And Feed Shaft Subsystems Transmission Take Up Motor A
66. P 600H FGI Level Ioline part Description LEG ASSY LEFT 1 5 600 105166 COVERJLLEFTEND 588 22 106263 SHAFT ASSY TAKEUP 00 1 106244 DANCER BAR ASSY FRONT P600 1 106245 DANCER BAR ASSY REAR P600 21 106243 COVER ASSY TAKE UP P600 106284 2 BOX SHIP 60 2 107030 PACKING LIST 600 28 1 106287 60 2 r 1 105969 KEY TAKE UP 600 28 21000 101031 FOAM BLOCK 2 IN X2 IN X 2 IN Lae 107029 LABEL CARTON END 600A 28A 32 103560 LABEL SHIPPING CARTON IOLINE 20 2 105762 LABEL REAR PANEL FCC CE 1 106018 LABEL FRONT P600 LABEL WARNING HAZARD VOLT j 119 JOLINE Addendum 600Ae JOLINE Addendum 600Ae This addendum covers the major maintenance and repair differences between the 600Ae and the P 600 The following information is covered here Product Overview 600Ae Operation Maintenance and Repair Distinctions Technical Drawings and BOMs for Unique 600Ae Components Product Overview The Ioline 600Ae Marker Plotter can handle any large format plotting operation up to 72 inches 1 8 meters wide and 600 yards meters long Three industry standard plotter languages HPGL 7475 HPGL 7596 and DMPL are supported It is most commonly used in conjunction with apparel design software for plotting large marker plot patterns The 600Ae also comes with Control Center s
67. Positioning the Chartwheels Make sure the paper is taut and square in front and in back of the Machine Clamp the paper to the grit shaft by lowering the chartwheel lever on the keypad side of the P 600 31 AOLINE Chapter 2 Setting up the P 600 M 28 z Installing the Dancer Bars and Paper Guide Flanges To keep the paper taught at all times during operation install the dancer bars Slide the dancer bars into the dancer bar channels as shown in figure 2 16 Front Dancer bar longer EE Rear Dancer bar Shorter Figure 2 16 Installing the Dancer Bars Adjust the take up shaft paper guide flanges to within 1 32 of an inch 1 mm of each edge of the paper Then tighten the paper guide flange thumb screws 32 JOLINE Chapter 2 Setting up the P 600 M 28 Preparing to Send a File 1 Make sure a is installed in the pen holder With the left or right arrow keys move the pen carriage to the position where the next plot should begin Press the Start Point key See Chapter 3 for more infor mation 3 The Plotter will create a measured feed loop the length of the plotter s frame size length setting The factory default frame size is 46 inches 117 cm 4 Check the paper path against Figure 2 17 to ensure proper installation 5 The P 600 Marker Plotter will then switch to Start mode green LED on and be ready to accept a plot file from the computer Front of Plotter Rear of Plott
68. See Chapter 5 X Axis Motor Replacement section for the replacement procedure Carriage Y Axis Motor Replacement If the carriage quickly accelerates and jams and the FETs are not defective or if unex plainable jams occur the motor may be defective See Chapter 5 Y Axis Motor Re placement section for the replacement procedure Roll Feed Motor Replacement If the front roller quickly accelerates and jams and the FETs are not defective or if unexplainable jams occur the motor may be defective See Chapter 5 Take Up Motor Replacement section for the replacement procedure Testing the New Motor 1 Test the new motor s with the keypad arrow keys for five to ten seconds 2 It is important that care be taken when changing the motor and that proper belt tensions and alignment be attained after the new unit is installed Never separate the motor and encoder assembly 3 If replacing and adjusting the motor cannot be accurately accomplished contact a qualified service dealer or Ioline customer service for assistance If the difficulty persists and the Diagnostic Record see below is completed contact an Ioline dealer Ioline Customer Service for further help 70 FOL INE Chapter 4 Troubleshooting and Testing x _ Contacting Ioline Customer Service If the suggestions and guidelines in this manual cannot help resolve the difficulty contact Ioline Customer Service When speaking with a customer service representa tiv
69. Testing the Motors Use this procedure if The procedures in Testing the Logic Board did not resolve the difficulty Tools Required Phillips head screw driver Allen wrenches 1 16 5 64 Initial Motor Inspection Rotate the grit shaft and front roller and move the carriage while listening to the associated motor 2 If there is any grinding squeaking or clicking from within the motor it is prob ably defective Return the motor to Ioline for a replacement Modes of Motor Failure An internal short has occurred This malfunction exhibits itself as a jam and causes the motor to be more difficult to turn by hand To determine if a carriage motor has shorted unplug the input power leads and move the carriage by hand If the motion has a high resistance the motor is probably shorted The front roller and grit shaft cannot be tested this way due to the nature of the transmissions If these motors are suspect they will have to be removed and tested at Ioline The motor encoder has failed The encoder allows the plotter logic to keep track of axis positions and speeds When an encoder fails the motor may work at low speeds but during acceleration it speeds up abnormally then jams 69 FOL INE Chapter 4 Troubleshooting and Testing Grit Shaft X Axis Motor Replacement If the grit shaft quickly accelerates and jams and the FETs are not defective or if unexplainable X axis jams occur the motor may be defective
70. When a file is sent to the plotter the electronic logic system translates the vectors into instructions for the X Axis paper motion and Y Axis pen motion motors and uses optical encoder feedback to ensure that plotting accuracy is maintained Long plots are ac complished by breaking the plot file into frame segments and rolling the completed frames onto a take up shaft 13 FOL INE Chapter I Indtroduction and Overview Paper Movement Media motion is accomplished by pinching paper between a grit shaft and chartwheels mounted on a square shaft The X Axis transmission rotates the grit shaft so that when the chartwheels are locked in the down position paper can be moved in two directions on the X Axis Long plots are rolled onto a front take up shaft that also helps pull paper off of the feed roll during frame advance Pen Movement The Y Axis transmission powers a timing belt that transports a V wheel carriage along the Y Axis traverse extrusion The pen is attached to the carriage and is made to contact the paper by actuating a voice coil When not plotting the pen is held above the paper by spring action Limit Of Liability Statement It is the responsibility of the operator to monitor the performance of the P 600 and maintain it in proper working condition by following the operating and regular main tenance instructions It is also the responsibility of the operator to follow all safety precautions and warnings that
71. _ SPACERMOUNT VC SCOS 1 106949 DOWEL PIN 0625DIA X 625 21 106954 FILTER SENSORLENS 1 106869 PCBASSY CARRIAGE 1 5 600_ 7 2411 106236 PCBASSY CARRIAGE P0 1 106458 ARM CARRIAGE 698 1 106460 MOUNT VC CARRIAGE 698 1 106230 WHEEL CARRIAGE SCOS 3 106254 FLEXURE CARRIAGE Z AXIS 2 103481 WSHR 1961D 3120D 062TH NYLON 1 106073 _ SCREW SHOULDER 187DIA 375LG 2 106462 NU 0 ROUND AD 107018 SCREW 6 32 625 LG FHP 0 625 117 Addendum 600 H Carriage PCB Assembly P 600H Ioline part Description Number of Number Parts used PCB CARRIAGE 28 600 12 PCB CARRIAGE 1 102624 CONN FLEXCABLE 12PIN RANGLE 1 103720 TYRAP JINX3IN BLACK 1 1466 VOICE COIL 1 WAND FRAMESENSOR WA 1 105691 100237 CONN TERMINAL RING 4 22 18 GA 1 106332 CABLE ASSY 3 WITHLUG 100223 _ WIRE 22 GA ST GN X 3 IN 011007 100 1 101370 HEATSHRINK 250DIA BLK 05 101369 HEATSHRINK 125 DIA BLK 0025 Assembly P 600H 107047 P 600H PCB Assembl Ioline part Description mme 105418 IC ROM DSP 2200 PROG 105510 FPGA PROG 1010B 2200 910 1 1 107048 C ROM 600H PROG 105419 PCBASSY LOGIC 2200 118 Addendum 600 H x FGI Level Bill of Materials P 600H 107050
72. aces all of the screen values with the factory defaults A dialog box will appear that allows these values to be sent to the plotter ROM Version Displays the current ROM version installed in the plotter Memory Buffer Displays the amount of buffer memory on the logic board This value should be 12 K kilobytes 45 FOLI NE Chapter 3 Operation Calibration Plotter 600 Control Center Figure 3 6 Calibrate Menu Calibrate Plotter Provides methods to calibrate the plotter for maximum accuracy To calibrate the P 600 Select Calibrate Calibrate Plotter from the menu bar A window like figure 3 7 will appear 3 Set Calibration Figure 3 7 Calibration Screen 46 FOL INE Chapter 3 Operation Calibrating Cont 1 Load the P 600 with paper making sure the paper is at least 41 inches long by 48 inches wide and that it is the type of paper used by the plotter most often 2 Select Calibration Plot The plotter will draw four ruled lines 40 inches 101 cm and 46 inches 116 cm wide 3 Precisely measure one length X Axis and one width line Y Axis in either inches or centimeters and record the results Select Set Calibration Enter the measured X value Enter the measured Y value Select Set Calibration again Select Done Only use Reset Calibration to restore original factory calibration settings DA CEN BA Test EE Plotter 600 Control Center File Setup Display
73. are described in this manual Ioline is not responsible for injuries that may occur as a result of unsafe operating procedures or for degraded performances as a result of failure to maintain the P 600 This Service Manual is provided for informational purposes only The con tents are subject to change without notice and Ioline Corporation assumes no responsibility for any errors that may be contained herein No part of this Service Manual may be copied disseminated or distributed without the ex press written consent of Ioline Corporation Ioline Warranty Policy Ioline Corporation provides a 12 month parts and labor warranty on all new equip ment and 90 days on repair parts unless specifically noted otherwise Every unit is recorded by serial number when it leaves the factory If the serial number indicates the unit exceeds 15 months old then the user must provide proof of extended war ranty 14 F OLINE Chapter 1 Indtroduction and Overview x For warranty service the end user must work through their dealer Ioline Customer Service is available to assist Authorized Dealers in the performance of their equip ment support Serial Number Identification Identification of Ioline Corporation products is accomplished by use of a serial num ber located on the back of the plotter You can determine the model and date of manufacture by interpreting this serial number M600 99 4102 l Sequence Number Week of Manufacture Ye
74. ber Parts used 105966 PCB CARRIAGE 28 600 106385 PCB CARRIAGE 102624 CONN FLEX CABLE 12 PIN ANGLE 103726 TYRAP 1 IN X 3 IN BLACK 104646 VOICE COIL WAND FRAME SENSOR W A 105691 106332 CABLE ASSY 3 WITH LUG DD 100223 WIRE22GASTGNX3IN UL1007 10 101369 HEATSHRINK 125DIA BLK PCB Assembly 600Ae Ioline part Description Number of Number Parts used PCB ASSY LOGIC 68331 600 28AE 106783 DATA IMAGE 600AE 127 Addendum 600Ae FGI Level 600Ae Ioline part Description Number of Number Parts used OVER LEFT END S88 FOAM BLOCK 2 IN X 2 IN X 2 IN LABEL CARTON END I S 600 28AE 2 AB WAR HAZARD v NTN VO n R 2 U 2 416 050 W ZW HD BLACK WA A 770 ms F D IR DIA U L lt N YO rt A D H v W its DHD SCREW 5 52 575 LG PHPSEMS SCREW 75 32 375 BLACK NUT 28 32 KEP STRAIN RELIEF PLASTIC 50 591D IYRAP do IN A2 U n n VU 4 3 1 7 V 3 r r 3 128 129 130 131 132 133 CORPORATION Appendix of Drawings For the P 600 600H amp 600Ae 134 Fan Assembly Part Number 104745 N 2 a Y s 5 l i m LO ko N 135 Fan Assembly Bill of Materials COMPONENT PART NUMBER COMPONENT DESCRIPTION DRAWING NU
75. ccess above Remove the gray ribbon cable blue socket at J2 near the right end plate by pushing the blue tabs away from the center of the connector The plug should be easy to pull out Pull the plug through the hole in the end plate The encoder wires may have to be moved out of the way Disconnect the gray ribbon cable from keypad circuit board connector Discon nect the three power wires from the power entry module Cut the cable tie that holds the wire bundle to the ground wire Loosen and remove the two nuts holding the rear panel assembly to the right end plate Attach the new rear panel assembly making sure that the power switch faces the rear of the plotter Connect the gray ribbon cable to the keypad assembly with the red stripe pin 1 on the edge closest to the mounting holes Plug the three power wires into the power entry module using figure 5 8 below as a guide Push the logic board plug through the hole in the end plate The encoder wires may have to be moved out of the way Open the blue tabs away from the center of the connector before inserting the gray ribbon cable into the blue socket at J2 Gently push the plug into the slot The tabs will snap closed when the plug is properly seated The red stripe pin 1 on the edge should be closest to front of the machine Cable tie the wire bundles together to ensure that they do not interfere with mov ing parts and end cover replacement Plug the power cord into the P 600 and
76. creen allow adjustment of a variety of settings for computer control of the Ioline plotter File management plotter setup and serial port testing can all be accessed from the menu bar File Plotter 600 Control Center B iani xl File Setup Display Options Calibrate Test Help Special Features Acceleration X Sensor Enable 9 g ws JR Send Cut Plot File Open Settings File Save Settings As Exit Panel Size Figure 3 3 File Menu Send Cut Plot File Use this option to send plot files plt format to the P 600 Open Settings File Opens custom settings for the P 600 that have been stored with the Save Settings As option below When the P 600 is shut off these settings will be lost The factory default settings will be in effect the next time the plotter is powered up Save Settings As Allows custom settings to be saved to a file so that they can be sent to the P 600 at a later time To retrieve these files use Send Settings File explained above 44 FOLI NE Chapter 3 Operation mm Figure 3 4 Setup Menu Plotter Setup Allows selection of the plotter model and COM port Com Port Setup Provides a list of COM ports to select from Display Plotter 600 Control Center pu Figure 3 5 Display Menu Plotter Settings Replaces all of the screen values with the current settings stored in the logic Factory Defaults Repl
77. d belt When tightening the set screws make sure that one set screw contacts the shaft on the flat machined surface 9 Reconnect the power cables to the base of the motor with the red wire attached at 89 FOL Chapter 5 Repair and Maintenance v and the black wire attached at 2 Make sure to route the wiring through the plastic 10 11 12 13 14 clips so that it is held away from moving parts and is accessible after the logic board is installed Install the logic board making sure that the rear edge fits into the proper track in the platen Secure with the phillips screws Connect all of the plugs on the logic board Use the Interconnect Diagram in the Appendix section to properly make all of the connections Plug the power cord into the P 600 and into a wall outlet Move the grit shaft back and forth with the keypad keys while watching the X Axis belt If there is excessive noise or if the belt is loose the phillips head screws that retain the motor can be loosened and the motor can be adjusted slightly to achieve proper belt tension Cable tie the wire bundles together to ensure that they do not interfere with mov ing parts and end cover replacement Reconnect the serial cable and perform test plots Reassemble the P 600 in the reverse order that it was disassembled See General Disassembly Procedures above If problems arise contact Ioline customer service Square Shaft and Chartwheel Assembly Replacement
78. disposable HP style fiber roller ball ball point or felt tip 0 25 in to 0 90 in diameter Power Requirements 90 264 VAC 47 66 Hz 160 watts Overall Physical Dimensions Height 1 17 m 46 in Width 2 26 m 89 in Depth 56 m 22 in Shipping Weight 129 kg 285 Ibs Environmental Range Temperature 0 35 C 32 95 F Relative Humidity 3096 8596 non condensing Hardware Interface Standard RS 232C serial interface 9600 Baud No parity 8 data bits 1 stop bit hardware or software XON XOFF handshaking DB 25S connector requires DB 25P mating connector Command Languages DM PL HP GL HP 7475 amp HP 7596 This measurement requires that Frame Gap be properly set in the Control Center software that comes with the M 28 Marker Plotter How The M 28 Works The M 28 uses the same technology described above in Chapter 1 How The P 600 Works The exception is that a frame sensor and registration logic is not included to ensure frame accuracy over very long distances These mechanical and electronic differences limit the plotting length to 25 meters 28 yards 104 JOLINE Addendum M 28 P 600 M 28 Operation Maintenance and Repair Distinctions The only operating difference between the M 28 and P 600 marker plotters is the maximum length of the plot The mechanical and electronic implications are that the carriage and logic board are different Software operation differs because Frame Gap settings will have
79. duction and Overview x 2 2 amp Product Overview The Ioline P 600 Marker Plotter can handle any large format plotting operation up to 72 inches 1 8 meters wide and 600 yards 545 meters long Three industry standard plotter languages HPGL 7475 HPGL 7596 and DMPL are supported It is most commonly used in conjunction with apparel design software for plotting large marker plot patterns The P 600 also comes with Control Center software that allows adjust ment of a variety of system settings from the computer Figure 1 1 Ioline P 600 Marker Plotter 12 FOL INE Chapter I Introduction and Overview Specifications Width 1 88 m 74 0 in 455 m 500 yd 35 paper Pens Refillable or disposable HP style fiber roller ball ball point or felt tip 0 25 in to 0 90 in diameter Overall Physical Dimensions Height 1 17 m 46 in Width 2 26 m 89 in Depth 56 m 22 in Shipping Weight 129 kg 285 Ibs Environmental Range Temperature 0 35 C 32 95 F Relative Humidity 30 85 non condensing Hardware Interface Standard RS 232C serial interface 9600 Baud No parity 8 data bits 1 stop bit hardware or software XON XOFF handshaking DB 25S connector requires DB 25P mating connector How The P 600 Works The P 600 combines media and pen motion to create vector plots Vector files are sent to the plotter via a serial connection with a computer or file server
80. e LED Codes section The LED is red after power is turned on and the carriage resets A red LED also indicates that the communication line is interrupted between the plotter and the computer When communication in open between the plotter and the computer the LED will be green Rear Panel ON OFF Control The power on off switch is located on the power cord entry module which is acces sible on the back of the unit behind the keypad Control Center Software The Control Center Software provides and interface that allows detailed changes to the Summit plotting parameters Screen Options The main Control Center screen provides control over the primary plotting param eters Any changes that are made must be sent as temporary or permanent settings before they take affect Press the Start Stop key and make sure the green LED Start mode is on before attempting to send any changes to the plotter 40 FOLI NE Chapter 3 Operation nm Figure 3 2 The Ioline Control Center Main Screen Measurement Units English or Metric unit systems may be used for length and speed settings Acceleration The acceleration setting determines how quickly the pen will reach full speed when starting or ending a marker line The factory default acceleration setting is 1 0 g 1 g 32 2 ft s The setting range is 0 1 to 2 0 g Speed Speed refers to pen and media speeds during plotting Lower speed settings will improve the line quality but wi
81. e they will ask a number of questions regarding the results of the diagnostic inves tigation Use the following form to record the observations so Ioline can expedite solving the difficulties Diagnostic Record What is the serial number for this unit Logic board revision Who was the dealer that sold it to you Has the unit been working properly up to the point of the recent failure YES NO Are there any blinking LEDs or beeping sounds associated with this problem YES NO If yes please describe them Were there communication or computer software problems If yes please describe them When the plotter is first turned on does the pen carriage move fully to the right YES NO Does the fan come on YES NO With the power off slide the carriage from side to side Does the carriage slide easily to each side YES NO Is there more resistance to move the carriage to the left the right Or is it equal Was a SIMM installed at U27 on the logic board YES NO Were all of the cable connections securely fastened to the logic board YES NO Were all logic components seated in the logic board YES NO Were the power supplies shorting at the terminals YES NO Were the power supply voltages within the tolerances YES NO Record the power supply voltage readings here J3 VMOT 24V J7 VMOT 24V J3 12V J7 12V J3 12V J7 12V J3 5 1 J7 5 1 J3 5 2 J7 5 2 Were any of
82. ean the grit shaft refer to the Cleaning the Grit Shaft procedure Adjust the up down delay values ncrease the pen force FOL INE Chapter 4 Troubleshooting and Testing _ Regular or intermittent tearing Cause Solution 1 The pen is dry 1 Replace the pen 2 The pen tip is broken possibly due 2 Decrease the pen force and or replace the pen to pen force set too high 3 Dirt or debris is stuck on the pen 3 Clear or replace the pen 4 The up Down delay is set incorrectly 4 Reset the defaults in the Ioline Control Center Occasionally the paper will bubble during X axis movement and will cause the pen to snag Check the grit shaft and chartwheels for unusual wear debris or damage Paper Tearing Under the Chartwheels Occasionally the paper will tear under the chartwheels during roll feed advance This problem has been primarily traced to light paper usage Large format plotting exerts higher than normal stresses on the media Lighter weight paper has a tendency to fail when the torque of frame advance is applied To solve this problem Ioline rec ommends that 35 Ib high quality paper be used for all large format plotting If 35 Ib paper is not available the following suggestions may improve plotting performance Add extra chartwheels to the square shaft Removable chartwheels are available from Ioline Ensure that the paper is loaded correctly every time a new plot is made Higher quality paper
83. econds If unusual noises or mechanical malfunctions are present remove the transmission and return it to Ioline for a replacement If these procedures are not effective read Internal Cabling and Connection Inspection for the next step in the diagnostic process Internal Cabling and Connection Inspection WARNING The P 600 is very heavy and could cause an injury if it falls Make sure that another person assists with moving the plotter to and from the stand and that it is held while not connected to the stand When the bottom cover of the plotter is removed and the power is on there is an electric shock hazard These diagnostic procedures should only be performed by qualified technical personnel or individuals that are aware of safe practices with 110 VAC and 220 VAC devices 64 FOL INE Chapter 4 Troubleshooting and Testing ww Do not lift the P 600 M 28 by its top dust cover or traverse assembly Use the bottom surfaces of the end plates for lifting and moving the plotter Use this procedure if The procedures in External Inspection did not resolve the difficulty Tools Required Phillips head screw driver 5 32 allen wrench supplied Two people capable of lifting 100 pounds each Grounding strap optional Initial Internal Inspection Fully disassemble the P 600 as described in Chapter 5 General Disassembly Procedures 2 Many components in the P 600 are sensitive to static discharge Make sure t
84. ent Procedure Warning This procedure uses a plot file to test the frame alignment of the paper The plot file is made for 72 wide paper If you have a smaller width paper you must adjust the Y axis scale setting in the Ioline Control Center before running the plot file A scale of 75 is usually good enough for 63 paper If this adjustment is not made before running the plot file the pen could run off the left side of the paper and break 1 Follow the paper loading instructions in the floline Model 600 amp 28 Users guide Ensure proper installation of the paper roll on the feed shaft Ensure proper chartwheel placement 2 Position the pen where you want to start the marker and press Start Point on the keypad 3 Click on the Ioline Control Center icon to start the Control Center program Model P 600 600H and 600Ae Disable the sensor by clicking on the Sensor Enable box under special Features Then click Temporary at the bottom of the screen to send this change to the plotter This is not necessary with models M 28 28H and 28Ae 4 Set the frame gap in the Control Center The frame gap with vary depending on the size of the roll of paper you are using The larger the roll the larger the overlap the smaller the roll the smaller the overlap Model M 28 28H and 28Ae The frame gap must be adjusted as the roll gets smaller to heighten accuracy during normal plot ting Full Roll of paper 130 150 Ha
85. er Takeup Shaft Rear Dancer bar Feed roll Figure 2 17 The Correct Paper Path 33 JOLINE Chapter 2 Setting up the P 600 M 28 Software Installation The Ioline Control Center is a Microsoft Windows compatible program that comes on a 3 1 2 floppy disk with the Plotter or it is available on line at www ioline com A Macintosh version is available upon request The Control Center software has three functions l Allow adjustment of plotting parameters 2 Send completed plot files plt to the Plotter 3 Provide diagnostic tests and test files for troubleshooting Installing the Ioline Control Center Software The Microsoft Windows version of the Control Center program can use either a mouse or the keyboard of the computer to change the default plotter settings If using the keyboard note the following guidelines Use the Tab key to cycle through the screen fields Use the up down cursor movement or numeric keypad keys to change a numeric value within a highlighted menu field Use the Alt key to toggle between the screen fields and the pull down menus Use the Enter key to select a highlighted field when a pull down menu is open Microsoft Windows 3 1 Installation Start Windows Insert the Control Center disk into drive A or B Make sure the plotter is turned on and that the green LED is visible Choose File Run from the Program Manager menu bar Type A SETUP or B SETUP and Click OK
86. er and serial cables Remove the right 4 screws and left 4 screws end covers and dust cover 1 screw on each side See Removing the End Covers and Dust Cover above Loosen the allen screw on the belt tensioner until the screw is not exposed Do not remove the screw With a pair of needle nosed pliers grasp one of the metal T connectors on the end of the Y Axis belt and pull it out and toward the center of the carriage until it pops free Make sure that the tensioner assembly is not tangled in the belt Re move the other end of the belt from the carriage Pull the Y Axis belt through the holes in the left end plate The belt will have to be threaded through the tensioner assembly Once the belt is removed the tensioner assembly will have to be set aside because it is not attached to the end plate Pull the Y Axis belt through the holes in the right end plate The belt may have to be threaded through the pulleys in the Y Axis transmission Thread the new Y Axis belt through the access slots in the right end plate and around the empty pulley in the transmission The easiest way to thread the belt through the traverse is to first thread a tape measure through and tape the new belt to the tape measure It is very important to make sure that there are no twists in the belt and that the belt teeth properly engage the pulley Continue to thread the belt through the holes in the left end plate and through the belt tensioner Make sure that the belt
87. eral Disassembly Procedures then consult Testing the Logic Board and Testing the Motors later in this chapter Perform the following disassembly 1 Unplug the power cord from the wall outlet and the serial cable from the com puter 2 Remove the plastic end covers from the end plates following the procedures out lined in Chapter 5 63 FOL FINE Chapter 4 Troubleshooting and Testing 3 4 Rotate the front take up roller and pull the take up shaft out of the support blocks Remove all media and the rear paper roll Front Roller Motor Key With the take up shaft off the machine inspect the square block that turns the roller The key should be tight and should not rotate easily If it does tighten the HEX screw located in the hole on one end of the block Carriage Y Axis Transmission 1 Turn the power off 2 Make sure that the carriage Y axis transmission belts are not damaged mistracking or loose Closely check the belt teeth for excessive wear Loosen the transmission retaining nuts there are four with the 11 32 nut driver and re tighten them Tighten the allen set screws on the pulleys with the 1 16 and 5 64 allen wrenches Ensure that the three allen screws 5 64 allen wrench holding the motor to the transmission bracket are not loose Actuate the transmission by depressing the left and right keypad arrows with the power on Test both directions for at least 5 s
88. hat any static electricity is discharged before attempting any service procedures A grounding wrist strap works the best and can be provided by Ioline on request 3 Inspect all of the connectors on the power supply logic board and at the motors to determine if anything came loose during shipping or from rough handling Gently push on all plugs and socketed logic chips to ensure that they are properly seated 4 If a SIMM is present at U27 remove it 5 The P 600 will operate lying on it s back so long as there are no obstructions to the motion of the carriage grit shaft and front roller WARNING When the plotter is connected to a wall outlet there are high voltages on the power supplies that could cause an injury Be extremely careful 6 Plug the plotter back into the wall and turn it on Check to see if the plotter resets If these procedures are not effective in solving the problem continue to Testing the Power Supplies for the next step in the diagnostic process 65 FOL INE Chapter 4 Troubleshooting and Testing Testing Power Supplies Use this procedure if The procedures in the nternal Cabling and Connection Inspection did not resolve the difficulty Tools Required Multimeter capable of reading DC voltage Power Supply test fixture available from Ioline or one 20w 5W resistor with long 6 cm or more leads Soldering apparatus optional Insulating material electrical tape mylar strips etc
89. he square shaft is in place Attach the chartwheel lever and make sure that the chartwheels are oriented properly with respect to the lever position and that the set screw in the lever body is tightened Insert and tighten the square shaft allen screw and cap in the left end plate Plug the power cord into the P 600 and into a wall outlet With the chartwheel lever down move the grit shaft back and forth with the keypad keys while watching the chartwheels and square shaft If there is excessive noise check the set screws and other hardware to be sure it is tight Reconnect the serial cable and perform test plots Reassemble the P 600 in the reverse order that it was disassembled See General Disassembly Procedures above If problems arise contact Ioline customer service Grit Shaft Assembly Replacement Electrostatic discharge preventative measures must be adhered to during all assembly replacement procedures Shut off the plotter and remove the power and serial cables Remove the right 4 screws and left 4 screws end covers and dust cover 1 screw on each side See Removing the End Covers and Dust Cover above Loosen the allen screw on the belt tensioner until the screw is not exposed Do not remove the screw With a pair of needle nosed pliers grasp one of the metal on the end of the Y Axis belt and pull it out and toward the center of the carriage until it pops free Remove the other end of t
90. he X Axis belt If there is excessive noise or if the belt is loose the phillips head screws that retain the motor can be loosened and the motor can be adjusted slightly to achieve proper belt tension 8 Ifthe motor needs to be changed use the procedure below 9 Reconnect the serial cable and perform test plots Reassemble the P 600 in the reverse order that it was disassembled See General Disassembly Procedures above If problems arise contact Ioline customer service X Axis Motor Replacement 1 Shut off the plotter and remove the power and serial cables Remove the right 4 screws and left end covers 4 screws See Removing the End Covers and Dust Cover above 3 Perform the procedures in Removing the Bottom Cover for Internal Access above 4 Discharge any static electricity that has accumulated and remove all of the plugs on the logic board Use the nterconnect Diagram in the Appendix section to find all of the connections 5 Remove the logic board by loosening the phillips head screws and pulling the unit out of the track in the platen 6 Disconnect the motor power cables Red and black from the base of the motor 7 Remove the motor pulley and belt This operation can be accomplished with the chartwheel lever in place but the lever assembly can be removed as described in the above procedure Loosen and remove the three phillips head screws that hold the motor on the end plate 8 Replace the motor and attach the pulley an
91. he belt from the carriage Pull the Y Axis belt through the holes in the right end plate The belt may have to be threaded through the pulleys in the Y Axis transmission Perform the procedures in Removing the Bottom Cover for Internal Access above Discharge any static electricity that has accumulated and remove all of the plugs and connections on the logic board and power supplies Use the Interconnect 91 FOL Chapter 5 Repair and Maintenance Diagram in the Appendix section as a location guide 8 10 11 12 13 14 15 16 17 18 19 20 2 Remove the logic board four screws and power supplies 2 screws in the re movable metal pan by loosening the phillips head screws and pulling the units out of the track in the platen Rotate the P 600 so that it is in normal operating position Carefully cut the cable ties that surround the wire bundle that contains the Y Axis encoder wire Feed the wire and plug through the access hole The plug may need to be bent flat to accomplish this Disconnect the motor power cables Red and black from the base of the motor Loosen and remove the four 11 32 nuts that hold the Y Axis transmission onto the end plate Remove the Y Axis transmission and set it aside Remove the chartwheel lever assembly as described above in X Axis Transmis sion Assembly Replacement Loosen but DO NOT remove the phillips head screws securing the X Axis motor Push the motor asse
92. ht 4 screws end cover See Removing the End Covers and Dust Cover above Loosen and remove the two nuts holding the keypad assembly to right end plate 98 FOL INE Chapter 5 Repair and Maintenance The Y Axis transmission will have to be pulled off of the threaded studs with the belt completely loose to accomplish this task Make sure that the belt tensioner is not tangled in the belt while moving the transmission 4 Disconnect the gray ribbon cable from keypad circuit board connector Remove keypad assembly 6 Connect the gray ribbon cable to the new keypad assembly with the red stripe pin 1 on the edge closest to the mounting holes 7 Fasten the new keypad assembly to the end plate with the hardware from above 8 Plug the power cord into the P 600 and into a wall outlet Test all of the keypad keys and make sure that all of the functions are working When the carriage moves on the traverse extrusion watch the Y Axis belt If there is excessive noise or if the belt is badly misaligned the 11 32 nuts can be loosened and the transmission can be adjusted slightly to achieve proper alignment 9 Reconnect the serial cable and perform test plots Reassemble the P 600 in the reverse order that it was disassembled See General Disassembly Procedures above 10 If problems arise contact Ioline customer service Installing a ROM Upgrade Electrostatic discharge preventative measures must be adhered to during all assembly replaceme
93. ilable has been selected The Control Center opened the COM port but could not get a response from the plotter The last operation requires that the plotter be connected to the serial port but the Control Center could not find it The Control Center cannot match the plotter that was chosen at start up with the one found during initialization The ROM is not compatible with the Control Center currently in use 51 Select a serial port that is available Be sure the plotter is connected to the selected serial port that the plotter s green LED is on and that the serial cable is functioning Due to the nature of serial communication it is possible to get this message if an attempt is made to interact with the P 600 while it is plotting If this is the case wait for the plot to finish and send the file again Be sure the plotter is connected to the selected serial port that the P 600 s green LED is on and that the serial cable is functioning Select the correct plotter from the plotter list The plotter is shipped with a Control Center that is designed to function with specific ROM versions If this error occurs contact to determine the correct ROM and software combination FOL FINE Chapter 4 Troubleshooting and Testing o L E D Codes C Continuous Beeping 3 Second pause then repeat 3 Second pause then repeat 3 Second pause then repeat The frame sensor was unable to find the reg
94. in the socket by gently pushing down on both ends 10 Replace the bottom cover 11 Move carriage to left end plate Connect power cable and turn on the plotter 101 JOLINE Addendum M 28 JOLINE Addendum M 28 This addendum covers the major maintenance and repair differences between the M 28 and the P 600 The following information is covered here Product Overview P 600 M 28 Operation Maintenance and Repair Distinctions Technical Drawings and BOMs for Unique M 28 Components Product Overview The Ioline M 28 Marker Plotter can handle any large format plotting operation up to 72 inches 1 8 meters wide and 28 yards 25 meters long Three industry standard plotter languages HPGL 7475 HPGL 7596 and DMPL are supported It is most commonly used in conjunction with apparel design software for plotting large marker plot patterns The M 28 also comes with Control Center software that allows adjust ment of a variety of system settings from the computer Figure A 1 Ioline M 28 Marker Plotter 103 POL INE Addendum M 28 Specifications Plotting Speed Max Pen Force 1 to 275 g Plotting Throughput Up to 47 nyhr 52 yd hr Maximum Frame Size Width 1 88 m 74 0 in Frame To Frame Alignment Intra Frame Repeatability Roll Media Inside Core Diameter Maximum Outer Roll Diameter Maximum Paper Take Up 545 m 600 yd 30 paper 455 m 500 yd 35 paper Pens Refillable or
95. into a wall outlet Test all of the keypad keys and make sure that all of the functions are working When the carriage moves on the traverse extrusion watch the Y Axis belt If there is excessive noise or if the belt is badly misaligned the 11 32 nuts can be loosened and the transmission can be adjusted slightly to achieve proper alignment 96 FOL Chapter 5 Repair and Maintenance v 14 Reconnect the serial cable and perform test plots Reassemble the P 600 in the reverse order that it was disassembled See General Disassembly Procedures above 15 If problems arise contact Ioline customer service Brown Wire Blue Wire Green Wire Figure 5 8 Power Cable Connection Diagram Electronic Subsystems Main Logic Board Replacement N Electrostatic discharge preventative measures must be adhered to during all assembly replacement procedures 1 Shut off the plotter and remove the power and serial cables Perform the procedures in Removing the Bottom Cover for Internal Access above 3 Mark all of the main logic board connectors with a felt tip pen before disconnect ing them This will make it easier to correctly install the connectors after insert ing the new logic board 4 Discharge any static electricity that has accumulated and remove all of the plugs and connections on the logic board Use the nterconnect Diagram in the Appen dix section as a location guide 97 Chapter 5 Repair and Maintenance Remove
96. ions throughout the Service Manual Appendix sections contain technical drawings and reference material 10 FOL INE Chapter I Introduction and Overview 2 7 Safety Warnings And Cautions Please read the safety guidelines that are explained below before beginning the test ing and replacement procedures explained in chapters 5 and 6 WARNING Warnings call attention to safety procedures that must be followed in order to avoid potential personal N Cautions call attention to procedures that are required to maximize equipment performance Basic Safety Guidelines Comply with the following safety guidelines in order to prevent electrical shock and other injuries Only qualified service personnel should attempt any of the subsystem testing or replacement procedures that are described in this manual Unless otherwise noted all subsystem testing or replacement procedures must be performed with the P 600 turned off and the power cord removed from the rear panel This will avoid the possibility of electrical shock Before beginning any subsystem testing or replacement procedure make sure that the P 600 is on a flat stable clean and dry surface Keep fingers hair and clothing well clear of the P 600 whenever moving parts are being tested When working on electronic components use a grounding wrist strap to prevent electrostatic damage If a wrist strap is not available Ioline can provide one 11 FOL INE Chapter 1 Intro
97. is more forgiving of poor paper loading See Chapter 2 for the correct paper loading method Check the Loss Of Registration Between Frames and Tracking sections below for suggestions to ensure that the paper path is functioning properly 56 FOL INE Chapter 4 Troubleshooting and Testing Loss of Registration Between Frames Loss of accuracy between the frames of the completed marker plots may indicate a loss of registration during frame advance Check the following items to ensure that the P 600 is setup properly Make sure the frame sensor is ON in the Control Center If the frame sensor is OFF mark the check box and send settings to the plotter so that it functions prop erly Registration problems may be able to corrected by reducing the speed and accel eration settings from the Control Center The frame size may be mismatched between the P 600 and the apparel design software Check that the frame size in the software is equal to or lower than the P 600 default of 46 Check the set screws on the timing belt pulleys to ensure that they are tight This problem can cause registration loss because the axis lines are distorted Registration problems can also arise from the paper slipping under the chartwheels or from other tracking problems If everything appears to be setup properly see Track ing below or contact Ioline Customer Service Tracking Tracking is the process that controls the media motion over the platen and
98. ission can be adjusted slightly to achieve proper alignment Reconnect the serial cable and perform test plots Reassemble the P 600 in the reverse order that it was disassembled See General Disassembly Procedures above If problems arise contact Ioline customer service Replacing the Carriage Ribbon Cable 1 10 Shut off the plotter and remove the power and serial cables Remove the right 4 screws and left 4 screws end covers and dust cover 1 screw on each side See Removing the End Covers and Dust Cover above Perform the procedures in Removing the Bottom Cover for Internal Access above Disconnect the ribbon cable from the carriage by sliding the rectangular locking collar away from the socket The collar is fragile so be very careful when loos ening it Gently pull the ribbon cable out of the channel A piece of two sided foam tape holds the cable on the channel bottom so do not pull hard Feed the cable through the top slot in the end plate Another piece of foam tape holds the rib bon cable to the end plate so take care in removing the ribbon cable from the slot Discharge any static electricity that has accumulated and remove all of the plugs and connections on the power supplies Use the nterconnect Diagram in the Appendix section as a location guide Remove the power supplies 2 screws in the removable metal pan by loosening the phillips head screws and pulling the units out of the track in the platen Disconnect
99. istration mark because of light ink or paper misalignment Buffer overflow Communications problems Defective RS 232 chip Frame advance size mismatch Outdated ROM version Plotter language syntax error Carriage Y axis or take up roll jam due to crumpled media or other objects blocking motion Grit shaft X axis jam due to crumpled media or objects blocking motion Press Sensor Test to allow the frame sensor to try to find the mark again Clean sensor lens with alcohol and a Q Tip Press Start Point to continue plotting without frame correction Perform communication tests as outlined below Send the marker plt from the control center to verify communication integrity Replace RS 232 chip U25 Change software frame advance size to match the X axis panel size Check the ROM version to ensure it is 1 05 or greater replace the ROM if is not Make sure that the P 600 and the computer software are set to the same plotter language HP 7475 HP 7596 DM PL Send the marker plt from the control center to verify communication integrity Clear media or objects causin g the jam Clear media or objects causing the jam Legend Solid GREEN Light Emitting Diode LED on the keypad Blinking GREEN Light Emitting Diode LED on the keypad 1 l Blinking RED Light Emitting Diode LED on the keypad 71 52 FOL INE Chapter 4 Troubleshooting and Testing w
100. lf roll of paper 100 130 Close to end 70 100 5 Click on the Temporary button in the Control Center to send the gap settings to the plotter 59 FOL INE Chapter 4 Troubleshooting and Testing 6 From the Control Center click on file at the top left of the Control Center win dow Then click on Send plot file Send the sqwave plt Square Wave Plot which Ioline has provided for this procedure Allow the plot to complete one time A total of 3 frames so the paper feeding stabalizes Run the file again Roll the take up shaft back so the front dancer bar goes down Look for the point where the frames make a cross and stop Refer to the diagram below for adjustment of the frame gap and rear bar 7 After making your adjustments run the square wave plot again to ensure frame to frame accuracy Frame gap number too high L1 LJ Frame gap number too low Move back bar forward Move back bar back 60 FOL INE Chapter 4 Troubleshooting and Testing ww Mechanical Electrical and Electronic Diagnostic Process The diagnostic processes that follow are detailed and invasive Do not attempt to service the P 600 until it has been determined that simpler solutions see above will not resolve the problem It is recommended that the sequence represented in the following diagram be followed when troubleshooting the P 600 Marker Plotter Make sure to record the results of any diagnostic examination on
101. ll reduce throughput The factory default speed is 20 ips inches per second The setting range is 1 to 20 ips 41 FOLI NE Chapter 3 Operation Up Down Delays Up down delay controls how long the pen hesitates when actuated Zero delay makes the pen rise instantly when line drawing is finished By default it takes the pen 6 milliseconds to lower onto the paper when the logic powers the voice coil Longer pen delay settings make the pen move more slowly but may improve the quality of the plotted line The setting range is O to 250 ms milliseconds Sensor Enable The Sensor Enable check box provides the ability to turn off the frame sensor This is useful to produce completed marker plots more rapidly with the P 600 Ioline recommends that the frame sensor be used for long markers because inter frame accuracy may be degraded without registration checking Frame Gap settings see below can be used to correct X Axis misalignment when the frame sensor is dis abled Frame Gap Frame Gap will only affect plotting when the frame sensor is disabled Frame Gap affects the size of the X Axis gap between each plotted frame Overlap ping and separation that result from not using the frame sensor can be accounted for with frame gap adjustment If the completed plot frames are overlapping enter a positive number in the frame gap field If there is too much space between completed plot frames enter a negative number in the frame gap field To
102. ly Bill of Materials M 28 109 FGI Level Bill of Materials 28 0 45068 80 nnn nnn 110 Addendum 60 111 Product Overview 112 SpecifiCatl liS Seelen 113 Flow The 600H Works Seo Race tcc febr dio adu a tate coax A Pad Lade os 113 600H P 600 Operation Maintenance and Repair Distinctions 114 600H Part Number Eguivalerite 25 22 dedi ee 115 LED Code Differences a are Seem her ERR a auqa qi 115 Bill of Materials for Unique 600H Components 116 Accessory Kit Bill of materials P 600H mnn 116 Carriage Assembly Bill of Materials P 600H 117 Carriage PCB Assembly P 600H nnn nnn nnn 118 PCB Assembly P 600H ee a En 118 FGI Level Bill of Materials 600 41 84200000 119 Addendum 600Ae 120 Product Overview 121 Specification S nee ee 122 How The 600Ae Works 122 600Ae P 600 Operation Maintenance and Repair Distinctions
103. mbly toward the grit shaft pulley until the belt is loose Re move the belt Now rotate the machine back to the forward position to gain access to the bot tom Loosen the allen screws securing the grit shaft Slide the old grit shaft out in the direction of the keypad Install new bearing clips on new grit shaft bearings Gently slide in new grit shaft When the grit shaft is inserted far enough the grit shaft pulley will be 1 8 from the end plate and will rotate freely Some minor squeezing may be necessary to feed the bearing clips into the platen Using a torque driver with a 5 32 hex bit tighten the screws securing the grit shaft to 6 in Ibs Place the X axis belt on the grit shaft pulley then loop the belt over the motor pulley Pull the motor pulley away from the grit shaft pulley until the belt is tight but not strained then tighten the phillips screws that hold motor onto the end plate Replace the power supplies and logic board using the chassis assembly diagrams in the Appendix as a guide Connect all of the plugs Use the Interconnect Dia gram in the Appendix section to properly make all of the connections Plug the power cord into the P 600 and into a wall outlet Move the grit shaft back and forth with the keypad keys while watching the X Axis belt If there is excessive noise or if the belt is loose the phillips head screws that retain the motor can be loosened and the motor can be adjusted slightly to achieve proper 92 F
104. mine if there are communications problems and isolate where the difficulty is occurring The last two tests require a diagnostic module available from an Ioline dealer con nected to the serial port on the computer or the P 600 If the following tests do not resolve the problem and the computer and software are working properly proceed to the Mechanical Electrical Diagnostic Process later in this chapter 53 FOL INE Chapter 4 Troubleshooting and Testing ww Serial Communication Test Run this test from the P 600 Control Center The diagnostic module will NOT be needed to run this test WN 8 9 Connect the serial ports on the P 600 and the computer with a serial cable From the P 600 Control Center screen select Test Select Serial Test Turn on the P 600 while holding down the Sensor Test key on the keypad until the P 600 beeps and the LEDs flash three times Press the Start Stop key on the keypad to verify that the handshake line CTS displayed on the computer toggles ON and OFF Leave the handshake lines ON Press the roll feed down arrow key to switch the P 600 into ECHO mode The green LED will come on Press any key on the computer and verify that the character transmitted equals the character received If the P 600 and the computer pass all these tests there should not be any problems producing markers from plot files Select Exit after completing the serial test Turn off the P 600 at the end of the
105. motor 9 Reassemble the take up motor assembly by reversing the order of these instruc tions Support Block Replacement 1 The support block is fastened with three nylock nuts use the 3 8 nut driver to loosen and remove the hardware A strong pull may be required to remove the block from threaded studs 2 Replace the support block using the old fasteners that were removed above Test the take up shaft with the Roll key on the keypad If any binding occurs the hardware can be loosened and small adjustments can be made DO NOT lubricate the support blocks They are designed to provide a certain amount of drag on the feed and take up shafts Take Up Shaft Repair The components on the take up shaft are permanently bonded together with the ex ception of the set screws on both ends of the shaft If the take up shaft 1s slipping on the inner shaft use a 1 8 HEX wrench to tighten the screws Damaged parts have to be replaced with a complete new assembly 94 FOL Chapter 5 Repair and Maintenance v Feed Shaft Repair All of the components on the feed shaft are permanently bonded together so there are no user serviceable items Damaged parts have to be replaced with a complete new assembly Electrical Subsystems Power Supply Replacement AN Electrostatic discharge preventative measures must be adhered to during all assembly replacement procedures 1 Shut off the plotter and remove the power and serial cables Perf
106. n rolled the speed will increase after a few seconds of rotation AN Never press the keypad roll feed key when the P 600 is stopped in the middle of a plot Pen Force You can set the pen force by using the knob on the keypad The minimum and maxi mum values of the available force can be set from the P 600 Control Center Pen type determines the correct force setting and range Excessive pen force could cause the paper to tear Sensor Test The Sensor Test switch provides a means of testing the frame sensor wand To per form the test the plotter must be in Stop mode Press the Start Stop button until the keypad LED turns red Press Sensor Test switch The P 600 will draw a dual axis frame mark and then use the frame sensor to detect the outer edge of each axis The sensor will pass back and forth over the frame mark beeping after each pass until the Sensor Test switch is pressed again 39 FOLI NE Chapter 3 Operation Mn Start Stop The Start Stop key controls serial communication between the plotter and the com puter When the communication line is open the LED will be green Start mode The LED turns red when communication is stopped Stop mode Plot files can only be sent to the plotter when communication line is open green LED Power LED The light emitting diode LED immediately above the Start Stop switch indicates the state of communication and provides error codes LED error codes can be found in Chapter 4 in th
107. n the end of the Y Axis belt and pull it out and toward the center of the carriage until it pops free Make sure that the tensioner assembly is not tangled in the belt Re move the other end of the belt Remove the carriage from the machine by pushing down on the top and pulling out the bottom wheels Mount the new carriage on the traverse extrusion by aligning the upper wheel with the upper rail push down on the carriage then slip the lower wheels onto the bottom rail and let the carriage rest Insert one of the metal T connectors into the grooves on the front of the car riage body With a pair of needle nosed pliers grasp the other and slip into the grooves This operation may require a strong pulling force Align the tensioner assembly with the indentations on the end plate and apply light tension to the belt by tightening the allen screw Move the carriage to the far right Adjust the belt tension by tightening the belt tensioner until the spring scale measurement at the center with the belt pulled 1 out from the normal position is 320 20 grams 81 FOL INE Chapter 5 Repair and Maintenance gt 12 13 14 Plug the power cord into the P 600 and into a wall outlet Move the carriage back and forth across the traverse extrusion with the keypad keys while watching the Y Axis belt If there is excessive noise or if the belt is badly misaligned the 11 32 nuts can be loosened and the transm
108. ng all assembly replacement procedures It is important to note that the X Axis transmission consists of two pulleys and a motor There is no assembly to replace but the components can be changed if necessary Shut off the plotter and remove the power and serial cables Remove the right 4 screws and left end covers 4 screws See Removing the End Covers and Dust Cover above To replace either pulley or the timing belt the chartwheel lever must be removed Loosen and remove the allen screw with a 5 32 hex wrench the nylock nuts with a 3 8 nut driver and the set screw in the lever body with a 5 64 hex wrench Then remove the spring Pull the lever off the end plate and set it aside Make sure that the metal spacer under chartwheel lever is retained for re assem bly To change either pulley loosen the set screws pull the pulley off and replace with a new part Reuse the set screws from the old pulley because they have 88 FOL INE Chapter 5 Repair and Maintenance gt Loctite residue on the threads When tightening the set screws in the motor pulley make sure that one set screw contacts the shaft on the flat machined surface 6 Reattach the chartwheel lever Make sure that the chartwheels are oriented prop erly with respect the lever position and that the set screw in the lever body is tightened 7 Plug the power cord into the P 600 and into a wall outlet Move the grit shaft back and forth with the keypad keys while watching t
109. not correct loosen the clamp screw on the bracket 2 Place 2 pennies stacked on the paper just under the frame sensor and lower the sensor until it rests on the pennies Lift up on the sensor a little So you can get the pennies out and tighten the screw to hold the sensor Remove the pennies Turn the P 600 off then on so that the carriage is positioned near the keypad side of the machine Press Sensor Test on the keypad If the measurement is correct you should hear a Beep each time the sensor passes over the marks on the paper If you don t hear the beeps then while the sensor test is still going loosen the set screw that holds the sensor and gently move it up and down until you hear the beep Don t forget to tighten the sensor set screw Transmission Y Axis Transmission Assembly Replacement N Electro static discharge preventative measures must be adhered to during all assembly replacement procedures Shut off the plotter and remove the power and serial cables Remove the right 4 screws and left 4 screws end covers and dust cover 1 screw on each side See Removing the End Covers and Dust Cover above Loosen the allen screw on the belt tensioner until the screw is not exposed Do not remove the screw With a pair of needle nosed pliers grasp one of the metal T connectors on the end of the Y Axis belt and pull it out and toward the center of the carriage until it pops free Make sure that the tensioner as
110. nserting The Screws To keep the P 600 square on the stand it needs to be mounted with six 6 Hex screws Use the six short screws and the hex wrench to attach the machine to the stand Use three screws per side to attach each end plate to the stand See Figure 2 6 Short Screws 6 Figure 2 6 Mounting the P 600 to the stand 24 LINE Chapter 2 Setting up the P 600 M 28 Cabling Connections AN Make sure the power to the computer and the P 600 is off Use the power cord in the accessory kit to connect the P 600 to a surge protector Plug the surge protector into a 3 prong grounded wall outlet Use the serial cable to connect the serial ports on the rear panel of the plotter and the computer Serial Cable a Power cord Figure 2 10 The P 600 Marker Plotter s Rear Panel 25 JOLINE Chapter 2 Setting up the P 600 M 28 Loading You can use any pen that has a diameter of 25 to 90 6 4 mm to 22 9 mm or any Hewlett Packard compatible pen A pressurized ball point pen is optimal Pens with a ball writer or plastic tip will also work but are not as effective Ioline does not recommend that a ceramic tipped pen be used Gently insert the flange of the pen between the grooves of the pen holder and tighten the thumb screw Do not over tighten the screw so that the pen becomes dented Loading Paper One of the most important user operations is paper loading P
111. nsistor s on logic board Defective power supply Defective motor encoder Short or other problem with motor 3 Second pause then repeat Cycling power supply due to Incorrect power supply sequence or defective power supply Defective transistor s on logic board ale Less than 2 Short or other problem with motor C second pause 1 then repeat Plug unit into wall outlet Check internally for damaged cabling and loose plugs Test power supplies with fixture orresistor and replace if defective Switch power supply input plugs J3 and J7 on logic board Replace defective transistor or entire logic board Replace keypad Clear media causing jam Clear mechanical jam Check internally for damaged cabling and loose plugs Test power supplies with fixture or resistor and replace if defective Replace defective transistor or entire logic board Replace defective motor Clear media causing jam Clear mechanical jam Check internally for damaged cabling and loose plugs Test power supplies with fixture or resistor and replace if defective Replace defective transistor or entire logic board Replace defective motor Check internally for damaged cabling and loose plugs Test power supplies with fixture or resistor and replace if defective Switch power supply input plugs J3 and J7 on logic board Replace defective transistor or entire logic board Replace
112. nt procedures eater to follow these directions explicitly may cause permanent damage to the ROM and may cause the plotter to malfunction 1 Leave the ROM in the protective case until it is ready to be installed Shut off the plotter and remove the power cable 3 Perform the procedures in Removing the Bottom Cover for Internal Access above 4 Ensure that the same static potential is achieved by attaching a grounding wrist strap to a non painted surface on the inside of the plotter and then attaching the strip to the technician 5 Carefully remove the old ROM in the US socket on the logic board using small flat tool under one end between the ROM and its socket and then the other end gently rocking the ROM out of its socket 6 Remove the new ROM from its protective case Ensure the pins are straight and 99 FOL INE Chapter 5 Repair and Maintenance evenly spaced 7 10 11 12 Install the new ROM Make sure that the notch in the ROM is pointed the same way as the other components on the logic board In this case the notch must be pointed toward the center of the logic board When inserting the ROM be careful not to bend any of the pins also be sure that all the pins are inserted in the socket Ensure the ROM is firmly seated in the socket by gently pushing down on both ends Replace the bottom cover Move carriage to left end plate Connect power cable and turn on plotter while holding in the Up
113. nto the feed shaft support blocks on the lower front of the machine see figure 2 11 Make sure the paper pulls from the bottom of the roll when placing it on the stand The flanged coupling should be on the keypad end of the plotter 26 JOLINE Chapter 2 Setting up the P 600 M 28 Centering the paper roll Center the paper roll between the two stand end plates by sliding it to the left or right along the feed shaft Make sure the hubs remain securely in place in the paper roll When you have the paper centered use the hex wrench to tighten the button head screws on each paper hub Flange Coupler Figure 2 11 Installing the Feed Shaft 27 JOLINE Chapter 2 Setting up the P 600 M 28 v Assembling The Take Up Shaft Hold the paper guide flanges together with the flat sides of the flanges touching Slide them both onto the take up shaft Put the roll feed take up shaft onto the take up shaft supports on the front of the machine The flanged coupling must be on the keypad side of the plotter N D Flanged Coupling Takeup shaft Figure 2 12 Loading The Take Up Shaft Slide each of the take up shaft paper guide flanges toward the stand end plates to create enough room for the width of the paper You may have to loosen the guide flange thumb screws 28 AOLINE Chapter 2 Setting up the P 600 M 28 Feeding Paper Over the Platen Turn on the P 60
114. of the cover then remove the right cover See figure 5 4 below Remove the two black phillips head screws and the two silver phillips head screws on the bottom that hold the left cover on the P 600 then remove the left cover See figure 5 4 below Use a screw driver to remove the two dust cover screws one from each end of the P 600 Make sure to only remove the two dust cover screws refer to figures 5 4 through 5 6 Remove the dust cover 78 FOL Chapter 5 Repair and Maintenance Wi 19 d EIN 5 EXE AN P Figure 5 5 Right End With Cover Removed 79 FOL Chapter 5 Repair and Maintenance v ns Figure 5 6 Left End With Cover Removed Removing the Bottom Cover for Internal Access WARNING The Summit P 600 M 28 is very heavy and could cause an injury if it falls Make sure that another person assists with moving the plotter to and from the stand and that it is held while not connected to the stand When the bottom cover of the P 600 is removed and the power is on there is an electric shock hazard These diagnostic procedures should only be performed by qualified technical personnel or individuals that are aware of safe practices with 110 VAC and 220 VAC devices Do not lift the P 600 by its top dust cover or traverse assembly Use the bottom surfaces
115. oftware that allows adjust ment of a variety of system settings from the computer N N 14 SS Figure 1 Ioline 600 Marker Plotter 121 Addendum 600Ae lt BE E Specifications Width 1 88 m 72 0 in Maximum Paper Take Up 545 m 600 yd 30 paper 455 m 500 yd 35 paper Refillable or disposable HP style fiber roller ball ball point or felt tip 0 25 in to 0 90 in diameter Overall Physical Dimensions Height 1 17 m 46 in Width 2 26 m 89 in Depth 56 m 22 in Shipping Weight 129 kg 295 165 Environmental Range Temperature 0 35 C 32 95 F Relative Humidity 30 85 non condensing Hardware Interface Standard RS 232C serial interface 9600 Baud No parity 8 data bits 1 stop bit hardware or software XON XOFF handshaking DB 25S connector requires DB 25P mating connector How The 600Ae Works The 600Ae uses the same technology described above in Chapter 1 How The P 600 Works 122 JOLINE Addendum 600Ae 600Ae P 600 Operation Maintenance and Repair Distinctions There are very few operating differences between the P 600 and the 600Ae On the P 600 the sensor is to the left of the pen on the 600Ae the sensor is to the right of the pen So you have to allow enough room on the right side of the paper for the sensor mark to be drawn and scanned The pinch wheels for the 600
116. orm the procedures in Removing the Bottom Cover for Internal Access above 3 Discharge any static electricity that has accumulated and remove the power connector brown and blue wires from power supplies Unplug the output cable J3 or J7 on the logic board Use the Interconnect Diagram in the Appendix section as a location guide 4 Remove the 4 screws that hold the unit in the metal pan and pull the assembly out 5 Install the new assembly with the same hardware removed above Make sure that the output cables face the logic board 6 Connect the power plug to the supply and the output cable to the logic board They only fit on one way Use the nterconnect Diagram in the Appendix 7 Plug the power cord into the P 600 and into a wall outlet Test all of the func tions with the keypad 8 Reconnect the serial cable and perform test plots Reassemble the P 600 in the reverse order that it was disassembled See General Disassembly Procedures above 9 If problems arise contact Ioline customer service 95 FOL Chapter 5 Repair and Maintenance Rear Panel Replacement 10 11 12 13 N Electrostatic discharge preventative measures must be adhered to during all assembly replacement procedures Shut off the plotter and remove the power and serial cables Remove the right 4 screws end cover See Removing the End Covers and Dust Cover above Perform the procedures in Removing the Bottom Cover for Internal A
117. r 1 Introduction and Overview 9 How To Use This Manual 10 PUR 11 WarningssAnd Cautions een 11 Basic 11 Product 12 Sp c IfICatIOrnS u age 13 How The P 600 area las 13 Limit Of Liability Statement 14 Ioline Warranty PO lICY nennen 14 Serial Number Identification 15 GIOSS ANY ee 15 Chapter 2 Setting up the P 600 M 28 17 Assembling The P 600 18 Assembling The Stand ae been 18 l evelingithe Standes sua The e ines dies 22 Attach Plotter To The Stand sense 23 Cabling COMME CHONG s roues coelos c LI ME 25 Loading A uoce 26 Loading u Dame 26 Assembling The Feed Shaft au 26 Centering the paper Foll 27 Assembling The Take Up Shaft essere nennen nenne nnn nnn nnn 28 Feeding Paper Over the Platen r 29 Attaching Paper to the Take Up Shaft 29 Positioning the Chartwheels 31 Installing the Dancer Bars and Paper Guide Flanges
118. r received Plotting Quality Problems Good plotting quality is dependent upon a number of different factors The type of paper environmental conditions and operator habits are only a few of the variables that can affect the quality of a plot It is important that the P 600 is loaded and main tained according to the guidelines in the P 600 User s Guide and in Chapters 2 and 5 The table below is a summary of the most common difficulties If a marker plot file has been sent and the output is erratic If the frame sensor does not detect a frame axis mark the P 600 stops functioning and emits audible beeps and the keypad LED is green If the corners of the lines on the completed marker plots are not completely meeting The marker plot file was sent with the wrong plotter language setting The pen is dry The pen ink is not black The frame sensor is broken The paper is slipping The up down delay values are set incorrectly The pen force setting is too low 55 Make sure the apparel design software and the P 600 are set to the same plotter language either HP7475 or HP7596 Replace the pen Replace the pen with a new black ink pen and press the keypad sensor test key to perform the frame axis mark procedure again or press the Start Stop key to proceed to the next frame axis mark Press the Start Stop key to proceed to the next frame axis mark and call Ioline Customer Service Cl
119. rcuit schematics for all of the major components that are unique to the M 28 The follow ing subsystem details are available M 28 Chassis Internal Assembly M 28 Chassis External Assembly and Accessory Kit Carriage Assembly and Logic Main Logic Board Assembly Accessory Kit Bill of materials M 28 106287 P 600 M 28 Accessory kit Number Parts used 100150 CUTTER PAPER 104352 BRUSH GRIT SHAFT PEN PRESSURIZED BALL POINT WRENCH ALLEN 156 TEE 104921 CABLE RS 232 15 FT DISK CONTROL CENTER 3 5 106242 USER GUIDE 600 28 HUB FEED ASSY PEN PILOT V BALL BELT UNWINDING 600 28 104362 STATIC GARLAND 77 56 IN 105118 CABLE SERIAL 9F 25M PIN FORM ADDENDUM UG 600A 28A 101934 2 SCREW 1 4 20 1 00 LG BTN HD SOCK SCREW 1 4 20 625 LG BTN HD SOCK BOX SHIPPING 9 X 7 X 5 FORM WARRANTY 106283 PACKING LIST ACC KIT 600 28 PROC UNWINDING BELTS 600 28 106393 106746 PROC INST ANTI STATIC 1063422 WARRANTY LIMITED 600 28 107 Carriage Assy Bill of Materials M 28 106365 Carriage Assembly M 28 Ioline Part Part Description Number of Number Parts used 1 106366 r r r 3 6 105894 CREW SHOULDER 250 DIA 625LG 2 106246 1 106247 1 106248 AW CARRIAGE r T r 1 LAMP PEN CARRIAGE 1 O LEXURE CARRIAGE Z AXIS 2 1 1 mazim sx gt Im soo 2 mi ou 5
120. riape Replacements ses oeste i Ubri EL 81 Replacing the Carriage Ribbon een asien 82 Frame Sensor Adjustment aeta ein 83 Transmission na ee UT 84 Y Axis Transmission Assembly Replacement enne 84 Y Axis Motor Replacement 86 Y Axis Belt Replacement eue aaa ann 67 X Axis Subsystem 88 u ETT ILI TT 88 X Axis Transmission Assembly Replacement eene 88 X Axis Motor Replacement Rn aA 89 Square Shaft and Chartwheel Assembly Replacement 90 Grit Shaft Assembly Replacembent uu usd e sive tieni iade in 9 Chart Tape Replacement anne 93 Take Up Shaft And Feed Shaft Subsystems 93 ruler 93 Take Up Motor Assembly Replacement eese sees nennen nennen 95 Support Block Replacement epu EI YR EHE UL asl 94 Take Up Shaft Repair dise ierit etae eret esee i sr Nh act Cres aA 94 Feed Shaft Repair ida Ga 95 Electrical Subsystems ID Power Supply Replacement
121. roper media loading directly affects tracking and can vastly improve the plotting performance of the P 600 It is important at this point to distinguish between the feed shaft and the take up shaft The feed shaft is a hollow tube with a flanged hub on one end that supports the unplotted paper roll The take up shaft is similar to the feed shaft except that it has a three inch 7 6 cm diameter silver tube attached to it and it rolls up the plotted frames during the marker plotting process Assembling The Feed Shaft Use Figure 2 11 as a reference 1 Two feed shaft paper hubs are located in the stand accessory kit Make sure that both set screws will not interfere with the free movement of the hubs on the feed shaft 2 Slide one hub onto the feed shaft with the narrow end pointing away from the flanged coupler 3 Insert the feed shaft and hub through the paper roll until the hub is snugly seated into the cardboard dowel at the center of the paper roll Slide the other paper hub onto the feed shaft with the tapered end pointing toward the flanged coupler Seat the second hub into the cardboard dowel 4 Firmly insert the metal hub on the flanged coupling end of the roll by hitting the end of the feed shaft with a rubber mallet 5 Slide the feed shaft through the paper hub on the end opposite of the flanged coupler so that it does not protrude Firmly seat the second hub with a rubber mallet 6 Lift the feed shaft with the paper roll i
122. s P 600 only 222 22 2 2 2 2 0000000000000000000000000000000000 164 Tak up Shaft Assembly uu ics aao ioa aan 165 Take up Shaft Assembly Bill of Materials eese esee 166 reed Shale Assembly un 167 Feed Shaft Assembly Bill of Materials 166 Cable Assembly Power Motors 1 1 4 1 1 4 1 1 1 4 nnn n nnn 169 Cable Assembly Bill of Materials au EU ARR 170 Takesup Transmission Assembly ee 171 Take up Transmission Assembly Bill of Materials 172 Chassis Assembly 600 amp P 600H only Sheet 1 173 Chassis Assembly 600 amp P 600H only Sheet 2 174 Chassis Assembly 600 amp P 600H Bill of Materials 175 Y Axis Transmission Assembly 600Ae amp P 600H only 177 Y Axis Transmission Assembly Bill of Materials 600Ae amp P 600H only 176 Take up Transmission Assembly 600Ae amp P 600H only 179 Take up Transmission Assembly Bill of Materials 600Ae amp P 600H only 180 Carriage Assembly 600 amp P 600H only 181 Carriage Assembly Bill of Materials
123. s level Use the bubble level included in the accessory kit If it is not level according to the instructions in Chapter 2 The chartwheel pressure on the grit shaft creates an impression on the marker plot The underside of the completed marker plot will always have at least six visible grit tracks which should be identical If one grit track is more pronounced or markedly different than the others there may be a chartwheel or grit shaft problem The paper may be slipping because debris has accumulated on the grit shaft pre venting proper paper traction Inspect and clean the grit shaft Refer to the Clean ing section of Chapter 5 for further instructions Contact Ioline Customer Service if damaged equipment is causing tracking diffi culty or if the plotting quality problem cannot be resolved Poor Line Quality If the marker plot line quality is uneven try the following suggestions in order 1 NM BW Use the keypad force knob to select a pen force that produces adequate line qual ity Replace the pen with a new one Adjust the plotting speed in the Control Center Software Plot on a higher quality paper Check that the pen is approved by Ioline Check the set screws on the timing belt pulleys to ensure that they are tight This problem usually causes letters and lines to distort Contact Ioline Customer Service for further help 58 FOL INE Chapter 4 Troubleshooting and Testing ww Paper Alignm
124. sembly is not tangled in the belt Re move the other end of the belt from the carriage Pull the Y Axis belt through the holes in the right end plate The belt may have to be threaded through the pulleys in the Y Axis transmission Perform the procedures in Removing the Bottom Cover for Internal Access above Discharge any static electricity that has accumulated and remove the Y Axis encoder plug from the logic board The plug is located at J10 on the right side of the board Never separate the motor and encoder Rotate the P 600 so that it is in normal operating position Carefully cut the 84 FOL Chapter 5 Repair and Maintenance v x 7 11 12 13 14 15 16 17 18 19 20 21 cable ties that surround the wire bundle that contains the encoder wire Feed the wire and plug through the access hole The plug may need to be bent flat to accomplish this Disconnect the motor power cables Red and black from the base of the motor Loosen and remove the four 11 32 nuts that hold the Y Axis transmission onto the end plate Install the new transmission on the end plate with the motor body pointing down Secure the assembly with the 11 32 nuts from the previous step Reconnect the encoder cable at J10 The P 600 will have to be rotated back to expose the bottom of the machine for this operation Reconnect the power cables to the base of the motor with the red wire attached at 1 and the black wire
125. ssembly Replacement 1 2 AN Electrostatic discharge preventative measures must be adhered to during all assembly replacement procedures Shut off the plotter and remove the power and serial cables Disconnect the black Take up motor cable from the bottom of the P 600 Located 93 FOL Chapter 5 Repair and Maintenance gt under the keypad on the right side of the machine 3 Remove the Strain Relief This is the piece of black plastic that keeps the take up motor cable from rubbing against the motor housing To remove it use a pair of pliers to press the top and bottom of the strain relief together Caution Don t crimp down too hard Then pull the strain relief toward the plotter while gently rocking up and down Remove the strain relief from the cable and set it aside 4 Remove the two phillips head screws on top and bottom of the take up motor housing 5 Slide the silver housing off the motor and unplug the black cable from the motor 6 Remove the take up key from the motor shaft On one side of the key use a 1 8 HEX wrench to loosen the set screw Slide the key off the motor shaft When reattaching the key be sure to tighten the set screw against the flat side of the motor shaft 7 Remove the motor from the take up plate by removing the 4 11 32 nuts around the motor 8 The motor will have a plate attached to it Remove it by unscrewing the 4 screws with a 5 64 HEX wrench Reattach the plate to the new
126. teeth face the pulley wheel and that there are still no twists Insert one of the metal T connectors into the grooves on the back of the car riage body With a pair of needle nosed pliers grasp the other and slip into the grooves This operation may require a strong pulling force Align the tensioner assembly with the indentations on the end plate and apply light tension to the belt by tightening the allen screw 87 FOL Chapter 5 Repair and Maintenance v 10 11 12 13 14 Move the carriage to the far right Adjust the belt tension by tightening the belt tensioner until the spring scale measurement at the center with the belt pulled 1 out from the normal position is 320 20 grams Plug the power cord into the P 600 and into a wall outlet Move the carriage back and forth across the traverse extrusion with the keypad keys while watching the Y Axis belt If there is excessive noise or if the belt is badly misaligned the 11 32 nuts can be loosened and the transmission can be adjusted slightly to achieve proper alignment Reconnect the serial cable and perform test plots Reassemble the P 600 in the reverse order that it was disassembled See General Disassembly Procedures above If problems arise contact Ioline customer service X Axis Subsystem Transmission X Axis Transmission Assembly Replacement N Electrostatic discharge preventative measures must be adhered to duri
127. th 1 88 m 72 0 in Frame To Frame Alignment Intra Frame Repeatability Roll Media Inside Core Diameter 76 mm 3 0 in Maximum Paper Take Up 545 m 600 yd 30 paper 455 m 500 yd 35 paper Refillable or disposable HP style fiber roller ball ball point or felt tip 0 25 in to 0 90 in diameter Overall Physical Dimensions Height 1 17 m 46 in Width 2 26 m 89 in Depth 56 m 22 in Shipping Weight 129 kg 295 Ibs Environmental Range Temperature 0 35 C 32 95 F Relative Humidity 30 85 non condensing Hardware Interface Standard RS 232C serial interface 9600 Baud No parity 8 data bits 1 stop bit hardware or software XON XOFF handshaking DB 25S connector requires DB 25P mating connector Command Languages DM PL HP GL HP 7475 amp HP 7596 How The 600H Works The 600H uses the same technology described above in Chapter 1 How The P 600 Works 113 FOL INE Addendum 600 H 600H P 600 Operation Maintenance and Repair Distinctions There are very few operating differences between the P 600 and the 600H On the P 600 the sensor is to the left of the pen on the 600H the sensor is to the right of the pen So you have to allow enough room on the right side of the paper for the sensor mark to be drawn and scanned The pinch wheels for the 600H are wider than the P 600 to allow for better tracking The pinch wheel lever is located on the back of the plotter instead of the front
128. the belt and pulley teeth are aligned when pushing the pulley onto the motor shaft Reuse the set screws from the old pulley because they have Loctite residue on the threads 10 When reinstalling the pulley make sure that one set screw contacts the shaft on the flat machined surface 11 Reconnect the encoder cable at J10 The Summit will have to be rolled onto the back for this operation Reconnect the power cables to the base of the motor with the red wire attached at 1 and the black wire attached at 2 Use cable ties to rewrap the encoder cables and ribbon cables securely together 12 Plug the power cord into the P 600 and into a wall outlet Move the carriage back and forth across the traverse extrusion with the keypad keys while watching the Y Axis transmission belt If there is excessive noise or if the belt is loose the allen head screws 5 64 allen wrench that retain the motor can be loosened and the motor can be adjusted slightly to achieve proper belt tension 13 Cable tie the wire bundles together to ensure that they do not interfere with movement 86 FOL Chapter 5 Repair and Maintenance v of parts and end cover replacement 14 Reconnect the serial cable and perform test plots Reassemble the P 600 in the 15 reverse order that it was disassembled See General Disassembly Procedures above If problems arise contact Ioline customer service Y Axis Belt Replacement 1 Shut off the plotter and remove the pow
129. the hard drive of the computer Open the hard drive Double click on the SCC Icon The Control Center will open Read the installation notes and follow the instructions that appear on the screen You will see the P 600 Control Center screen seen in Figure 2 20 N NM Plotter 600 Control Center E English Metric Sensor Enabled Acceleration g s Force grams Panel Size in Accel Speed ips Speed Frame Gap mils Frame HPGL Default Send Temporary Settings 7475 7596 Send Permanent Settings Update Display Figure 2 20 The Macintosh Control Center Main Screen 36 JOLINE JOLINE Chapter 3 Operation A OLINE Chapter 3 Operation This section contains guidelines for basic operation of the P 600 Marker Plotter The following primary topics are explained and illustrated Keypad Controls Control Center Screen Options Control Center Menu Items Keypad Controls The keypad on the P 600 provides control of the motion systems on the plotter as well as access to pen force and frame sensor testing Communication can also be interrupted and restored and the initial plotting point can be set from the keypad Figure 3 1 The P 600 Keypad Arrow Keys The arrow keys control paper vertical arrows and pen carriage horizontal arrows movement within the parameters of the P 600 s frame setting The plotter m
130. the logic board by loosening the four phillips head screws and pulling the unit out of the track in the platen Replace the new logic board making sure to insert the top edge into the support track in the platen Insert and tighten the four phillips screws from above The fasteners only need to be snug and can damage the logic board if over tightened Connect all of the plugs on the logic board Use the nterconnect Diagram in the Appendix section and the notes from step 4 as a guide Plug the power cord into the Summit and into a wall outlet Test all of the func tions with the keypad Reconnect the serial cable and perform test plots Reassemble the Summit in the reverse order that it was disassembled See General Disassembly Procedures above 10 If problems arise contact Ioline customer service Resetting the Factory Defaults There are two ways to restore the factory default system parameters Hold down the Start Stop key while Resets all factory parameter defaults turning on the power but keeps the X Y calibration values Resets all factory parameter defaults Hold down the Up Arrow key while and clears the X Y calibration values turning on the power This option should only be used when replacing a ROM chip Keypad Replacement N AN Electrostatic discharge preventative measures must be adhered to during all assembly replacement procedures Shut off the plotter and remove the power and serial cables Remove the rig
131. the ribbon cable from the logic board by sliding the rectangular locking collar away from the socket The collar is fragile so be very careful when loosening it Feed the ribbon cable out of the plastic retainers on the underside of the platen and through bottom slot in the end plate Feed the new ribbon cable through bottom slot in the end plate and into the plastic retainers on the underside of the platen Make sure that the exposed metal 82 FOL INE Chapter 5 Repair and Maintenance v leads face up toward the bottom of the platen 11 12 13 14 15 16 17 18 Connect the ribbon cable to the logic board by inserting the cable into the rectan gular connector until it stops the locking collar must be pulled out Make sure that the exposed metal leads face up toward the bottom of the platen Slide the locking collar toward the socket until it snaps shut The collar is fragile so be very careful when closing it Replace the power supplies using the chassis assembly diagrams in the Appendix as a guide Connect all of the plugs using the Interconnect Diagram in the Ap pendix section Rotate the P 600 back so that it is in normal operating position Feed the ribbon cable through the top slot in the end plate The exposed metal leads should face up toward the top of the plotter Make sure that the cable is stuck to the foam tape on the end plate Gently pull the ribbon cable taut and press it onto the two sided
132. the transistors on the logic board defective YES NO If yes which ones QI Q2 Q3 04 05 Q6 Q7 Q8 Q9 010 011 Were any of the motors or encoders bad If yes which ones X motor encoder__ Y motor encoder__ Roll Feed motor encoder__ Please list any other difficulties Be very specific about the nature of the problem and any symptoms associated with it 71 FOL FINE Chapter 4 Troubleshooting and Testing mm hm Re Packing the P 600 If the P 600 must be returned to Ioline for repair it must be shipped in the original packaging supplied with the plotter To repackage the P 600 use the plotter Packing Assembly Diagram in the Appendix Contact Ioline Customer Service for shipping instructions 72 JOLINE Chapter 5 Repair and Maintenance FOL Chapter 5 Repair and Maintenance gt This section contains instructions for replacing failed assemblies and maintaining the P 600 The testing procedures for determining if an assembly is causing difficulties are located in Chapter 4 The following subsystems and procedures are explained and illustrated Cleaning and Regular Maintenance General Disassembly Procedures Y Axis Subsystem X Axis Subsystem Take Up Shaft and Feed Shaft Subsystems Electrical Subsystem Electronic Subsystem List Of Recommended Tools And Equipment All of the tools and equipment that are needed to perform the repair and adjustment procedures are listed below pq ume es
133. ures above If problems arise contact Ioline customer service 85 FOL Chapter 5 Repair and Maintenance Y Axis Motor Replacement Electrostatic discharge preventative measures must be adhered to during all assembly replacement procedures 1 Shut off the plotter and remove the power and serial cables Remove the right 4 screws and left 4 screws end covers and dust cover 1 screw on each side See Removing the End Covers and Dust Cover above 3 Perform the procedures in Removing the Bottom Cover for Internal Access above 4 Discharge any static electricity that has accumulated and remove the Y Axis encoder plug from the logic board The plug is located at J10 on the right side of the board Never separate the motor and encoder 5 Rotate the plotter back so that it is in normal operating position Carefully cut the cable ties that surround the wire bundle that contains the encoder wire Feed the wire and plug through the access hole The plug may need to be bent flat to accomplish this 6 Disconnect the motor power cables Red and black from the base of the motor 7 Loosen the allen set screws 1 16 allen wrench in the pulley and pull it off of the shaft It may be difficult to remove because the set screws are glued into place and they cause small burrs on the shaft when tight 8 Remove the allen head screws 5 64 allen wrench that retain the motor 9 Remove and replace the motor assembly Make sure that
134. ust be in stop mode red LED to use the keypad arrow keys The pen and media speeds be come greater the longer the key is depressed The pen carriage has a safety feature that will not allow it to collide with the end plates The grit shaft will not allow paper motion outside of the plotting frame during plotting operations Diagonal motion is possible by pressing a vertical and horizontal arrow key simultaneously 38 OLI NE Chapter 3 Operation Start Point You have to set a start point before sending a plot to file the P 600 When the Start Point key is pressed the plotter logic will use the current Y Axis position of the pen carriage as the starting point of the next marker plot A measured feed loop the length of the page frame length setting will then be created The factory set page frame length is 46 inches When the start point process is finished the LED will turn green and the Summit will accept a plot file paper is taut between the paper roll and the take up roll There should N Before pressing the keypad Start Point key always make sure the be no feed loop in back of the plotter Roll Switches The roll feed switches control the rotation of the take up shaft The plotter has to be in Stop mode Red light on the keypad for the roll feed keys to function The Roll switch down arrow can be used to pull paper off the feed roll The Roll switch up arrow will unroll a completed marker plot onto the floor When a plot is being u
135. w No Power When The P 600 is Turned On If the P 600 does not initialize or the fan does not spin when the power is turned on there are a few simple steps to follow to determine if a serious problem has occurred 1 Check the power cord Make sure that it is firmly plugged into the wall and into the back of the plotter 2 Check the voltage at the wall outlet and verify that it is within the operating limits as specified in Chapter 1 Specifications If there are no problems with the power to the P 600 proceed to the Mechanical Electrical and Electronic Diagnostic Process later in this chapter The P 600 Won t Respond to the Computer If there is a problem getting the P 600 to accept commands from the computer per form these procedures Verify that the communications cable is correctly connected to the plotter and to the proper communications port on the computer Check to see that the computer COM port that is being used is configured to match the P 600 s serial COM port settings Make certain that the marker file and the P 600 are set to the same plotter lan guage If the connection is good and the COM port assignments appear to be correct proceed to the next section Communications Problems Many plotting problems can be resolved by testing and adjusting the communications between the plotter and the computer There are three diagnostic tests that can be run from the P 600 Control Center These tests are designed to help deter

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