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P-600 service manual

1. SECURE ALL PULLEY SET SCREWS WITH LOCTITE 222 BE SURE ONE SET SCREW IS AGAINST FLAT ON SHAFT CLEAN MATING SURFACES OF BEARINGS ITEM 6 AND BRACKET ITEM 1 WITH LOCTITE PRIMER N SECURE BEARINGS TO PLATES WITH LOCTITE 609 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 INSTALL PULLEY SO THAT THE GAP BETWEEN THE PULLEY FLANGE AND BRACKET IS 100 010 MOTOR ITEM 5 IS STATIC SENSITIVE COVER MOTOR AND CONNECTOR WITH 3 X 5 STATIC BAG AND SECURE WITH A RUBBER BAND 90 M CAUTION SENSITIVE ELECTRONIC DEVICES BO NOT SHIP OR STORE NEAR STRONG ELECTROSTATIC ELECTROMAGNETIC MAGNETIC OR RADIOACTIVE FIELDS Y axis Transmission Bill of Materials Drawing Number Component Part Number Component Description Quantity Used 1 10535 BRACKT YTRANS SUMMIT97 1 3 10533 PULLEY 16TX 080X1 4 1 3 107346 PULLEY SMM BORE 16T X 080 X 1 4 1 4 105934 PULEY 60T X 080X 1 4 21 5 10747 MOTOR 5MM SHAFT SERVO 24V 1 6 10017 BEARING BALL 2510 62500 196 2 8 104730 JPULEY 080X3 8X25T 1 9 410080 6 LOCK EXTSTAR 3
2. 94 Tray Belt Idler Assembly Right side Bill of Materials 95 Tray Belt Idler Assy Left Side 96 Tray Belt Idler Assembly Left Side Bill of Materials 97 Carriage Assembly 98 Carriage Assembly Bill of Materials 99 Shaft Assembly aaa ua Sasa ua saa Saa 100 Shaft Assembly Bill of Materials 101 System 300 Chassis Assembly 102 System 300 Chassis Assembly Bill of Materials 103 System 300 Chassis Assembly Bill of Materials Cont 104 System 300 Wrapping Procedure 105 System 300 Wrapping Procedure Bill of Materials 106 System 300 Boxing procedure 107 System 300 Boxing Procedure Bill of Materials 108 Service Bulletins ben EE E dr Ta 109 Installation Error 301 Software 109 Creating Barudin
3. 45 Common Problems u a aD sb euis 45 Error Messages z de 46 Software u uuu unu tay PERI DUE 46 LED COGS UMOR 47 No Power When The 300 System is Turned 48 The 300 Won t Respond to the 48 Communication Problems 48 Serial Communication Test 49 Testing the 300 Plotter Port 49 Testing the Computer 49 Cutting Quality Problems ceu days 50 Mechanical and Electronic Diagnostic Process 51 Expanded LED Ood6s 4 1 3 52 External I nSPpeCtU 6 m uuu a oo cinco da evo wd usa eub UE 53 Required T 53 Inspecting the Outside of the Unit 53 Internal Cabling and Connection Inspection 54 Tools Required u u uapa assia 54 Initial Internal Inspection i I aQ a 54 Testing the Power Supply vedo
4. es 39 Open Settings tos u an 39 Saves Settings d 39 aus S R 39 Plotter ELM S 40 Con Port Y Fux da EEG ded 40 Display Saya E PN CUR a CERE 40 Plotter Settings exa edat RE mimes 40 Factory u usa u ua uw 40 animi cep 40 Memory Buffer oue A AA E eee 40 Blade Holder Stats eiu da erede e aue ro aa 40 Voltage ER 40 41 xe docena ees ae 41 HPGL SERING a uu LR vie ras La halus 41 Install New Firmware version 41 ela 42 Calibrate Plotter eben 42 Seral uy aux zna 42 Computer Port Test uyu u aaa ki read u aqu ca iud 42 un RR 42 PLS Us w a Sau Sa 43 8 E 43 wets Oe DR 43 Chapter 4 Troubleshooting and Testing 44 Basic Operational Difficulties
5. 77 X Axis Motor Replacement 78 Table Assembly Replacement 79 Power oe Four ec 82 Power Supply Replacement eee nnne nnns 82 Rear Panel Replacement 11 83 Electronic SUD SYSLOIMNS iu ua Nan SEN 84 Main Logic Board Replacement 84 Resetting the Factory Defaults 85 Keypad Replacement tria ocdx dca dE curb Ri do aub cy Eu 85 Installing new Firmware 32 ds da e t er de lem aede 86 Chapter 6 Drawings and Bulletins 87 Belt Tensioner Y AXIS vau Fai deo ties 88 Belt Tensioner Bill of materials 89 EE TTC 90 Y axis Transmission Bill of Materials 91 Table Assembly u sz a y R yan h ass 92 Table Assembly Bill of Materials 93 Tray Belt Idler Assy Right Side
6. into the grooves on the back of the car riage body 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 mea surement at the center with the belt pulled 1 out from the normal position is 320 20 grams Plug the power cord into the 300 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 moving parts and end cover replacement Reconnect the computer data cable and perform test plots Reassemble the 300 in the reverse order that it was disassembled See General Disassembly Procedures above If problems arise contact Ioline customer service Motor power wires Motor encoder plug Fig 5 7 Motor wires Power amp Encoder 73 FOL INE Chapter 5 Repair and Maintenance v 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 computer data cable Remove the right
7. Wo Chapter 4 Troubleshooting and Testing v L E D Codes LED Sequence 3 Second pause then repeat 3 Second pause then repeat Constantly Repeating 3 Second pause then repeat 3 Second pause then repeat 2 Red Flash 2 Green Flash repeat 1 Buffer Overflow 2 Communication Problems 3 Defective RS 232 Chip Outdated Firmware Plotter Language syntax error Carriage Y axis jam Table X Axis jam Logic Board Error was 1 Perform cutter reset as outlined later in this chapter 2 Perform communication test as outlined later in this chapter 3 Replace the RS 232 chip Check the Firmware version install firmware if needed Contact loline Tech Support The file being sent to the cutter is not of the same language that the cutter is looking for Open the loline Control Center and run a test file If the error doesn t happen again check the original file for problems Check to make sure the carriage moves side to side freely and remove all objects causing the jam to occur Chack to make sure the tray moves in and out freely and remove any objects causing the jam to occur Call Customer Service Solid GREEN Light Emitting Diode LED on the keypad Blinking GREEN Light Emitting Diode LED on the keypad Blinking RED Light Emitting Diode LED on the keypad 47 3 Chapter 4 Troubleshooting and Testing No Power When The 300 System is Turned On If the
8. 61 Chapter 5 Repair and Maintenance 62 List Of Recommended Tools And Equipment 63 Cleaning And Regular Maintenance 64 Cleaning the Traverse Extrusion and Carriage Wheels 64 General Disassembly Procedures 65 Removing the End Covers rioris este eod Febr o nain beens 65 Removing the Bottom Cover for Internal Access 67 TOOIS Require ass 67 Y AXIS SUDSYStEM aides 69 CARR A GE cit M LUE 69 Carriage Replacement 69 Replacing the Carriage Ribbon Cable 70 Y AXIS dust ate Fo te vou ob Poe d uuu etel lob oru on 72 Y Axis Transmission Replacement 72 Y Axis Motor Replacement 74 Y Axis Belt Replacement U U 75 u 77 X Axis Transmission Assembly Replacement
9. Be sure to plug in the arrow side to the printer port Printer Cable If you have a printer or another Dongle you can plug it into the other end of the Hardlock Fig 3 5 Rear view of computer showing correct installation of the Hardlock and printer 31 FOLI NE Chapter 3 Setup amp Operation v Using the 301 software The 301 software is very easy to use and anyone can learn to use it in just a few minutes The first thing to remember is that the 301 software is a tool to help you cut appliques and create stitches for those pieces It is not an Automatic process so some learning on your behalf is required The 301 software uses many different input file types such as Tajima DST Melco EXP Toyota 100 Barudan DAT Autocad DXF and Hewlet Packard PLT These files can contain plot and stitch coordinates at the same time allowing you to create a stitch disk from another embroidery software package The 301 software can import the file and cut the appli que piece or pieces out while keeping the stitch file intact for your embroidery machine to sew Using the 301 software 1 Double click on the 301 icon on the desktop Seen below Ioline 301 2 The first window to open is the main import screen This window allows you to choose the type of file and location of the file you wish to open Ioline 301 r Import File Type Import File Name Tajima dst 2COLOR
10. 250 OD 37 001G 1 2 10690 PULLEY 18X 080 X 3 8 2 3 1016 BEARING BALL 2510 6250D 196 5 4 1 10534 PULLEY 60T X 080 X 1 4 t 100823 SPACER 255ID 380D 250LG 5 6 104820 CLIP BEARING ae 106221 WSHR 25 ID 375 OD 03 THK ENEE GENES 101 TM System 300 Chassis Assembly 106882 CORPORATION FLEX CABLE REAR PANEL 1 JREF MOTOR POWER 8 REF 11 REF Y MOTOR ENCODER CABLE 17 13X 5 REF 9 REF s Z 15 3X REF Q I 31 61 1 REF 41 REF VIEW C C Seb FLEX CABLE X MOTORENCODER Y MOTOR ENCODER REAR PANEL ABLE CABLE CABLE vewpp POWER SUPPLY CABLE 9 REF 2 Ep VIEW B B AC CABLE FLEX CABLE NOTES 1 gt POSITION ENDS OF PLASTIC STRIP BETWEEN 2 HOLES ON ENDPLATE LEG TOPS DO NOT COVER HOLES 2 gt SECURE SET SCREWS W LOCTITE 222 e CLEAN SCREWS WITH ALCOHOL TORQUE TO 32 IN OZ AND SECURE WITH LOCTITE 290 AFTER ASSEMBLY CUT TO 9 1 AND SECURE TO ENDPLATE WITH LOCTITE 401 CUT TO 8 5 AND SECURE TO ENDPLATE WITH LOCTITE 401 SECURE WITH TAPE 20 AS REQUIRED NO No N PLACE RUBBER STRIP BETWEEN PUNCH MARKS AS SHOWN 102 System 300 Chassis Assembly Bill of Materials Drawing Number Component Part Number Component Description Quantit
11. 3 screws end cover See Removing the End Covers above 3 Disconnect the motor power and motor encoder wires from the base of the mo tor See Fig 5 5 4 With a 9 64 HEX wrench loosen the two HEX setscrews on the motor gear pulley See fig 5 6 5 With a 1 8 HEX wrench remove the three black HEX screws at the base of the gear pulley See fig 5 6 6 Carefully slide the gear pulley off the motor shaft and remove the motor from the transmission housing Sometimes the pulley can be hard to remove you may need to pry the pulley off the motor shaft 7 Follow the procedures in reverse order to remount the new motor then adjust the belt tension See Fig 5 9 amp 5 10 on Pg 76 et 8 If problems arise contact Ioline customer service Gear Pulley Setscrews Motor Mounting screws Fig 5 8 Motor mounting screws and gear setscrews 74 lt Chapter 5 Repair and Maintenance Y Axis Belt Replacement 1 10 12 13 14 15 16 Shut off the cutter and remove the power and computer data cables Remove the right 3 screws and Left 2 screws end covers See Removing the End Covers Loosen the allen screw on the belt tensioner until the screw is not exposed Do not remove the screw 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 Make sure that the tensioner assembly is not tangl
12. 91 Table Assembly T 106894 d CORPORATION SEE DETAIL B SEE DETAIL B SEE DETAIL B DASH MARK DETAIL B 4 REF B REF 2 REF JBE NOTES 1 gt ADHERE PROTECTIVE STRIP 6 TO TRAY 8 WITH LOCTITE 401 a 1 9 2 gt CUT TO THE 18 25 MARK ON THE RULER N 3 gt ALIGN CORNERS OF ADHESIVE SHEET 5 TO THE CORNER MARKS ON THE TRAY 2 4 gt ALIGN RULER 1 ALONG THE WALL OF TRAY 2 POSITION RULER AS SHOWN IN DETAIL B USING DASH MARKS 5 gt AFTER THUMB NUT 7 IS TURNED ONTO THE THREADED STUD CRIMP THREAD WITH PLIERS SO THE THUMB NUT CAN NOT BE REMOVED NOTE THE THUMB NUT MUST BACK OUT FAR ENOUGH H TO REMOVE AND INSTALL THE TRAY 6 CUT TO 32 50 3 SEE DETAIL B DETAIL A 7 gt CUT TO 23 05 1 REE 92 Table Assembly Bill of Materials Component Part Number Component Description Quantity Used 106895 RULER 30 INCH 106893 TRAY 300 Pp 6 052 JjSTRP PROTECTVE 48 8 106892 TABLE APPLIKOO 1 93 Tray Belt Idler Assy Right Side n a CORPORATION 2X gt 2X 9 VS SEE DETAIL A NOTES gt INSTALL THIS E CLIP FIRST DETAIL A Tray Belt Idler Assembly Right side Bill of Materials Drawing Number Component Part Number Component Description Quantity Used BRACKET IDLER
13. Clear any media causing the jam Check internally for damaged cabling or loose wires Replace power supply Replace defective transistor or entire logic board Replace defective motor Clear any media causing the jam Check internally for damaged cabling or loose wires Replace power supply Replace defective transistor or entire logic board Replace defective motor Replace the defective power supply Remake the plot file or plot a file from the loline Control Center to verify the cutter is working properly S Chapter 4 Troubleshooting and Testing External Inspection Use these procedures if e The 300 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 300 User s Guide e The 300 has been working but did not initialize after being reset by turning the power off then on e Jam messages occur without media or other objects obstructing normal operation e The carriage is making loud or unusual sounds Required Tools e Multimeter capable of reading AC voltage e Phillips head screw driver e Allen wrenches 1 16 and 5 64 e Nut driver or socket wrench with extension 11 32 Inspecting the Outside of the Unit 1 Turn the plotter off 2 Inspect the unit for damage or obvious signs of mechanical malfunction 3 Measure the voltage at the wall out
14. 1 6 105859 L 7 JL 0646 L 7 SS BS L dH o O 12 10626 5 Ha 10545 17 105543 L ase 154 2 106041 0603 2 60 28 165 3 1604 L 3 198 3 1600 3 106903 3 10606 0 7106996 43 15 Z wW 06560 oe ee L d7 10328 n nn 8 10712 9 03 15 16 16 160 0 10408 _ 23 0997 gt 10326 2 a o 29 1054 9 033 3 164 3 039 3 1004 38 163 1652 99 Shaft Assembly 106903 T v CORPORATION Co REF REF REF REF REF REF REF REF REF 16 221 s L 16221 REF REF REF REF NOTES gt INSTALL ONE SET SCREW WITH FLAT ON SHAFT gt INSTALL ALL SET SCREWS WITH LOCTITE 222 gt INSTALL LABEL PRINTED WITH P N 106903 300 CLEAN BEARING INNER RACE ITEM 3 AND GRITSHAFT PIN ITEM 1 THOROUGHLY WITH ALCOHOL APPLY LOCTITE 406 PRISM TO BOTH CAUTION DO NOT GET LOCTITE INSIDE BEARING 100 Shaft Assembly Bill of Materials Drawing Number Component Part Number Component Description Quantity Used t 1698 SHAFT
15. FOL INE Chapter 1 Introduction and Overview v M 7 Product Overview The Ioline 300 System Cutter can handle many different plotting and cutting operations up to 30 inches wide and 18 inches long Three industry standard plotter languages HPGL 7475 HPGL 7596 and DMPL are supported It is most com monly used in conjunction with the Ioline 301 software for cutting applique patterns and producing embroidery stitch files for those appliques to be output to the most common embroidery machines The 300 System also comes with Control Center software that allows adjustment of a variety of cutter settings from the computer Figure 1 1 Ioline 300 System Cutter 12 Chapter 1 Introduction and Overview Specifications 18 25 x 30 25 463m x 768m mU EU O Remy Mm Markers Pens Pencils to 22 2mm 875 Minimum size 30 7 6mm Overall Physical Dimensions Height 12 30m Width 24 61m Depth 45 1 14m Shipping Weight 124 Ibs 56 Kgs Environmental Range Temperature 0 35 C 32 95 F Relative Humidity 30 85 Non Condensing Hardware Interface Standard RS 232C Serial interface 9600 Baud rate No parity 8 Data bits 1 stop bit Hardware or Software XON XOFF Handshaking DB 25S connector requires DB 25P mating connector Parallel communication IEEE 1284 Command Languages DM PL HP GL HP 7475 amp HP 7596 How The 300 System Works The 300 System combines media and Blade motion t
16. Files 301 Software 110 Run Time Error Codes 301 Software 110 Stitches Overlap to Wrong Side 301 Software 110 How to KISS CUT evt ex o dee iw e 111 TM CORPORATION Chapter 1 Introduction and Overview lt V i Chapter 1 Introduction and Overview ww Chapter One provides an overview of the Service Manual and important background information about the 300 System Cutter 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 300 System Cutter including product specifications installation directions and testing and repair procedures Chapter 1 of the manual provides introductory information and general specifications Chapter 2 provides descriptive drawings showing part names for the 300 System cutter This section is intended to supplement the 300 System User s Guide Chapter 3 familiarizes the user with how the 300 System operates and how to use the software to maximum benefit This section also supplements the 300 System User s Guide Chapter 4 is a troubleshooting and testing guide Chapter 5 provides details for repair and ma
17. Inspection 1 Fully disassemble the 300 as described in Chapter 5 General Disassembly Proce dures Many components in the 300 are sensitive to static discharge Make sure that any static electricity is discharged before attempting any service procedures A ground ing wrist strap works the best and can be provided by Ioline on request 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 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 4 Plug the cutter 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 54 Chapter 4 Troubleshooting and Testing Testing the Power Supply Tools Required Multimeter capable of reading DC voltage Ioline power supply test fixture Soldering apparatus optional Insulating material electrical tape mylar strips etc Inspecting the Fuse and Output Terminals 1 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 b
18. PLT Melco exp Plotter Control Center Toyota 100 Barudan dat lt Help c embdata pit AutoCAD dxf 1 HP GL G3 c loline 301 Revision 4 About Fig 3 6 301 Software Main Window Select the type of file and it s location and click on Load import file 32 loline 301 DESIGN c VembdataX2color pit Fig 3 7 301 design view Display Options Zoom Function zoom CUTTER Display Choose whether to display the cut file or the stitch file sh Ju St C STITCH Display 2 mps In stitch display mode clicking on Single Step shows the order that the embroidery machine will stitch the file Design setup allows the user to change certain parameters of the cut file It also allows easy changing of Design Setup f the layers See detail on Pg 34 Send to Cutter sU Sends the file to be cut Save File 1 Saves the stitch file for your embroidery machine to sew Create Stitches Create Stitches allows the user to create stitches and modify them to the users liking See detail on Pg 34 Prints the current view to a standard Windows printer Ovtions If you are cutting out a DXF file this option allows the user to rescale the file to work better in the 301 Port Set software Also you can choose to use the mouse button to Pan the drawing Port Setup allows the user to change
19. X DRIVE RIGHT IDLER X DRIVE APPLI K 99 SHAFT IDLER X DRIVE APPLI K 99 106530 WSHR 195 ID 245 OD 03 THK 106626 WSHR 195 ID 2450D 02 THK 106896 BEARING 187 ID 375 OD 125 W 95 Tray Belt Idler Assy Left Side m 106902 CORPORATION E 2 y 9 Fo REF REF REF REF ND REF NOTES REF gt INSTALL THIS E CLIP FIRST DETAIL A 96 Tray Belt Idler Assembly Left Side Bill of Materials Component Part Number Component Description Quantity Used 106822 BRACKET IDLER X DRIVE LEFT 106890 IDLER X DRIVE APPLI K 99 106891 SHAFT IDLER X DRIVE APPLI K 99 106530 WSRR 195 ID 245 OD 03 THK 106626 WSHR 195 ID 2450D 02 THK 106896 BEARING 187 ID 375 OD 125 W RING RETAINING E CLIP 3 16 97 TM CORPORATION Carriage Assembly 106905 25 REF a 2x rer DETAIL A MUST BE ORIENTED AS SHOWN ATTACH TO SPRING PRIOR TO ASSEMBLY w DETAIL B ASSEMBLED DETAIL B EXPLODED 1 gt LUBRICATE INNER RACES WITH TRI FLOW 2 gt SECURE SCREWS WITH LOCTITE 425 ASSURE 3 gt TORQUE SCREW TO 9 IN LB 4 gt FOLD TEFLON TAPE IN HALF AND PLACE ON BASE EDGE 6 gt CALIBRATE VOICE COIL S
20. ay ususi EYE Y SPERTI AY aX AERE ayasa E 27 Test CUT 28 Repeat maa sa Enron DE Eun eae 28 Software Installation 29 Installing the 301 and Control Center Software 29 Windows 95 98 ME installation 30 Windows NT 2000 mmm 30 Installing the Hardlock Key 31 Using the 301 SoftWare iioii iri rro pM ov bor eee 32 Control Genter SoftWare eiii uuu a u levee cnet e io pov node eoe 36 Screen OPtlOnS uu sus Y 36 M asuremehnt UNITS uuu u 37 Acceleration aa n 37 Up D wn Delays 37 HPGL DETAUIE y 37 Send Settings the 30 sa 37 eas 38 Panel Size n 38 S1 ara AT A A 38 Blade Verbs iu EE 38 Menu diodes ce alea dte gei educere te ioca aa 39 ma e skua 39 Send Gut PIOE Fil
21. file Common Cut Quality Problems 50 Chapter 4 Troubleshooting and Testing Mechanical and Electronic Diagnostic Process The diagnostic processes that follow are detailed and invasive Do not attempt to service the 300 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 300 System cutter Make sure to record the results of any diagnostic examination on the Diagnostic Record at the end of the chapter Computer Software Resolution Computer Software Resolution LED Codes Pg 47 52 Communication Problems Begin Recording Diagnostic Information Pg 60 Examine The External Components Pg 53 Logic Problem Test Chapter 4 Communication Test Pg 48 Power On Test Power On Test Power On Test Disassemble Check Cabling and Connections Pg 54 Examine Power Supply Pg 55 Examine Logic Board Pg 57 Examine Motors Pg 58 Contact Ioline Customer Support If required Pg 60 Figure 4 1 Mechanical Electrical and Electronic Diagnostic Flow Chart 51 Wo Chapter 4 Troubleshooting and Testing Expanded LED Codes LED Sequence Probable Cause Solution e 300 System not plugged in e Cycling power supply due to Dark or erratic flashing LED 3 Se
22. files plt format to the 300 Open Settings File Opens custom settings for the 300 that have been stored with the Save Settings As option below When the 300 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 300 at a later time To retrieve these files use Send Settings File explained above Setup 300 Control Center File Setup Display Options Calibrate Test Help Plotter Setup t Acceleration EM i r Delays Figure 3 16 Setup Menu 39 FOLI NE Chapter 3 Setup amp Operation v Plotter Setup Allows selection of the plotter model and COM port Com Port Setup Provides a list of COM ports to select from Display til loline 300 Control Center Ael Es File Setup Display Options Calibrate Test Help Plotter Settings Factory Defaults Delays 5 rw ms rete I 1ra1 Plotter Settings Replaces all of the screen values with the current settings stored in the logic Version Memory Buffer Blade Holder Status Motor Voltage Figure 3 17 Display Menu Factory Defaults Replaces 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 in
23. it was disassembled See General Disassembly Procedures earlier in this chapter If problems arise contact Ioline customer service Replacing the Carriage Ribbon Cable 1 Shut off the plotter and remove the power computer data cable Remove the right 3 screws and left 2 screws end covers See Removing the End Covers and Dust Cover earlier in this chapter Perform the procedures in Removing the Bottom Cover for Internal Access earlier in this chapter Perform the procedures in Replacing and removing the carriage earlier in this chapter 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 loosen ing 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 Interconnect Diagram in the Appendix section as a location guide Remove the power supply 2 screws in the removable metal pan by loosening the phillips head screws and pulling the unit out of the track in the platen Disconnect the ribbon cable from the logic board by sliding the re
24. red stripe pin 1 on the closest edge to the keypad 83 FOL INE Chapter 5 Repair and Maintenance no 13 Cable tie the wire bundles together to ensure that they do not interfere with moving parts and end cover replacement 14 Plug the power cord into the 300 and into a wall outlet Test all of the keypad keys and make sure that all of the functions are working 15 If problems arise contact Ioline Customer Service Electronic Sub Systems Main Logic Board Replacement Electrostatic discharge preventative measures must be adhered to N during all assembly replacement procedures 1 Shut off the plotter and remove the power and computer data cable 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 84 Q Chapter 5 Repair and Maintenance v 5 Remove the logic board by loosening the four phillips head screws and pulling the unit out of the track in the platen 6 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
25. ruler The reading on the fish scale should read from 300 to 360 Grams See fig 5 10 Adjust the belt tensioner until the belt tension is correct If you can t find a fish scale the belt can be adjusted by hand Tighten the ten sioner until you feel there is enough tension on the belt Slide the carriage back and forth by hand If you feel slipping the belt is too loose If you hear Clicking the belt is too tight 75 Y Axis Belt Assembly Fig 5 9 Tensioning the Y axis belt assembly Hook the scale to the belt and pull to the Pull the belt until it reads between 300 and 360 Grams Fig 5 10 Pulling the belt to 1 and measuring 300 to 360 Grams 76 FOL IINE Chapter 5 Repair and Maintenance ww X Axis Subsystem X Axis Transmission Assembly Replacement o2 N Electrostatic discharge preventative measures must be adhered to during all assembly replacement procedures It is important to note that the X Axis transmission consists of two pulleys a motor and the table assembly along with it s belts There is no assembly to re place but the components can be changed if necessary Shut off the cutter and remove the power and computer data cable Remove the right 3 screws end cover See Removing the End Covers above To change either pulley loosen the set screws See Fig 5 11 pull the pulley off and replace with a new part Reuse the set screws from the old pulley because there is Loctite res
26. screws from above The fasteners only need to be snug and can damage the logic board if over tightened 7 Connect all of the plugs on the logic board Use the Interconnect Diagram in the Appendix section and the notes from step 4 as a guide 8 Plug the power cord into the 300 and into a wall outlet Power the machine on using the reseting procedure below Test all of the functions of the keypad 9 Reconnect the serial cable and perform test plots Reassemble the 300 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 If you have replaced the logic board or the 300 System is acting wierd the machine should be reset to 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 Electrostatic discharge preventative measures must be adhered to during all assembly replacement procedures 1 Shut off the plotter and remove the power and computer data cables 2 Remove the right 3 screws end cover See Removing the End Covers above 3 Loosen a
27. that might have caused their original failure 57 lt Chapter 4 Troubleshooting and Testing v Testing and Replacing the Other Logic Components 1 Ifall 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 Testing the Motors Use this procedure if e The procedures in Testing the Logic Board did not resolve the difficulty Tools Required e Phillips head screw driver e Allen wrenches 1 16 5 64 Initial Motor Inspection 1 Move the tray in and out and move the carriage side to side 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 Likely Modes of Motor Failure 1 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 2 The motor encoder has failed The encoder allows
28. the Start Stop button so the keypad light is Red Press the repeat button and it will Re cut the same file directly over the previous cut This technique is good for thick material that doesn t cut right the first time and may take several Repeats to cut through fully 28 gOLEIN Chapter 3 Setup amp Operation Software Installation The Ioline 301 Embroidery software is a Microsoft Windows 95 98 ME 2000 compatible program that comes on a CD ROM disk with the cutter or is available online at www ioline com A Macintosh version of the 301 software is not available The 301 software will perform the following 1 Import some of the most popular embroidery files including Tajima Toyota PLT DXF and Baraudan 2 Export in some of the most popular file formats like Tajima Toyota PLT DXF and Baraudan 3 Cut out multiple appliques in multiple layers 4 Create multiple stitch files in multiple layers 5 Stitch editor program for editing all facets of a stitch 6 Design Setup window for easy shape duplication rotation and layer selection Installing the 301 and Control Center Software The 301 software 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 Usethe 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 high lighted m
29. the allen screw on the belt tensioner until the screw is not exposed Do not remove the screw Grasp 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 Make sure that the tensioner assembly is not tangled in the belt Remove 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 Disconnect the motor power cables Red and black and the encoder plug in Black connector at the bottom of the motor from the base of the motor See Fig 5 7 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 72 gol Chapter 5 Repair and Maintenance 10 11 12 13 14 15 16 17 18 Secure the assembly with the 11 32 nuts from the previous step Reconnect the power cables with the red wire attached at 1 and the black wire attached at 2 and the encoder plug in at the base of the motor 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
30. the port the cutter is plugged into Help Edit Design allows the user to edit the stitches manually to fix problems See detail Pg 35 Close Help using the 301 software Close the design view Fig 3 8 301 Display Options buttons defined 33 Chapter 3 Setup amp Operation JOLINE Design Setup Adjust Imported Design Color Setup Needle down After first stitch following jump s V ira fo _ eu Me oo ows the user to Adjust Imported Design on individual layers and Allows the user to adjust create a different stitch Rotation Mirror and units Mirror G Vertical file for each layer Or work on all the layers and create stitches for all the layers at once of measure for the design Ruler Type c 46 E Margins and Copies _ Raton h Allows the user to easily duplicate a single shape to fill the tray of fabric C Maximum Copies Horz Count Set Count s Vert Count Margins Horz Margin 4 25 Between ia am num Vert Margin 4 25 Cutter Size Show ALL colors Show FRET color only KC ALL K C ALL This is a specialty function for KISS Cutting Turn ALL on 175 rone 44 4t Save Setup Recall Setup Detauit Setup if you intend to cut multiple Material Dimensions var 255 745 Fam Allo
31. v Re Packing the 300 If the 300 must be returned to Ioline for repair it must be shipped in the original pack aging supplied with the plotter To repackage the 300 use the plotter Boxing Procedure Diagram in Chapter 6 Contact Ioline Customer Service for shipping instructions 61 TM CORPORATION Chapter 5 Repair and Maintenance 62 Chapter 5 Repair and Maintenance Repair and Maintenance This section contains instructions for replacing failed assemblies and maintaining the 300 system cutter 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 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 SS SS RS KS KS OO 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 Exacto Blade Double back tape Needle nose pliers Volt Ohm Meter Sta
32. will make a beep sound and the light will turn off The new firmware will now Start to load into the plotter When it s done close the Ioline Control Center and turn the plotter off 6 Reset the plotter by turnning it back on while pressing and holding the UP arrow key on the keypad of the 300 System 41 FOLI NE Chapter 3 Setup amp Operation v Calibration Plotter 600 Control Center loj Fie Setup Display Options Calibrate Test Help Acceleration p Ju Calibrate Plotter Speed X Sensor Enable ws 9 r a Figure 3 19 Options Menu Calibrate Plotter Provides methods to calibrate the cutter for maximum accuracy The 300 System is calibrated at the factory and does not need dimensional calibration If you feel the cutter is not dimensionally accurate contact Ioline Tech Support Test Plotter 600 Control Center File Setup Display Options Calibrate Test Help Acceleration P Measurement Units Serial T est Speed C Metric Computer Port Test 7 Ix Plotter Port Test Frame Gap a e rPanel Size Figure 3 20 Options 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 C
33. 300 System Without Removable Tray Rear View 19 Chapter 2 Nomenclature Logic Board X Axis Motor P wer Supply See Detail Below Assembly Fig 2 3 300 Cutter Bottom View with bottom cover removed Tray strip Keeps the removable tray down Adhesive Sheet Y Axis drive belt Removable tray thumb screws Fig 2 4 300 Cutter Top View 20 NE Chapter 2 Nomenclature m Keypad Assembly X sembly Right End Plate Axis Transmission Rear Panel Assembly Assembly See detailed drawing on Pg 21 Fig 2 5 300 Cutter Right view with cover removed Belt Tensioner Assembly Left End Plate Fig 2 6 300 Cutter Left view with cover removed 21 FOLI NE Chapter 2 Nomenclature m 5v Regulator Parallel Port r Connection My Axis Fan gm RL Motor ENC Connectors EN oe Power Motor ENC Supply Connection Servo Keypad amp Motor Serial Connection Connection Carriage Ribbon Cable Connection Program mable ROM Fig 2 7 Logic Board Table Assembly Non Removable Fig 2 8 Tray amp Table Assembly 22 FOLI NE Chapter 2 Nomenclature m Top Spring Voice coil Wires Wheel Main Voice coil Secondary Voice coil nil gt I K m yoe Axis Belt Y Axis Belt el CUM Blade holder i thumb screw Blade holder Sensor See detailed dra
34. 300 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 300 System proceed to the Mechanical Electrical and Electronic Diagnostic Process later in this chapter The 300 Won t Respond to the Computer If there is a problem getting the 300 to accept commands from the computer perform these procedures e Verify that the communications cable is correctly connected to the plotter and to the proper communications port on the computer e Check to see that the computer LPT or COM port that is being used is configured to match the 300 s serial or parallel port settings e XWYAE THE TOMEP AVS ov AYALV PECET THE YOMMVVLYATLOV TOPTS ov tne 300 e Make certain that the file and the 300 are set to the same plotter language e If the connection is good and the port assignments appear to be correct proceed to the next section Communication 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 300 Co
35. 3000 0 0 1 Pp 4 1004 508 300 Jo 1 5 10779 J BOXSHPPIG30 1 6 10705 BOX LABEL UNPACKING 300 SYSTEM 2 7 107076 SHEET ADHESIVE 18 5X305 3PK 1 8 10 786 MATERIAL BACKING 18X30 1 SIDED 2 1008 MATERIAL BACKING 18X30 2 SIDED 2 10 108 JYRA d51NX9IN 4 10 177 GUIDE QUICKSTART 20 30 21 1 N N 108 Service Bulletins Installation Error 301 Software This bulletin pertains to versions 9 17 or higher of the Ioline 301 Software that do not install successfully Error Message could not install to C windows or c windows system Error Message a required file MSVBVM50 dll was not found 1 Make sure that any virus checking program that might prevent writing to the Windows system area is disabled 2 Close all Windows application programs 3 Using Windows Explorer make sure that Windows is installed the standard directory C windows system If not note the Windows path for use in step 7 4 Ifyou have not already done so copy the attached programs WSUP EXE and WSUPE EXE to a dis kette Use these diskettes for steps 5 and 6 5 Place the disk with WSUP in drive A Click on the Windows Start button then click on Run Enter the following path into the Open field A WSUP Click the Unzip button 6 Place the disk with WSUPE in drive A Click o
36. 598 1 9 121650 0800 14 107 1 10 1 106030 PCBASSY 68331 APPLEK PROG 1 10 1 1035 55 68331 300 PROG 1 HO 177090 PCBASSY 68331 V REG PROG 300 1 11 106817 TRANS ASSY Y DRIVE 24V 1 12 1 1069 JPULEY 16TX 080X1 4 1 12 107346 PULLEY SMM BORE 16T X 080 X 1 4 1 31 1 106695 FERRITE SPLIT 100MHZ 74IDX1 6L_ 1 ele e e P P K F 106717 COVER BOTTOM SC98 30 104 System 300 Wrapping Procedure miel iiis a v Wrapped Level CORPORATION NOTES 1 CUSHION CARRIAGE AT LEFT END OF PLOTTER WITH FOAM BLOCK ITEM 11 NOT SHOWN AND SECURE TO END OF PLOTTER WITH TYRAPS ITEM 10 NOT SHOWN SUPPORT CARRIAGE JAW WITH FOAM BLOCK ITEM 11 NOT SHOWN 105 System 300 Wrapping Procedure Bill of Materials Drawing Number Component Part Number Component Description Quantity Used WSHR 8 32 190 ID 416 OD 080THK 8 c cr 1 TYRAP 28 CABLETIE NAT NYLON FOAM BLOCK 2 IN X 2 INX 2 IN SCREW 8 32 375 LG PHP SEMS SHEET ADHESIVE HT 18 5X30 5 3PK 106 System 300 Boxing procedure 106880 Pa v CORPORATION FGI Level 107 System 300 Boxing Procedure Bill of Materials Drawing Number Component Part Number Component Description Quantity Used 1 10681 WRAPPED 300 1 1077 LABEL SHIPPING BOX 30 2 _3 __ 1003 PACKNGUST
37. FOLINE N CORPORATION 300 System Cutter Service Manual MLINE Edition Notes This is the first edition of the 300 System Service Manual Subsequent updates or revisions will be an nounced on this page Copyright Notice Copyright 2001 Ioline Corporation All Rights Reserved Printed in the United States of America P N 107571 REV 0 April 2001 Trademarks Ioline System 300 and 301 Software 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 system 300 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 Table of Contents Chapter 1 Introduction and Overview 9 How To U
38. Internal Access above Cut plastic cable ties around wires Remove the gray ribbon cable blue socket at J2 near the right end plate by push ing the blue tabs away from the center of the connector The plug should be easy to pull out Remove the Light blue ribbon cable Light blue socket at J12 Unplug the power supply cable Brown and Blue wires located on the side away from the logic board Pull the wires 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 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 Hint The cable is keyed to fit one way in the socket 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 Reattach the light blue ribbon cable with the
39. Overview Serial Number Identification Identification of Ioline Corporation products is accomplished by use of a serial num ber located on the back of the plotter See fig 2 2 on Pg 17 You can determine the model and date of manufacture by interpreting this serial number SS300 00 25 01 Sequence Number Week of Manufacture Year of Manufacture Model Number Figure 1 4 Ioline Serial Number Indications Glossary 1 BOM Bill s of materials for an assembly 2 BOTTOM PAN Metal housing protecting the underside of the cutter The component that holds the knife It 3 CARRIAGE travels along the Y Axis on the traverse assembly Where the user controls simple plotter 4 KEYPAD functions Carriage and media motion is accessible from here during stop mode s TRAVERSE ASSEMBLY 02 that supports and sudes the carriage 6 X AXIS Direction of tray moving in and out of the machine 7 Y AXIS Direction of knife motion Usually associated with the carriage 17 CORPORATION Chapter 2 Nomenclature TM FOLI NE Chapter 2 Nomenclature x Nomenclature Defining the different parts of the 300 System Carriage Assembly See detailed drawing on Pg 20 Cover On Removable Tray Figure 2 1 300 System With Removable Tray Front View Serial Number Plate Table Assembly Without Removable Tray Rear Panel Assembly See Detailed drawing on Pg 21 Figure 2 2
40. PRING SYSTEM TO PRODUCE 50 GRAMS CUTTING FORCE SEE CALIBRATION PROCESS NOTES 7 gt SECURE ITEM 27 IN PLACE WITH LOCTITE 290 AFTER CALIBRATING VOICE COIL SPRING SYSTEM 8 gt SECURE WITH LOCTITE 222 98 Carriage Assembly Bill of Materials Drawing Number Component Part Number Component Description Quantity Used 105554 OVER MOLDED MACHINED 106934 TANDOFF F F 48 32 1 0 LG 106998 106213 106230 105859 SPRING EXTENSION SHORT 106462 107178 104716 CREW THUMB 1 4 20 1 00 106526 CREW SHOULDER 187 DIA 5625 LG 105546 IN CARRIAGE SHORT 105545 105543 105544 BUSHING BALL PREC 25 106041 106073 105860 RACKET CALIBRATION CARRIAGE 106115 PACER 188 ID 313 OD 188 LG 106214 CREW 4 40 250 LG HEX 106208 RACKET LOWER VCM 106210 RACKET UPPER VCM 106933 PCB ASSY CARRIAGE APPIL K 99 gt 79 106906 106996 101581 107274 104560 107327 OVER CARRIAGE TOP 200 300 107328 CREW 4 40 187 LG PHP SEMS 104712 CREW 4 40 312 PHP NYLON 104337 106626 106530 WSHR 195 ID 245 OD 03 THK 104008 1 100037 1 103726 YRAP 1 IN X 3 IN BLACK 101860 CREW 2 56 312 LG PHP 104471 APE UHMW 43 WIDE 105547 100333 106314 3 103896 100074 1 106353 3 106532 1 72 N A IN jejejejeje le CO 72 1 0554 2 94 pT 10698 1613
41. Quality Problems Good cutting quality is dependent upon a number of different factors The type of material environmental conditions and operator habits are only a few of the variables that can affect the quality of a cut It is important that the 300 is loaded and maintained according to the guidelines in the 300 User s Guide and in Chapters 2 and 5 of this manual The table below is a summary of the most common difficulties Problem Cause Solution If a cut file has been sent and the output is The file was sent with the wrong plotter Make sure the file was created with the language setting correct plotter language or the cutter and the Ioline Control Center are setup correctly If the corners of lines on the completed 1 Knife Offset is not set correctly 1 Knife offset can be changed in the applique are not completelly meeting Ioline Control Center See Chapter 3 setup amp operation of Ioline Control Center 2 Knife overcut is set too low 2 Overcut should be set to 20 for standard twill 3 Loose set screw or loose belt on 3 See chapter 5 for procedures on the cutter how to fix a loose setscrew or belt If a cut file has been sent and the output is The cut file has too many Nodes in If you are using Corel Trace to VERY slow no matter how fast the speed is it create applique files the output will take a long time and won t cut very nice Instead hand trace the file to reduce the amount of Nodes in the
42. Turn the power off and disconnect the computer data and power cables Move the carriage assembly to the right side of the cutter Remove the right side cover See Removing the covers earlier in this chapter Use your assistant to help you flip the 300 cutter over onto it s top dust cover Use the right side cover to place under the tray so it doesn t fall over while it s on it s top See figure 5 5 Remove the phillips screws along the bottom cover s edge See figure 5 6 While removing the bottom cover take care in unplugging the fan wire from the logic board 67 FOL INE Chapter 5 Repair and Maintenance Bottom Cover Right side cover under the tray Fig 5 5 Turn 300 over and place right side cover under tray Bottom cover screws Fig 5 6 Bottom cover screws 68 Chapter 5 Repair and Maintenance v Y Axis Subsystem E CARRIAGE Carriage Replacement 1 Shut off the cutter and remove the power and computer data cables Remove the right 3 screws and left 2 screws end covers See Removing the End Covers earlier in this chapter 3 Loosen the allen screw on the belt tensioner left side of the machine until the the bracket is flat against the end plate Do not remove the screw 4 Grasp 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 tensione
43. bove 3 Discharge any static electricity that has accumulated and remove the power connector brown and blue wires from power supply 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 cable Big plug face the logic board Hint The screw holes only line up one way on the bracket 6 Connect the power plug to the supply and the output cable to the logic board They only fit on one way Use the Interconnect Diagram in the Appendix 7 Plug the power cord into the 300 and into a wall outlet Test all of the functions with the keypad 8 Reconnect the computer data cable and perform test plots Reassemble the 300 in the reverse order that it was disassembled See General Disassembly Procedures above 9 If problems arise contact Ioline customer service 82 A Chapter 5 Repair and Maintenance Rear Panel Replacement 10 11 12 Electrostatic discharge preventative measures must be adhered to during all assembly replacement procedures Shut off the plotter and remove the power and computer data cable Remove the right 3 screws end cover by following the Removing end covers earlier in this chapter Perform the procedures in Removing the Bottom Cover for
44. cond pause then repeat 3 Second pause then repeat Less than 2 second pause then repeat Alternating Red amp Green 01 oT Incorrect power supply or defective power supply Defective transistor s on the logic board Short or other problem with motor e Defective power supply e Defective transistor s on the logic Carriage Y Axis jam due to Media or mechanical jam Transmission failure Defective power supply Defective transistor s on the logic board Defective motor encoder Short or other problem with motor e Tray X Axis jam due to Media or mechanical jam Defective transistor s on the logic board Defective power supply Defective motor encoder Short or other problem with motor Cycling power supply due to Incorrect power supply sequence or defective power supply Defective transistor s on the logic board Short or other problem with motor e Syntax Error due to Defective power supply e Incompatible Syntax in plot file 52 Plug unit into wall outlet Check internally for damaged cabling and loose plugins Replace defective transistor or replace logic board Replace the defective motor Replace defective transistor or replace logic board Replace defective keypad Clear any media causing the jam Check internally for damaged cabling or loose wires Replace power supply Replace defective transistor or entire logic board Replace defective motor
45. ctangular lock ing collar away from the socket The collar is fragile so be very careful when loosening it 70 A Chapter 5 Repair Maintenance Ribbon cable replacement cont 10 11 12 13 14 15 16 17 18 18 19 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 leads face up toward the bottom of the platen 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 supply plug using the chassis assembly diagrams in the Appen dix as a guide Connect all of the plugs using the Interconnect Diagram in the Appendix section Rotate the 300 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 t
46. cy and correct depth For more information see Chapter 4 Cutting quality problems Blade Force You can set the Blade force by using the knob on the keypad The minimum value 10 Grams and maximum value 175 Grams of the available force can be set from the 300 Control Center if you are plotting with a pen If you are using a blade then the force is set at 700 grams and is not adjustable from the control center software Material type and thickness determines the correct force setting range on the keypad force knob Start Stop The Start Stop key controls serial or parallel communication between the plotter and the computer 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 and Control Center settings can only be sent to the cutter 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 the 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 cutter and the computer When communication is open between the cutter and the computer the LED will be green 27 Test Cut Pressing Test Cut on the keypad will cut a small square with a circle cut into 4 pie pieces Se
47. der is over the lower right corner of the material lower left origin of plot file Press Set Origin on the Keypad to obtain a green Keypad light Open the 301 software Select the directory and file you wish to open See 301 Main Window on the next page Double click on the file or select the file and click on Load Import File Select Design Setup Under the Color Setup heading select K C ALL Kiss Cut All See Design Setup window on the next page Under the Color Setup heading select the color that corresponds to the Top layer of the design to be cut This should be the profile with the Smallest perimeter See Design setup window on the next page Select OK Select Send to Cutter Select OK When the first cut is done press the Start Stop button the light should turn Red and move the tray forward Weed away the excess material around the top letter Press Start Stop button on the cutters keypad the light should turn back to green and the tray and head will move back to the original starting point Under the Color Setup heading select the color that corresponds to the next layer of the design to be cut and deselect the color that was just cut This profile should have a larger perimeter than the one previously cut Select OK Select Send to Cutter After it has finished cutting weed away the excess material Note As an alternative method you can also cut the pieces in re
48. e drawing below This internal cut is designed for adjusting the correct blade depth on the blade holder For a diagram showing correct blade depth see the 300 User s Guide under Setting up the blade Pressing the test cut key for approximatelly 2 3 seconds will cut the Ioline logo This is designed as a further test to see how the blade is cutting with more complex shapes and letters Fig 3 2 Test Cut Repeat The repeat button serves two purposes 1 To repeat the same cut over and over again on a new piece of material without having to re send the file from the computer 2 To repeat the same cut on the same piece of material if the material is hard to cut such as Leather or Felt When a file is sent to the 300 to be cut the file is stored in the memory buffer of the 300 system cutter After loading the tray with a new piece of material press the Start Stop button so the keypad light is Red After setting the blade in the starting posi tion you can press the repeat button The same file will then cut out on the new piece of material without having to re send the cut file from the computer Note It is only neccessary to press the Star Stop button after sending the file from the computer Pressing the repeat button will leave the light red when it is finished If you are cutting Hard to cut material such as Leather or Felt then the repeat button serves a valuable function When the file is done cutting press
49. e not affected To solve rename the file to something less than 16 characters then import into the design view of the 301 software and export in Tajima format as normal Run time error 6 Overflow Occurs when a design is imported into the design view containing coordinates greater than 32 760 This is never a problem with designs appropriate for embroidery rarely coordinates greater than 15 000 However there are plot plt designs that do contain larger coordinates for sign cutters etc This error should not occur when running 301 version 02 4 or higher on Win 95 98 However it will occur with Windows NT and 2000 Beta version 02 7 solves the problem 301CD8 1 exe and 301CD8 2 exe Run time error 13 Type Mismatch Unknown circumstances Run time error 57 Device I O Involves Printer or Serial Port Usually this error will be trapped within 301 but sometimes not Run time error 75 Path File Access Error File location or path does not exist DLL Not Found or Procedure in DLL Not Found Occurs if a dll file was not properly installed Verify Hardlock vxd Win95 98 Hardlock sys Windows NT IolineLPT dll and Tiffw32 dll exist in either C windows system or C winnt system folder Stitches Overlap to Wrong Side 301 Software Occurs most often when converting an outline which is from an embroidery file versus outlines generated from Corel Draw or the like This is because the stitch segm
50. e platen 6 Disconnect the motor power cables Red and black from the base of the motor and the black encoder plug with 4 wires at the base of the motor 7 Remove the motor pulley and belt Loosen and remove the three phillips head screws that hold the motor on the end plate 8 Replace the motor and attach the pulley and 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 1 and the black wire attached at 2 Make sure to route the wiring through the plastic clips so that it is held away from moving parts and is accessible after the logic board is installed 78 10 11 12 13 14 15 N E Chapter 5 Repair and Maintenance 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 300 and into a wall outlet Turn the power to the cutter on Move the tray 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 th
51. e wire bundles together to ensure that they do not interfere with moving parts and end cover replacement Reconnect the computer data cable and perform test plots Reassemble the 300 in the reverse order that it was disassembled See General Disassembly Procedures above If problems arise contact Ioline customer service Table Assembly Replacement AN Electrostatic discharge preventative measures must be adhered to N e during all assembly replacement procedures Shut off the plotter and remove the power and computer data cable Remove the right 3 screws and left 2 screws end covers See Removing the End Covers above Loosen the 2 11 32 nuts located on either side of the X axis tray gear See Fig 5 12 4 belt adjustment nuts Right end plate Left end plate Nut w slotted hole Fig 5 12 Right and left end plates showing tray adjustment nuts 79 FOL INE Chapter 5 Repair and Maintenance 4 Unclip the belts under the right and left side of the tray One on each corner of the table See Fig 5 13 Belt T clip Bottom view Fig 5 13 Tray clip Right front clip shown with nuts removed 5 With all four belt ends detached from the underside of the table slide the table out the front of the cutter 6 Install the new table in reverse order Be sure to get the sides of the table locked into the side wheels The wheels should rest on the gray plas
52. ed in the belt Remove 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 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 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 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 right side of the machine Closest to the keypad To make sure the belt has the proper tension use a fish scale that measures in Grams place the hook on the fish scale around the belt See fig 5 9 Place a ruler on the bottom of the traverse extrusion See fig 5 9 Pull the fish scale to the 1 One inch mark on the
53. en working properly up to the point of the recent failure YES NO e Are there any blinking LEDs or beeping sounds associated with this problem YES NO If yes please describe them e Were there communication or computer software problems If yes please describe them e When the plotter is first turned on does the pen carriage move fully to the right YES NO e Does the fan come on YES NO e With the power off slide the carriage from side to side e Does the carriage slide easily to each side YES NO e Is there more resistance to move the carriage to the left the right OF is it equal e Were all of the cable connections securely fastened to the logic board YES NO e Were all logic components seated in the logic board YES NO e Was the power supply shorting at the terminals YES NO e Was the power supply voltages within the tolerances YES NO e 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 e Were any of the transistors on the logic board defective YES NO If yes which ones Q1 Q2 Q3 Q4 Q5 Q6 Q7 Q8 e Were any of the motors or encoders bad If yes which ones X motor encoder__ Y motor encoder__ e Please list any other difficulties Be very specific about the nature of the problem and any symptoms associated with it 60 POL JIVE Chapter 4 Troubleshooting and Testing
54. ent 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 Testing the New Motor 1 After installation test the new motor s with the keypad arrow keys for five to ten seconds 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 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 next page is completed con tact an Ioline dealer Ioline Customer Service for further help 59 S Chapter 4 Troubleshooting and Testing Contacting Ioline Customer Service If the suggestions and guidelines in this manual cannot help resolve the difficulty con tact Ioline Customer Service When speaking with a customer service representative they will ask a number of questions regarding the results of the diagnostic investigation Use the following form to record the observations so Ioline can expedite solving the difficulties Diagnostic Record e What is the serial number for this unit Logic board revision _ e Who was the dealer that sold it to you e Has the unit be
55. ents are small and more irregular Also when a portion of the outline overlaps the algorithm gets confused Best results occur when there is no overlap ping or doubling of outline segments 110 v How to KISS CUT Kiss cutting is the process of cutting through one layer of a stack of material and not cutting through the layer s below Typically the upper layer s has a pressure sensitive backside which adheres to the lower layer of material Kiss cutting creates more scrap material for the upper layer s compared to cutting individual layers and hand placing them on the lower layers but can result in a considerable time savings since multiple layers do not need to be aligned and the placement stitch for the upper layer may be eliminated from the embroidery process 1 Place Background material onto adhesive sheet and smooth it flat Place the foreground material top of the background material making sure the sticky side is down 2 Load Blade Holder into Carriage Jaw 3 Adjust Blade Holder as described in the quick start guide Test with single button test cut Adjust 16 17 18 19 blade exposure and cutting force so that only the material is cut Adhesive sheet may be scored lightly Note It is recommended that the materials are of similar type and thickness so the blade does not need readjustment Once blade is adjusted use the Keypad Arrow keys to position the Table and Carriage so that the Blade Hol
56. enu field Use the Alt key to toggle between the screen fields and the pull down menus Select Install Components Fa The Control Center and 301 only work with Windows S NT Adobe Acrobat is required to read ar print the documentation Install 107069 RU Control Center 1068465 AO 301 107071 A04 Disk Space Required 18004 k Free Space Remaining 875453 Install 301 and Control Center software 8255 k Install Adobe Acrobat 4 0 5840 k Install User Guide Acrobat required 532 k v Install Quick Start Guide Acrobat required 3530 k Fig 3 3 301 and Control Center installation screen 29 Chapter 3 Setup amp Operation Use the Enter key to select a highlighted field when a pull down menu is open Windows 95 98 ME installation 1 Place the disk in your CD ROM drive 2 The CD should Autorun once it is placed in the drive and the drive door is closed The install wizard will now start the installation process Follow the prompts until the installation of the Ioline 301 and Control Center software is finished See Fig 3 2 on the previous page 3 If the CD does not Autorun click on the Start button and then Run 4 In the Run window click on Browse and select your CD ROM drive in the box labeled Look in 5 Select the file IOSETUP EXE and click OK 6 In the Run box click OK The install wizard will now start the installation proc
57. ess Follow the prompts until the installation of the Ioline Control center is finished Windows NT 2000 Installation Installation of the CD ROM is the same for Windows NT 2000 as for Windows 95 98 ME The difference is in the Hardlock Driver See the next section Installing the Hardlock Windows 95 98 ME uses different hardlock driver that will not work with Windows NT 2000 To obtain this driver go to www ealaddin com hardlock downloads asp and download the file HLDRV32 EXE This file is a self extracting file so when the download is complete Run the file from the Run dialog box After installation is complete you can use the 301 software in Windows NT 2000 If you can not obtain this driver over the internet contact Ioline Tech Support for a disk or e mailed file 30 FOLI NE Chapter 3 Setup amp Operation oo Installing the Hardlock Key The Hardlock key is a device that allows you to use the 301 software A common name for this device is a Dongle Without it the software will not work The Hardlock key comes with the 300 system cutter in the accessory kit and plugs into your computers printer port See drawing below Directional Arrow This shows the end to plug into the printer port Printer Pass Through p Allows the printer to be used y UE 2 wc ej Printer port Receptacle Fig 3 4 301 Software Hardlock Key L Back of computer Ioline 301 Hardlock Dongle
58. fficulties Other errors can occur with the operating system or the design software and should be resolved with the software vendor Software Errors Could not open COMx or LPTx The software could not locate the cutter Verify the cutter is connected to that on the specified COM or LPT port port or check that the operating system recognizes the port Green light not on or cutter not connected The software opened the port but could sure the cutter is connected to the to COMx or LPTx not get a response from the cutter selected port that the cutters green LED is on and that the cable connecting the computer to the cutter is functioning Due to the nature of serial and parallel communication it is possible to get this message if an attempt is made to interact with the cutter while it s cutting If this i the case wait for the 300 to finish cutting and send the file again Setup COM port and check plotter present The last operation requires that the Be sure the cutter is connected to the plotter be connected to the port but the selected port that the cutters green LED software could not find it is on and that the cable connecting the computer to the cutter is functioning The plotter that you selected is not the The Control Center cannot match the Select the correct plotter from the list same as the one connected to your cutter that was chosen at the start up computer with the one found during initialization 46
59. g 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 J3 and J7 and are labeled Q1 Q8 and 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 kQ the part is suspect If any readings are below 1 Q 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 the defective FETs can be replaced with exact duplicates The transistors at locations 1 Q5 Q7 and 10 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
60. hapter 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 42 FOLI NE Chapter 3 Setup amp Operation x Plotter 600 Control Center Figure 3 21 Help Menu Contents Lists the contents of the help screen About Provides revision information about the Ioline Control Center software 43 TM CORPORATION Chapter 4 Troubleshooting and Testing 44 Chapter 4 Troubleshooting and Testing v This section contains guidelines and testing procedures for resolving most cutting difficulties Some of this information coincides with repair procedures located in Chapter 5 The following primary topics are explained and illustrated e Basic Operational Difficulties e Mechanical Electrical and Electronic Diagnostic Processes e 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 parallel or serial cable the design software or the 300 If the problem appears to be with the computer or design software consult the appropriate documentation or an Ioline dealer first The information in the following sections has been organized to eliminate minor p
61. he angle of the blade Your body represents the center or pivot point of the blade and the tip of the stick represents the tip of the blade If you draw a box in the sand with your feet it will look fine But if you draw the same box with the stick behind you the corners will be rounded This is where the overcut comes in It extends the tip of the blade past the corner point so it makes the corners square instead of rounded Blade Steering Arc The blade steering arc is simply the rotational angle of the blade around a corner If the blade is cutting a box each corner is a 90 degree angle In order for the angle to be cut right by an angled blade the machine must perform a rotation around the 90 degree angle for it to look good Typically the Blade Steering Arc is 30 degrees for a 45 de gree blade and 15 degrees for a 60 degree blade These are good standards for cutting out most materials 38 FOLI NE Chapter 3 Setup amp Operation Menu Bar Items The menu items along the top of the screen 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 loline 300 Control Center File Setup Display Options Calibrate Test Help in ik 5 Acceleration Open Settings File a s s Save Settings Exit Delays Fig 3 15 File Menu Send Cut Plot File Use this option to send plot
62. he two sided foam tape on the channel bottom Connect the ribbon cable to the carriage by inserting the cable into the rectangular 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 Remount the carriage to the traverse following the carriage removal instructions in reverse Plug the power cord into the 300 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 computer data cable and perform test plots If the carriage does not function check that the cable is oriented correctly in the rectangular connec tors Reassemble the 300 in the reverse order that it was disassembled See General Disassembly Procedures above If problems arise contact Ioline customer service 71 FOL INE Chapter 5 Repair and Maintenance no Y Axis Transmission Y Axis Transmission Replacement m Electrostatic discharge preventative measures must be adhered to during all assembly replacement procedures Shut off the plotter and remove the power and computer data cables Remove the Right amp left end covers See Removing the End Covers Loosen
63. idue 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 Plug the power cord into the 300 and into a wall outlet Move the tray 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 77 gol Chapter 5 Repair and Maintenance x loosened and the motor can be adjusted slightly to achieve proper belt tension 6 If the motor needs to be changed use the procedure below 7 Reconnect the computer data cable and perform test plots Reassemble the 300 in the reverse order that it was disassembled See General Disassembly Procedures above If problems arise oombactiioljae customer service X Axis servo motor Gear Setscrews Cu X Axis belt Fig 5 11 X Axis motor gears and belt X Axis Motor Replacement Shut off the cutter and remove the power and computer data cable Remove the right 3 screws end cover See Removing the End Covers above 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 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 th
64. indow See below for the four types of stitches Fig 3 11 1 Placement Stitch 2 Tackdown Stitch 3 Zig Zag Stitch 4 Satin Stitch 34 Fig 3 12 Edit Design Window WWW M Fig 3 13 Edit Stitches Window 35 FOLI NE Chapter 3 Setup amp Operation v Control Center Software The Control Center Software provides and interface that allows detailed changes to the 300 cutting 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 E i loline 300 Control Center File Setup Display Options Calibrate Test Help Panel Size 825 1825 Y Axis grams grams Blade Update Display Blade Offset Send Temporary mils Settings to Minimum loline 300 Permanent Angle deg Scale _ 79 Fig 3 14 Ioline Control Center Window 36 go Chapter 3 Setup amp Operation v Measurement Units English or Metric unit systems may be used for length and speed settings Acceleration The acceleration setting determines how quickly the blade will change speed when starting or ending a line The factory default accelera
65. intenance of the 300 System Appendix sections contain technical drawings and reference material 10 lt V i Chapter 1 Introduction and Overview 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 injury 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 e Unless otherwise noted all subsystem testing or replacement procedures must be performed with the 300 System 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 300 System is on a flat stable clean and dry surface e Keep fingers hair and clothing well clear of the 300 System whenever moving parts are being tested e 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
66. l plotting point can be set from the keypad Set et Origin V Q a Test Cut Repeat Start Stop Fig 3 1 300 Keypad Arrow Keys The arrow keys control paper vertical arrows X and Blade carriage horizontal arrows Y movement within the parameters of the 300 s frame setting The plotter must be in stop mode red LED to use the keypad arrow keys The Blade and media speeds become greater the longer the key is depressed The Blade carriage has a safety feature that will not allow it to collide with the end plates The tray will not allow forward motion outside of the frame during cutting operations Diagonal motion is possible by pressing a vertical and horizontal arrow key simultaneously 26 go Chapter 3 Setup amp Operation v Set Origin You have to set an origin point before sending a cut file to the 300 When the Set Ori gin key is pressed the plotter logic will use the current X Axis position of the tray and Y Axis position of the Blade carriage as the starting point of the next plot When the Set Origin key is pressed the LED will turn green and the 300 will accept a plot file Cutting Speed You can set the speed of cutting by adjusting the knob on the keypad If the knob is put in the Minimum position 6 00 this puts the cutter in Crawl Mode which allows the blade to move very slowly for precise positioning Different materials require different speeds for cutting accura
67. let to verify that it is between 100 and 250 VAC 4 Clear all media paths and ensure that nothing is obstructing the movement of the tray 5 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 General 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 data cable from the computer 2 Remove the plastic end covers from the end plates following the procedures out lined in Chapter 5 53 lt Chapter 4 Troubleshooting and Testing v Internal Cabling and Connection Inspection WARNING The 300 cutter is very heavy and could cause an injury if it falls Make sure that another person assists with moving the cutter When the bottom cover of the 300 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 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 50 pounds each Grounding strap optional Initial Internal
68. low fuse or equivalent 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 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 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 Testing the Power Supply Output Voltage 1 2 3 4 Turn the power off Mark the power supply connectors with their associated socket number J3 or J7 Unplug both power supplies from the logic board It is very important that they be disconnected from the logic board for correct voltage readings Connect one of the power supplies to the Ioline Power Supply Test Fixture The plug will only fit on one way Tf the Ioline test fixture is not available insert a 20Q 5W resistor into the plug between one of the red 5V wires and one of the black or brown ground wires The volt ages are labeled on the logic board at the J3 and J7 connectors 55 D w Chapter 4 Troubleshooting and Testing 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
69. n off the 300 at the end of the test Normal communications will be restored when the power is turned back on If this test is successful the next two tests are not necessary Testing the 300 Plotter Port Run this test from the 300 Control Center The diagnostic module WILL be needed to run this test 1 Connect the diagnostic module directly to the 300 serial port 2 Turn on the 300 while holding down the Test Cut key on the keypad Hold down the Test Cut key until the 300 beeps and LEDs flash three times Press any arrow key to transmit and receive characters Verify the 300 beeps and the green LED flashes Turn off the 300 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 300 Control Center The diagnostic module WILL be needed to run this test 49 Chapter 4 Troubleshooting and Testing Connect the diagnostic module directly to the serial port on the computer From the 300 Control Center select Test Select Computer Port Test 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 character received Cutting
70. n the Windows Start button then click on Enter the following path into the Open field A WSUPE 7 If Windows was found in a nonstandard location enter that location in the box when prompted Unzip to Folder If Windows is in the standard location leave the entry I Unzip to Folder as is 8 Click the Unzip button 9 Reboot system 10 Click on the 301 software icon If any error messages are displayed write them down and call Ioline Technical Support 109 Creating Barudin Files 301 Software Barudin files can be created in several different formats 1 Theloline Bridge 301 software reads Barudin DAT files on DOS diskettes 2 Ifa customer can only create Barudin FMC diskettes which are a CPM format disk the customer must convert these by means of a conversion utility such as the one available from Sydex 541 683 6033 It is called the Barudin Only version of 22 disks and costs 50 00 It runs on DOS not Windows and will read an FMC disk and create DAT files on a DOS disk 3 Ifacustomer can only create Barudin FDR diskettes there is no conversion path The customer must replace his software with software that creates disks that are Barudin DOS Tajima DOS etc Run Time Error Codes 301 Software Run time error 5 Invalid Procedure Call Occurs only when the file name you are exporting exceeds 16 characters prefix and export in Tajima format Other formats ar
71. nance instructions It is also the responsibility of the operator to follow all safety precautions and warnings that are described in this manual Ioline is not respon sible for injuries that may occur as a result of unsafe operating procedures or for de graded performances as a result of failure to maintain the 300 System 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 equipment and 90 days on repaired units unless specifically noted otherwise Every unit is re corded by serial number when it leaves the factory The warranty period is based on the serial number of the unit and extends from the date of manufacture up to 12 months plus an extra 3 months for self life Making the total warranty period 15 months from the date of manufacture See Fig 1 4 on page 17 for an explanation of how to read the serial number of the machine For warranty service the end user must work through their dealer Ioline Customer Service 15 available to assist Authorized Dealers in the performance of their equipment support 16 Chapter I Introduction and
72. nd remove the two nuts holding the keypad assembly to right end plate 85 A Chapter 5 Repair and Maintenance Disconnect the gray ribbon cable from keypad circuit board connector Remove keypad assembly Connect the gray ribbon cable to the new keypad assembly with the red stripe pin 1 on the edge closest to the mounting holes Fasten the new keypad assembly to the end plate with the hardware from above Plug the power cord into the 300 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 Reconnect the serial cable and perform test plots Reassemble the 300 in the reverse order that it was disassembled See General Disassembly Procedures above 10 If problems arise contact Ioline customer service Installing new Firmware Failure to follow these directions explicitly may cause permanent damage to the Logic Board and may cause the plotter to malfunction Make sure the 300 cutter is powered on and the computer data cable is plugged in Press the Set Origin button on the keypad of the cutter Start the Ioline Control Center See Chapter 3 Setup amp Operation for help with the Ioline Control Center When the Control Center window is open click on the Options drop down menu and click Install New Firmware Version When the Install new firmware window opens click
73. ns exist to make the changes take effect Sending the settings with the Temporary button will replace the current plotter param eters until the power is turned off or new settings are sent from the control center If the Permanent 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 The update Display button displays the Current status of the cutter If your unsure about the settings currently setup on the plotter pressing the Update Display button will show you what they are 37 Force The Force settings control in the 300 Control Center is not adjustable when you are using a Blade The ability to cut fabric takes a lot of grams of force and therefore does not need adjusting Panel Size The default panel size for the 300 System is 18 25 long by 32 25 wide This size is the cutting area of the 300 cutter and can not be set any bigger than the default size Scale By default the 300 will produce a cut at 100 the size of the specified in the plot file no scaling If the X and Y scale is set to 50 the 300 will produce an applique that is half the specified size You can set either or both the X and Y scaling of the plot from 1 to 999 Blade Overcut Because of the angle of the blade the machine must perform an Overcut to meet up with another line If you picture dragging a stick in the sand behind you the angle of the stick is t
74. ntrol Center These tests are designed to help determine 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 300 If the following tests do not re solve the problem and the computer and software are working properly proceed to the Mechanical Electrical Diagnostic Process later in this chapter 48 lt Chapter 4 Troubleshooting and Testing Serial Communication Test Run this test from the 300 Control Center The diagnostic module will NOT be needed to run this test gt 8 9 Connect the serial ports on the 300 and the computer with a serial cable From the 300 Control Center screen select Test Select Serial Test Turn on the 300 while holding down the Test cut key on the keypad until the 300 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 Repeat key to switch the 300 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 300 and the computer pass all these tests there should not be any problems producing appliques from plot files Select Exit after completing the serial test Tur
75. o create vector cuts Vector files are sent to the cutter via a serial or parallel connection with a computer or file server When a file is sent to the cutter the electronic logic system translates the vectors into instructions for the X Axis material motion and Y Axis Blade motion motors 13 FOLI NE Chapter 1 Introduction and Overview v M Table Movement Tray motion is accomplished by mounting the material to be cut on an adhesive sheet that is mounted to a removable tray The tray is then fastened to a fixed table on the machine The X Axis transmission rotates a shaft which in turn rotates a gear assembly Belts on the right and left underside of the fixed table wraps around the gear assembly which in turn moves the fixed table in and out Fig 1 2 Table X Axis Motion 14 FOLI NE Chapter 1 Introduction and Overview v M Blade Movement The Y Axis transmission powers a timing belt that transports a V wheel carriage along the Y Axis traverse extrusion The Blade is attached to the carriage and is made to contact the material by actuating a voice coil When not cutting the Blade is held above the paper by spring action Fig 1 3 Carriage Y Axis Motion 15 ge Chapter I Introduction Overview Limit Of Liability Statement It is the responsibility of the operator to monitor the performance of the 300 system and maintain it in proper working condition by following the operating and regular mainte
76. on the Install button A dialog box will open asking for the location of the BIN file This file is avail able through the Ioline webs ite at www ioline com or through Ioline Customer Service Locate the file and click OK The LED on the keypad of the cutter will blink Red as the new firmware installs After installation is complete the Control Center will close automatically and the 300 cutter should be turned off and reset back to factory defaults before sending any files to it See Reseting the factory defaults Pg 85 If a problem should arise and the cutter won t power up after installation of the new firmware contact Ioline Customer Service for instructions 86 TM v CORPORATION Chapter 6 Drawings and Bulletins 87 Belt Tensioner Axis 106708 g v CORPORATION SEE DETAIL REF DETAIL A 88 Belt Tensioner Bill of materials Drawing Number Component Part Number Component Description Quantity Used BRACKET TENSIONER SC98 IDLER TENSIONER 1 5 106431 7 250D TENSIONER SC98 SPACER SHAFT B 100316 EARING BALL 25ID 62500 196 102222 RING RETAINING E CLIP 1 4 7 100046 SCREW 8 32 1 25 LG SHC FULL THD 89 YY Axis Transmission 106817 NOTES 291 4 1 Pa W 3 CORPORATION REF REF
77. ove the two black phillips head screws and remove the left cover See figure 5 3 on the next page Rear cover screw Right side a Front cover screw Right side Fig 5 2 Right side cover screws Black Phillips head 65 FOL INE Chapter 5 Repair and Maintenance Front cover screw Rear cover left side screw left side Move cover to the right and rotate to the front when it reaches the keypad control knobs Fig 5 4 Removing the right side cover 66 Chapter 5 Repair and Maintenance Removing the Bottom Cover for Internal Access WARNING The 300 system cutter is very heavy and could cause an injury if it falls Make sure that another person assists with moving the cutter When the bottom cover of the 300 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 300 by its top dust cover or the tray assembly Use the bottom surfaces of the end plates for lifting and moving the plotter Tools Required Phillips head screw driver Two people capable of lifting 50 pounds each Grounding strap optional Perform the Following Disassembly gt
78. r assembly is not tangled in the belt Remove the other end of the belt 5 Remove the carriage from the machine by pushing down on the belt attachment brackets and pulling out on the bottom wheels 6 Mountthe new carriage on the traverse extrusion by aligning the upper wheel with the upper rail push down on the belt attachment brackets then slip the lower wheels onto the bottom rail and let the carriage rest 7 Insert one of the metal T connectors into the grooves on the front of the car riage body 8 Alignthe tensioner assembly with the indentations on the end plate and apply light tension to the belt by tightening the allen screw 9 Move the carriage to the far right closest to the keypad 10 Adjust the belt tension by tightening the belt tensioner until the spring scale mea surement at the center with the belt pulled 1 out from the normal position is 320 20 grams See Y axis belt replacement on Pg 74 69 Chapter 5 Repair and Maintenance 11 12 13 v Plug the power cord into the 300 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 computer data cable and perform test plots Reassemble the 300 in the reverse order that
79. roblems 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 en The cut file doesn t start in the The Origin has not been set Press the Set Origin button correct place on the tray on the keypad with the knife positioned where the cut file should start A file has been sent from the A communication problem has Make sure the serial or parallel software but the 300 won t cut occurred or the 300 is in Stop ports on the computer and the mode Red LED 300 are configured properly Or press the Start Stop button on the keypad to obtain a Green LED 45 Chapter 4 Troubleshooting and Testing Error Messages Error messages that are specific to the 300 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 300 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 di
80. se This 10 Safely guau HY 11 Warnings And Cautions ert meat iai ciae g rdiet emet etis 11 Basic Safety Guidelines 11 Product FEM MEE DU VEU ipa dads 12 Specification S kasa 13 How The 300 System Works 13 Table MOoVelieriE cid cS XT du uwawan 14 Blade Mo Vemernti uuu a iced aai Fave Limitar aad Gintama Cid o a CU 15 Limit Of Liability Statement 16 Ioline Warranty Polly cu ce erat pue cup tesa aat pu dca xir da vex cuite 16 Serial Number Identification 17 Glossary aqusapa TT mat uama 17 Chapter 2 Nomenclauture Q 18 Chapter Setup amp Operation 25 Keypad Controls FN 26 ALFOW KEYS oi aida bens oaie cies satan a aa aaa aaa E AEE a a a 26 Set 27 Cutting Speed 27 Blade aaa ales aioe hae tele aay 27 Star m saku aurea tami i tinet te teste 27 POWerF LED
81. stalled in the plotter Memory Buffer Displays the amount of buffer memory on the logic board This value should be 12 K kilobytes Blade Holder Status Displays weather or not the blade holder is installed Motor Voltage Displays the voltage of the motors that are installed in the 300 cutter This option will only work with ROM version 106882 0 and higher 40 FOLI NE Chapter 3 Setup amp Operation v Options loline 300 Control Center OF x File Setup Display Options Calibrate Test Help Filtering Measurement Units Dip 00 Acceleration Ongis JK a s Install New Firmware Version Delays Up ms D oin 1 Figure 3 18 Options Menu Filtering Displays the filtering dialog window Some files don t produce quality curves and line structure enabling the filtering option helps to smooth out some of these lines HPGL Setting Allows the 300 cutter to switch between HPGL 7475 Corner origin and HPGL 7596 Center origin Install New Firmware version 1 Copy the file that was sent to you by Ioline Tech Support or downloaded off the Ioline web site to the hard drive of the computer that is connected to the 300 System Cutter 2 Click on Install New Firmware Version 3 Click on Begin Version Install 4 The next window shows the file structure on your computer Find the file that was sent to you BIN file Click on the file and click on OK 5 The plotter
82. the associated ground pin the 5 V shares common ground and should read as labeled 10 Repeat this procedure for the other power supply 6 If any voltage fluctuates wildly or is not within 10 of the specified value then replace the power supply If the voltages are within the tolerances continue to the next step 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 200 5W resistor between 5V red and ground black or brown will also work for test ing svioad 20 Q 3 watt 1 250 ma pasa 200 Q 1 2 watt use 2 X IKO res for 1 24 ma 1vloaa 24 Ma 500 Q 1 2 watt use 2 X 1K Q for I 1K Q 1 2 watt use 2 X 2KQ 1 4 watt resistor for L I 24 ma 12vload 24vload 2 qu All load resistors should be within a 20 tolerance AAR A 56 S 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 Q Soldering apparatus and groundin
83. 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 Tray X Axis Motor Replacement If the tray quickly accelerates and jams and the FETs are not defective or if unexplain able X axis jams occur the motor may be defective See Chapter 5 X Axis Motor Replacement section for the replacement procedure 58 S Chapter 4 Troubleshooting and Testing 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 retighten 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 seconds 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 Carriage Y Axis Motor Replacem
84. tic Grounding Strap supplied on request Joline Power Supply Test Fixture available from Ioline Ioline Serial Port Test Fixture available from Ioline Plastic Cable Ties 63 FOL INE Chapter 5 Repair and Maintenance 7 Cleaning And Regular Maintenance Cleaning the Traverse Extrusion and Carriage Wheels As dust and debris accumulate on the traverse extrusion it will have to be wiped off with an isopropyl pharmacy alcohol dampened lint free cloth 1 With a clean cloth dampened with Isopropyl alcohol wipe the traverse extrusion where the carriage wheels ride on the rail Move the carriage side to side while wiping the traverse so as to clean the entire surface See chapter 2 Nomenclature for the location of the traverse Figure 5 1 Cleaning the Traverse Extrusion 64 EINE Chapter 5 Repair and Maintenance General Disassembly Procedures The following procedures describe the basic disassembly of the 300 system cutter to gain access to the keypad power and drive components Please pay close attention to the Warning and Caution notes Removing the End Covers 1 Turn off the 300 and unplug the computer data and power cables 2 Remove the two black phillips head screws and the single silver phillips head screw on the bottom of the cover then remove the right cover To access the rear black screw you may have to move the tray forward See figure 5 2 below 3 Rem
85. tic rails located on the right and left 7 Reattach the belt clips on all four corners of the underside of the table 8 Tighten the belts by tightening the tray adjustment nuts on the right and left end plates Refer to Fig 5 12 The nut with the slotted hole is the main tightening nut Before tightening fully push the nut in the direction of the back of the 300 cutter then tighten 9 Be sure the belts are Taught similar to a cars fan belt If the belts are loose cut quality will be affected 80 POL INE Chapter 5 Repair and Maintenance v 10 Plug the power cord into the 300 and into a wall outlet Turn the power to the 300 cutter on Move the tray 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 tray adjust ment nuts can be adjusted slightly to achieve proper belt tension 13 Reconnect the computer data cable and perform test plots Reassemble the 300 in the reverse order that it was disassembled See General Disassembly Proce dures above 14 If problems arise contact Ioline customer service 81 FOL IINE Chapter 5 Repair and Maintenance x Power Supply Power Supply Replacement Electrostatic discharge preventative measures must be adhered to during all assembly replacement procedures 1 Shut off the plotter and remove the power and computer data cable Perform the procedures in Removing the Bottom Cover for Internal Access a
86. tion setting is 1 0 g 1 g 32 2 ft s2 The setting range is 0 1 to 1 0 g Up Down Delays Up down delay controls how long the blade hesitates when actuated Zero delay makes the blade rise instantly when line drawing is finished By default it takes the blade 6 milliseconds to lower onto the paper when the logic powers the voice coil Longer blade delay settings make the Blade move more slowly but may improve the quality of the cut line The setting range is 0 to 250 ms milliseconds HPGL Default Your 300 cutter supports three industry standard plotter languages HPGL 7475 HPGL 7596 and DMPL Your 300 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 300 begins 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 300 begins cutting from the center of the panel and measures everything from this location Send Settings to the 300 When changes are made in the screen dialog boxes the plotter logic has to be updated via the serial or parallel link Three optio
87. uo deterrere aho cies 55 Tools Regul ed 55 Inspecting the Fuse and Output 55 Testing the Power Supply Output Voltage 55 Reference Information for the Power Supply Test Fixture 56 Testing the Logic BOGE xri Ed kei 57 Tools RECUIRCG T cm 57 Testing the FETs Transistors 57 Testing and Replacing the Other Logic Components 58 Testing 6 uo 2 RN 58 Tools Requil ed uyta yau dex Xr on or rdv nia d 58 Initial Motor Inspection an exce 58 Likely Modes of Motor 58 Tray X Axis Motor Replacement 58 Carriage Y Axis Transmission 59 Carriage Y Axis Motor Replacement 59 Testing the New Motor 59 Contacting Ioline Customer Service 60 Diagnostic RecOLG c2 la q 60 Re Packihg tie
88. verse order For example cut out the background piece s first then lay the top piece of fabric on and cut those pieces out This method allows you to cut a whole tray of Kiss Cuts and weed the two pieces of fabric together 111 3 8 loline 301 F Import File Type Import File Name Tajima dst Load Import File 2color plt Melco exp Fabrics plt Plotter Control Center Toyota 100 Barudan dat c ET Help AutoCAD dxf HP GL Brc loline 301 Revision 4 About 301 Main Window Design Setup Adjust Imported Design V Needle down After first stitch following jump s V Remove extra pen up movement jumps Iv heen Segments less 0 51 Rotata v aw Can ma C 20 None C Horzontsl 7 Yorticsl Ruler Inches 7 Centimeter Margins and PU Design 46 i om Margins Bottom 46 7 Maximum Copies Horz Count Step 10 amp Step 16 Set Copy Count s Vert Count Step 9 Show ALL colors Show FIRST color only 25 ME Margins Horz Margin 4 Between Vert Margin 4 i Copies gt Cutter Size K C color Material pusa Horz 47 5 44 45 4 28 5 74 95 19x24 18x35 Ioline 301 Design Setup Window 112
89. wing wa on Pg 21 Blade Jaw Fig 2 9 Carriage Assembly With Blade installed Flex Cable Top Traverse Wheel socket Carriage PCB Spring Loaded Traverse Wheel Fig 2 10 Carriage Assembly Rear View 23 NE Chapter 2 Nomenclature m Blade removal pin Push to remove blade Blade holder body Jaw Flange Foot O Ring Foot Blade Fig 2 11 Blade Holder Assy 1 With foot 2 With foot removed 3 Removing blade Right side cover Parallel cable receptacle Power cord IEEE 1284 Power switch plug in Commonly called the Printer port Parallel port Cable Clip Serial cable receptacle RS 232 Commonly called the COM port Fig 2 12 Rear Panel Assembly 24 TM MELA CORPORATION Chapter 3 Setup amp Operation 25 FOLI NE Chapter 3 Setup amp Operation This section contains guidelines for basic operation of the 300 System Cutter The following primary topics are explained and illustrated 300 Keypad Controls 301 Software Screen Options 301 Software Menu Items Control Center Screen Options Control Center Menu Items Keypad Controls The keypad on the 300 provides control of the motion systems on the cutter as well as access to speed and force control Blade depth can be adjusted by using the Test Cut button and repeatability is performed by pressing the repeat button Communica tion can also be interrupted and restored and the initia
90. ws the user to change the Escape pu E a cut one another after cut dimensions of the fabric to be Cutter Size Allows the user to change easily back and forth from 18 x24 and 18 x30 Fig 3 9 Design setup window Outline Running Stitch Makes an outline around the letter or shape for accurate Create Stitches Embroidery Setup Lx placement on the garment Outline Running Stitch Tackdown Running Stitch Tackdown Running Stitch Makes a stitch that is indented the fabric to Tack Down the letter or shape to the garment before applying the Zig Zag or Satin stitch Stitch Fragmentation Length for running stitch segments Lock Stitch Before Jumps 1 Double lock Extra filtering for troublesome stitches Close Polygons 1 0 mm Group Internal Polygons Save Setup Recall Setup Default Setup Zigzag Column Stitching Density Overlap Contour Satin Column Stitching Density 14 Overlap 75 V Add Corner Buffer Points Shortstitching in Corners Zig Zag Column Stitch Creates a zig zag stitch around the letter or shape Allows easy adjustablity of the stitch to accommodate many embroidery styles Satin Column Stitch Creates a satin stitch around the letter or shape Allows easy adjustability of the stitch to accommodate many embroidery styles Fig 3 10 Create Stitches W
91. y Used 4 143 ROWER SUPPLY 2 15 104713 SCREW 6 32 375 PHP SEMS 7 23 1 10388 7 SPRING COMPRESSION 240 OD 032 1 9 116144 COVER DUST S98 30 1 3 1 1616 PLATE POWER SUPLY 598 3 1 1 N 46 1 106905 CARRIAGEASSY 300200 1 13 1 1005 PENCAP 1 4DIA 1 14 103026 CONNCABECLP 18DA 4 15 1006 SCREW amp 632 51G PHP SEMS 7 16 10403 QNU 8 GQ KP 12 17 1 10307 TRAP 1INX53 41G 13 2 104590 SCREW 8 50LG ST FHP 7 2 110652 268 16900 4 2 1641 WSHR 8 32 190 ID 416 OD 080THK 4 38 17710650 WSHR 195 ID 2450D 03THK 2 10326 1 IINX3IN BLACK 1 d 1 10508 5 10 32 6251256 5 48 1126 _ SETSCREW 10 32 75 LG STEEL 5 501 10099 8 32 HEX NYLOCK 9 51 100252 STRIP PROTECTIVE 61 10628 TAPE DOUBLE COATED 125 W 2 62 1 103973 WSHR 170 D 3750D 035TH SS 1 1 10507 J ASSYREARPANE SCOB 1 106867 7 REAR I O PANEL ASSY S 600 1 Pp 3 161 ASSY Y BELT SCO9 30 s l ele _ A 12 10453 JPOWERSUPPY O 5 106816 MOTOR SERVO 24V 103 System 300 Chassis Assembly Bill of Materials Cont 7 104745 1 8 177 10649 jJASSY CABLE MOTOR POWER

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