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Chapter 4 - Troubleshooting and Testing
Contacting Ioline Customer Service
If the suggestions and guidelines in this manual cannot help resolve the difficulty contact Ioline Customer Service. When speaking with a customer service 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
•
What is the serial number for this unit? _______________ Logic board revision # ? _____
•
Who was the dealer that sold it to you? _________________________
•
Has the unit been working properly up to the point of the recent failure?
YES_____ NO_____
•
Are there any blinking LEDs or beeping sounds associated with this problem?
YES_____ NO_____
If yes, please describe them. ________________________________________
•
Were there communication or computer software problems?
If yes, please describe them. ________________________________________
•
When the plotter is first turned on, does the pen carriage move fully to the right?
•
Does the fan come on?
•
With the power off, slide the carriage from side-to-side.
YES_____ NO_____
YES_____ NO_____
•
Does the carriage slide easily to each side?
YES_____ NO_____
•
Is there more resistance to move the carriage to the left _____, the right _____, or is it equal? ______
•
Were all of the cable connections securely fastened to the logic board.
YES_____ NO_____
•
Were all logic components seated in the logic board.
•
Was the power supply shorting at the terminals?
•
Was the power supply voltages within the tolerances?
•
Record the power supply voltage readings here:
YES_____ NO_____
YES_____ NO_____
YES_____ NO_____
J3, VMOT(+24V)__________ J7, VMOT(+24V)__________
J3, +12V__________
J3, -12V__________
J7, +12V__________
J7, -12V__________
J3, +5 (1)__________ J7, +5 (1)__________
J3, +5 (2)__________ J7, +5 (2)__________
•
Were any of the transistors on the logic board defective?
YES_____ NO_____
If yes, which ones?
Q1___ Q2___ Q3___ Q4___ Q5___ Q6___ Q7___ Q8___
•
Were any of the motors or encoders bad?
If yes, which ones? X motor/encoder__ Y motor/encoder__
•
Please list any other difficulties. Be very specific about the nature of the problem and any symptoms associated with it.
60
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Table of contents
- 9 Chapter 1 Introduction and Overview
- 10 How To Use This Manual
- 11 Safety
- 11 Warnings And Cautions
- 11 Basic Safety Guidelines
- 12 Product Overview
- 13 Specifications
- 13 How The 300 System Works
- 14 Table Movement
- 15 Blade Movement
- 16 Limit Of Liability Statement
- 16 Ioline Warranty Policy
- 17 Serial Number Identification
- 17 Glossary
- 18 Chapter 2 Nomenclature
- 25 Chapter 3 Setup & Operation
- 26 Keypad Controls
- 26 Arrow Keys
- 27 Set Origin
- 27 Cutting Speed
- 27 Blade Force
- 27 Start/Stop
- 27 Power LED
- 28 Test Cut
- 28 Repeat
- 29 Software Installation
- 29 Installing the 301, and Control Center Software
- 30 Windows 95/98/ME installation
- 30 Windows NT/2000 Installation
- 31 Installing the Hardlock Key
- 32 Using the 301 software
- 36 Control Center Software
- 36 Screen Options
- 37 Measurement Units
- 37 Acceleration
- 37 Up/Down Delays
- 37 HPGL Default
- 37 Send Settings to the
- 38 Force
- 38 Panel Size
- 38 Scale
- 38 Blade Overcut
- 39 Menu Bar Items
- 39 Send Cut/Plot File
- 39 Open Settings File
- 39 Save Settings As
- 39 Setup
- 40 Plotter Setup
- 40 Com Port Setup
- 40 Display
- 40 Plotter Settings
- 40 Factory Defaults
- 40 ROM Version
- 40 Memory Buffer
- 40 Blade Holder Status
- 40 Motor Voltage
- 41 Options
- 41 Filtering
- 41 HPGL Setting
- 41 Install New Firmware version
- 42 Calibration
- 42 Calibrate Plotter
- 42 Serial Test
- 42 Computer Port Test
- 42 Plotter Port Test
- 43 Contents
- 43 About
- 44 Chapter 4 Troubleshooting and Testing
- 45 Basic Operational Difficulties
- 45 Common Problems
- 46 Error Messages
- 46 Software Errors
- 47 L.E.D Codes
- 48 No Power When The 300 System is Turned On
- 48 The 300 Won’t Respond to the Computer
- 48 Communication Problems
- 49 Serial Communication Test
- 49 Testing the 300 Plotter Port
- 49 Testing the Computer Port
- 50 Cutting Quality Problems
- 51 Mechanical, and Electronic Diagnostic Process
- 52 Expanded LED Codes
- 53 External Inspection
- 53 Required Tools
- 53 Inspecting the Outside of the Unit
- 54 Internal Cabling and Connection Inspection
- 54 Tools Required
- 54 Initial Internal Inspection
- 55 Testing the Power Supply
- 55 Tools Required
- 55 Inspecting the Fuse and Output Terminals
- 55 Testing the Power Supply Output Voltage
- 56 Reference Information for the Power Supply Test Fixture
- 57 Testing the Logic Board
- 57 Tools Required
- 57 Testing the FETs (Transistors)
- 58 Testing and Replacing the Other Logic Components
- 58 Testing the Motors
- 58 Tools Required
- 58 Initial Motor Inspection
- 58 Likely Modes of Motor Failure
- 58 Tray (X Axis) Motor Replacement
- 59 Carriage (Y Axis) Transmission
- 59 Carriage (Y Axis) Motor Replacement
- 59 Testing the New Motor
- 60 Contacting Ioline Customer Service
- 60 Diagnostic Record
- 61 Re-Packing the
- 62 Chapter 5 Repair and Maintenance
- 63 List Of Recommended Tools And Equipment
- 64 Cleaning And Regular Maintenance
- 64 Cleaning the Traverse Extrusion and Carriage Wheels
- 65 General Disassembly Procedures
- 65 Removing the End Covers
- 67 Removing the Bottom Cover for Internal Access
- 67 Tools Required
- 69 Y Axis Subsystem
- 69 CARRIAGE
- 69 Carriage Replacement
- 70 Replacing the Carriage Ribbon Cable
- 72 Y Axis Transmission
- 72 Y-Axis Transmission Replacement
- 74 Y Axis Motor Replacement
- 75 Y-Axis Belt Replacement
- 77 X Axis Subsystem
- 77 X-Axis Transmission Assembly Replacement
- 78 X Axis Motor Replacement
- 79 Table Assembly Replacement
- 82 Power Supply
- 82 Power Supply Replacement
- 83 Rear Panel Replacement
- 84 Electronic Sub-Systems
- 84 Main Logic Board Replacement
- 85 Resetting the Factory Defaults
- 85 Keypad Replacement
- 86 Installing new Firmware
- 87 Chapter 6 Drawings, and Bulletins
- 88 Belt Tensioner (“Y” Axis)
- 89 Belt Tensioner (Bill of materials)
- 90 “Y” Axis Transmission
- 91 “Y” axis Transmission (Bill of Materials)
- 92 Table Assembly
- 93 Table Assembly (Bill of Materials)
- 94 Tray Belt Idler Assy (Right Side)
- 95 Tray Belt Idler Assembly - Right side (Bill of Materials)
- 96 Tray Belt Idler Assy (Left Side)
- 97 Tray Belt Idler Assembly - Left Side (Bill of Materials)
- 98 Carriage Assembly
- 99 Carriage Assembly (Bill of Materials)
- 100 Shaft Assembly
- 101 Shaft Assembly (Bill of Materials)
- 102 System 300 Chassis Assembly
- 103 System 300 - Chassis Assembly (Bill of Materials)
- 104 System 300 - Chassis Assembly (Bill of Materials) Cont
- 105 System 300 Wrapping Procedure
- 106 System 300 - Wrapping Procedure (Bill of Materials)
- 107 System 300 Boxing procedure
- 108 System 300 - Boxing Procedure (Bill of Materials)
- 109 Service Bulletins
- 109 Installation Error/301 Software
- 110 Creating Barudin Files/301 Software
- 110 Run Time Error Codes/301 Software
- 110 Stitches Overlap to Wrong Side / 301 Software
- 111 How to “KISS-CUT