INTELLIQUILTER INSTALLATION ON GAMMILL MACHINES VERSION

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INTELLIQUILTER INSTALLATION ON GAMMILL MACHINES VERSION 11.10.13 1. COMPUTER BRACKET From the left side of the head (viewed from the front) remove the three screws circled on Fig

1 INTELLIQUILTER INSTALLATION ON GAMMILL MACHINES VERSION COMPUTER BRACKET From the left side of the head (viewed from the front) remove the three screws circled on Fig 1. Fig. 1 Remove the tablet from the docking station. Remove the yellow thumbscrews, the other screws and the double nuts from the docking station. Mount the docking station on the computer bracket as Fig. 2 shows. The slanted brackets of the docking station go on the outside, the double nuts on the inside of the tablet mounting bracket. Insert the #10-32 x 3/8 screws on the top, the thumbscrews on the bottom of the double nuts. 1

2 Fig. 2 Mount the tablet bracket using three #8-36 X 3/4screws and lockwashers. NOTE: On newer machines there is a DIFFERENT thread cut in the head. It is close enough to #8-36, so you can still drive in the supplied screws. 2

3 Fig THREAD BREAK DETECTOR Position the thread break detector on the top of the arm, so the hole in the bracket is about 4" (100mm) from the rear edge of the head and the black wheel is aligned with the thread path. Mark the position of the edge of the bracket. Clean the surface where the bracket will be placed. It is very important to fully remove any grease and oil that may have accumulated on the surface. You may need to use a stronger de-greaser in addition to alcohol to make the surface suitable for the adhesive mounting. Remove the clear protective foil from the double-sided tape on the bracket and push it firmly to the surface. Set the wheel position so it is aligned with the thread path as Fig 4 shows. Note the proper threading direction: it should be wrapped around the wheel clockwise. 3

4 Fig. 4 4

5 3. Y-MOTOR Remove the laser bracket from the right side of the lower arm. Fig. 5 Mount the Y-motor bracket using the laser bracket mounting screws and the two large washers, pushing the bent-down edges of the washers to the edges of the bracket. The openings should accommodate all the different hole configurations. Set the height of the bracket so the motor mounting plate s bottom surface is about 1/8 above the vertical edge of the L-beam on the inside of the track. NOTE: In some cases you will not be able to lower the motor mounting plate to the desired level, even if you set the bracket at the lowest point on the mounting screws and use the maximum allowance on the adjustment screws. In these cases, remove the motor mounting plate, flip over the bracket and remount the plate. This conversion drops the motor plate by another ½. Remove the plastic cover from the motor. 5

6 Align the bracket so that both the drive roller and sensor wheel run in the middle of the track. There should be a 0.08" (2mm) gap (about two credit cards thickness) between the drive roller and the track when all the screws are fully tightened. Move the drive roller and sensor wheel in/out to achieve the best alignment. For detailed installation, alignment and adjustment instructions see the "SM-V3 Installation and the Motor Alignment Procedure" documents. NOTE: if the tracks are uneven, the gap setting should be done at the highest point of the tracks. NOTE: It is very important that the sensor wheels run parallel with the tracks. Any angular misalignment would cause measurement errors. Use the adjustable bracket to set the sensor bracket perfectly parallel with the track. Place a long ruler at the side of the sensor wheel to determine whether it is parallel with the track. NOTE: On the SuperMotor-V2 and V3 make sure that the motor bracket is leveled. The top of the head of the sensor bracket limiting screw should be 1/10 to 1/8 raised above the aluminum block to provide proper movement range to the sensor. Fig. 6 6

4. X-MOTOR Remove the tab and spacer form the right side of the bracket. Hold the motor bracket on the left side of the front crossbar (viewed from the front) and put back the mounting tab.

7 4. X-MOTOR Remove the tab and spacer form the right side of the bracket. Hold the motor bracket on the left side of the front crossbar (viewed from the front) and put back the mounting tab. Push the rear edge of the bracket to the crossbar of the track and tighten the tabs. NOTE that some older carriages have lower-profile rails. Take out one or both small washers to make the tabs clamp firmly. Fig. 7 Remove the plastic cover from the motor. Mount the motor and set its position so both the drive roller and the sensor wheel run securely on the top of the front table rail, as shown on Fig. 7. There should be a 0.08" (2mm) gap (about two credit card s thickness) between the drive roller and the track when all the screws are fully tightened. Move the drive roller and sensor wheel in/out to achieve the best alignment. For detailed installation, alignment and adjustment instructions see the "SM-V3 Installation and the Motor Alignment Procedure" documents. 7

NOTE: if the tracks are uneven, the gap setting should be done at the highest point of the tracks. On the SuperMotor-V2 make sure that the motor bracket is leveled.

8 NOTE: if the tracks are uneven, the gap setting should be done at the highest point of the tracks. On the SuperMotor-V2 make sure that the motor bracket is leveled. The top of the head of the sensor bracket limiting screw should be 1/10 to 1/8 raised above the aluminum block to provide proper movement range to the sensor (see Fig. 6). Mount the stabilizer roller assembly in the slot of the X-motor bracket. Move the arm all the way to the front. Position the hex standoff in the slot and the bolt holding the roller so the roller is riding on the bottom edge of the horizontal bar of the table. Tighten the bolts and nuts at this position. Fig. 8 8

9 5. JUNCTION BOX, STOPPERS Mount the cable junction box with the clamp pushed up at the rear left side of the left carriage rail as Fig. 9 shows. Position it about 1 back from the rear edge of the table track and tighten the screw. Fig. 9 Move the machine all the way to the left (viewed from the back). Stop where the Y- motor is at a safe distance from the bars on the side of the table. Clean the top of the rail next to the EdgeRider wheel on the left. Remove the protective foil and mount one of the rubber stoppers on the top of the rail. 9

10 Move the machine all the way to the right (viewed from the back). Stop where the X- motor s sensor wheel still stays on the track. Clean the top of the rail next to the EdgeRider wheel on the right. Remove the protective foil and mount the other rubber stopper on the top of the rail. Fig

6. INSTALLATION OF TABLE BRACES Install the two table braces between the rear table legs and the lower horizontal beam. Drill and tap a #10-32 hole at about 9.

11 6. INSTALLATION OF TABLE BRACES Install the two table braces between the rear table legs and the lower horizontal beam. Drill and tap a #10-32 hole at about 9.5" down from the top edge of the right leg (where it meets the lower horizontal beam), centered horizontally. Mount one end of the table brace with a #10-32 hex head screw and #10 flat washer, but don't tighten the screw. Flip up the other end of the brace and hold it at the center of the lower horizontal beam. Mark the position of the hole and drill and tap a #10-32 hole. Mount the brace and tighten both screws. Mount the other table brace on the left side the same way. Fig

12 12

13 7. LASER BRACKET Remove the rear right EdgeRider wheel, discard the bolt, but keep all the washers at the same places where they were installed. Mount the laser bracket on the outside of the sliding hub, using the bolt that fits the thread in the axle. Place the washers the same places where they were installed. Add one washer between the bracket and the sliding hub, if necessary for clearance. Tighten, but don t over-tighten the bolt. Fig

8. INSTALLATION OF CABLES For the switch cable installation, see the separate document for the model of the machine ( Switch Cable Gammill Vision, Switch Cable Gammill Plus, Switch

14 8. INSTALLATION OF CABLES For the switch cable installation, see the separate document for the model of the machine ( Switch Cable Gammill Vision, Switch Cable Gammill Plus, Switch Cable Gammill w. I/S or Switch Cable Unregulated Gammill ). Plug in the switch cable, the communication cable and the thread break detector s phone cable on the interface board. Fig

Clean their location and place adhesive clamps along the right side

14 Run the computer cable from the back at the left side of the arm

In front of the computer bracket cross over to the right side and

15 Clean their location and place adhesive clamps along the right side of the carriage as Fig. 11 shows. Insert the X-motor cable in the clamps. Leave some slack at the motor and plug in the cable. Fig. 14 Run the computer cable from the back at the left side of the arm (viewed from the back). In front of the computer bracket cross over to the right side and plug in the power jack and the two-pin screw connector. Clean their locations and mount adhesive clamps on the inside of the arm as Fig. 12 shows. Insert the computer cable in the clamps. Fig

Run the Y-motor cable from the back and plug it in. Clean their locations and place adhesive clamps on the lower arm. Tie together the Y-motor and computer cables as Fig. 13 shows.

Arrange the Gammill power, sensor cables and the IQ cables so they don't interfere. Fig. 16 Remove the protective cover from the terminal of the motor power supply.

16 Run the Y-motor cable from the back and plug it in. Clean their locations and place adhesive clamps on the lower arm. Tie together the Y-motor and computer cables as Fig. 13 shows. Leave enough slack at the back to keep the cables loose at full forward and full backward movements of the arm. Arrange the Gammill power, sensor cables and the IQ cables so they don't interfere. Fig. 16 Remove the protective cover from the terminal of the motor power supply. Connect the power cable to the power supply: BLACK wire to the negative terminal, the wire with the in-line diode to the positive terminal. Replace the protective cover. Tie the in-line DC power connector to the hole on the side of the power supply with wire tie. Plug in the AC adapter jack. 16

17 Fig. 17 Mount the power supply at the middle of the back of the table, under the tabletop, using 12" cable ties to secure it to the horizontal bar. 17

18 Plug in the connectors of the motor cables. Tie the cables to the post as Fig. 15 shows. Fig

19 Put the plastic covers on the motors. Pull up the cable in the slot at the side of the cover as Fig. 16 shows. Fig

20 Dock the computer and adjust the height and angle of the computer docking station. Tighten the four screws at that position. Turn on the computer. When the booting completes, the motors will be engaged with the tracks. Select and quit Manual Mode repeatedly to see if the motors are sufficiently disengaged all along the tracks and make the necessary height adjustments. Make sure that the gap between the rollers and the tracks is not more than 0.08" (2mm). Try to set the gap to the minimum safe distance, so there is no intermittent drag along the tracks. Go to Utilities->Preferences. Set the motor engagement strength for each motor separately. Start with a lower number, then increase the number and test the resistance of the motor in each direction, until there is definite resistance everywhere. The optimal settings range is on the standard motors, 3 6 on the SuperMotors. You need to raise the motor if the final setting is below the lower limit, lower it if the setting is above the upper limit. Go to Utilities->Measure/Calibrate and calibrate the sensor wheels following the on-screen instructions. Go to System->Interface Setup/Test. Enter all the settings shown on the screenshot that was taped to the top of the box containing the tablet and the docking station. Test the single stitch and start switches, and the thread break detector. Note that the detector works only when the machine is stitching (the Start Switch label is red). If the needle positioner is slow on the machine, increase the delays before and after the single stitch. Set the local date and time. Enter at least eight digits: two digits for the month, two digits for the day, two digits for hours (in 24-hour format) and two digits for minutes. Continue with another four digits for the year only if the display does not show the proper year. Show the brightness control to the customer and set the desired level (1 7). COPY THE LOGS AND POST THE logs.tar.gz FILE TO THE SUPPORT PAGE OF 20

INTELLIQUILTER INSTALLATION ON APQS MILENNIUM/FREEDOM/ULTIMATE-I VERSION

INTELLIQUILTER INSTALLATION ON APQS MILENNIUM/FREEDOM/ULTIMATE-I VERSION 10.18.13 If EdgeRider wheels are included in the conversion kit, install them first, following the instructions in the packaging