INTELLIQUILTER INSTALLATION ON INNOVA VERSION 04.25.16 1. EDGERIDER WHEELS ON THE CARRIAGE Slightly loosen the bolts ( A ) on the bracket that holds the front wheels, so it can allow for changes in the alignment of the rear wheels. Fig. 1 Prop up the middle of the rear wheel bracket and replace one of the outer wheels with a fixed-hub E/R wheel. Use the existing washer ( A ) and locknut ( B ). Move the bolt in the middle of the slot and tighten the nut. 1
Fig. 2 Replace the other outer wheel. Use the enclosed height leveler block ( A on Fig. 3) instead of the original nut. Set the adjusting screw ( B on Fig. 3) to its outermost position and push the wheel mounting screw to the top of the slot. Tighten the bolt enough to hold the wheel, but allow adjustments. Drive in the adjusting screw to pull the wheel down, until all four wheels have traction. 2
Fig.3 Remove both inner wheels and position the E/R wheels on the top of the track. You may need to slide the front wheel bracket in/out to allow this. Prop up the front of the carriage and replace both front wheels with sliding-hub E/R wheels using the existing washers and locknuts. Move the front bracket in/out until the middle of the groove of the wheels is aligned with the top of the rails and there is equal clearance on the sliding hub on both sides of the wheel. Roll the carriage all the way along the table and check the alignment of the wheels. If you find bent spots on the rails, or misaligned rails, correct them. The carriage should roll freely, with no noticeable drag. 3
2. COMPUTER BRACKET Remove one of the bolts that hold the front handles. Place the computer bracket on the top as Fig. 4 shows and mount it over the handle using the included bolt and the serrated washer above, the spacer below the computer bracket. Keep the bolt loose. Repeat the above on the other side. Push the mounting block of the handles against the black block on the head and tighten the bolts firmly to avoid any movement of the handles. Fig. 4 4
Remove the yellow thumbscrews and the other two screws on the docking station. Mount the docking station on the bracket. 3. THREAD BREAK DETECTOR Position the thread break detector on the top of the arm, so the hole in the bracket is about 2" (50mm) from the rear edge of the head and 1-1/4" (32mm) from the edge of the arm, as Fig. 5 shows. Clean the surface where the bracket will be placed with alcohol. 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. 5 shows. NOTE the proper threading: the thread goes up/down/up in the three-hole guide, then wrapped around the wheel once clockwise. Fig. 5 5
4. Y-MOTOR The EdgeRider wheels come with proper spacing, you don t need to use any of the original washers. Remove the rear left wheel (viewed from the font). Loosen the hex bolt that holds the sensor bracket to the rear axle and slide off the sensor from the axle. Mount a fixed EdgeRider wheel on the axle; don t use any of the original washers. Don t tighten the bolt, for it will be removed when you install the Y-motor. Fig. 6 Remove the wheel from the front left axle (viewed from the front). Remove the screws ( A and B on Fig. 7) holding the sensor and turn the sensor 180 degrees. 6
Slide in the sensor bracket, so the sensor is facing the back as Fig. 7 shows. NOTE that you may need to pull the sensor wire from the back to provide enough slack. Mount a fixed-hub E/R wheel on the front axle Fig. 7 Remove the rear right wheel (viewed from the front) and mount a sliding EdgeRider wheel on the axle. Install a sliding EdgeRider wheel on the front right axle. 7
Fig. 8 Push up the sensor wheel of the Y-motor and hold it at its highest position with the included spacer tool as shown on Fig. 8. Loosen the T-nuts (1 and 2) on the bracket. Remove the EdgeRider wheel from the rear left axle and slide the T-nuts in the top groove. Replace the wheel and tighten its bolt. Hand-tighten the screws and align the motor so the bracket is parallel with the carriage track and the gap between the drive roller and the side of the track is about 3/32 (2 mm), as shown on Fig. 9. Tighten the 1 and 2 screws firmly. Remove the spacer tool from the sensor limiting screw. 8
Fig. 9 Set the drive wheel parallel with the side of the track as Fig. 10 shows, using screws C and D on Fig. 9. 9
Fig 10 10
Hold a long ruler at the sensor wheel s side and adjust the bracket with screws A and B until the ruler is parallel with the top of the track. Tighten all four screws at this position. Fig. 11 11
5. X-MOTOR Remove the nut and washers from the ¼ -20 bolt ( A ). Loosen the B screw until its end is flush with the tab on the bracket adjuster. Push the motor bracket to the tab. Fig. 12 Hold the bracket aligned with the second hole from the bolt that holds the front wheel bracket on the right-hand rail (viewed from the front). Drive in and tighten the ¼ -20 bolt. It is recommended to use a C-clamp or vise-grip to hold the bracket to the bottom of the carriage rail, as shown on Fig. 13. Put back the flat washer, the lock washer and the nut on the bolt and tighten the nut just enough so you can use the B adjustment screw. Push up the sensor wheel of the X-motor and hold it with the spacer tool. Mount the motor on the bracket. 12
Fig. 13 Turn the B adjustment screw to move the bracket closer to the track. The gap between the drive roller and the side of the track should be about 3/32 (2 mm), as shown on Fig. 10. Tighten the 1/4-20 bolt firmly. Remove the spacer tool from the sensor limiting screw. 13
Fig. 14 Fig. 15 14
Set the drive wheel parallel with the side of the track using screws A and B. on Fig. 15. Hold the ruler at the sensor wheel s side and adjust the bracket with screws C and D until the ruler is parallel with the top of the track. Tighten all four screws at this position. Fig. 16 Install the two rubber stoppers on the top of the rear table rail, at positions that prevent the motors from bumping into the frame. 15
6. JUNCTION BOX Remove the drop-in nut from the junction box bracket and insert it in the top channel of the rear cross-bracket of the carriage. Mount the junction box horizontally, with the cables facing the back, using one ¼ - 20 x 1/2 screw. Fig. 17 16
7. INSTALLATION OF CABLES Remove the cover from the back of the arm. Push the switch cable through the hole of the rear plate ( A ) and run it to the front in the lower channel on the left side of the upper arm (viewed from the front). Tie the cable to the cable harness ( B ) as Fig. 18 shows. Fig. 18 Unplug the R1 and L1 connectors from the main board. Plug in the connectors to the switch cable adapters as Fig. 19a shows: - R1 to the socket with R1 marker (BLACK and RED wires). - L1 to the socket with L1 marker (GREEN and WHITE wires). Plug in the adapters to the corresponding R1, L1 connectors as Fig 19b shows. 17
Fig. 19a Fig. 19b Insert the switch cable to the 6-position screw terminal as Fig. 20 shows. (1-GREEN, 2-WHITE, 4-RED, 5-BLACK) Fig. 20 18
Bring forward the computer and Y-motor cables on the bottom of the rear compartment and push them through the opening on the front. Fig. 21 Run the computer cable up in the outer channel of the rear column and in the lower channel of the upper arm, where the switch cable is inserted, as Fig. 22 shows. Plug in the 2-position green communication connector and the power jack on the docking station. Pull back the cable, leaving some slack at the docking station, as Fig. 24 shows. Run the Y-motor cable directly to the motor. Plug in the cable and pull it back, leaving some slack at the motor. 19
Fig. 22 Hold together the Y-motor and computer cables at the back with wire ties and form a loop that allows both extreme arm positions without pulling the cables, as Fig. 17 shows. Tie the cables to the machine s power cord and replace the rear cover. Run the X-motor cable on the inside of the left carriage rail (viewed from the back) toward the front, as Fig. 23 shows. Clean their locations with alcohol and place sufficient number of cable clips along the rail. Plug in the cable on the X-motor, leaving some slack. 20
Fig. 23 21
Fig. 24a Fig. 24b Plug in the thread break detector cable, arrange the cables and tie them with wire ties, as Fig. 24b shows. Secure the cables in the channels by replacing the channel covers. 22
Tie the cables on both motors with a wire tie as Fig. 25 shows. Fig. 25 23
Put the plastic covers on the motors. Pull up the cable in the slot at the side of the cover as Fig. 26 shows. Fig. 26 24
Remove the protective cover from the terminal of the motor power supply. Push the power cable through the wire-tie loop and connect the wires to the power supply: BLACK wire to the negative terminal, the wire with the in-line diode to the positive terminal. Tighten the wire tie. Replace the protective cover. Fig. 27 25
Mount the power supply on the rear middle table leg using two 14" cable ties as Fig. 28 shows. Fig. 28 26
8. COMPUTER SETUP Turn on the computer. When the booting completes, the motors will be engaged with the tracks. Select Manual Mode and move the motors all the way on the tracks. Check the gap between the drive wheel and the track. If the gap changes over the range, set the gap to 3/32 (about 2 mm) at the closest location. 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 8...14 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. Set the X-motor engagement strength when the arm is pushed all the way back. Go to Utilities->Measure/Calibrate and calibrate the sensor wheels following the onscreen instructions. Go to System->Interface Setup/Test. Ask the customer to set her/his preference for half or full cycle when the single stitch switch is pushed. Set the Single Stitch Phase accordingly. If the half stitch option is selected, warn the customer that the needle should be set at the top position before entering the Sew Quilt or Preview mode. Set the delays and pulse durations to match the electronic control of the quilting machine. 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. COPY THE LOGS AND E-MAIL THE logs.tar.gz FILE TO support@intelliquilter.com. 27