Machine Manager Supplement
Contents
1. COM ports iBox serial cable iBox machine gt paper tape cable reader port arallel Parallel E 3 7 ES 2006 Chapter 2 Networking Embroidery Machines 26 iBox Machine Interface Module The iBox is a hardware device that connects multi head and monogram embroidery machines to a PC Designs are transferred to the machine through the PC s serial port via iBox to the paper tape reader port on the embroidery machine The iBox buffers up to 85 000 stitches and transmits them in parallel to the embroidery machine For more details see the Wilcom iBox User Manual Multi parallel connections More than four parallel interfaced embroidery machines can be networked using a Multi Port Serial Card in conjunction with several iBox boxes This becomes a very expensive option as the number of machines increases Ethernet Serial Thin Server solution ES 2006 Ethernet is a relatively inexpensive widely understood networking solution It allows for wide propagation ideal for a large or distributed factory situation It also permits much more efficient cabling than other multi serial connections Although very few embroidery machines interface directly to Ethernet you can add an Ethernet to Serial Thin Server connection The great advantage of this type of network solution is that the Ethernet Serial Thin Server is owned by the supervisor PC and becomes an extension of that PC Its ports appear as local ports on th2. 2 to 4 CPUs each Pentium II 400 with 128Mb of RAM ES Machine Manager PC The ability of a production supervisor to manage 128 machines is doubtful in a busy workshop An architecture including multiple PCs running ES Machine Manager for multiple production supervisors is suggested here The ES Machine Manager PC must power the Multi Port Serial hardware installed in it Wilcom Multi Port Serial hardware draws power from all of the 5v 12v and 12v arms of the PC power supply as shown in the following Number of Ports Power Supply 5V 12v 12v 4 ports 410mA 100mA 160mA 8 ports 600mA 110mA 160mA 16 ports 940mA 220mA 320mA 32 ports 1 9A 440mA 660mA Note If a modem is attached to the ES Machine Manager PC and is powered from a serial port add the modem s power consumption to the above figures Basic multiport requirement Any Windows compatible multi port serial board e g a Hostess Decision or a lower specification Comtrol board will work with ES Designer A basic configuration is ES 2006 ES Machine Manager Supplement 35 ES 2006 4 No machine feedback 4 Only iBox or serial connections 9600 baud rate Higher multiport requirement A higher specification for a higher requirement is 4 Machine feedback 4 Baud rate higher than 9600 ES Designer has been tested with the Comtrol RocketPort Multi port Serial Card for this higher specification The types tested were 4 RocketPort 4 port serial I
3. sent clear the Auto Download option See also Setting up embroidery machines in ES Machine Manager 4 Ifthe Auto Download option in the Embroidery Machine Connection dialog is not selected select the machine and select Machine Manager gt Send Next Design Stitching designs from ES Designer If you are a designer most of your designs will be sent to production from inside ES Designer This minimizes the time you spend before getting back to the next design In larger factories the design s progress will be monitored by production staff but you can still monitor the design queue using ES Machine Manager if necessary To stitch a design from ES Designer 1 From ES Designer open or digitize a design 2 Choose File gt Stitch to Machine Manager ES 2006 ES Machine Manager Supplement 9 ES 2006 Note If no machines have been set up you will be prompted to add a new machine unit See Setting up embroidery machines in ES Machine Manager for details Send To Machine Manager x Design Name Cat Cancel i Machine Identification Machine 1 w Connected to MelcoNetwork Output as Machine Format IMelco X l M Prompt Changing Machine Format Select the required machine from the Machine Identification dropdown list Select the correct machine format from the Output as Machine Format dropdown and click OK ES Machine Manager opens in Queue View mode The machines registered in the system appear in the l
4. Cance MS Access 5 Choose an export report file format from the list enter a suitable file name and click OK Note Do not add a file extension e g TXT to the file name ES Machine Manager adds the correct extension automatically The export report file is written to the bin subdirectory of your current software installation You can now view and further analyze the data using a database or spreadsheet program depending on the file format you have chosen Initializing the ES Machine Manager database ES Machine Manager will continue to collect machine data indefinitely Periodically you may want to clear the database to free up disk space You may decide to do so every time you export any required statistics to another application Simply select Initialize Database from the File menu Warning Once the ES Machine Manager database has been initialized the data is no longer available for export Setting up embroidery machines in ES Machine Manager ES 2006 You can access all of your available machines from within ES Machine Manager using the procedures below Details can be modified at any time and you can delete machines when they are no longer needed ES Machine Manager Supplement 13 ES 2006 Setting up embroidery machines To set up a machine you need to define a name the port it is attached to and the protocol it uses You can select whether to download automatically to the selected machine and for ma
5. Category 5 CAT5 data cable 4 gt Shielded Twisted Pair STP 4 4 pair stranded plus foil shield with separate drain wire 4 RJ45 male plug with metal case on plug or shielded DB9 DB25 as applicable 4 DB25M male plug without shielding on DB25 connector with screw locks at embroidery machine end 4 Length nominal 5 meters 16 feet suggested only others may be suitable 4 Custom pin connections as below crossed with custom hardware handshaking 4 Custom pairing combinations to avoid RxD and TxD in same pair 4 2 conductors used for signal ground connection one each paired with RxD and TxD to minimize noise on these signal lines 1 RxD fixed reference Pin 6 performed via power supply of device carry ing RJ45 socket ES Machine Manager Supplement 32 4 Crossed TxD RxD crossed DTR CTS and crossed RTS DSR conform to Tajima Embroidery Machines Network Two Way Serial Communication Specifications v1 00 revi Signal Name RJ45 Pin DB9 Pin DB25 Pin Wire DB25 Pin Signal Name RTS 1 7 4 Pair 1 Blue 6 DSR DTR 2 4 20 Pair 1 Blue White 5 CTS Signal Gnd 3 5 7 Pair 2 Orange 7 Signal Gnd TxD 4 3 2 Pair 2 3 RxD Orange White RxD 5 2 3 Pair 3 Green 2 TxD DCD 6 1 8 Pair 3 Green White Fixed Reference DSR 7 6 6 Pair 4 Brown 4 RTS CTS 8 8 5 Pair 4 Brown White 20 DTR Earth Gnd metal case metal case metal case Drain Wire Shield Foil Guidelines 4 Unshielded serial cables will work in
6. can display it on screen or export it to Excel Access or text files for further analysis or export it to the optional Reporting Utility for complete analysis of all available data Summary statistics for each machine include 4 ao A A A total number of stitches total number of stops total number of thread breaks total minutes stopped total minutes operated Warning Once design stitching is finished you need to wait two minutes before submitting statistics data Before that the information submitted may be wrong This is because the operation of the Statistics database consumes system resources causing a bottleneck in the system To avoid this it is delayed by two minutes To change to Statistics view 1 ES 2006 Start ES Machine Manager See Starting ES Machine Manager Select View gt Statistics Static Update Machine Machine 5 nd Close Model TMCE 600 Info Number of Heads 4 Number of Needles 8 Date From 01 11 00 DateTo 09 11 00 Machine Statistics Reference TotStitches TotStops Tot Thread Breaks Tot Mins Stopped Tot Mins OJ Thread Breaks per Head ES Machine Manager Supplement 7 Stitching designs Designs can be sent for stitching directly from ES Machine Manager or sent to ES Machine Manager from inside ES Designer You can also send designs for stitching from the Design Workflow option Use the method that best suits your workflow and the type of work you do Stitching designs
7. from ES Machine Manager If you are working in the production area you will probably send most designs to the machines from ES Machine Manager It allows you to monitor the design s progress and lets you adjust the machine queues so that higher priority work is finished first To stitch designs from ES Machine Manager 1 Open ES Machine Manager See Starting ES Machine Manager for details Pee If no machines are set up you must do so now See Setting up embroidery machines in ES Machine Manager for details Designs remain in queue until Send next design downloading starts W ES Machine Manager Queue View File Edit View Machine Manager Window Help Machine 1 Status of Maina current design i displayed RPM 0 Downloading African Machine 2 Malan Stitch and color data displayed 2 Click the thumbnail of the machine that will stitch the design 3 Add a design or designs to the selected machine s queue To do this either ES 2006 Chapter 1 ES Machine Manager 8 4 Select File gt Open browse to the folder containing the design s select the design s and click Open 4 Drag and drop or cut and paste designs onto the machine s thumbnail from Windows Explorer See also Changing to Design Details view Note If you want queued designs to be sent to this machine automatically select the Auto Download option in the Embroidery Machine Connection dialog Or if you want to control when designs are
8. of machine performance for a given period 4 exporting machine statistics to other applications for further analysis and reporting 4 producing sophisticated production analysis reports from machine feedback including head needle and thread break information and performance for any given period 4 generating ready made production efficiency reports Starting and exiting ES Machine Manager ES 2006 ES Machine Manager can be started and closed using the normal Windows options You can start it using a desktop icon from the Windows Start button by double clicking the ES Machine Manager EXE file in Windows Explorer and from inside ES Designer You can also exit the program using the standard Windows program options Starting ES Machine Manager ES Machine Manager can be started in a number of ways 4 via the File menu inside ES Designer 4 from the Windows desktop 4 from Windows Start gt Programs Tip If there is no ES Machine Manager icon on your Windows desktop add one by making a shortcut of the ES Machine Manager EXE file and then dragging the shortcut to your desktop see Shortcuts in Windows Help for details To start ES Machine Manager 4 If ES Designer is not being used double click the ES Machine Manager icon on the Windows desktop Chapter 1 ES Machine Manager 2 Tip If the desktop is not visible right click a blank area of the Windows taskbar then select Minimize all Windows or press M If ES D
9. over short distances to decrease interference Multiple serial connections Where more than eight serial interfaced embroidery machines are networked a Multi Port Serial Card can be used These cards typically use only one IRQ to provide multiple serial ports e g eight to 32 ports Supported cards include 4 Comtrol RocketPort 8 port serial ISA PCI card with fan out cables 4 16 port PC Card and associated interface requires an interface box ES Machine Manager Supplement 23 ES 2006 Multi Port Serial Cards are plugged directly into the PC ISA or PCI BUS With multiple multi port cards a PC running Windows 9x can support up to 128 virtual COM ports and thus potentially 128 serial interfaced embroidery machines Windows NT can support up to 256 machines Proprietary software is required to make many ports available to the operating system This is provided by the card manufacturer This type of network has the following general layout Multi Port Serial Card UTP or STP UTP or STP cables cables serial port Multi Port Serial Cards Multi Port Serial Cards can provide anything from four ports upwards They use a single IRQ address and usually plug into a BUS slot on the PC motherboard Chapter 2 Networking Embroidery Machines 24 Limitations Where many machines are involved this type of layout can become very clumsy as it involves running a point
10. to point connection from the supervisor PC to each machine as shown in the following diagram Parallel interfaced network solution While relatively few machines are parallel interfaced they still appear in networked environments The following network solutions represent pure parallel interfaced configurations which may not represent real world situations Simple parallel connections The simplest kind of pure parallel interfaced network involves a single supervisor PC running Wilcom ES Machine Manager and up to three parallel interfaced embroidery machines Windows 9x and NT support up ES 2006 ES Machine Manager Supplement 25 to four native COM ports This type of network has the following general layout Supervisor PC LPT port shielded 25 conductor unpaired cables ar aller Cable connections Parallel connections generally use shielded 25 conductor unpaired cable Serial to parallel connections Embroidery machines which have only a paper tape reader parallel port can be networked with the aid of Wilcom Direct Connect Interface iBox boxes Up to four machines can be connected directly to the PC using this type of configuration This type of network has the following general layout iBox Machine Interface Module
11. 5 Enter the IRQ Base Address and DMA network card settings and click OK Note If you do not know the correct settings for the Melco StarLAN network card in this PC see Finding Melco StarLAN network card settings for methods you can use to obtain them Select Auto Download if you want designs in ES Machine Manager queues to be sent to this machine as soon as it finishes stitching the previous design Or clear Auto Download if you want to be prompted first 7 Click OK to complete the setup of this machine Adjusting ethernet settings Enter the following information when setting up embroidery machines that are connected using an ethernet network To adjust ethernet settings 1 Open the Embroidery Machine Connections dialog See Setting up embroidery machines for details Select Ethernet from the Port list An additional field Peripheral Name and three checkboxes display in the Connected To panel Connected to Port Protocol Ethernet F Auto Download a Peripheral Name F Auto Delete Z I Auto Queue MV Thread Break per Head From the Peripheral Name list select the embroidery machine you are setting up The system searches automatically for all machines connected on the ethernet and adds them to the dropdown list Select Auto Download if you want designs in ES Machine Manager queues to be sent to this machine as soon as it finishes stitching the previous design Or clear Auto Download if you wa
12. C WILCOM ES Embroidery Software 2006 Machine Manager Supplement Copyright 1998 2005 Wilcom International Pty Ltd All rights reserved No parts of this publication or the accompanying software may be copied or distributed transmitted transcribed stored in a retrieval system or translated into any human or computer language in any form or by any means electronic mechanical magnetic manual or otherwise or disclosed to any third party without the express written permission of Wilcom International Pty Ltd A B N 62 062 621 943 146 156 Wyndham Street Alexandria Sydney New South Wales 2015 Australia PO Box 581 Alexandria 1435 Phone 61 2 9578 5100 Fax 61 2 9578 5108 Email wilcom wilcom com au Web http Awww wilcom com au The Stitch Processor SP portion of this product is protected by the following patents US Patent N 4 821 662 European Patent N 0221163 Japanese Patent N 2029491 Curve Line Fill Stitching in this product is protected by US Patent No 6 587 745 TrueView and Point amp Stitch are trademarks of Wilcom International Pty Ltd Portions of the imaging technology of this product are copyrighted by AccuSoft Corporation The EPS File Import Export Convertor used in this product is copyrighted by Access Softek Inc All rights reserved Wilcom International Pty Ltd makes no representation or warranties with respect to the contents of this publication and specifically discla
13. SA amp PCI cards with RJ45 sockets 4 RocketPort 8 port Serial ISA card with Fan out cables 4 16 port PCI Card and associated interface requires an interface box Theoretically any multiple serial port card with similar specifications will work but Wilcom only supports this model of multi port serial card Specific technical details of the RocketPort card The 36Mhz ASIC Application Specific Integrated Circuit enables the RocketPort to transmit and receive data at rates far higher than multiport cards based on conventional 16550 UART technology up to 921 Kbps full duplex across all ports simultaneously Along with improved throughput speed and reduced load on the host system CPU the AIOPIC chip also adds increased reliability it has the highest level of integration and longest mean time between failures of any multiport serial card currently on the market RocketPort uses transmit FIFOs of 256 bytes and receive FIFOs of 1024 bytes for multiport cards designed with 16550 UARTs This helps eliminate bottlenecks at the serial controller level while conserving CPU resources For more technical details please refer to the RocketPort website at http www comtrol com Please refer to the setup documentation that came with the device for details on how to set up the device under Windows Once the device is set up in Windows ES Designer will recognize the ports and a list of the available ports will be available to choose from S
14. ard ALE T F A JP1 sets the Base I O Address JP2 sets the IRQ address te sooo so o FPS J5 TN JP3 amp JP4 Sometimes named DREQ and DACK on the card set the DMA address 3 Note the following settings 4 JP1 which sets the Base I O Address 4 JP2 which sets the IRQ Address 4 JP3 amp JP4 DREQ and DACK on the card set the DMA address both must be set to the same setting whether it is 0 1 or 2 4 Replace the PC case when finished Modifying and deleting embroidery machines Machine settings can be changed at any time to suit your needs and machines can be deleted from ES Machine Manager when they are no longer needed ES 2006 Chapter 1 ES Machine Manager 20 ES 2006 Modifying machine settings Embroidery machine settings can be changed at any time from inside ES Machine Manager The methods used are similar to those used to set up the machine initially To modify machine settings 1 Start ES Machine Manager See Starting ES Machine Manager Select the machine to be modified Select Machine Manager gt Modify Machine to open the Embroidery Machine Connection dialog Follow the procedure in Setting up embroidery machines Click OK when all settings are correct Pee You will see a message Updating Settings Please Wait This may take up to several minutes to complete Deleting machines Delete embroidery machines from your system when they are no longer requ
15. chines that support serial feedback whether to view design feedback as you stitch out For every machine you need to select the machine formats it supports You can select from a selection of standard formats or create new formats if necessary To set up an embroidery machine 1 Connect the embroidery machine using the instructions that came with 4 5 the machine Carefully note the port settings which must also be entered in the ES Machine Manager Embroidery Machine Connection dialog Start ES Machine Manager See Starting ES Machine Manager for details Select Machine Manager gt Add Machine The Embroidery Machine Connection dialog opens Embroidery Machine Connection m Machine Identification Name Machine q Cancel Model Taima TMCE 100 Info DO y O Number of Heads f Number of Needles i m Connected to Port Protocol fcom2 7 Standard Serial 7 Setup I Auto Download IV Thread Break per Head m Machine Type Available For this machine Tajima TMCE 100 Tajima TMCE 600 Barudan Barudan Chenille Barudan Z Series x LL In the Name field enter a name for the machine e g Machine 1 In the Model field enter the brand and model of the machine Chapter 1 ES Machine Manager 14 In the Info field enter a comment as required In the Number of Heads field enter the number of machine heads In the Number of Needles field enter th
16. e number of needles Oo An A In the Machine Type panel select the compatible machine formats To do this select compatible machine types in the Available list and click gt to move them to the For this machine list Machine Type Available For this machine T ji TEA supported machine ajima l machine type Tajima TMCE 100 E types Barudan Barudan Chenille Click gt to move machine types to the For this machine list Pee Machine format values can be added or changed if required See the ES Designer User Manual for details 10 From the Port dropdown list select the port to which the machine is connected 4 If you select a serial port e g COM1 COM2 etc go to Adjusting serial port settings 4 If you select a parallel port e g LPT1 LPT2 etc go to Adjusting parallel port settings 4 If you select Network go to Adjusting network settings 4 If you select Ethernet go to Adjusting ethernet settings Adjusting serial port settings PC serial COM ports are male connectors and can be either 9 pin or 25 pin They are named COM1 COM2 COM3 etc Read the instructions that came with the embroidery machine and take particular note of the recommended Port and Protocol settings Note You must be able to identify the ports on your computer If in doubt consult a PC technician To adjust serial port settings 1 Complete the initial setup of the embroidery machine See Setting up embroidery machin
17. e supervisor PC and feedback from the embroidery machines returns to ES Machine Manager as local data ES Machine Manager Supplement 27 Network layout The Ethernet Serial Thin Server type network has the following general layout Network Interface Card NIC UTP cables UTP cables Any Ethernet UTP device ay printer etc A Ethernet Hub d ace 4 ports and u s gt 4p p Ethernet Serial Thin Server 1 port and up Network components The Ethernet Serial Thin Server type network is made of the following components Network Interface Cards Network Interface Cards NIC are now standard on most PC motherboards Note that some NICs may cause interrupt conflicts Ethernet Hubs Ethernet hubs come in many configurations and styles starting from four ports Most range from eight to 24 ports ES 2006 Chapter 2 Networking Embroidery Machines 28 ES 2006 Note Both the NIC and Ethernet Hub must be capable of running at 10 Mbps because this is the fastest speed currently supported by Ethernet Serial Thin Servers Some Ethernet implementations are not capable of running that slowly Ethernet Serial Thin Servers Why server Because it manages data to and from the peripheral device in this case a serial interfaced embroidery machine Why thin Because it does not have to do much apart from manage the data flow Ethernet Serial Thi
18. eft side of the window The design s for stitching are queued to the right Chapter 1 ES Machine Manager 10 Note If you want queued designs to be sent to this machine automatically select the Auto Download option in the Embroidery Machine Connection dialog Or if you want to control when designs are sent clear the Auto Download option See also Setting up embroidery machines in ES Machine Manager Designs remain in queue until Send next design downloading starts W ES Machine Manager Queue View File Edit View Machine Manager Window Help e 0 apax ajm ae km Machine 1 Status of Melco current design displayed RPM 0 Downloading African Machine 2 Malan Stitch and color data displayed 6 Ifthe Auto Download option in the Embroidery Machine Connection dialog is not selected select the machine and select Machine Manager gt Send Next Design 7 Send other designs to ES Machine Manager as required Press Alt Tab to toggle between ES Designer and ES Machine Manager The designs you send will appear in the design queues waiting to be stitched to the specified machines See Changing to Design Details view for details Design Statistics Design statistics collected by ES Machine Manager from serial interfaced embroidery machines can be displayed on screen and exported in Excel Access and text formats for analysis ES 2006 ES Machine Manager Supplement 11 Note The optional Reporting Utility allows c
19. es for details ES 2006 ES Machine Manager Supplement 15 ES 2006 Select a serial port e g COM1 from the Port pulldown Select a serial protocol from the Protocol pulldown The protocol selected should be one recommended by the machine s manufacturer Click Setup to open the Seria Port Setup dialog Port Baud Data Bits Stop Bits Parity Handshaking Enter the Baud rate Data Bits Stop Bits and Parity and Handshaking settings for the device Note The port settings must match those of the embroidery machine or selected device The type of handshaking must match the type of cable you are using Check the communications setup section of the documentation that came with the device Select Auto Download if you want designs in ES Machine Manager queues to be sent to this machine as soon as it finishes stitching the previous design Or clear Auto Download if you want to be prompted first Select Feedback if you want to view machine feedback and or collect machine statistics This option is only available for machines that support serial line feedback Click OK to complete the setup of this machine Adjusting parallel port settings Parallel ports are used to connect some embroidery machines They are named LPT1 LPT2 etc Read the instructions that came with the embroidery machine and take particular note of the recommended Port and Protocol settings To adjust parallel port settings 1 Comple
20. esigner is not being used click Windows Start gt Programs gt Wilcom ES gt Machine Manager If ES Designer is being used select File gt Stitch to Machine Manager If Design Workflow is being used select File gt Stitch to Machine Manager Exiting ES Machine Manager You can close ES Machine Manager at any time using the standard Windows File gt Exit or by clicking the x button at the top right of the window To exit ES Machine Manager 4 Select File gt Exit or 4 Click the x button at the top right of the window Note If any designs are queued you will be asked whether you want save the queue until the next time you open ES Machine Manager We recommend that you save the queue ES Machine Manager views ES 2006 Depending on the options available in your software implementation ES Machine Manager provides a number of views for managing your design queues These are 4 Queue view the default which shows each machine plus thumbnails of any designs in its queue Machine view which shows all of the machines on line with details of their current status Design Details which shows a large thumbnail of the selected design plus all of its design details Statistics which displays all of the details of designs sent to machines over a selected period plus feedback from machines that generate serial feedback ES Machine Manager Supplement 3 ES 2006 Changing to Queue view The Queue view window prov
21. etup and troubleshooting of a multiple serial port card To set up and troubleshoot a multiple serial port card refer to the troubleshooting section of the manual provided with the device or refer to Chapter 3 Networking Specifications 36 ES 2006 the device manufacturer To troubleshoot the regular serial ports refer to the Windows troubleshooting guide found in Start gt Help gt Contents gt Troubleshooting ES Machine Manager Supplement 37 Index A Auto Delete Ethernet setting 18 Auto Queue Ethernet setting 18 C cabling STP with Ethernet 29 STP with serial 23 UTP with Ethernet 29 UTP with serial 23 connection settings Ethernet 18 Melco StarLAN 17 network 17 parallel ports 16 serial ports 15 D deleting machines from Machine Manager 21 design details view Machine Manager 6 embroidery machines automatic download 14 feedback 14 setting up 13 Ethernet Auto Delete setting 18 connection settings 18 Ethernet serial thin servers 29 hubs 28 network interface cards 28 networking 27 Ethernet setting Auto Queue 18 exiting Machine Manager 2 ES 2006 H hardware setting up machines 13 hybrid networks complex 31 serial parallel networks 30 simple 30 Machine Manager deleting machines 21 design details view 6 exiting 2 features 1 initializing database 13 machine view 5 modifying machine settings 21 queue view 4 setting up machines 13 14 starting 2 stitching 8 stitching from main a
22. good office conditions but are susceptible to electronic interference and data errors Use shielded twisted pair CAT5 cable instead 4 For the shielding to be effective the cable shield must be connected at the Ethernet Serial Hub or Multi port Serial Card plug and thence to AC earth ground through the Ethernet Serial Hub The cable must not be earth grounded at the Tajima machine end to avoid ground loops 4 Each end of this cable must be labelled RJ45 end Tajima Machine Serial Cable STP Connect to RJ45 PC or HUB SERIAL PORT DB25M end Tajima Machine Serial Cable STP Connect to Tajima Serial Port ONLY Specification for use with ES Machine Manager software ES 2006 Large numbers of embroidery machines downloading at high data rates require ES Machine Manager Supplement 33 4 Wide bandwidth in the Multi Port Serial Card and interface serving them 4 Large receive FIFO buffers that allow feedback multiple bursts to be accepted and buffered whenever the software is momentarily unable to accept feedback 4 High performance from the PC running the ES Machine Manager software Large numbers of machines and high data rates require both high CPU specification and high serial performance Specification 4 Serial interface meeting RS 232C 4 Supplied driver software for Wilcom supported CPU operating system 4 Device driver control matching selected data bits parity and stop bits 4 PCI or ISA bus connector to suit CPU system 4 4 t
23. ial cabling 23 unshielded twisted pair cabling 29 V viewing designs with Machine Manager 4 views design details view 6 machine view 5 queue view 4 statistics view 6 ES 2006 ES Machine Manager Supplement 39
24. ial ports needed by ES Designer varies according to the number of peripherals required The following network solutions represent pure serial interfaced configurations i e networking serial interfaced embroidery machines only A real world environment may however also incorporate other interface types ES Machine Manager Supplement 22 ES 2006 Simple serial connections The simplest way to provide serial ports is via the two standard PC serial ports COM1 and COM2 You can increase the number of embroidery machines and other peripherals attached to a PC by adding extra COM ports You can increase the number further by using a switch box that allows the PC to share existing COM ports between different peripherals Note however that only one embroidery machine on a switch box can provide feedback at any one time A simple serial interfaced network has the following general layout l Supervisor PC UTP or STP serial port Serial interfaced machines Shielded Twisted Pair STP cable Serial connections which need only eight conductors generally use Category 5 twisted pair cable This should be shielded i e STP With STP capacitance increases with length of cable which can cause signal drops over long distances Unshielded Twisted Pair UTP cable Unshielded Twisted Pair UTP cable is sometimes used instead of STP because it is cheaper but it should only be used
25. ides a flexible visual environment for managing your design queues You can scroll through all of your machines and see a thumbnail and brief details for all queued designs Most designs are sent for stitching from this view W ES Machine Manager Queue View OF x File Edit View Machine Manager Window Help 28 ajaa Machine 1 Melco RPM O0 Downloading African Machine 2 Malan To change to Queue view 1 Start ES Machine Manager See Starting ES Machine Manager 2 Select View gt Queue View 3 Use the appropriate methods below 4 To change a design s position in a queue drag it to any position in the current queue 4 To stitch a design to a different machine drag and drop it to any position in that machine s queue 4 To delete a design from a queue select it and press Delete You will be asked to confirm the deletion 4 To stitch a copy of the same design in a queue select the design press Ctrl C then press Ctrl V to paste the design in the queue Alternatively right click the design select Number of Runs enter the number of runs required in the dialog and click OK 4 To add more designs to the queues drag and drop one or more designs directly from Windows Explorer onto a ES Machine Manager queue Chapter 1 ES Machine Manager 4 ES 2006 Tip Drag selected designs from Explorer over the minimized ES Machine Manager taskbar icon ES Machine Manager will automatically maximize and all
26. ims any implied warranties of merchantable quality or fitness for any particular purpose Further Wilcom International Pty Ltd reserves the right to revise this publication and to make changes in it from time to time without obligation of Wilcom International Pty Ltd to notify any person or organization of such revisions or changes The screen illustrations in this publication are intended to be representations not exact duplicates of the screen layouts generated by the software Subject to any warranties implied by law which are incapable of limitation or exclusion the software is purchased as is without any warranty as to its performance accuracy freedom from error or to any results generated through its use and without any implied warranty of merchantability or of fitness for any particular purpose for which the software is being acquired The purchaser relies on its own skill and judgement in selecting the software for its own use and assumes the entire risk as to the results and performance of the software Wilcom International Pty Ltd specifically does not warrant that the software will meet the purchaser s requirements or operate without interruption or error Rev 1 July 2005 Chapter 1 ES Machine Manager ES Machine Manager is a tool for controlling the workflow of multiple embroidery machines Its main tasks are to download designs to machines manage queues monitor machine and job status and collect productivity and
27. ired To delete a machine 1 2 Select the machine in either Queue View or Machine View Select Machine Manager gt Delete Machine You will be prompted to confirm deletion of the selected machine Note that any queued designs for that machine will also be removed ES Machine Manager Supplement 21 Chapter 2 Networking Embroidery Machines This section provides information about the three styles of embroidery machine for which networking solutions are required serial interfaced parallel interfaced and ethernet interfaced and describes a variety of networking solutions for each Most networked machines are serial interfaced and these make up about 90 of installations Parallel interfaced machines which are generally older in style account for about 5 of the installed base The newer style ethernet interfaced machines also comprise a relatively small proportion of installations Some configurations include a mixture of some or all of these machine types so any networking solution needs to cater for all eventualities including hybrid configurations ES Machine Manager can theoretically support up to 128 machines under Windows 9x or 256 machines under Windows NT 4 Serial interfaced network solution ES 2006 Windows uses seria ports to connect the PC to all manner of peripheral devices cutters digitizers scanners printers plotters tape punch readers as well as embroidery machines The number of ser
28. maintenance statistics ES Machine Manager is machine rather than design oriented It is ideally suited for use in larger embroidery factories where production managers and supervisors must know exactly what many machines are doing and how jobs are progressing You can also use ES Machine Manager to send designs to machines from within ES Designer or Design Workflow and then view and manage job queues ES Machine Manager features ES 2006 Depending on the options available in your software implementation ES Machine Manager allows you to 4 Download multiple designs to many machines 4 Manage and view all design queues simultaneously in an embroidery machine network 4 Change the design queues by drag and drop and cut and paste i e move designs around in the queue or move designs to a different machine Designs can even be moved between different brands and models of machine 4 Delete one or more selected designs or the entire design queue using Delete or Cut or Delete Queue 4 Drag and drop or cut and paste one or many designs from Windows Explorer directly onto a ES Machine Manager queue 4 Recall designs that were queued when ES Machine Manager was last closed ES Machine Manager Supplement 1 Serial line feedback The following features are also available for machines that can send feedback via a serial connection 4 monitoring stitching progress of each design on each machine 4 displaying a statistical summary
29. n Servers may come in configurations of one four or eight ports Note The only Ethernet Serial Thin Server to date found to perform according to required specifications is the Comtro Ethernet Serial Hub 4 port Unshielded Twisted Pair UTP cabling Unshielded Twisted Pair UTP cabling is sufficient for use between PC and Ethernet Hubs and between Hubs and Ethernet Serial Thin Servers This is because Ethernet runs at 900 MHz a frequency higher than most potential sources of interference Shielded Twisted Pair STP cabling Shielding is required between Ethernet Serial Thin Servers and serial interfaced embroidery machines Shielded Twisted Pair STP cables are recommended Interference can come from three potential sources 4 High frequency welders used for welding plastic appliqu to fabrics 4 Large motors 4 Inductors e g fluorescent light ballasts Note The STP needs to be of the proper configuration to permit handshaking with the particular embroidery machine Serial connections Both Ethernet Serial Thin Servers and embroidery machines generally implement the RS232 C serial port standard of the Electronics Industry Association ES Machine Manager Supplement 29 Hybrid serial parallel network solutions The Ethernet Serial Thin Server combination can service a completely hybrid environment incorporating elements of both serial interfaced and parallel interfaced network solutions Simple scenario Both serial i
30. n information including design name stitch count number of colors and color sequence 4 current stitch count progress and percentage completion serial line feedback only 4 current machine status serial line feedback only To change to Design Details view 1 Start ES Machine Manager See Starting ES Machine Manager 2 Select View gt Queue View 3 Right click the design s thumbnail 4 Select View gt Design Details from the dropdown menu W ES Machine Manager Design Details Canoe Ox File View Window Help lej x Ei Lf Design information stop Sequence Summary Design Name Canoe Imported outlines Version V6 0 Stitches 9146 Stops i Color Changes 6 Trims gi Colors th Objects 26 Machine Melco Maximum Stitch Length 11 7 mm Total Thread 92 41 ft Minimum Stitch Length 0 2mm Total Bobbin 59 86 ft Jump Length 6 9 mm From start point Left 1 8in Right 1 8in Up 14in Down 1 4in End 0 0in EndY 0 0in Height 28in Width 3 6in Machine Machine 1 Total Runs 1 Design status Model Melco Current Run 1 Speed RPM Info Current needle Number of Heads 1 Curent Stitch Cur stitch Design progress Number of Needles i Changing to Statistics view ES Machine Manager automatically collects machine data for machines that support serial line feedback This data provides summary statistics ES 2006 Chapter 1 ES Machine Manager 6 collected from each machine for a given period You
31. nt to be prompted first Select Auto Delete to automatically delete files from machine memory after stitching is complete Chapter 1 ES Machine Manager 18 ES 2006 6 7 Select Auto Queue to automatically send designs to the head of the machine s memory queue i e as the next one to stitch Clear it to send the design to the end of the existing queue Note This setting is different from Auto Download which only controls designs before they go to machine memory Click OK to complete the setup of this machine Finding Melco StarLAN network card settings Before embroidery machines can be installed to run on a network using a Melco StarLAN network card you need to know the card s IRQ Base Address and DMA settings There are a number of ways you can do this Try the following 4 If you can find the documentation that came with card read that carefully If the card has been working with ES Designer on this PC check the present settings from inside ES Designer If the card has been working with other software check the settings from inside that software see that software s documentation If none of the above methods provide the settings open the PC s case and examine the card You may require help from a PC technician to do this To find Melco StarLAN network card settings 1 Disconnect the PC from the power ES Machine Manager Supplement 19 2 Open the PC case and locate the Melco StarLAN network c
32. nterfaced and parallel interfaced machines can be connected to a Ethernet Serial Thin Server The parallel machines are connected through a iBox box added to the chain Network Interface Card NIC Ethernet Hub 4 ports and up iBox serial cable Ethernet Serial ee Thin Server 1 port and up iBox Machine STP Interface Module iBox machine cable ES 2006 Chapter 2 Networking Embroidery Machines 30 ES 2006 Complex scenario Ethernet Serial Thin Server technology can theoretically support a completely hybrid environment including and preserving legacy components The following diagram shows one such scenario el Multi Port Serial Card Network Interface Card NIC Ethernet Hubs 4 ports and up Ethernet Serial Thin Server 1 port and up iBox serial cable iBox Machine Interface Module iBox machine cable ES Machine Manager Supplement 31 Chapter 3 Networking Specifications Specification for DB25M Tajima Machine serial cable ES 2006 This section details networking specifications for embroidery machine networks See also Networking Embroidery Machines The following specification details the serial cable connection for Ethernet Serial Hub ESH or Multi port Serial Cards to Tajima Serial Port embroidery machines Componentry 4
33. o 128 ports available in modules of 4 8 16 and 32 ports with a maximum of four modules per CPU system 36MHz ASIC I O processor maximum 8 ports per processor I O memory mapped design This does not require IRQ allocation Receive FIFO buffer 1024 bytes per port Transmit FIFO buffer 256 bytes per port Data rate support both PCI ISA card and interface box if applicable up to 230 4kbps on every port with all ports in simultaneous use 4 DB9 DB25 or RJ45 data connectors to match chosen serial cable system ao A A A A 4 Agency approvals for example Canada EMC requirements USA FCC requirements UL product safety requirements European EMC requirements Surge protection EN 50082 1 and others as may be required for the territory of installation 4 CPU and power supply guidelines RJ45 data connectors The Multi Port Serial hardware should have RJ45 data connectors to minimize the use of adapters between cables and the data connectors We offer these RJ45 connectors on our 4 8 16 and 32 port units Wilcom ES 2006 Chapter 3 Networking Specifications 34 standard serial cables see separate specification will plug directly onto our Multi Port Serial hardware without intervening adapters CPU capability Under Windows NT a very general guideline to the required CPU capability is 4 up to 32 machines Pentium 200 with 48Mb of RAM 4 up to 64 machines Pentium II 400 with 64Mb of RAM 4 upto 128 machines multiple processor
34. omplete analysis of all available data from your embroidery machines See your Wilcom dealer for full information about this valuable tool Exporting design statistics You can export the statistics collected by ES Machine Manager in common spreadsheet database and text formats You can then use the power of your spreadsheet or database program to provide meaningful management statistics To export design statistics 1 Select Statistics from the ES Machine Manager menu Or right click a machine unit in the left panel and select Statistics from the popup menu Static m Machine Machine 5 ji Close Model TMCE 600 Export data to Info external file Number of Heads 4 Number of Needles 8 Specify period for Rens ie are gt DaeFom 01110 DateTo 0811 00 required Machine Statistics Reference Tot Stitches Tot Stops Tot Thread Breaks Tot Mins Stopped Tot Mins OJ Statistics viewing panels Thread Breaks per Head 2 Inthe Date From and To fields specify the period for which machine statistics are required 3 Click Update ES 2006 Chapter 1 ES Machine Manager 12 Data stored in the ES Machine Manager database is extracted and displayed in the Machine Statistics and Thread Breaks per Head viewing windows 4 Click Export to export the data for further analysis in a database or spreadsheet The Export Statistics dialog opens Export Statistics x Format of Export File Name X MS Excel
35. ow you to drop the design s onto a queue Where necessary you will be prompted to change machine format Changing to Machine view Machine view displays details for all the machines in a factory It shows the reference number e g Machine 1 and model e g Melco of each machine the name and icon of the last design that was downloaded and the number of stitches and colors in the design If no design is running on a machine only the machine s reference information and status are displayed For machines without feedback the download progress displays as a percentage When the design is downloaded the status displays as Downloaded amp Stitching Machines with serial feedback show the actual stitching progress of the current design and current machine status To change to Machine view 1 Start ES Machine Manager See Starting ES Machine Manager 2 Select View gt Machine View W ES Machine Manager Queue View Iof x File Edit View Machine Manager Window Help Machine 1 Machine 2 Machine 3 Melco Melco Melco RPM O0 RPM 0 RPM O0 Idle Idle Idle Machine 4 Machine 5 Machine 6 Melco TMCE 600 TMCE 600 RPM O0 RPM 0 RPM O0 Idle Idle Idle ES Machine Manager Supplement 5 Changing to Design Details view The Design Details window displays a selected design for detailed enlarged viewing It includes the following information 4 basic machine information including machine reference number and model 4 desig
36. pplication 9 summary statistics 12 using queue view 4 viewing statistics 6 machine view Machine Manager 5 Melco StarLAN network card settings 19 network settings 17 modifying machine settings Machine Manager 21 network card settings Melco StarLAN 19 network settings 17 Ethernet 18 networking 22 31 all parallel machines 25 all serial machines 22 Ethernet and serial 27 Ethernet hubs 28 Ethernet network interface cards 28 Ethernet serial thin servers 29 hybrid serial parallel networks 30 multiple parallel connections 27 multiple serial connections 23 serial to parallel connections 26 simple parallel connections 25 simple serial connections 23 P parallel connections multiple 27 serial to parallel 26 simple 25 parallel ports connection settings 16 parallel interface hybrid networks 30 networking 25 ports parallel 16 serial 15 Q queue view 4 Machine Manager 4 R Reporting Utility statistical analysis option 12 S serial connections multiple 23 simple 23 serial devices recommended settings 15 ES Machine Manager Supplement 38 serial ports connection settings 15 serial interface hybrid networks 30 networking 22 setting up machines in Machine Manager 13 StarLan see Melco StarLAN starting Machine Manager 2 stitching designs queue view 4 using Machine Manager 8 9 STP Ethernet cabling 29 serial cabling 23 shielded twisted pair cabling 29 U UTP Ethernet cabling 29 ser
37. te the initial setup of the embroidery machine See Setting up embroidery machines for details Chapter 1 ES Machine Manager 16 2 Select a parallel port e g LPT1 from the Port pulldown 3 Select a parallel protocol from the Protocol pulldown The protocol selected should be one recommended by the machine s manufacturer 4 Select Auto Download if you want designs in ES Machine Manager queues to be sent to this machine as soon as it finishes stitching the previous design Or clear Auto Download if you want to be prompted first 5 Click OK to complete the setup of this machine Adjusting network settings If an embroidery machine connection uses a Melco StarLAN network with a Melco StarLAN card enter the network settings To adjust network settings 1 Complete the initial setup of the embroidery machine See Setting up embroidery machines for details 2 Select Network from the Port pulldown Connected to Port Protocol ID Network Melco StarLAN Network Setup F Auto Download 3 Select Melco StarLAN from the Protocol pulldown and enter the ID number ae The ID number appears in the Melco machine s LCD display when it is switched on ID 1 is displayed as Machine 01 ID 2 as Machine 02 etc 4 Click Setup to open the Me co Network Card Setup dialog Melco Network Card Setup Card Melnet Ra 7 Cancel Base Address 3E0 X DMA 0 7 ES 2006 ES Machine Manager Supplement 17 ES 2006
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