PowerMax AH50-55 [PDF]

Zitiervorschau

l Technician Mode............................................................................... 18

Contents

l Administrator Mode........................................................................... 20 3.1.3 Function Operation................................................................................. 22

Preface ............................................................................................................... 1

l Normal Sewing.................................................................................. 22

Safety Instruction ............................................................................................... 1

l Simple Sewing Mode........................................................................ 22

1

Product Introduction.................................................................................. 3

l Constant-Stitch Sewing .................................................................... 23

1.1 Overview ...................................................................................................... 3

l Start/End Back Tracking ................................................................... 25

1.2 Components & Accessories ........................................................................ 3

l Auto Thread Trimming ...................................................................... 27

1.3 Functions & Specification............................................................................ 5

l Presser Foot Lifting........................................................................... 27

2

Installation Instructions ............................................................................. 6

l Needle Stop Position ........................................................................ 27

2.1 Installation .................................................................................................... 6

l Back Tacking and Compensating Stitch .......................................... 27

2.1.1 Installation of Synchronizer...................................................................... 6

l Stitch Corrections.............................................................................. 28

2.1.2 Installation of Panel(HMI)......................................................................... 8

l Parameter Monitoring ....................................................................... 30

2.1.3 Control Box Installation ............................................................................ 8

3.2 Optional Operation Panel Instruction ....................................................... 31

2.1.4 Foot Pedal Installation.............................................................................. 9

3.2.1 Optional Operation panel (HMI) Description......................................... 31

l Foot Pedal Adjustment ..................................................................... 10

l Optional Panel LCD Area ................................................................. 31

l Foot Pedal Operation........................................................................ 10

l Optional Panel Keys Definition......................................................... 32

2.1.5 Power Connection .................................................................................. 11

3.2.2 Optional User Mode ............................................................................... 33

l Signal Wire Connection.................................................................... 11

l Operator Mode.................................................................................. 33

l Grounding.......................................................................................... 11

l Technician Mode............................................................................... 34

2.2 Adjustment ................................................................................................. 12

l Administrator Mode........................................................................... 35

l Restore Default Setting .................................................................... 13

3.2.3 Function and Operation.......................................................................... 36

Operation Instructions............................................................................. 15

l Normal Sewing.................................................................................. 36

3.1 Embedded Operation Panel Instruction ................................................... 15

l Simple Sewing .................................................................................. 36

3.1.1 Embedded Operation Panel (HMI) Instruction...................................... 15

l Constant-Stitch Sewing .................................................................... 36

l Embedded Panel Display Instruction............................................... 15

l Back Tacking Sewing........................................................................ 37

l Keys Functions.................................................................................. 16

l Thread Trimming............................................................................... 38

3.1.2 Embedded User’s Modes....................................................................... 17

l Presser Foot Lift................................................................................ 38

l Operator Mode.................................................................................. 17

l Needle Stop Positioning ................................................................... 39

3

-i-

-ii-

l Back Tacking and Compensating Stitch .......................................... 39 l Stitch Corrections.............................................................................. 39 l Operation Monitoring ........................................................................ 39 4

Work Environment................................................................................... 40

5

Troubleshooting....................................................................................... 41

Preface Please read this manual carefully, also with related manual for the machinery CAUTION: before use the controller. For installing and operating the controller properly and safely, qualified personnel are required. This product is designed for specified sewing machines and must not be used for other purposes. If you have any problem or any comment, please feel free to contact us.

Safety Instruction 1.

All the instruction marked with sign

must be absolutely

observed or executed; otherwise, personal injuries or risk to the machine might occur. 2.

This product should be installed and operated by persons with appropriate training only.

3.

Before connecting power supply cords to power sources, it’s necessary to make sure that the power voltage is in the range indicated on the product name plate.

4. -iii-

Make sure to move your feet away from the pedals while · 1 ·

power on. 5.

Turn off the power and remove plug prior to the following

1 Product Introduction

operations: u Connecting or disconnecting any connectors on the control box. u Repairing or doing any mechanical adjustment. u Threading needle or raising the machine arm. u Machine is out of work. 6.

Make sure to fasten all the fasteners firmly in the control boxes prior to the operation of the system.

7.

Allow an interval of at least 30 seconds before repowering the system after power off.

8.

Repairs and maintenance work may be carried out by special trained electronic technicians.

9.

All the replacement parts for repairing must be provided or approved by the manufacturer.

10. The controller must be firmly connected to a properly grounded outlet.

CAUTION:

Be sure to connect the controller to a properly grounded outlet. If the grounding connection is not secured, you may run a high risk of receiving a serious electric shock, and the controller may operate abnormally.

· 2 ·

1.1 Overview PMX AH50 Series Digital AC Servo System, the motor and the controller are separately mounted on the same bracket, providing a very flexible mounting solution for customers. The system can be easily configured with different motors to match with various sewing machines, such as lockstitch, duel-needle lockstitch, heavy duty, and direct-driven sewing machines. To meet customers’ varying needs ranging from thread trimming-only machines to fully automatic machines, the system is equipped with duel control panels, one is mounted on the sewing machine for easy access, and the other is embedded in the controller for simple settings. The solenoid outputs are over current protected, preventing damage of the controller in case of mis-wiring of external accessories. Employing a switch-mode power supply for the sensitive control circuitry, the system can operate over a much wider voltage range. Side-mount connectors make the connection more reliable and reduce the malfunction caused by oil leakage.

1.2 Components & Accessories The system contains main body and accessories. Main body of the system composes of control box (Fig.1):

· 3 ·

1.3 Functions & Specification Function and specification of PMX AH50 series Digital AC Servo System (see table 1). Table1: Controller Type

PMX AH50-55

PMX AH70-65

Fig.1 Control Box

Motor Type

Synchronizer unit contains a synchronizer (shown in Fig.2-1 and 2-2) and adaptable magnetic cylinder & installation unit upon different adaptable sewing machine head.

Voltage Range

AC 220±20% V

Output Power

550W

650W

Max. Sewing Speed

5000rpm

3000rpm

2200rpm

1800rpm

Max. Torque

3.4Nm

6Nm

Nimble Positioning

★

★

Needle up/Correction

★

★

Slow Start

★

★

Presser Foot Lift

★

★

★/★/★

★/★/★

Overload Protection

★

★

Operation Panel

Optional, Blue Backlight LCD

Optional, Blue Backlight LCD

Weight

9Kg

10.5Kg

Dimension

485X280X395mm

485X280X395mm

Max.

Back

AC Servo Motor

AC Servo Motor

50/60HZ

AC 220±20% V

50/60HZ

tacking

Speed

Fig.2-1 Synchronizer for Juki

Fig.2-1 Synchronizer for Brother

As the Brother series require different operation panel installation methods than the Juki series, the controller provides two different types of operation panels (see Fig.3), which have different shapes but identical functions.

Thread Trimming, Thread Wiping, Back tacking

Fig.3-1 Panel for Juki series

Fig.3-1 Panel for Brother series

Please check whether the components listed on the packing list are all included. Please contact supplier for compensation in case of missing parts. (Packing list is inside the package box).

(★It indicates the function.)

· 4 ·

· 5 ·

2 Installation Instructions 2.1 Installation Fig.4c

2.1.1 Installation of Synchronizer

Fig.4d

Note:

Power off and remove the pulley CAUTION: while implementation. Step 1:

Juki series pulley: Mount the magnet in the left (Hole A)(Hole A in Fig.5). Brother series pulley: Mount the magnet in the third hole (Hole C) clockwise from the mount screw Po (Hole C in Fig.5).

Remove the pulley of the sewing machine; put the synchronizer on the upper axis (For Juki series see Fig.4a, for Brother series see Fig.4b). Note: 1) There are scales at the right side of the positioning synchronizer’s indicator. Make sure to keep the longest scale at a position vertical to the central line of the upper axis. 2) Keep the indicator of the positioning synchronizer at the Upper position).

Fig.5

Step 3:

Put the assembled pulley back as shown in Fig.6; ensure that there is no sense of attrition in rotation.

Note: Skip this chapter if it has been done.

Fig.4a JUKI series

Step 2:

Fig.4b Brother Series

Mount the magnets on the pulley (For Juki series see Fig.4c, for Brother series see Fig.4d). Fig.6

· 6 ·

Fig.7

· 7 ·

2.1.2 Installation of Panel(HMI) Firstly mount the operation Panel on the bracket, and then set onto the machine via tightening the two screws (see Fig.7) (Note: Skip this chapter if it has been done or not be selected.)

2.1.3 Control Box Installation Step 1:

Mount lifting bracket, drill holes as shown in Fig.8 if the machine table is not ready, half-tighten the screws after lifting bracket positioned by screw stem frame.

Fig.9

2.1.4 Foot Pedal Installation As shown in Fig.10, mount nut ② in the pedal pin ① and then insert the pin into position B of the lever ③. Tighten the mechanism with the spring washer ④ and nut ⑤.

Fig.8

Step 2:

Mounting the control box under the machine table (as shown in Fig.9), and then screwing the lifting bracket.

Fig.10

· 8 ·

· 9 ·

l

Foot Pedal Adjustment

Adjust the pedal connecting pole to obtain the optimised pedal angle according the practical level. If the pedal pressure is too weak, move the pedal pin from position B to A (see Fig.10).

l

will stop at the needle-up position.

2.1.5 Power Connection

l

Signal Wire Connection

Connections between control box and other accessories are illustrated in Fig.12. Plug these connectors into the corresponding

Foot Pedal Operation

Operation Panel Interface

Caution: Take your foot off the pedal before power on.

Synchronizer

Pedal operation is shown in Fig.11:

Power

Fig.11

When the pedal is gently depressed from the neutral position ① to position ②, low-speed sewing is carried out. If it is then depressed as far as ③, high speed sewing is carried out. If the pedal is gently depressed backward from the neutral position ① to position ⑤, the presser foot lift is raised automatically (Assuming this feature is installed and enabled). If the pedal is depressed backward fully from the neutral position ① to position ⑥, the thread trimmer/wiper operates. The machine · 10 ·

Solenoid

sockets in control box. Fig.12

Caution:

l

Please check if all connectors match or not, pins are found right definition or not.

Grounding Ground wire (Green/yellow, see Fig.13) must be grounded. · 11 ·

Use the correct connector and extension wire when connecting ground wire to Earth and secure it tightly.

Fig.14-1

u

Fig.14-2

Down position adjustment: adjust the needle bar to the lowered position (the needle bar shall be at its lowest position), loosen the fixing screws of Down magnet (do not take them off), slide the magnet left and right in the orifice of the pulley (as shown in Fig.14-3). Fix the magnet immediately after the red indicator turns on (as shown in Fig.14-4).

Fig.13

Ensure all power cord, signal wire and grounding wire not be pressed by other Caution: matter or over-twisted ,and not be too close to belt and belt wheel, keep 3cm-distance for safety.

2.2 Adjustment System power on after it is steadily grounded (permanent fixed grounding) ensure the voltage range and technical requirements complied with the indication on nameplate. u Up position adjustment: adjust the needle bar to the up position (when the thread take-up lever is at its highest position), loosen but do not remove the fixing screws of Up magnet, slide the magnet left and right in the orifice of the pulley (as shown in Fig.14-1). Fix the magnet immediately after the green indicator turns on (as shown in Fig.14-2).

Fig.14-3

Fig.14-4

If the above operation cannot lighten the LED, it indicates the synchronizer position need to be adjusted. Remove the pulley, slightly loosen the fixing screws, and turn the synchronizer anti-clockwise (approximately 2-4mm). After that, refasten the screws, install the pulley and repeat adjustment steps explained above.

l

Restore Default Setting Ensure that each parameter is consistent with the default

· 12 ·

· 13 ·

setting after power on. PMX AH50 series servo system’s default setting: u u u u u

Normal sewing mode selected Needle Down at machine stop as default Slow start sewing disabled Double Start/End Back Tacking Automatically thread trimming & auto foot lift after trimming enabled The installation and adjustment of the system is finished as shown in Fig.15 (For Juki series sewing machine):

3 Operation Instructions PMX AH50 Series Control System is equipped with dual control panels, one is mounted on the sewing machine for easy access, and the other is embedded in the controller for simple settings.

3.1 Embedded Operation Panel Instruction 3.1.1 Embedded Operation Panel (HMI) Instruction

l

Embedded Panel Display Instruction

Embedded HMI has two areas: display area and keys operation area (see Fig.16). The display area indicates the current status of the system.

Fig.16 Embedded Panel (HMI) Fig.15 The whole machine installation sketch · 14 ·

· 15 ·

l

3.1.2 Embedded User’s Modes

Keys Functions

In the function selection area, 12 keys stand for different functions. Table 2 shows function of each key. Table 2: Functions of Keys No. 1

2

Key

l

Function Enter Parameter setting, Parameter Monitoring selection

function)/select sewing mode

4

Trimming Selection: Select or not/Increase Hundred bit Presser foot lifting key: Set presser foot lift mode/Increase Ten bit

6

One-shot-Sewing Selection: Select or not/Increase Entries bit

7

Set Start Back Tacking Mode

9

Running status of the system (See Fig.17):

Increase Parameter Index Value of corresponding bit(with carry

Needle Up/Down Position selection/Increase Kilobit

8

Operator Mode

combination Key/parameter setting save

3

5

This product can define three user’s modes: Operator, Technician and Administrator.

Set End Back Tacking Mode /Decrease Parameter Index Value of corresponding bit(with borrow function) Normal Sewing Key: Set Normal Sewing Mode/Decrease Kilobit

10

W Type Sewing Key: Select W Type Sewing/Decrease Hundred bit

11

One-segment Sewing /Decrease Ten bit

12

Four-segment Sewing Key: Set Four-segment Sewing/ Decrease Entries bit

Key:

· 16 ·

Set

One-segment

Sewing

Fig.17

Two LED under the 8 segment LED will be lightened from left to right in orderly during running. When the corresponding function of

,

,

, keys is selected, the corresponding LED

upper the key is lightened, otherwise will not. As the default setting, the system enters this mode when the controller is powered on. The operator can set the needle stop position (Needle down stop position is the default setting; the corresponding LED will be lightened). The setting is available only after the next trimming. It’s not available to modify any parameter and setting under operator mode (Details are shown in function · 17 ·

operation section). press key to save the current parameter value and exit the technician mode. (See details in table 3). Table 3: Technician parameters Display P01 P02

Fig.18

l

Technician Mode

In this mode, technical parameters corresponding to various functions can be adjusted or reset according to practical needs so that the system may run in the best condition. Step 1:

Range

Default

Remarks

100～300

200

spm

100～5000

3500

spm

1～100

80

%

P03

Pedal speed curve slope

P04

Maximum constant sewing speed

100～4000

3000

spm

P05

Start back tacking speed

200～2200

1800

spm

P06

End back tacking speed

200～2200

1800

spm

200～2200

1800

spm

200~4000

4000

spm

100～300

200

spm spm

key, the

P09

system will enter the parameter index select mode.

P10

Constant back tacking speed Maximum manual back tacking speed Stitch compensation speed Trimming speed

100～300

250

P11

Slow start option

0~1

0

Under technician mode, use

P12

Slow start stitches

1~9

2

stitch

P13

Slow start speed

100～300

200

spm

0~50

24

ms

0~50

20

ms

0~50

24

ms

0~50

20

ms

Under running status, press

key and

key and

key to change

the technician parameter index, then use ,keys and , Step 2:

Parameters definition Start speed Maximum sewing speed

,

,

,

,

,

keys to change the values.

After change the parameters values, changing the technician parameter index will save the current parameter value and switch to the other parameter, or

· 18 ·

P07 P08

P14 P15 P16 P17

Start back tacking compensation 1 Start back tacking compensation 2 End back tracking compensation 1 End back tracking compensation 2

stitch stitch stitch stitch

· 19 ·

P18 P19 P20 P21

Continuous back tacking compensation 1 Continuous back tacking compensation 2 Step of speed adjustment (It is only available for the optional panel.) Restoring to factory setup

0~50

24

ms

technician mode. Only press key and key to enter this mode

0~50

20

ms

(The detailed parameters are shown in table 4). Table 4:

0~200

50

spm

0

Recovery of default parameters: Enter technician parameters mode and replace the last two numbers of P21 with 88, then press key, the default (factory) parameters can be recovered. (After the recovery of Default setting the value of P21 will recover to initial value). Slow start setting: Enter technician mode, set the last number of the parameter P11 as 1 and then slow start setting is ok. One-shot-sewing setting:

Display P31 P32 P33 P34 P35 P36 P37 P38 P39

Use

key to select the one-shot-sewing setting. This mode is

only valuable for constant-stitch sewing mode (one-segment, four-segment, six-segment, seven-segment and eight-segment sewing). One-shot-sewing mode makes beginning sewing of each segment by one shot pressing; pressing pedal doesn’t need during the whole process. The LED upper the key will be lightened if it be selected otherwise will not.

l

100~200 10~90 100~200

Default value 175 60 120

5~80

30

ms

50~300

150

ms

1~20

5

ms

1~20

6

ms

2~60

20

s

2~60

20

s

0~800

200

ms

0~800

300

ms

0~800

150

ms

1~100

10

100ms

0～1

1

Auto Needle Up positioning after Power on

Range

Remarks degree degree degree

Start delay after P40

switching off the foot lifting signal

P41 P42

Administrator Mode

P43

The operation of administer mode is similar with the

P44

· 20 ·

Parameters definition Trimming angle 1 Trimming angle 2 Trimming angle 3 Thread wiping delay Lifting presser foot start time Pulsing of foot lifting ON time Pulsing of foot lifting OFF time Maximum time of foot lifting Maximum time of backstitch

Foot lifting confirming time Time of Compensating stitches Auto test interval time Auto Needle Up positioning after Power on

· 21 ·

P45

Back stitch button

0～1

1

P46

Special run mode selection

0～2

0

P47 P48 P49

motor/machine 800~1200 head run rate Password(only for 0~9999 optional panel) Pulsing of back tack 70~500 solenoid ON time

HMI compensating stitch 0:operator select 1:simple sewing mode 2:test motor initial angle

1000

0.001

****

Password can get from product supplier.

100

ms

Test motor initial angle: Under administrator mode, change the value of the parameter P46 to 2. It means changing the operator mode to testing motor initial angle mode (suggest to detect the angle without load); the motor initial angle can be monitored by parameter index SP4. Please change this parameter to original value after testing the initial angle.

If stop stepping the pedal, the operation will also stop and the needle stop position setting auto trimming is disabled. When error of the machine synchronizer occurs, you can select to use simple sewing mode to instead of the free sewing mode.

l

Constant-Stitch Sewing Use ,

,

key to select the corresponding mode, the LED

upon the corresponding mode will light and glitter, and switch to the mode select status synchronously, such as W Type sewing status(see fig.19) and four-segment sewing status(see Fig.20).

3.1.3 Function Operation

l

Normal Sewing Press

key, then press

key will enter the free sewing

Fig.19: W Type Sewing

mode. It is ready for operation just by stepping the pedal.

l

Simple Sewing Mode

Under administrator mode, set P46=1, it means to change the operator mode to simple sewing mode. Under simple sewing mode, the controller only controls the sewing speed. It is ready for operation just by stepping the pedal. · 22 ·

· 23 ·

type sewing, one segment sewing, four segment sewing, six segment sewing, seven segment sewing, eight segment sewing, auto test mode, the number sequence is 1~8. Use key and key select the parameter among E, F, G, H; Use

,

,

,

keys to change the stitches values of the

parameters E, F, G, H. Use key to return the run status.

Fig.20: Four-segment Sewing

Use the key to select switch to the other mode select status,

l

Start/End Back Tracking

for example, seven-segment status (see Fig.21), the LED on the Start back tacking:Use key lights and glitters.

key switch to start back tacking

status (see Fig.22).The current back tacking parameter A will display. Temporality, one or two LED upper

key will glitter. It

means changing the start back tacking parameter currently. Use the

key and the

between A and B; Use

key to change the parameters

key and key to adjust the stitches.

Fig.21: Seven-segment Sewing

Under mode select status, use the

key and

key can

change the current mode. Use number symbol, free sewing, W

· 24 ·

· 25 ·

l

Auto Thread Trimming Under running status, use key to select the thread trimming

setting between trimming on and trimming off. If select the trimming function, the LED on the key will light, otherwise will not light.

l

Presser Foot Lifting

Fig.22: Start back tacking status

Under running status, use Use key switch to the end back tacking sewing status (see

key to select auto foot lift in

Fig.23).The end back tacking parameter C or D will display.

sewing stop or auto foot lift after thread trimming. If the function is selected, the LED on the key will light, otherwise will not light.

Temporality, one or two LED upper

l

key will glitter. It means

Needle Stop Position

changing the end back tacking parameter currently. Under running status, use key to select the needle up/down Use

key to return the run status.

stop position. If the needle down stop position is selected, the LED on the key will light, otherwise will not light.

l

Back Tacking and Compensating Stitch

Fig.23: End back tacking status

The back tacking button on the machinery can be set to do compensating-stitch function. The back tacking speed and compensating stitch can be adjusted. The button corresponds to following conditions in different stitch modes: Normal sewing mode: Press the button to get back tacking in running; when machinery stops, press the button to compensate stitch. Compensating stitch depends on the condition

· 26 ·

· 27 ·

of button trigger: trigger the button to compensate half a stitch, press the button gently and release to compensate one stitch; Keep pressing the button can get continuous compensating stitch according to needs. Constant-stitch sewing mode: Under this mode, the button is only available for compensating stitch. Stop before one-segment sewing is finished, it can be adjusted to needle up position (if the needle is up, the system will not response), by pressing back tacking button. Stop after one-segment sewing is finished, compensate stitch carries out, compensate stitch depends on the condition of button trigger: trigger the button to compensating half a stitch, press the button gently and release to compensating one stitch; press the button not release can realize continuous compensating stitch according to needs. Remarks:Under whatever sewing mode, it is unavailable to press the button when the sewing machine is standstill after thread trimming.

l

A

B

Below is an example for stitches correction. (Double Start back tacking, A=B=4 stitches) If the stitch loci are appeared abnormally, please correct it as below: ¡ The first stitch of B becomes shorter or lost, as shown in Fig.a. Correction: Add the value of P14 (Double End back tacking: Add the value of P16).

· 28 ·

B

Fig.a

¡ The last stitch of A becomes shorter or lost, as shown in Fig.b. Correction: Reduce the value of P14 (Double End back tacking: Reduce the value of P16). A

B

A

B

Fig.b

¡ The first stitch of free sewing becomes shorter or lost, as shown in Fig.c. Correction: Increase the value of P15 (Double End back tacking: Increase P17). A

Stitch Corrections

A

B

A

B

Fig.c

¡ The last stitch of B becomes shorter or lost, as shown in Fig.d. Correction: Reduce the value of P15 (Double End back tacking: Reduce the value of P17).

· 29 ·

A

B

A

B

3.2 Optional Operation Panel Instruction 3.2.1 Optional Operation panel (HMI) Description

l Optional Panel LCD Area

Fig.d

If the stitch loci are appeared abnormally in end back tacking sewing, please correct the parameter value of P16 and P17. If the stitch loci are appeared abnormally in W type sewing, please correct the parameter value of P18 and P19.

l

Parameter Monitoring Under operator mode, press

key and

key to enter

monitoring mode. Change the monitoring parameters index by pressing

key and

key. The system will not exit for overtime

under monitoring mode, please press key to exit the monitoring mode. The detailed parameters are shown in the table 5.

PMX AH50 series digital AC servo system, implement its various functions and technical parameters via operation panel (also called HMI shown in Fig.24). HMI has two areas, LCD area and keys operation area. In the functions selection area, 13 keys stand for different functions, 13 visualized icons is chosen to distinguish them from each other. For example sewing mode,

denotes free

means constant-stitch sewing mode with

optional stitch numbers,

denotes auto presser foot lift function

etc..

Table 5:Monitoring parameters Parameter

Parameter

Normal Value

Display

Instruction

Range

SP01

DC Bus Voltage

270～350

V

SP02

Motor Current

xxxx

0.01 A

SP03

Motor rotate speed

xxxx

rpm

SP04

Motor initial angle

xxxx

Degree

Fig.24 Operation panel (HMI)

SP05

Software Version

Fact Value

※Operator, Technician and administrator all can enter this mode.

LCD area, located at upper half of the left side, indicates the current status of the system (Fig.25), including sewing mode,

· 30 ·

· 31 ·

Unit

stitches, start/end back tacking settings, presser foot lifting, needle stop position, thread trimming, thread wiping and soft start etc.. The system will do self test after power on, during self test, all icons of display area will lighten then display the current setting of the system, and other icons without optional function will not lighten. For example, auto thread trimming is selected then the icon

will lighten, otherwise it is dark.

Fig.25 Display Area of LCD

l Optional Panel Keys Definition Table 6 shows definition of each key. Table 6: Keys definition NO.

Key

Function Select to enter technician parameters

2

Increase parameter value

None

3

Decrease parameter value

None

5 6

Double start back tacking key: set single, double start back tacking Four start back tacking key: set four start back tacking Four end back tacking key: set four end back tacking · 32 ·

Four end back tacking key: set four end back tacking

8

Select free sewing mode

9

W type sewing key

10

One-segment sewing key

11

Four-segment sewing key

12

Select constant-stitch(six-segment, seven-segment, eight-segment) sewing and auto-sewing mode

13

Set up automatic press foot lifting

14

Set up automatic trimming

15

One-Shot-Sewing selection

16

Select Up/Down position/ Stitch compensation

17

Acceleration key

None

18

Deceleration key

None

3.2.2 Optional User Mode Display Icon

1

4

7

l Operator Mode In this mode, various sewing modes are available after technical parameters settings. As the default setting, the system enters this mode when it starts. Under this mode, such basic functions as normal sewing work and modes change can be realized but no inside parameters and setting can be changed (details are shown in function operation section). · 33 ·

l Technician Mode

l Administrator Mode

In this mode, technical parameters corresponding to various functions can be adjusted or reset according to practical needs so that the system may run in the best condition. Parameters setting

In this mode, various solenoid parameters set can be regulated according to the practical need so that the servo system can normally run on every sewing machine. Parameters setting under technician mode:

under technician mode: Step 1:

Under operator mode, press

key and

Under operator mode, press

Step 2:

administrator mode. Change administrator parameters index by the second

key, the LCD

will display psd-0000, and then set the password by administrator.

and the third Step 2:

Use the last four

keys and

password, and then press

Step 3:

key and

Step 5:

keys. The parameters are shown in

table 3. Parameters values can be changed by the last four keys and

keys.

Under technician mode, press return to operator mode.

key under administrator

mode. The details of technician parameters are shown in table 4.

key. If the password is

correct then enter technician mode, otherwise, it will return to operator mode. Change technician parameters by the second and the third

Step 4:

keys to input the

key and

and

keys to enter

Step 1:

key, the panel will

Step 3:

Parameters values can be changed by the last four keys and

Step 4:

keys.

Under administrator mode, press

key, the panel will

return to operator mode. Password modification: Administrator parameter P48 is the password to enter the technician and administrator parameter. When restore the factory setup, the password also restore to the default value. Test motor initial angle: The operation is same with the embedded control panel.

· 34 ·

· 35 ·

3.2.3 Function and Operation Step 2:

l Normal Sewing Press

one-segment stitch mode has been selected. Change the corresponding parameters (E value) by using

key, normal sewing mode icon

in display area is

lightened, other icons are not, which indicates normal sewing mode has been selected, it is ready just step the pedal for operation.

l Simple Sewing

and

keys, the value range is 0-99 stitches.

Step 3: It is ready just step the pedal for operation. 3. Four-segment stitch Step 1:

Press

Step 2:

lightened, other icons are not, which indicates four-segment stitch mode has been selected. Change corresponding parameters E, F, G and H values

key, back tacking icon

in display area is

The operation is similar with the embedded control panel. by using

l Constant-Stitch Sewing Step 1:

Press

key, back tacking icon

Step 2:

lightened, other icons are not, which indicates back tacking mode has been selected. Change the corresponding parameters (A, B and D

in display area is

Step 1:

Continuously press

key, select the required mode , stop pressing the key and the

among

Step 2: and

keys, the value range is 0-99 stitches.

Step 3: It is ready just step the pedal for operation. 4. Other sewing modes

1. Back tacking

values) by using

and

stitch mode has been selected. Change the corresponding parameters (E, F, G and H

keys, the value range is 1-9 values) by using

and

stitches. Step 3: Tread pedal to start sewing after finish setting. 2. One-segment stitch

Step 3:

Step 1:

l Back Tacking Sewing

Press

key, back tacking icon

in display area

keys, the value range is 0-99

stitches. It is ready just step the pedal for operation.

lightens, other icons is not displayed, which indicates Step 1: · 36 ·

Press

key or

key to change the setting of back · 37 ·

tacking. Start back tacking has following four modes: u None start back tacking

Step 2: Step 3:

, auto foot lift in sewing stopping

Single start back tacking

u

Double start back tacking

u

Four start back tacking

Stop pressing to confirm, then this back tacking mode has been selected. Change the corresponding parameters (A and B values) and

keys, the value range is 0-9 stitches.

The start back tacking setting implemented after finishing the stitches setting.

Press key to select the desired mode, stop pressing to confirm, then foot lift setting has been finished.

l Needle Stop Positioning Press key to set needle stop position; it can be set as two modes: needle up mode and needle down mode. Repeatedly press

setting method basically, except the key.

l Thread Trimming

key, the cursor will switchover between

(needle down)

and (needle up). Select the desired mode and stop pressing to confirm, then needle stop position setting has been finished.

l Back Tacking and Compensating Stitch The operation is similar with the embedded control panel.

Note: End back tacking setting method is similar with start back tacking

l Stitch Corrections The operation is similar with the embedded control panel.

Press key to enter thread trimming setting, it can be set as two modes: trimming or non-trimming. Repeatedly press key, the icon in display area will lighten or darken, respectively standing for trimming and non-trimming.

l Presser Foot Lift Press

and auto foot lift both

after thread trimming and in sewing stopping.

u

by using Step 4:

setting modes: non-auto foot lift, auto foot lift after thread trimming

l Operation Monitoring Under operator mode, press

key and

key to enter

monitor mode. Change the monitoring parameters by the third

key to enter presser foot lift setting, it has four

· 38 ·

and

keys. The parameters details are shown in table 5.

· 39 ·

4 Work Environment

5 Troubleshooting u The system can automatic test itself after power on, and

1. Electromagnetic Interference: provides a failure alarm function (only for optional panel). The To avoid the false, please keep the product away from the

controller will stop and automatically initiate its protection

high electromagnetic machinery or electro pulse generator. program to prevent accidents. 2. Temperature:

u If a failure occurs during system running, it also will display a

a. Please don’t operate the controller in room temperature is above 45℃ or under 5℃.

failure alarm (Error code) on the control panel (HMI).

u If a failure occurs, the HMI will buzz and the corresponding error

b. Avoid operating it directly in sun light or outdoors. c. Avoid operating near the heater.

code will glitter on the display (see Fig.26):

d. Avoid operating in the area which humidity is less than 30% or higher than 95%; also stay away from dew area. 3. Atmosphere: a. Please don’t operate in dusty area, and stay away from corrosive material.

Fig.26

u The following table 7 shows the Error codes, possible causes

b. Avoid operating in evaporate or combustible gas area.

and solutions for failures.

4. Aeration a. Put the control box near the aeration opening. b. Clear dust, paper scrap and cloth scrap deposited on machine box periodically to avoid motor overheat. · 40 ·

· 41 ·

10

11

Synchronizer failure

Shut down the controller, check input power voltage, if the voltage is lower than 190V, please restart the controller after the voltage is normal, if the controller still can not work normally after the voltage is recovered to the normal level, please replace it and inform manufacturer. Shut down the controller, check input power voltage, if it is higher than 245V, please restart the controller after the voltage is normal, if the controller still can not work normally after the voltage recovered to the normal level, please replace it and inform manufacturer. Control box is burned down because of short-circuit of magnets loops, please check magnets loops and inform manufacturer as well as recovery and replace the controller.

12

Initial motor angle detection failure

Restart for 2~3 times, if the controller still can not work normally, Please inform manufacturer.

13

HALL failure

Please replace the controller and inform manufacturer.

14

DSP access failure EEPROM

15

Motor overspeed protection

16

Irregular motor operation

Shut down the controller, Re-start it 30s interval, if the controller still can not work normally replace it and inform manufacturer.

17

HMI access EEPROM failure

Shut down the controller, check all connection wire; if the controller still can not work normally after restart, please replace it and inform manufacturer.

Shut down the controller, check the motor power cord whether it is broken off, loosen, damaged, or be tangled on the machinery by other stuffs. Restart controller after recovery, if the controller still cannot work normally please replace it and inform manufacturer. Please replace the controller and inform manufacturer.

18

Motor overload

Shut down the controller, Re-start it after 30s interval, if the controller still cannot work normally replace it and inform manufacturer.

Table 7: Error Code

Error Definition

Solution

01

Hardware overload

Shut down the controller, Re-power it after

02

Software overloaded

abnormally,

03

Low voltage

04

Voltage is too high while stopping

05

Voltage is too high during Operation

06

07

Malfunction in solenoid loops Malfunction in current control loops

08

Motor stalled

09

Dynamic Braking failure

Shut down controller power, check if the connection between HMI and controller is broken or loosen; if the controller still can not work normally after restart, please replace it and inform manufacturer. Shut down controller power, check if the connection wire between synchronizer and controller is loosened; if the controller still can not work normally after restart please replace it and inform manufacturer.

HMI Communication failure

30s interval, if the controller still works replace

it

and

inform

manufacturer.

· 42 ·

Shut down the controller, Re-start it after 30s interval, if the controller still cannot work normally replace it and inform manufacturer.

· 43 ·

n Special Remind:If the follow abnormalities happen to the system, it is possible that there is no buzz or error code displayed. Please check as following instruction and feedback to manufacture in time. Faults

Checking methods

Both controller and HMI work normally, pedal does not work and no error alarm.

Check if the back tacking button switches on, the solenoid socket is steady connected; the plug of pedal sensor is steady connected.

Controller indicating light is dark after power on and there is no display on HMI. The motor does not run.

Open front cover of controller and check fuse.

Thread trimming does not work.

Check if the trimming setting is canceled, the grounding is connected, the plug of pedal sensor is steadily, and the trimming solenoid is damaged or not.

Thread cannot be trimmed.

Check if P31 parameter setting is correct, and if the trimmer is damaged.

· 44 ·

Measures

n n Caution:

n

Replace the damaged fuse wire (it is better to do this job by authorized or specially trained personnel from manufacturer).

Turning off the power before installing or removing HMI. Do not change HMI settings while sewing. Don’t start sewing after setting HMI until HMI returns to the ready status signaled by a BEEP. Keep daily cleaning well to avoid those errors caused by dust deposition or other poor operation environment. — End — 2006

Properly adjust P31 parameter after eliminating the mechanical problems of sewing machine (i.e. the trimmer of sewing machine is abnormal).

· 45 ·