FRANCK MD-600 Series AC Servomotor for Industrial Sewing Machines SERVICE MANUAL MD-601 (Single-Phase Type) MD-611 (Three-Phase Type)Contents Outline « Featuresssrssssssssersesssseeseesnseressasseeenesseserses Model configuration +++ Operation panel and options-++++++++++e0+++ Spare parts list (MD-601, 611) Explanation of the control box's name plate «-~ Pulley selection and DIP switch settings Explanation of each mode « 8-1 Initialization mode ~ 8-2 Head setting mode - 8-3 Memory switch setting mode and parameter setting mode, ete. 84 Stitching speed setting mode +++++++++ 85 Memory switch and parameter lists ++ o @ oa a @ seeseeseeeeeee 1g A. Memory switch list --- B. Parameter li seeeseeeseeeese 16 18 seen 19 soeseeses 20 Error display and details « Other functions « Panel display table +--+se+sssesesssseesseesssseees Operation instructions s++++sssssesesseseessseeees Checking the c. boxe+ssssessresssesssssseessseseanses C. box troubleshooting guide ++++++++++++++++++0++ How to VR1 & VR2 setting of treadle unit »++++++++ Checking the machine solenoids «++ Checking the motor ++++++++++ Solenoids table +++++++++++++++ Adjustment +++ soeeseeseenee ST soeeneeees 33 SSBSGEQ88885888 Sewing speed of each machine «+ CONTROL SYSTEM BLOCK DIAGRAM OF SEWING MACHINE IMSMK2-ASSY «-s++sses-0sseeess IMP1110V-ASSY - IMP1230V-ASSY « IMP3220V-ASSY « IMP1230VC-ASSY vrersresrre ree eeses OPERATION PANEL ++++++++ TREADLE UNIT ++++++++ (Note) Functions indicated with sx mark are activated on the new CPU version (J02954-B). They are not activated on the old CPU version (J02781-A),AC servomotor is @ substitute for the MD800 Series DC servomotor, incorporating an induction motor. This motor is maintenance-free and has less noise. Improvements have been made in the vibration and heating, ‘and the operability and reliability have been further improved with an all-digital control. ‘The model configuration follows the conventional MD800 Series. 2] Features © Incorporation of induction motor By incorporating an induction motor instead of the conventional DC motor, a stout motor without brushes, mech- ~anical brake and magnet has been achieved. ® Maintenance-free By using electric brake instead of the conventional mechanical brake, and by eliminating the brushes and mechan- ical brake, a completely maintenance-free motor with no wear parts has b 3. ® Quiet operation Motor noise has been eliminated with the sine wave control without strain. By using electric brake instead of mechanical brake, the sound of the mechanical brake conventionally heard when decelerating and stopping has been reduced. By using an integrated structure for the box and motor, the vibration conveyed to the pedal has been made crea- ting a user-friendly quiet environment. © Lightweight By using an induction motor, integrated box and motor structure, and resin case, the weight has been reduced to 48kg from the 21kg for the conventional DC motor. This lighter weight also makes setting up easier. Furthermore, by using a cooling structure, the temperature rise of the motor’s outer frame has been dropped by approx. 10°C according to Brother comparisons. © Strengthened functions ‘Ample memory switches and parameter settings that allow the functions and characteristics to be changed and en extensive self-diagnosis function are provided om igital control With the all-digital control, the stitching speed can be input with numerical inputs from the operation panel instead of the conventional volume knobs settings, allowing accurate and swift settings. © Others + A.commercial tapered pulley (490 or $105) can be used. + The installation pitch onto the table is the same as the conventional clutch motor, etc.3] Model configuration wp-6010 T_ None : Forward rotation R: Reverse rotation 0; Single-phase, 50/60Hz common (Voltage 100V, 110V, 220V, 230V, 240V) § types 31 1 B-phase 50/60Hz common {Voltage 200V, 220V, 380V, 400 to 415V) 4 types 4E1: The 200V, 230V and 240V specifications are common by reinserting the connector 342: The 380V and 400 to 418V specifications are common by reinserting the connector internally [Product Code] 137-601-710-S1 Last digit Last digit Single phase S-phase 7: 110V, lamp 6v Taiwan 4:220V, lamp 6 ‘Taiwan, Korea 2:110¥, lamp 6V, OR usa usa [&110V, lamp 6V, SUT (Canada Teanada 4 230V, no lamp, no switches _| Germany, UK, France ‘Germany, UK France 5: 220V, lamp 6V Korea (Hong Kong) | [5° 38OY, lamp 6V ‘China é 380, lamp 6V, OCR [South Africa [7:230V, lamp 6V ‘Singapore, 7: 400V, no lamp Spain, Portugal [8 230V, no lamp. ‘Spain, Portugal & {Now Zealand) & 2 0:240V, lamp 6 Australia (0 415V, lamp BV Ausivalia. Last two digits {i Export, 8798, $20, 2000spm 2: Export, B748, 990, 2500spm |_{or: Domestic single needle, 490, 4000sem 5 (2: Domestic, single needle, $90, 3600eem _ | 4: Export sige needle, 990, 35008om 99, 25008pm 5: Expor. single needle, 490, €000em 7 1 Export, single needle, $105, 4600spmn | tector Bvaat gun aconepm ELEC] Export, embroidery, $105, 450089m 7: Export, single needle, #105, 60005pm Export, covering, #105, 5000apm /& Export, overlock, 4105, 6000spm (06: Domestic, 8852, 90, 4000spm 07. 01 packed in cardboard box (08: Domestic, overlock, 9196, 6900spm Export, covering, #105, 6000spm (08: Domestic, verlock, $105, 8000spm [& Export, overiock, $105, 800055 Sk: Domestic, twin needle, 90, 3000sprm T: Export, 8852, 4105, 45008m [S2: Domestic, win needle, 490, 3500spm U:Export, twin needle, 490, 3000spm 'S% Domestic, twin needle, $90, 4000spm [V: Export. twin needle, $80, 3600spm |W:Export. twin needle, 480, 4000spm 3rd digit from last 0: Domestic specications, domestic weadle 1: Export specifications, domestic veadie External | 5: Export specifications, export treadle panel ‘6: Export specifications, export ead, diferent switches #3 ‘3: Export specications, domestic treacle 8: Export specifications, export treadie ‘: Export specifications, export treadle, diferent switches #3 2X3: With OCR switch Canada, Hong Kong, New Zealand, Australia (Switch for SAA) its from last Built-in pane! th and 5th di ne 71: MK2-F0, overlock 7a: MiKa-F20 73: ika-F40 [a 2-100 78: Covering4] Operation panel and options Attachable operation panel F-20 (X-20) F-40 (X40) F-100 (X-100} Attachable options ‘Standing work pedal Material edge sensor (Connect to S2 operation panel and use) (Note 1) A built-in type panel for B737 and an external type (twin needle, etc.) F-panels are available. (Note 2) The X-panels can be used with the MD600 Series, but these panels do not have the stitching speed switch 161. {Note 3) The E-panol for the MD800 series cannot bo used with the MD600 Series. 6 & JEG @ 86 {Assembly cord for standing work} Standing treale 40 variable speed #6 180061-040 Operation panel ‘Sewing nactine Tratallation | Type Cade ro. of ode! ype ‘eperation panel Foot plug J02496-001 oe | aT 207-1 ers builtin | Fea | aT-207-T12-11 F-400__| 197-207-713-11, eF-20 | 137-20 811-11 e201 butttein | Be-40 | 187-207-812-11 sF-j00_| 137-207-813-11, ‘Ghevatlon paral F— [ar-207- 111-10 (without install | attached = | P40 | 187-207-712-10 plate) F100 _| 137-207-719-10Spare parts list (MD-601, 611) MK2 BAST PW, Lock COV 1B737. BBA? etc. | LS2 B883 C53 B COL “BEE aon | OED | SRG | BREE "SRREL I * a Soazre-o) | 81-001 | Bae Mie cont ToT IRR) -assv THS-0-a5 board [8064/01 06/400) sub SSSRSRSRRSRRESEEEE; board power oard Tread ie WARD & BACKWARD OPERATION |S 2 POSITIONS haa (ARO OPERATION” 1ST POSTTTONS evans — Soha Former Fiaov | Tees edaov | “inzbu 00) ae | TM, IWADWY reat nizer [BSfer0-oot Bee Boece ae ———— #52 ¥TS-T. | Hig -oor | Sifo-oor_| Salon op F=40 CF=30— panel F-100 [F=100 *#13(291079-001):8737 group #14(291670-001):8842 group % : About dip SM setting of the control circuit board IWS-MK2-assy can be used for the specification of [LOCK] [BAST] and [PHB] . Please make a correct dip SW setting, depending on the type and specification of sewing head, the maximum speed of sewing head and the size of motor pully. (Please refer to the instruction sheet included in the spare parts for correct setting. )Explanation of the control box's name plate rane plate brother THREE PHASE ¥-611 (7) wars 400 AC SERVO MOTOR Vous 220 TRE HELTZ 50/60 @_ month RPM 3500 @® :year ‘WADE IN JAPAN @ — :modi fication No. No, DOB ROTHER INDUSTRIES, LTD w-o1 O17 a Bl Wy El m use treadle pully outer} sewing use lamp tap unit diameter | speed voltage, :Mark2(B737etc. ) 0:1000spm_ ALB C:with presser | 3:90 /1:2000spm [1 -Wark2 foot lifter 2:2500spm C:nul | 2:1Z2-B852etc. down sw. in | 42105. |3:3000spm (zigzas) treadle unit 4:3500spm 5:4000spm 3:8842 group 6:4500spm |6:BAST |D:without presser 7:5000spn foot lifter |8:6000spm down sw. in 9:8000spm treadle unit |P: PNB COV :Covering stitcher with thread trimmer. (FD4-B27X group & FD3-B25X group) BAST:Single needle basting lock stitcher with thread trimmer. (LS2-b883)7] Pulley selection and DIP switch settings Always set 2 pulley that meets the sewing machine head type and speed and the DIP switches before turning the power switch ON. A. DIP switch functions ON OFF DIP switch 1 | Specifications Export specifications __| Domestic specifications 2 [Pulley size $90 $105 (Note 0) 3 | Automatic presser Provided Not provided (Noto2) A | Neutral stop position changeover [Needle UP position ‘Needle DOWN position | (Note 3) 5 [Head Frwin neste Single neeate 6 7_|Max. speed Separate table @ {Note 1} Ifa pulley not within the designated size is used, the specified speed and torque will not be achieved. (Note 2) When using the head integrated electromagnetic presser (8737-9(1L]), disconnect only the capacitor on the head side. (Do not remove the flywheel resistor and diode.) (Note 3) The operation panel settings will have the priority when the oper n pane! is connected. B. Maximum speed and pulley setting Single needle and twin needle setting [Note 3) z000_| 2500 | 3000 | 3500 | 4000 | soo | 4700 on | om [on | om | on | oF | oN ofr | ON Oe a ON ore | or | om | on oN ON ON Pulley size 0 S105 (Note 1) Even the if the speed reaches 4500spm with the DIP switch 6, 7 and 8 settings, the speed will not exceed .4500spm when the 990 pulley is designated by turning DIP switch 2 ON. (Note 2) Even the if the speed reaches 4000spm with the DIP switch 6, 7 and 8 settings, the speed will not exceed 4000spm when the twin needle is designated by turning DIP switch 5 ON. (Note 3) If the high-speed stitching limit speed is set to 5000spm in the [8] 8-4 Stitching speed setting mode, the maxi- mum speed can be set up to 5000spm, % (Note 4) If the DIP switch 2 or DIP switch 5 setting is changed, the head settings in section [8] 8-2 willbe initialized. B-2 Overlock setting Hoverlock[ ou i Jisset the [| 8-2 head setting mode, the DIP switch settings will be as follow. Speed] Dipswiteh ———_| 5000 | 5600 | 6000 | 6500 | 7000 | 7500 | 8000 | e500 6 of | ON | ofF | ON | of | on | OF | ON 7 ofr | oF | ON ON | of | of | on | oN 8 ofr | off | ofr | ofF | ON ON ‘oN ON Pulley site 105 (Note 5) Use the overlack with DIP switch 5 set to OFF (single needle setting), 3 (Note 6) If the DIP switch 2 or DIP switch 5 setting is changed, the head settings in section {] 8-2 will be initialized. (The ‘overlock setting will be canceled.)©. Setting of maximum speed and start backtack stitching speed C-1_ Setting of maximum speed 1) When the stitching speed key [ © 1is pressed once, the { ( ] LED will light, and the maximum speed will display on the No. of stitches display section, 2) The No. of stitches can be set with the [v } and [4] keys. 3) When the single needle model is set, the speed can be set between 215spm and the DIP switch setting speed (max, 4700spm}, 4) When the twin needle mode! is set, the speed can be set between 250spm and the DIP switch setting speed (max. 4000spm) 5) During stitching, the [ © ] LED will go out, and the display will rturn to the backtacking display, ete. C2 Setting of start backtack stitching speed 41) When the stitching spoed key [ ©) J is pressed twice, { @ 1 and [ 1 | will light, and the start becktack stitching speed will display on the No. of stitches display section. 2) The No. of stitches can be set with the [¥ ] and [4 ] keys. 53) When the single needle model is set, the speed can be set between 218spm and 1800spm. 4) When the twin needle model is set, the speed can be set between 250spm and 1000spm. ') During stitching, the [ @ LED will go out, and the display will return to the backtacking display, ete.8 Explanation of each mode Besides the normal stitching mode, the head setting mode, initialization mode, and memory switch setting mode, etc. can be entered using the operation panel and various settings can be made. If the power switch is turned ON while hold ing down the designated key, the initial while the thread trimming needle is stopped at the UP position in the stite ‘te,, can be entered) tion and head setting modes can be entered. If the designated key is prossed mode, the memory switch setting mode, (Note) This function can be used only when the F-40 or F100 operation panel is connected. This cannot be used with the F-20 panel, Once the settings are made with the F-40 or F-100 operation panel connected, the set details will be registered even if the par a4 Various data can be registered in changed by mistake, the data can be i Indicates the display. Indicates a key operation. +++ Indicates simultaneous double operation. 1e memory on the control PCB, and can be changed as required. If the data is iaized with the initialization mode, (Note) Only this function can be used with the F-20 panel. Initialization mode l f— lalofB Lalota Initializetion of parameters. ‘memory switches [2 1+ Power switch ON Entire memory initialization tau Initialization of No, of stitch data When [ >< Js pressed, the display will change to the initialization mode menu. [BL ]willdisplay fit. yoreedlneorcnnnsontrcenerevensaseeeereent iaization mode menu [— Initialize by prossing [ >< J. Executel Sa J+ NPIS 2] Ct Jill display when executed. ‘The display will go out when the stitching mode is en- tered. The settings for 8] 8-2 head setting mode will also be in- ized. Initialize by pressing { > 1 [sa] Initialize by pressing [ >] Initialize to parameters, etc, of head data set in [8] 8-2 head sot- ‘and in] 8-2 head setting mode, Not initialized by pressing [ >< ], and instead move to stitching mode.8-2 Head setting mode Before the motor is shipped from the factory, the motor product code is determined for each head and is set to match the specifications of the head. If the motor is to be used for another head, replace the pulley with an appropriate one {according to maximum speed), and select the head No. with this mode. The specifications will tren match the head. The heads that can be set are determined by the DIP switch 6 setting, ‘Always set the DIP switch (pulley size, single needle/twin needle, maximum speed) before making ‘The backtack stitching timing, etc, differs slightly according to the head. Thus, setting this mode accurately is recommended. setting. A. Setting method ‘Act. When DIP switch s0t to OFF (single needle) t Lalofd | _ laloro TalofD f— Ls] Stitching mode Display No. [ 7 3 7 3 J indicates 0B2-B737- La [ 33 7S indicates 082-8737-008. [7.37 4 Jindicates 082-8737-001. ‘A-2. When DIP switch 5 is set to ON (twin needle} latorD Eaord (e423) }——_-[ 134251 } — Lieven - I ee EEE f— [4]ofB ¥ 1 [alofD [4] ofD (a723] 1__fTatest 1 OO poo Galol cons — >] a t, [alofo (ooo00) 4 + (o0007 } (Note 1) Each speed is automatically set to match the head specifications, but the maximum stitching speed ie limited by the [7-8 DIP switch 6, 7 and 8 setting. (Note 2} The settings will be registered when the [ > 1 key is pressed. If the settings ere not to be changed, turn the powor switch ON again without pressing the [ >¥ 1 key. aeB. List of setting heads B-1. When DIP switch § is set to OFF (single needle) 4) The factory setting is [3.7.3 J- 2) IL A 1. is executed in the initialization menu, this setting willbe initialized tol 3.2.3.) 4¢ 3) If the DIP switch 2 or DIP switch 5 sotting is changed, the head setting will be initialized IE DIP switch 5 is OFF, this setting will be initialized to[ 7 373 ] Head {ABC} display (Dj dsplav Maximum speed 5797 "i J APODepm | S-~8800e0m [|= 40008Rm 8731 et 3: 4800spm |S +--3600spm | B77 = 3 a800s0m |S += 850080 — ame 2 S7=88008pm | 1s== 280089 | 3798 3 | None == 2000s6m err 1 340080 = 8778 1 3 ---48005pm — ave a None === 40¢05pm 8652, 8855, 6854 ¥ 3+ 45008pm —— es x6 None === 880s0m Overs a7 ‘None =» Set with DIP switches 6, 7nd 31: The inching speed is set to 218spm, the thread trimming speed to 215spm and the start and end backtack stitching speed to 1800spm. 22: The inching speed is set to 215spm, the thread speed to 1200spm. #3: The inching spead is set to 215spm, the thread trimming speed to 215spm and the start and end backtack stitching speed to 1000spm. 44; The inching speed is set to 215spm, the thread speed to 1800spm. The option output is set to 3P output (thread release output) 25: The inching speed is set to 185spm, the thread trimming speed to 185spm and the start and end backtack stitching speed to 1200spm. The thread trimmer Is set to the timer output. 26: The inching speed is set to 250spm and the thread trimming speed to 170s. 3087; The inching speed is set to 216spm and the thread trimming speed to 215spm. The option output is set to the in- operation output (air output), {Note} When using the motor for reverse rotation, two of the three motor wires (red, w/ changed. ming speed to 215spm and the start and end backtack stitching ming speed to 215spm and the start and end backtack stitching e, black) must be inter- 8-2. When DIP switch 5 is set to ON (twin needle) 4) Tho factory setting is | 8.4 2.3 ]- 2) If[ 8 Jis executed in the initialization menu, this setting willbe initialized to( 8 4 2 3 J. % 3) Ifthe DIP switch 2 or DIP switch 8 setting is changed, the head setting wl be initialize. 1f DIP switch 6 is ON, this setting willbe initaized tol 8 4 2 3 J. Head {ABC display [D]dspiay Maximum spoed Bee wa | 842 | 3--a000pm | S-- 8500s [_1--- 40008em 072 mil eve 35+ 30009pm | 5+" 30008pm_[ Beas. 8675 | BAS | 3 8000s | S++ 9000pm | 1--- 5000smm Bee7 ma] 84 e+ 4000spm oo Bete [B48 | t--8000pm | sexes et | B37 | S++ s000spm —— 51, C53 (Seko) #2 | PU | @--2200sm | 4--2400sm | 6 --- 2600spm Dé: The inching speed is set to 185spm, the thread trimming speed to 250spm and the start and end backtack stitching speed to 1000spm. 2: The inching speed is set to 185spm, the thread trimming speed to 250spm and the start and end backtack stitching speed to 1000spm, ‘The correction is set to halt stitch operation. -10-83, Memory switch setting mode and parameter setting mod. te. ‘A memory switch mode for changing the functions and a parameter mode where the time and timing, ete, can be changed a Power switch ON provided, (Note 1) These settings cannot be made with F (%)-20. Use F (X}-40 or F (X)-100. (Note 2) To prevent unintentional changes of the parameters, the parameter setting mode cannot be entered unless the memory switch [ 01 ]is set 10 ON. Stitching mode _] [When the [ >¥ 1 key is pressed while holding down the [ wo] key, the seiting menu { d SJ display will appear. —_- ‘Setting mode menu 1 ({ Memory switch setting mode )) rosa PE Memory switch jt tl thread vimm | pays om fe) setting mode = $7 ing vatiity tire 2: off, : EE [4]of8 Presser UP after |, ‘thread trimming us $o [4] ofA F-- Talore Startbace |, tackdouble |! 2 ~~ [A] ofA f= LalofB {(OU-e] End code teal fb) [= [AlofA j te reeneneescnrarnaneceal (Note 2} jpovenscenerenneeeeneee (( Parameter setting mode )) mmmmmmm—eanmmeemeny TT Parameter senting mode ) wrens I>] Delay time to thread wiper aes Parameter setting |—}-—_—1-»} on [eooa) mode ‘Setting can be changed with (PA) F falet8 Talend [vJof[ CD}. ‘Thread wiper ON time [re igel 77 [4}ofB eet } 1ooo0o01 PE tsiors |— tajore End code (eel f- 01 t= [4] of B Display changes to[ S P ] when Lk LAL sre. are pressed. ---| Setting mode menu 2 Encode | —_[ After ending the len) Setting mode Stitching speed setting mode] ( S P | ‘menu 1 by press- jing the[ >] j— [A118 7 Input/output check mode ROM version mode “1(Continued from previous page} Stitching mode Lae 40>) +] Setting mode mena 1 Jeter] ver Setting mode menu 2 yrrvereeceseaceesensece (( Stitching speed setting mode }) (> rl tS t Stitching speed i_t—}—+] inching speed | [i 5) ——»{ 2:5] frie ete Change wit Jana | [TAlofB Cv Tkeys i] ia Y Thread trimmnin [ajete speed 8) feels +t 2:5) : ‘Change with [4] and Cv ]keys Fe=-— [alofB Ix) 1 ‘Stop improve- $08 ment apoed (Pol+——*[ i508 Change with [A] and [| — teres Change witht 1 Endeode | Ea) E talere ( Input/output check mods )) Tnpur/output ii F : check mode LA 1 key Reverse solenoid Tee [4] key ++ Thread trimming solenoid cP [MME] key +++ ‘Thread wiper solenoid 1£1( £9 1) key +++ Presser foot lifter solenoid [ 4 ] LED --+ Needle UP signal [¥ ] LED +++ Noodle DOWN signal [™ ] LED --+ ENC signal [ 1] LED +++ Actuator switeh LF LED -+- Presser foot lifter switch, otc. 7-segment display [A311] +++ Treadle Numerical value increases when pedal is pressed forward, Numerical value decreases when pedal is pressed back. to (ROM version mode )) | (1000) — ROMversion aisplay End the setting mode menu 2 when the [ > ] key is pressed, and return tothe setting made menu 1. ; a eae8-4. Stitching speed setting mode Each speed can be changed as deser 12d below by using the stitching speed setting mode. © Setting of each stitching speed. Normally, each speed determined by the product code corresponding to the head is set at the factory. To change the speeds, Use the following procedures. @-1 PresstheL > ]key while holding down the { 70} key, and enter the mode setting menu 1, 2 Pressthol -a J+[ we] koys, and enter the mode setting menu 2. ©-3 Press the[ >¢ Ikey, and enter the stitching speed setting mode, @-4 Select the speed type to be changed with the B [4] key. 5 —Whenthe[ > ]key is pressed, the display will change to the setting speed (numerical value). HfL tis pressed at this time, the sewing machine will rotate at that speed. The display will monitor the ac~ tual speed, and display it. If 1! Tis pressed again, the sewing machine will stop. 6 — Setwith the [4 ]end{ 7] keys. ©-7 Ifthe [ >< 1 key is pressed, the display will return to the setting speed type. DB Press the B [a] key several times, and display [ E = 1 ©-3 When the [ >< }key is pressed, the mode setting menu 1 will be returned to, ©-10 Press tho B [4 ] key several times, and display [ Em } ©-11_ When the [ 3¢ 1key is pressed, the stitching mode will be returned to. ‘The display end order of each speed type are as follows. Speed type Display | Setting unit Setting range Remarks Inching speed Lo | tepmunit | 160-280pm ‘Speod for low-spoed stitching and eorree tion setting “Thread wiring speed E’r | tspmunit | 150epm-inching speed | Speed for thread wimming ‘Slow start speed 5 L_| 100epm unit | inohing speed=1000epm | Speed for slow starting Start backtack sttchinglimit | L + | 100spmunit | Inching speed-8000spm | Limit speed for start boekteck stitching speed End bsctacksitching int |E | 100spmunit | tering spesd-3000spm | Lint sped for end backtack itching speed | 7 Wigh-speed stitching mit [Hs | S0spmunit | Inching speed-DIP awitch | Limit value for maximum stitching speed spe0d Wote 1) setting ee 7 “Automate altching speed Inching speed: High speed | High speed for automatic stitching Stitching lim spoed Stop improvement speed | Po | 100epmunit | 600-2600spm ‘Midale speed fr stop time improvernent (Note 1) Tho upper limit of the maximum stitching speed limit value is limited by the DIP switches 6, 7 and 8 shown in (Note 2) (Note 3) Table (7-8. 1 8000spm is set with DIP switches 6, 7 and 8, (when $108 pulley, single needle are designated), the speed can be sot to a maximum of 5000spm. the DIP switch 2 or 5 setting is changed, all these speed settings will bo initialized. ‘The [8] 8-2 head settings will also be initialized (3). a) When DIP switch is set to OFF (Initialized to head setting > 373.1) ( ‘Thread trimming speed = 215spm Inching speed = 215spm ‘Start/end backtack stitching speed = 1800som, etc b) When DiP switch is set to ON (Initialized to head setting 8 4 2 3 ]) ‘Thread trimming speed = 185spm ( Inching speed = 250spm Start/end backtack stitching speed = 1000spm, ete. ‘The setting range A Yj on the old CPU version (J02781-A) is as follows, Inching speed-High speed stitching limit speed — 200spm a13-8-5. Memory si A. Memory switch h and parameter lists [CID- © )~ Indicates that the switch is ON. [CIE g 1 Indicates that tho ewitch is OFF: Display No. | etal when set 19 ON D1 | Poremeter sting change enabied ” De _| Nointeriock during tweed wining | 2.2 | Momentary drop or failure of power supply check valid #0 ou (Reserved) 3#Normally OFF. as (Reserved) #Normally OFF. 1.6 | No penetration free UP operation D1 _| eserves) Normal OFF [58 | esenon Normally OFF a 1 “Tread trimming vllty seting enabled with {| >¢ They Presser foot lifter rise aftr thread trimming Prosser foot lifter rise efter neutral stop ‘Actuator ewitch « thread rimming switch ‘No immediate stop function No ever time [o£ J function Half stitch correstion with actuator switch Eg £8 | Backward correction with actuator switch aS: 2 1 _| Start Backtack double 22 _| Endbacktock double 2 3 __ | No.of start backtack stitches + 10 stitches 24__ | No.of end backtack stitches + 10 stitches 25 _| Rootstitching _| 26 __ | Noslow down to low speed on starting of end backtack 21 | Continuous backtack changeover xe 2B _| No.of continuous backtack stitches + 10 stitches {| Enable to stop during start backtack sewing, speed is variable with readie. ee 3.2 | F20,40 No.of backtack stitches change enabled #7 33 __| Callfixed stitchos when pleats sewing will be used. x8 3.4 _| NoLED call when continuous backteck[ AF Tis canceled. *o 31; Sot this to ON when the parameters are to be changed. When set to ON, the treadle operation pressed forward will be valid during thread trimming. 33: When set to ON, { P Iwill display f the power supply is shut off momentary during motor rotation. ‘ra: When set to ON, thread trimming validity can be set with[ > ] key on operation panel. "XS: When one is turned ON, the other will be sotto OFF. If there is no operation panel or if{ ; | {correction} is set to OFF, half stitch correction or reverse rotation correction will be applied. 16: When set to ON, the continuous backteck will be executed for [A,B] x [D] times, [Cl display is OFF. 27; When set to OFF: If | Jis validated on F-20, the No, of start/end backtack stitches will be fixed to four stitches. FE £2 Js validated on F-40, the No. of start/end backtack stitches will be fixed to four stitches. If f orl 14 1is validated on F-40, the No. of end backtack stitches will be [BA ‘When set to ON, the No. of start/end backtack stitches will be the No. of stitches set with [ABCD]. 28: When set to ON, the [ 1:4 ] (pleat stitching) will be constant stitch (forward feed) operation. 59; When set to ON, if [ V7 ] is canceled, the LED setting and display from before it was turned [ \¥ ] ON will not be returned to. ‘When set to OFF, the [ ¥ ] original LED setting and display will be called out. (Factory setting) aa(Continued from previous page) Indicates that the switch is ON. Indicates that the switch is OFF. Digplay No. | Details when ON 3.5 _| Softdown of presser foot ifter is timer mode 1 315 | Presser outputs not automaticaly OFF by timer Presser output chopping duty chengeover m2 Onty lower part of ransstr contrlles! during presser foot liter rises 2 Prohibit to rise of aressr fatliftr by treadle repressed backwards otter neutral sop | Prohibit to tread trimming by treale repressed backwards (Reserved) "Normally OFF a High-speed pedal during standing work is only high speed (no inching speed and variable speed ranges) [No delay start during standing work x8 [Emergensy stop with presser pedal disabled during standing work Emergency stop with high-speed pedal disabled during standing work Prohibit ise of presser fot iter with vimming pedal during sancing work (Reserved) "eNormatiy OFF (Reserved) 2xNormaly OFF Option output 1/Output during running (need cooler, ote) a) ea Option output 2/Thveed release output position) #6 Option output 3/Air(N itches at tert of sttching A after fabric edge sensor turns ON) 7 ‘Option oxthut a/Gondense output When B= or C=) Option output Program output (ON ster head vieming ater TO, during T1) Option output 6/Program output 2(ON during presser eynehroization after 2, during Option output 7/Spare) an Option utputSpare) = | Do] feo |senfin| e fuudna s os] 2] aforn} cle |e] ele] Shall e ‘When set to ON, the operation will follow the parameter £ 3 ]and| £ 4 ] settings. X2;_The ON/OFF duty during chopping will be as follows. Paste Memory switch 321 — OFF on. 25me ON tims ON Memoryswiten [OFF | 25ms _ OFF ims _OFF (3B) ims ON tims ON ON | sms OFF ims _ OFF ‘When set to ON, the pararneter[ ¢ { } setting is invalidated. When one is turned ON, the other willbe set to OFF. If all are turned OFF, the puller output will be applied. When the output is ON, it will turn OFF after the No. of stitches set in parameter( { @ Jis stitched or after 10 seconds have passed. Ilo GL — | {overlock) is set with the [8] 8-2 head setting, this will be set to ON. 19.8 1 Lis sotwith the [8-2 head sotting, this will be sot to ON. When set to ON, the option will be output for N stitches (set with parameter { {| ]} when stitching after thread trimming. When using sensor I, the output will urn ON when the sensor turns ON, After stopping, the output will turn OFF after the time setin parameter £ 5 has pessed. +8: When set to ON, if the No. of start backtack stitches Bis set to 0, the condense will be output while stitching (A). When set to OFF, ifthe No. of end backtack stitches C is set to 0, the condense will be output while stitching [D] When set to ON, the program willbe output at the timing set with parameters [ 2 Jend| £ 3 |. When set to ON, the program willbe output at the timing set with parameters | € 4 Jand[ ¢ § ]. + Nothing will be output aven when set to ON. eeB. Parameter list Display No. Inital data [Data seting range! Details £0 2 01-07(*10) | Delay ime to thread wiper Is turned ON after thread wimmerts tuned OFF (20ms) (10-70ms) e 05 (08-10(10) | Thread wiper ON time {0ms) (40-1008) ee 05 {05-10(10) | ‘Delay time to presser foot lifter is turned ON after thread wiper ie turned {60me) (50-100ms) | OFF Fo 30 10-80( 70) | Presser foot lifter fulton ime (300m) (100-900m9) Fd 26 (00-60(*5), Time of presser foot lifter is turned OFF (When set 0 00, the timer will not (Sminutes) (s-Sminutes) | turn OFF automaticaly) Fe 15 ‘00-25(«10) | Delay ime from presser fool liftr Is tured OFF to motor start (50ms) {(0-250m) FS 00 ‘00-88, 2) Delay time of upper part trersistor of presser foot lifter fs turned ON (Oms) (0-198) {soft down of presser foot fter) FY 00 (00-30 (10) | Time of upper part wansistor of presser foot lifter is turned ON (Oms) {0-300ms) {soft down of pressor foot iter) bo 24 ‘00-47 ‘Start backtack AB revorser changeover tning (puise) (pulse) (The larger the values, the longer the timing delay) be 24 0-47 ‘Start backtack B revarser chengeover timing {pulse} (pulse) (he larger the valuo is the longer the timing delay) be 4 00-47 End becktack CD reverser changeover timing (oulse) (oulso) {The larger the valueis, the longer the ting delay) ba 8 00-47 End backtack D~C or C ON raversor changeover ding (outse) (puise) [The larger the velue is, the longer the timing delay] a fo 0 00-98 No.of stitches to puller lower (Stith) {teh {Memory switches [71-178] ll OF, factory setting) a2 cai 10 (00-99 No.of option output ON stitches (N) (Stith) (Stitch) (When memory switch [73] is set to ON} ce 6 03-10(10) | Delay time to program output 1 ONTO) (0ms) (30-100ms) __| (When memory switch [75] s st to ON) 33 c3 08 (04-10(10) | Program output 1 ON time (T1) (20ms) (40-r00ms) _| (When memory switch [78] is et to ON) 53 cy ry 00-05(*10) | Delay time to program output 2 ON (72) (om) (0-50ms) [When memory switch [76's sot to ON) 4 oS 2 (00-99(+0.) | Program output 2 ON time (T3) 23) (0-993) {When memory switch [76] is set to ON) ma ao 18 10-30 >5) “Thread wimmer timer (ON) ime (90ms) {80-160ms)__| Whon{ 8 S 2 _ lis setinhead setting mode.) xe ai 08 (00-2010) | Standing work delay start time (coms) {(0-200ms) x6 |: This is valid when the C ON timing memory switch { 2 5 ]is ON. The puller will lower even ifthe output ON continues fa ten seconds. The ON delay time and ON time are the reference from the thread trimming needle UP stop signal. : The ON dolay time and ON time are the reference from the presser UP signal. This is vad only when [ S'2__ Jis setin the head setting mode, This is invalid when the memory switch | 4 § is set to ON. -16-(Continued from previous page) DisplayNo [trial data [Data seting renae Betas po. fe co-08 Treadle stroke, Weadle pressed back thread vimming) point {Wine the numerical valve is large, the stoke to thead timing is short) Pt 0-08 “Treadle stroke, reodle pressed back [presser fot ifter ON) point [When the numerical value is largo, the stroke tothe presser oat itter ON is shor) Pe @ 0-08 Tread sivoke, noual pint Pa 2 ‘0-08 “readlo stroke, inching start point (motor start point) {hen the numerical values smal the svoke to the motor statis short) Pa 02 00-0 Treadle stroke, variable speed range start point (When the numerical vlue is smal the variable speed area wil increas) {hen the numerical velus is large, the inching speed area wl increase) PS 2 0-04 Treadle stroke, figh speed each point (When the numerical values small the stroke to tho igh spood area is short) {When the numerical valu is large, the verable speed ere wil decrease) So o ooo Stending work pedal or variabie speed, variable speed area start oint {When the numerical vlue is small he variable spoed aree wl ncreas3) {When the numerical vale is age, the inching sped area wilincrease) st 2 00-08 Standing work pedal for variable spo0d, high opoed rach point. (When the numeric! value is smal, the stoke tothe high speed areais short) {When the numerical value sarge, the variable epee area wil decresse) 10 I 40-99(=1) | Brake tine during stopping Yoms (40-99ms) net * 05-15 Braking force during neutral stop " {When the numerical value is small the stopping sound wil decrease) te ” 05-15 Braking force during thread wriraming UP position stop " {When the numerical value is small he stopping sound wil decrease) na 7” 05-60 Return amount during neutral needle DOWN position stop 8 (When the numerical vlue is large, the needle wil stop a the forward posi tions nu ey 08-50 Return amount during naira needle UP poston stop 2 {When the numerical value sarge, the peele wil stp a the forward post tion) ns “1 05-50 Return amount during tread trimming needle UP position stop 28 {When the numeraal vlue fargo, the needle wil stop a he forwerd posi tion) 981: The initial data will differ according to the DIP switch 2 and 5 settings. I data is for when the DIP switch 2 is ON (890 pulley designation) and the DIP switch 5 is OFF (single needle The init designation). The initial date will be set again if the DIP switch 2 and § settings are changoc 382; The stopping accuracy will deteriorate ifthe value is too small (Note) There ere parameters other than the above, but these must not be changed. If they are changed by mistake, in- itialize the parameters with the [8] 8-1 initial ion mode, a19 Han error occurs, an error code, etc, will Error display and details Display Meaning Pe ee acore & t {Power transistor) (Overvoltage) (Undervoltage) (Overload) (Lock) (Fuse) (Power down) {Error 0) {Error 1) (Pulley) (Over time} All displays flickering others} (Clear) play on the No. of stitch display of the operation panel (AB). Details Driver overheat, overcurrent (IPM alarm) The power voltage is too high. The power voltage is too low. The load is too large. Motor lock or position detector fauit, BA fuse for solencid is blown. Instantaneous drop of power or power failure {Only when memory switch [03] is turned ON. The display wil return to the original display when the pedal is operated again. Panel switch error Asswitch other than { 424 1( { (2 1)is still ON. Itcannot be determined whether the connected panel is a 20, 40 or 100 specification panel. The pulley setting (DIP switch 2) is incorrect. {ifthe motor rotates abnormally, the sewing machine will be stopped. If the sewing machine will move for 3 minutes continuously, the sewing machine will be stopped for the safety. Memory element fault The pedal and operation panel can be operated, but the No. of stitches, ete, cannot be memorized, Memory initialization This display when [ Rt ]is exocuted in the initialization menu. Alter the display goes out, stitching can be executed, (Mode changes to the stitching mode) (Note) If an error display (other than P d_or all displays flickering}, the control box power LED (green) and operation panel display will not go out immediately after the power switch is turned OFF. ‘Turn the power ON again after the control box power LED {green} and operation panel display have gone out. -18-(1 Operational instructions 12.1 Operation at time of power input + When the power SW is ON,LED(RED)of the power circuit board illuminates and the direct voltage is impressed detween @PV-POV. (the vol tage rectified from three phase or single phase). ¥ Then the switching poner supply starts to operate, and it outputs each of the specified voltage to the secondary side of the switching transformer, QU, @N,@N and GX phase(+15V)as the power supply for control ling the power elenent( 1PM). @INF phase(120¥)is for monitoring of high voltage power so- urces. Adding @P@(+8V) and @N8V(-8V), the supply for the total 7 systems can become act ive. (note: O-®is of high voltage, therefore please be careful not to get an electric shock. ) + PBV outputs +5V on the control circuit board. When +5¥ is output, the CPU program starts to work and the LEDGreen) wil! illuminate. # The solenoid power supply rectities the AC3QY, which has been decreased in voltage by transformer, ‘on the control circuit board and then outputs DC4OV. From all the above procedures, al! the power supply can become act ive. + About resetting Hard reset | When power is ON: In the hard reset, the start up voltage of 6.6V is detected by the iC(#4), and after that CPUB3 pin becomes the (L] level for 30ns, and then CPU is reset. When power is OFF: Nhen the voltage is falling to less than 6 6Y, it becones [L] level and reset. tHlard reset Il ‘When poner is ON; By monitoring the solenoid voltage AC3OV, when the [L] level does not to come to ‘the CPU9O pin within 5 seconds at tine of building up of the poner supply, it outputs an error message of [Fu] to the operation panel. After [L-H edge) has been detected, it becones reset. When poner is OFF: After [L-H edge] has been detected by the CPUQ0 pin, if the [L] level continu- es for 30ms, it becones reset. + Next, by the programing operation, it accesses the 1/0 port of the operation panel, and if there is an error, it display an error,£0 and El. It accesses to the synchronizer(NOSYNC), Dip SW and other 1/0 port(except PRSH). “= RY.out becomes [L] level and the poxer relay becomes ON. (snapping sound) 12.2 Operation when the power is OFF. + When the poner SW is OFF, the hard reset ll functions and the power relay is OFF and the data of pan- el.etc, are written on the EEROM, The LEDI(Green) goes out lights instantly but the LED2 goes out lights after about 5 seconds. When pulling or inserting comector and cord,do it after the LED2 has ‘gone out of | ights. (note: If the LEDI(Green) does not go out of lights instantly, there has cocured some error, and it ‘the operation panel is connected, the contents of its error will be shown on the panel.) + It takes about three minutes for the LED(Red) on the power circuit borad to go out of lights due to the electric discharge of electrolytic capacitor. |t is dangerous, so conduct removal of the board only after the LED(Red) |ight has gone out. TagaPanel display table ‘The following alphabetic characters and symbols are displayed on the operation panel. segment display segment dispiay| 7-seument display [segment dapiey] ° a a a N a oN ° 1 { 8 b ° 2 OFF 2 z 2 ¢ c P P 2 3 ° é a q ‘ 4 E € R = 5 5 F f s 5 s & é o T t 7 7 H H v u 3 & 1 ; v ~ 8 3 z J w u + 4 K x i = L & ¥ ¥ M ° z -20-(Checking the control box 18.1 The operation of the porer circuit board and how to check it. + After three phase/single phase AC poner supply is rectified, DC voltage is impressed to between PV-PQY, (LED, red light illuminates)for example, in case of input of 3phase 220V, the high vol tage of DC 311V is impressed + When driving a motor, this DC voltage is converted to an AC voltage, and the motor is control led by inverter drive, # When the poner SW is turned OFF, an electric discharge starts, but it takes about three minutes for the LED(Red)to go out, and it is dangerous. Therefore, when you check this board, do it only after the LED(Red) has gone out. + Each ponar supplies for the control systen are sourceing fram switching regulator on the poner circ uit board, When the VCC terminal of HiC3 has reached 16V, the switching power supply starts oscil lat- ing, and as the output voltage, the power supply of the total seven systens becones active simi!taneo- usly, at PB(+8V), NB(-BV), U, V.N,X phase(each 415V) and NF phase( +20V). + The P8V outputs 45V in the control circuit board. ¢ When 45V is impressed to the CPUC(H3). the program starts and the LED(Green) wil! be il !uninated. ¥ If the LED(Green) illuminates, Stand by is OK. + If the LED(Green) illuminates, the switching poner is working correctly. # When the porer SW is turned OFF, the LED(Green) goes out instantly, but it takes about 5 seconds for the 5V to discharge completely. Therefore, please take out or insert the connector and cord only aft~ er the LED2 has gone out. (The termination of oscillation of the switching regulator ocours when the VEC terminal of HiC becomes below 10V. ) + The motor repeats the operation of start up, constant running and deceleration, but while decelerati- on the energy of the motor is regenerated and impressed between PV-PQV and its voltage increase. This voltage is always being monitored by the OV.det terminal, and when overvol tage happens, the O1 on the power circuit board is turned ON and avoids a rise of the voltage. This excess energy is consum- ed at the resistor 40#/1000. ¥ The VRI on the poner circuit board adjusts the voltage of the OV. det terminal, and for example, in the case of ACZ20V. it is adjusted to be DC2.2V. If ACZ30V, it is adjusted to be DC2.3V. (The high voltage between PV-POV is alnays being monitored. Also, this terminal is of the voltage of low volt ge group being separated by the insulation transformer. Therefore, depending on the variation of the OV.det voltage, it outputs an error message such as [Uv], [Ov] and [OL] . & To this board, high voltage is impressed, therefore when you check and repair this board, please be careful enough not to hurt you. 18.2 The operation of the control circuit board and how to check it # If 5V is generated correctly in the control circuit board and the hard reset | works normally, the LED(Green) is turned ON and the CPU program starts work. + There is one chip CPU to control by program the operation of motor, the sequence for the sewing head, the operation of the panel.etc., Also, most of the electronic parts in this board are well integrat- ed, and therefore it is difficult to exchange such parts. However, as to the transistor attached to the radiator fin, BD1,016,etc., they are possible to replace. -2a-12.3 Before operation(operation of the pedal ). After the power has been input, if the pedal pressed lightly forward from the neutral position, the mo- tor rotates at a slow speed, yhereas if the pedal is pressed deeply, the motor rotates at a high speed. If the pedal is pressed backnard, it works to do thread cutting and then stops at needie-up position. After the power has been input, if the neutral position is not detected once, the motor does rot rotate even if the pedal is pressed forward. Also, if the VC voltage is out of the area of 1. 5V0. 4V for the treadle unit at the pedal neutral position, it is not possible to detect the neutral position. When ‘the voltage for the 81 pin(AN3) of the CPUCf3) is out of the speci fied voltage, it prevents the start up of motor. 12.4 While running + After the above procedures, the motor is now awaiting start-up, By pressing the pedal forward, the PHOTO signal(2 pins of P11 on the contre! circuit board)becomes [L] level and it is now possible for the motor to start. The diversitied signals(U, V,W, U,V, W)from the internal ROM table of the CPU are output to the poner circuit board and after inverter contro! has been conducted, the motor now starts to run. If the PHOTO signal becomes [H) level, the motor decelerates and stops. There is one chip CPU aval lable, which does a programing contro! of motor control, sewing head/panel control, etc. and except for 1/0 port, it is not to check the circuit hardwarenise. It is possible to check the circuit of the power circuit board and the pedal PCB. However, power circuit board is of high voltage circuit,be careful not to take an electric shock. + OV. det terminal This voltage is analog voltage and it always watches the voltage fluctuation at the high voltage side(PV-POV)through the switching transformer, (insulation). If something is wrong with this vol tage, it outputs an error display of [Uv] , [Ov] , [OL] - OV. det (1. 3V] > [Uv] undervol tage detection(ACI30V) Ov. det (3. 0V] -> [Ov] overvoltage detect ion(AC300V) OV. det [2 BV] > [OL] overvoltage limit detection(ACZB0V) Cageff Control! box trouble shooting guide Power PCB a PROBLEM CHECK PROBABLE CAUSE REMEDY When poner SW is ONLED | Fuse FI,F2 blow? | Short circuit of the load on the | Do not switch ON (Red)does not i! luminate. power circuit. Someting wrong | unless short with BO?IPH7ZNR?CI-CE? Power transformer? circuit is solved. | Fuse FI, F2 OK? Has the Ri broken down? Has the pattern blown? Repiace the RI Replace poner PCB LED(Red) i Ifuninates but LED(Green) does not Fuse F4(2A) blown? Is the Q101 short-circuited? Sonet ing wrong with HiC3, 20101? Replace 0101, HiC3, 2101. appears. F3(2A fuse) blown’? ___| Fuse OCF Someting wrong with HiC3 20102? | Replace Wicd While running the motor | CN7(4QN/T00ohm 4QW/TO0Dohm bioken dow? Replace 408/100 OV or OL error sign broken down?) 01 broken down? Replace fuse, 1. Wotor does not run PT appears, sometines. While running, PT appears. static electricity head and box? Is earth good for motor and box? O error? Pressed the pedal so hard? Educate how to press the pedal Walfunction by noise | Ts earth surely taken for the | Take earth smoothly and an error sign | coming fram outside. | poxer supply? Mal funct ion by Is earth taken for the sewing | Take earth Operation of IPM ‘Something wrong with IPM, PHU-PHW Replace the poner PCB Wotor does not run ‘smoothly. Wirewould resistance of motor. Qperation of PHI-PHZ Operation of 1PM Weasure wirewould resistance 2. Gohm between each phases? Check IPM operat ion, Replace motor Replace poner PCB Wotor start up is not good and motor does not rise in Its rotation. Or, the porer Is power relay ON? Heating of the RI Ts the contact point of poner relay open? When the power switch is ON, the contact point Replace relay(RY). The lead wire of relay is broken, relay becomes OFF. resistor? | is closed Is RI resistor broken? | Replace RI Treadle unit 7 Wotor does not start when | Is VC voltage right | Is there about 1. 5V? [Adjust by VRT pressing the peda! at pedal neutral posi tion? He 7 VC voltage when Is there about 4, 5V? ‘Adjust by VR2 pedal is pressed fully forward VE voltage does not Sonething wrong with iCi? Replace iCi. Dt change? Din? co ichronizer While running an error [Remove synchronizer | No enooder signal, needle-up Replace sign LO appears. cord and check signal, needie-down signal. synchronizer operation. Machine and motor run | Remove synchronizer |Wotor is locked [Wotor cord and check Sewing head is locked. ‘Adjust sewing head operation. No running Control PCB? of machine and motor | Others Wotor does not run Renove synchronizer | Something is wrong with the Replace smoothly. Wotor rotate by | cord and check encoder signals. synchronizer doing inching. It rotate smoothly Tt does not rotate | Wotor is broken dow or Wotor smoothly. resistance value abnormal Others. Control PCB cae+ The speed setting for each speed is al autonatically set. For example, depending on the kind and type of the sewing head, Dip SW setting has priority over others. Therefore, conduct Dip SW setting according to the conditions set(sewing head, speci fication). 13.3 The operation of the pedal and how to check it * By the magnet electric conversion element, analog voltage is generated By the pressing stroke of the pedal, the analog voltage is changed straight, and it outputs the command signals for pedal for- ward ON, thread triming, presser foot UP and presser foot DOWN, and also motor speed, and then inp- tts the analog voltage to the CPU. + Adjustment of VRI: When the treadle pedal is at the neutral position, it is set at 1.5V. If the VRI is turned clockwise, the voltage decreases. If the VRI is turned anti-clockwise, the voltage rises. + Adjustment of VR2: When the treadle pedal is pressed forward fully, it is set at 4.5V. If the VR2 Is turned clockwise, the voltage rises. If the VR2 is turned anti-clockwise, the voltage decreases. + The adjustment of above 1.5V and 4.5V is done at time of delivery from the factory, and the paint lock is applied to the volume. When exchanging the printed circuit board or doing the repair on the printed circuit board, the voltage changes, therefore please make adjustment of the vol tage. 4 If the volune adjustment is not possible, replace the treadie unit. 13.4 The operation of the power transformer and how to check it + It outputs AC30V in order to drive the solenoid Uniess this voltage is input to the control circuit board, an error message of [Fu] appears. + The power supply of ACEV is output for the illumination lamp. % The resistance value of the primary side of the transformer is about 15Q. If this resistance value is extremely lox, the transtormer is burnt out. If the transformer is burnt out, the fuses Fl and F2 fon the power circuit board are blown, At that time, check the BD(bridge diode). 4 The resistance value of the secondary side of the transformer is extremely low and it is not possib- le to check, 13.5 How to check motor + The resistance value is about 2,60 between each phases of U phase, V phase and W phase. 4 Between U pahse and V phase, it is 2.62 + Between V pahse and W phast it is 26Q + Between W pahse and U phase, it is 2.60[5 How to VRI8VR2 setting of treadle unit PS-INV Assy (MD-601, 611) NAWE, CODE NOTE PS-INV Assy (BATA104) | J80640-001 After changing this circuit board, Please adjust the volume (VRI,VR2) since we suppose that the voltage of each position may change due to the aberration of position of magnet and hole element when you set this circuit board onto the treadie base. Points of adjustment; Please adjust the position of PZ with VRI and the position of PB with VR2 + Adjustment of the position of P2 means that the pedal-lever should be the neutral position. # Adjustment of the position of P§ means that the pedal-lever should be the position of ful! with fornard stepping operation. TESTER VOLUME | HEXACODE OF OPERATION PANEL PEDAL-LEVER NEUTRAL(P2) | DCI. 4~1. 6 4a1~51 1av | 4c PEDAL-LEVER FULL(P6) C4. 5~4. 6 ES~EA 45v | 5 There are two adjusting ways as fol lors. 1, Please indicate the voltage in hexacode after indicating (A3) in T-seguent display in (CP) check mode. Then please adjust VRI for hexacode to locate 47-51 in the neutral position, if you turn VRI in clock-wise the value goes dorn, Please adjust VR2 for hexacode to locate E5-EA in the full step position of pedal, if you turn VR2 in clock-wise the value goes up. Please adjust VRI, VR2 repeadly to locate the value within the above each limit. 2 Please measure the DC-voltage with the tester to put + pole to conecter No. 2 and - pole to conecter No.3 and then adjust VRI and VR2 to locate the volume within the above each limit. -27-Contor! PCB. When power is ON,an error | 8A fuse blown? Check transistor for solenoid Replace fuse ‘sign FU appears. BA fuse OK? Check power transformer Something is wrong with Replace control ‘the operation of sewing PCB | head and motor. Poner transformer ‘When power SW is ON, LED Fuses F1,F2 blown? | Check resistance value at the Replace (Red)does not j| |uminate. primary side of transformer. ‘transformer i Is there about 15ohn? L o Check BD. Replace BD.[16] Checking the machine solenoids oe —_— | penance nae GND Reverse solenoid Presser foot it switen Thread wiper Thread trimming solenoid solencid 6737) 1. Remove the load connector (12P connector) of the machine from the connector part of the control box. 2. Measure with the tester set in the resistance range * 1 as follows. (© The thread trimming solenoid at pins 4 and 5 is normal i the tester reads approx. ohms. ‘© The thread wiper solenoid at pins 7 and 8 is normal ifthe tester reads approx. Sohms. ‘© The actuator at pins 9 and 12s normal if the tester roads Oohms when pressed, and “ohms when released. ‘© ‘The presser lft solenoid at pins 1 and 4 is normal if the tester reads approx. Sohms, ‘© The presser lift switch at pins 2 and 5 is normal if the tester reads Oohms when pressed, and ohms when released. (Checking the motor 1.Remove the motor corc(3P connector) from the connector 1 _ pat of the power board. 2 2Measure with the tester set in the resistance range X1 as follows. If the tester reads approx. 2.6 ohms in 3 any position between 1(red) and 2(black) with the range X1. 1 and 3 approx. 2.6 ohms. 2 and 3 approx. 2.6 ohms. u Ly) ©@B)STROKE - VC (analog voltage) CHART he OF 4 Deraloa fe ae i vat ig i ® © Press Press Variable i just, _igonn j,i, speed ho o. Trim Neutral Low "Too" soeed soeed STROKE (mm) STROKE - SPM CHART a S68 81 S82 STROKE (mm) -28-[19] Adjustment AC servomotor % Tilt back the machine head and place the belt @ onto the motor pulley @ and machine pulley @. 4% Prose belt @ with e finger (force of 5 N}, and adjust the nut @ so that there is a deflection of 13 to 16mm, Note: + While using the machine, the belt will conform to the pulley and cause the belt tension to loosen. if the belt tension is too loose the following faults could occur. |. The stopping position may shift, ». The needle bar may drift when the machine stops, . An extra stitch may be sewing when the machine stops, d. An abnormal noise may be head due to belt sipping, and e. The belt may become too loose and contact with the cover. Needle position detector (synchronizer) Model DB2-B798 + Take off the synchronizer cover for adjustment. The synchronizer detects the needle with two sensors and controls the needle down signal and the thread trimming signal with one sensor. Noodte down Needle up stop position Stop position For medium materials 9~11 mm For thick materials i0-12mm, Semen 22-26 | 75mm 114mm + When adjusting each sensor, do not fail to turn off the power switch. Position adjustment for needle down signal + Turn the machine pulley and set the needie Smm up trom the bottom to align the lower end of the magnet @ with the upper end of the thread trimming needle down sensor @. {As for the model 8747 - 8748, adjust ho noodle 7mm up from the bottom and as for the mode! B798, 7.5mm) When the lower end of the magnet @ does not coincide with the upper end of the thread trimming needle down sensor @, loosen the screw ® and move the thread trimming needle down sensor for adjustment When the thread trimming needle down sensor @ is moved in the rotating direction, the needle bar comes up. And when in the reverse direction, the needle bar comes down. Turn on the power switch and stop the machine at the needle down stop postion so that the distance between the top of the needle piate and the lower end of the needle clamp screw is 18~22mm. (As for the model 8798, the distance is 22~ 26mm} Position adjustment for needle up signal 4 Stop the machine at the needle up stop position. The needle point stops 9~ 11mm away from the top of the needie plate for thin and medium materials, and 10~ 12mm for thick materials. {As for the model B798, the needle point stops 11 ~ 14mm away.) ‘When the needle point does not stop propery, loosen the screw @ and move the needle up stop sensor @ for adjustment. When the needle up stop sensor is moved in the rotating direction. the needle bar comes down. And when in the reverse direction, the needle bar comes up. Tighten the screws © and @ to a torque of 6~ 10kg-om. tea9 Solenoids Table (driving transistor No. 8 Q) control PCB spec. transistor No. trimmer solenoid — > resistance of sol. (0) transistor No. wiper solenoid - resistance of sol. (0) reverse solenoid | transistor No. (backtack) reeee resistance of sol. (Q) presser foot transistor No. 06 g(013) lifter solenoid — f~ nneeee] - resistance of sol. (Q) 7 10.0 ‘transistor No, 02(013) nipper solenoid resistance of sol. (Q) ‘condence transistor No, solenoid - - resistance of sol. (@) spreader thread transistor No. trimer solenoid} - resistance of sol.(Q) folder control transistor No. solenoid - resistance of sol. (Q) MIL: Straight lock stitcher with thread trimer. (B737 etc. ) BAST : Single needle basting lock stitcher with thread trimmer. (LS2-8883) OY : Covering stitcher with thread trimer. (FD4-B27X group and FD3-B25X group) #1: FD4-B276, FD3-B256 #2 + FD4-B27T, FO3-B257 =40-Sewing speed of each machine Wotor pul ley (Outer dianeter)‘Synchronizer Mode! DB2-B737 - B748-B774-B791 05mm Neodie up stop — Thin, regular materials: 10—12mm Thick materiats: 10~ 14mm 18~22mm % The synchronizer detects the needle position with two sensors. ‘The thread trimming signal is timed to the needle down position signal and the treadle reverse signal. * When the power Is turned on and the naedie stopped in the down position, the distance between needle plate top and needle set screw bottom should be 18 to 22mm, When the needle is stopped in the up position and the pulley reference fine is within the belt cover reference lines, the dis- tance between needle plate top and needle tip should be 10 to 12mm with thin and regular materials, 10 to 14mm with thick ‘materials. (With Model B748 the needle up stop position is 10~ 14mm) ‘Adjust as follows when necessary. + Turn the power off. Needle up position 1. Stightly loosen the two screws @. Move the set screws @ in the direction of normal pulley movement to raise the needle bar @ stop position. Turn the other way to lower the needle bar. Needle down position 1. Set the treadie to reverse and then release it to neutral. (This is the needle down stop position) 2. The distance between the needle plate top and the needle screw bottom should be 18 ~ 22mm, 2. Loosen screw @ and move the synchronizer @ to adjust. *" Check the needle up stop position, * When the machine pulley is removed once, provide 0.5mm clearance between the pulley bottom and the synchronizer for installation. {improper clearance causes improper machine operation) ‘When the synchronizer is out of order. ‘* Tum off the power switch and disconnect the synchronizer cord, Use the machine with standard function (without thread trimming) until the synchronizer is replaced.CONTROL SYSTEM BLOCK DIAGRAM OF SEWING MACHINE FILTER raverter Ui isy _]eeres Mons surely MotB 1 fie os Lee x. 16 7 paviav) Nay (av) [SOL susely ov =n Pw pw FAULT ov. DET, Ry. OUT OV. FAULT joreration PANEL TREADLE NLT SYNCHRO Ni2eR iE, 5 CONTROL Pc. 8 SaatJ Sov “Hlsare ar trp ena Va Jala. ent A gues nen \s|r-raece en er Vnssnd rv eet tt o[ereee 4 i Eel t a oe afie “te ‘a eee | pltor 1 MBit oa ante! E> uu “ ae aa Bpl< ISuare., oe nae reli “ Bl IT sore faec i LHS SETAE ao aE EL seaei * Bei nese 1 te, ipo aye