buttonfuse multi

Automatic Button Feeding & Wrapping Machines

buttonfuse multi T & S versions

Service manual for:

Serial No. BFM 025 onwards

MMS UK
3 South View Business Centre, Ghyll Royd, Guiseley
Leeds LS20 9PP United Kingdom
T: +44 (0)1943 884 334
E: sales@mmsuk.com
www.mmsuk.com

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Index
1 safety instructions 3
2 introduction 4
2.1 important notes 4
2.2 routine maintenance 4
2.3 installation 5
2.4 thread type 5
3 control system 6
3.1 display / select button 6
3.2 app 10
4 operating instructions 12
4.1 switching on the machine 12
4.2 threading procedure 12
4.3 shank length 13
4.4 number of wraps 13
4.5 wrapping a shank 14
5 settings 15
5 removing the covers 15
5.1 button deflector and clutch 16
5.2 heater 17
5.3 hooks 20
5.4 flag 20
Step by step setting procedure 24
6 6.1 valves 25
6.2 pressure control
7 electrics 26
7.1 supply voltage 26
7.2 seal cylinder reed switch 26
7.3 down reed switch 26
7.4 up reed switch 26
7.5 clockwise reed switch 26
7.6 anticlockwise reed switch 26
7.7 fuse 27
7.8 heating element 27
7.9 thermal switch 27
7.91 installing new software 27
8 trouble digest 28
error messages 30
9 Parts List
9.1 Main Chassis Assembly 31
9.2 Deflector and Fork Assembly 32
9.3 Disc Assembly 33
9.4 Thread Detector, Start Switch, Disc Stop 34
9.5 Front Shield and Chute 35
9.6 Wrapping Head Assembly 36
9.7 Hook Assembly 37
9.8 Magazine Tower – T version 38
9.9 Tower – S version 39
9.10 Electronic and Pneumatic Components 40

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7 Safety Instructions

1. Do not operate the machine without all safety guards and doors in place.

2. This machine must only be operated by persons who have been fully instructed to do
so.

3. This machine must only be used for the purpose it was designed for.

4. When carrying out any maintenance work or exchanging any parts ensure that the
electricity and air supply to the machine are disconnected wherever possible. In certain
cases it is helpful to check parts or settings with the power on – TAKE CARE NOT TO
BURN YOURSELF ON THE HEATING FORK – IT IS VERY HOT !

5. Maintenance work must only be carried out by suitably trained and qualified people.

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8 Introduction

8.1 Important notes

To avoid any possible damage to the machine or trouble with it, the following instructions
must be followed:

1. Before connecting the machine to the electrical supply ensure that the supply voltage is
single phase between 100 and 240 v.
2. Before connecting the machine to the pneumatic supply, ensure that the air is free of
excess water and is able to supply at least 1 metre cubed/hour (0.7 cfm) at 5 bar minimum.
3. Check that all parts appear to be in good condition.
4. Check that all necessary parts are lubricated.
.

8.2 Routine Maintenance

In order for the machine to work efficiently the heating fork requires regular cleaning. The
frequency of this depends upon the number of buttons wrapped per day but as a guide this
should be done every 10,000 cycles (approximately once a week). To do this disconnect
the power from the machine and remove the top cover and then the front stainless steel
cover. The heating fork will still be hot but this will aid the cleaning process TAKE CARE
NOT TO BURN YOURSELF! Clean up the front and rear faces of the fork and also the
internal faces of the bonding nose. The residue can be scraped off using a metal object
such as a small screwdriver.

The only parts that require lubrication are:

Linear bearings that carry the heater and the wrapping assembly - Lightly oil once every
two months.

The only other routine maintenance that should be required is cleaning. Every 10,000
cycles (or every week) remove top and front covers and remove any excess thread waste
pieces that may not have been removed by the venturi. At this time clean all working parts
and check their condition. Any worn parts should be replaced immediately.

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2.3 Installation
The MK22 machine is designed to be used either as a freestanding unit or as a tandem
installation incorporated next to a button sewing machine.

Freestanding installation – place the machine onto the table in the desired position.
Disconnect the power from the machine and remove the top cover. Locate the two holes
in the base of the machine and secure through these.
To install the cone holder remove the top cover first take off the front cover then slide the
two side covers forward and remove them. The screws securing the top cover can then
be accessed (just under the top cover on either side) -loosen these to remove the top
cover. Secure the cone holder with the screw through the frame.

2.4 Thread type

MMS UK button securing machines have been developed to use heat seal TF elastomeric
thread. So that the optimum speed, button security and efficiency is achieved during each
cycle it is recommended that the original MMS buttonfuse TF thread is used. The use of
other thread may cause performance problems and damage to components. For these
reasons the warranty may be void if non MMS thread is used.

Heat sealed button security

The shank of the button attachment is the most stressed part of the garment and therefore
to prevent button loss this shank must be reinforced.
TF (TF = thermofusion) thread is specially designed for button wrapping with securing
effect. The unique elastomeric gripping force and the heat sealing are the key to button
loss prevention as the thread permanently squeezes the attaching threads. The button is
secured and the slim button shank prevents the button holes from bulging and the button
has a clean finish and tail free shank

MMS buttonfuse TF thread

Strong heat - sealing layer
Coloured component
Flexible elastane core
• Bonds wrapping threads together
• Eliminates loose ends and tails
• Prevents loosening during use
• Increases overall strength
• No colour fading due to washing
• 72 colours
• High flexibility
• Unmatched grip
• Resistant to washing fatigue
• High internal strength
• 330% elasticity

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3 Control System
The control system has been specifically designed for the MK22 and therefore provides a
versatile method of selecting the desired variables in order to achieve a perfectly wrapped
shank..

3.1 Display / select button and program button

The control system has been specifically designed for the buttonfuse multi and therefore
provides a versatile method of selecting the desired variables in order to achieve a perfectly
wrapped shank..
The machine is fitted with a small touch screen display which is also a button for activating
the automatic threading and selecting a number of other options. In the run mode the larger
number on the display indicates the number of wraps. The two digit number on the bottom
line indicates the number of buttons in the magazine and the larger number on the bottom
line indicates the batch counter. To reset the magazine counter press screen once quickly.
To access other options the program access button (this is fitted on the right hand side of
the machine just underneath the air on / off switch), the screen will change from light blue
to light green. To scroll between the options press the screen. Once the desired screen is
displayed then to make an adjustment press the program button once – the screen colour
will change to pink. Press the screen to change the value then press the program button to
save the value.

The machine is fitted with a small touch screen display which is also a button for threading
the machine or accessing various settings as follows :

08 01316

At the bottom left of the display is the number of wraps and on the right is the batch counter.

After pressing the program button (on the side of the machine) this screen is displayed
which shows the machine type, the software version (3.7 C) and the machine number for
APP connection.

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BFM
V3.7 C
MMS 345

With this screen displayed then pressing the screen will select the next screen and repeated
pressing of the screen will access other options. At any point pressing the program button
will return to the home screen.

BC This screen shows the number of wraps set

and the batch counter value
07 01201 Press the screen to reset the batch counter.

Press the program button when this is

displayed and then press the screen
again so that the wrap number shows.
? Pressing the screen will increase the wrap
number. To decrease the wrap number
press the program button then the screen.

Safe mode ensures that the disc cannot

SAFE MODE
rotate if a button is not present in the start
position. The machine will wait until the
button activates the start switch. With this
ON screen displayed press the program
switch and the screen will turn orange.
Press the screen to switch on or off.

Tower feed is the automatic device that

TOWER FEED pushes the buttons down into the start
position. This can be turned off if manual
ON feed is desired. With the screen displayed
press the program button and the screen
will turn orange. Press the screen to
switch the feed on or off.

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This screen shows the seal time. 01

is 0.1 seconds. Press the program
ST button then press the screen to
01 increase the value. To decrease the
value press the program button then
press the screen.

This screen shows the heating fork

temperature setting. Press the
T
85
program button then increase the
value by pressing the screen. To
decrease the value press the program
button then press the screen.

This screen shows the status of

the thread break detector (if
fitted). To alter the status press
OFF the program button then press the
screen to toggle between on and
off

This screen shows the number of cycles

CREDIT
set on the machine before it requires
0498799
TOTAL recalibration. The top number is the pre-
0001201 set credit number and the lower number
is the number of cycles run. Contact
MMS to reset the credit and update by
connecting to the machine using the
‘MMS controller’ APP.

Number of wraps

Pressing the program access button once will activate the program menu. The screen will
turn light green and the first option of a question mark next to the button shank image is
displayed. If the program button is now pressed it will turn an orange colour which indicates
that it the wrap number can now be altered. If the screen is pressed then the number will
be reduced but if the program button is quickly pressed and then the screen is pressed the
wrap number will increase. Once the desired wrap number is reached then pressing the
program access button for 2 seconds will return the machine to the run mode.

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Thread detector

The next available option is the thread break detector. This can be switched on or off by
first pressing the program access button then pressing the display switch once. The screen
should now display the thread break symbol. Now press the program button quickly and
the screen will turn orange. Pressing the screen again will switched the detector on or off.
Press the program button for 2 seconds to return to the run menu.

Batch counter

The number displayed in lower right hand corner of the screen is the batch counter. This
can be reset by pressing the program button on the side of the machine then pressing the
screen until BC is displayed. The program button should then be pressed one more time
so that the screen changes to an orange colour then the counter can be reset by pressing
the screen. To return to the run menu press and hold the program button for 2 seconds.

Main counter

A main counter can be found by pressing the program access button and then pressing the
display button twice so that ‘C’ is displayed with the number underneath. This is the number
of buttons that the machine has wrapped since new and it cannot be reset. Press the
program button to return to the run menu.

Credit

The status of the cycle credit limit or weekly lease status (if relevant) can be found by
pressing the program access button and then pressing the display button three times. Press
the program button to return to the run menu. Note – if credit is activated and is nearing run
out cycle or time period then the screen will turn pink to indicate that more credit is required.

System check

A system check menu can be found by pressing the program access button and then
pressing the display button three times until the nut and bolt symbol is displayed. At the
time if the program button is pressed then the screen will display the input first few input
states. Pressing the display again will access the next few inputs and again the next few.
Press and hold the program button to return to the run state.

Disengage all

The program access button can be used to disengage the disc feed by pressing and holding
it for 2 seconds (dark blue screen will be displayed). This may be necessary if the machine
has become jammed with fabric etc. Once the machine is freed then the disc should be
positioned with the ‘V’ aligned with the slot in the magazine then the program button should
be pressed once again to return to the run menu.

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Error – if an error occurs then the screen will turn red and the error number will be
displayed. Check what has caused the error (air off, shank too short etc.) then press the
screen. If the error is more serious it will remain on the display and will require the program
button to be pressed.

3.2 App

The machine is capable of connecting to a mobile phone or tablet via a blue tooth
connection.
To connect first download the MMS controller app from the app store onto the device. Once
this is loaded turn on the machine and then press the ‘connect’ button on the app home
screen. A list of available blue tooth devices will then be displayed from which the relevant
machine should be selected. Each device is identified with a number and the correct one
can be selected by matching the last three digits with the number on the label at the back
of the machine. The device and machine will then connect automatically and the home
screen will be displayed.

On the home screen the following is displayed :

Button – next to this is a number and scrolling either up or down will select a different wrap
number.

Temperature gauge – this indicates the current temperature of the heating fork in the
machine. Once the needle reaches the green section the machine will run.

Numerical display top left of screen – this is an indication of the cycle time. After a button
has been wrapped the actual cycle time will be displayed here. This time will alter
depending upon the number of wraps and the heating time.

Numerical display top right of screen – this is the batch counter. It counts every cycle and
can be reset simply by touching it.

Buttons 1 to 3 -These buttons are used to select any of the three available preset programs.

Three dots at top right of screen – pressing these will access the following functions:

Diagnostics - pressing this will access the MMS diagnostics menu. The initial screen that
appear shows a graphic of the heating fork mechanism. Touching the screen in the various
positions of the cylinders will cause the movement to take place. Swiping the screen across
will access other diagnostics pages.

Programs – pressing this will access the list of the 3 programs. Touching on any of the
programs will allow changing of the wrap value.

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Settings – pressing this will access the following settings –

Heater seal time – this can be varied from 0.5 to 1 second (0.6 is standard)

Lock screen – ticking this box will lock the machine screen so that it cannot be tampered with.

Counter – this is the total machine cycle counter (non resettable).

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4 Operating Instructions

4.0 Switching on The Machine

To switch on the machine first turn on the air supply switch. This is the blue headed twist
switch mounted on the right hand side machine

The power should then be switched on by pressing the switch that is mounted on the back
face of the machine. The machine will then be in . warm up mode and the display flash
between blue and red to indicate that the warming up process is taking place (App will
show the temperature gauge needle moving).
The machine will not run until it has warmed up to the required running temperature which
is indicated by the screen turning to solid green. For maintenance purposes the machine
can be run before the optimum temperature is reached by pressing the display button.

4.1 Threading Procedure

Before wrapping a button shank for the first time it is necessary to check that the machine
is correctly threaded up and also that the desired wrap number is selected
.
Insert the cone of thread in the holder and pass the end through the smoothing device.
Take the end of the thread and hold it with enough spare between the hand and the end to
comfortably pass from the back of the machine to the front. Press the display switch and
hold this down whilst at the same time floating the end of the thread over the thread entry
nipple. Allow the thread to be sucked into the machine and blown horizontally out of the
front of the machine. Catch the thread and release the screen. Pull the loose end of thread
until it snaps off.
To change the thread take hold of the thread where it enter the entry nipple and then press
and hold down the display button. Pull the thread out.

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4.3 Shank Length

In order to achieve a consistently high standard of button shank wrapping it is essential

that the shank length is of sufficient length as failure to achieve this will reduce the yield
per cone and render the wrapping less effective in securing the button. This is a simple
setting on most button attaching machines.

With reference to the above diagram the minimum shank lengths before wrapping are as
follows :

Shirt, blouse 2.5mm

Casual trousers, trouser, jacket front 3mm
coat 4mm

4.4 Number of wraps

The number of wraps is a variable that can be adjusted to suit the design of the garment
or personal taste. The fewer the wraps the slimmer the shank and the more wraps the
thicker the shank. There are two methods of changing the wrap number.

Changing wrap number

Pressing the program access button once will activate the program menu. The screen will
turn light green and the first option of a question mark next to the button shank image is
displayed. If the screen is now pressed it will turn an orange colour which indicates that it
the wrap number can now be altered. If the screen is pressed then the number will be
reduced but if the magazine switch lever (black plastic) is lifted and then the screen is
pressed the wrap number will increase. Once the desired wrap number is reached then
pressing the program access button will return the machine to the run mode.

Changing the wrap number from the APP.

With a phone or tablet paired with the machine the wrap number can be changed by
sliding up or down on the number which is displayed on the home screen. The preset
values of the three programs can be set through the program tab at the top of the screen.

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Once the values as set in the programs, pressing P1, P2 or P3 on the home screen will
select the different wrap value.

Garment type Shank Length Number of Wraps Button Type

(before wrapping)
shirt 2.5mm 7 - 10
Trouser / jacket 3mm 14 - 18
coat 4mm 20 - 30

4.5 Wrapping a shank

Button dimensions

Maximum diameter = 26mm

Maximum thickness = 6mm

Single button

Once the machine has been threaded and the number of wraps has been selected a button
can be wrapped. Lower the button into the magazine slot. Lower the button into the disc
‘V’ until the machine starts the wrapping takes the button and begins the wrapping cycle.
After the shank is wrapped the button will be ejected out of the bottom of the machine.

Multiple buttons

The MK 22 is designed to allow the operator to load the magazine with unwrapped buttons
whilst it is wrapping. Any number of buttons can be loaded into the magazine as long as
they do not hinder the switch magazine counting switch. If a miscount has occurred and
the last button remains in the machine this can be ejected by pressing the program switch
once.

Shirt buttons

The Mk 22 is particularly suited to wrapping the buttons on shirt fronts and the complete
line of buttons can be loaded into the magazine. Note that the pitch between the buttons
must not be less than 65mm otherwise a jam will occur.

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5 Settings

Removing the covers

For some of the maintenance tasks it is necessary to remove one or more of the main
machine covers. Before this is done power should be disconnected from the machine
and it should be left for at least 10 minutes to for the heater to cool down.
To remove all covers first take off the front cover then slide the two side covers forward
and remove them. The screws securing the top cover can then be accessed (just
under the top cover on either side) -loosen these to remove the top cover. Secure the
cone holder with the screw through the frame

Caution – some settings need to carried out with the power on – take care as the
heating fork is very hot!

The easiest way to check the machine settings is via the diagnostics app on a mobile
phone or tablet. Using this each component can be moved into its second position. If
the app is not used then the air and power need to be switched off and the
components need to be moved into their second position by hand.

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5.1 Button deflector and clutch

Adjust rotation of disc here so that

the v lines up exactly with deflector
nose and magazine slot when
against the 2 hex screw stops.

With clutch nose out (engaged)

and rotated hard against one of
the hex bolt stops
This deflector nose must be
central in V of disc (slight
movement of disc up and down).
Adjust here

2.5mm gap
Adjust here

These settings are important as if there is any resistance as the deflector enters
the disc then error 28 will show.

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5.2 Heater

1.5mm adjust here

3mm gap when fork open -adjust here

Low edge of fork slot to be level with low

edge of V. Adjust by loosening these screws

0.1mm gap between

fork and disc adjust here

The heating fork settings can be checked either via the diagnostics in the APP or using
the manual override buttons on the pneumatic valves.

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5.3 Hooks
In order for the catcher hooks to work efficiently they must be in perfect condition,
free from any sharp edges and be set so that they make a good clamping contact with
the stop post. The hooks must be highly polished. If the hooks are damaged and a good
clamping contact on the thread cannot be achieved then they must be replaced.

The two lock nuts on the hook cylinder piston clamp the hook. These must be adjusted
together to ensure that when they are clamped onto the hook the cylinder movement is
stopped 1mm short of the end of its ‘in’ stroke. This will ensure that the thread is clamped
against the post.
To check that the hook is working perfectly place a piece of thread in it and close it
against the stop (either by hand with the air off or via the APP). The thread should be
100% clamped and not slip when pulled. If it does slip then try readjusting it or replacing
it.

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5.3 Hooks
Thread tube must be clear
of hook, hook post and
inside face of disc

Inside face of hook to be

set level to inside face of
disc. Adjust on piston rod

The left hand hook should be raised to the top position and pulled forward through the
slot in the disc. With the disc in its parked position (v lined up with magazine slot) there
should be 1mm clearance between the top of the hook and the top of the lost in the disc.
Adjustment is made by loosening the single screw clamping the cylinder to the bracket
and lifting the cylinder up or down. The right hand hook should not touch the disc when
it is in its top position.

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5.4 Flag

In order for the machine to be able to count the number of wraps and stop in the correct
position, it is fitted with a photocell and flag to provide rotational information to the
controller. This flag must be set correctly so that the machine hooks can catch the thread
reliably.

To check the stopping position press and hold the screen to thread the machine and
check that the thread tube stops directly behind the hole in the front plate. If it does not
then remove the top cover and locate the aluminium flag which is mounted on the centre
tube. Loosen the grub screw and then hold the flag whilst rotating the centre tube until the
thread guide is directly behind the hole. Ensure that the flag is pressing the bearing and
the centre tube is pushed back against its collar (to prevent axial movement of the centre
tube) and then tighten the grub screw. Replace the cover and run the machine to check
the setting. Fine adjustment to the flag setting may be required to achieve this correct
setting.

5.5 Motor/Gearhead/Encoder
The motor, gearhead and encoder should give reliable service if all conditions are correct.
Should any part become faulty then the complete motor unit including the bracket and
pulley must be replaced. To do this first remove the top cover then undo the two screws
which hold the motor bracket to the whipping carriage. Unplug the motor and encoder wires
from the circuit board and remove the motor assembly. Reverse this procedure in order to
fit the new motor/gearhead assembly. After reassembly of the machine check that the
motor is rotating the correct way. When viewed from the front of the machine the thread
tube should rotate clockwise. If it does not then reverse the motor wires where they connect
to the circuit board.

5.6 Belt Tension

The drive belt should be tensioned so that it has a between 2 and 5mm of free play at mid
distance between the two pulleys. Adjustment can be made by loosening the two 4mm
screws that hold the motor bracket in place and rotating it in its slot.

5.7 Tension Device

The tension device fitted to the MK22 is a robust unit that should give trouble free
service. To ensure this good service the parts of the assembly must be kept clean and
free from any rough edges or faces.
Tension Adjustment
The tension should be set so that it gives a nice tight wrap but overtightening it will cause
thread break. If the tension is too little then wrapping will be too loose and tails may be
left.

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Note – too much tension will result in thread breakage, too little tension will result
in tails!

5.8 Thread load blower

The blower is mounted on the back of the whipping carriage its purpose being to blow the
thread though the thread tube when threading the machine up. To work efficiently it must
be clean and free from any sharp edges inside.
Occasionally the cavity behind the thread tube or the actual thread tube may become
clogged with thread (especially if the machine is run with thread in but no button). To clear
it out remove the rear cover and locate the blower plate which is fastened by 3 screws
behind the centre tube. Loosen these 3 screws and remove the this for cleaning.

5.9 Waste ejection vacuum

The Mk.22 is fitted with two vacuum tubes that suck the waste and eject it out of the back
of the machine. Each tube should be set so that it is situated just behind the hook (when
closed) but is not touching. It may be necessary to slightly bend the tubes to achieve this.
The tubes should be free of any sharp edges and not blocked.

5.91 Thread Tube

The thread tube must be in good condition without bends and set the correct distance
from the disc. If it is bent out of shape it may be possible to bend it to its original shape.
If it is beyond repair then it must be replaced. The front of the thread tube should be
clear of the disc by 0.5mm. This adjustment can be made by loosening the carriage or
by just loosening the thread tube clamp. Also check that when the hooks are forward
and open the thread tube passes between the open hook and the post without touching.
It may be necessary to bend the thread tube to achieve this.

5.92 Magazine

The button feed magazine has adjustments for the button diameter and thickness.

Button diameter
To set the diameter plates loosen the M3 screws at the front of the tower which lock the
side adjuster plates. Set these so that they are equal about the centre slot and they
allow at least 1mm of play at the side of the button.

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Button should
slide freely
through

Button thickness
To adjust for the thickness of the button loosen the M4 socket screw which clamps the
curved adjuster arm located at the rear of the tower. Ensure that there is free movement
of the button up and down the magazine.

Magazine switch
The black plastic switch lever at the top of the magazine should be set so that the button
must be counted as it enters the magazine. If this needs adjusting loosen the two socket
button head screws on top of the magazine and move the switch backwards or
forwards.

5.93 Disc rotation

The disc is factory set to rotate exactly 90 degrees and park with the V directly under
the slot in the magazine. If adjustment is required then it can be achieved with the two
M4 hexagon head screws located above the disc shaft towards the rear of the machine.
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This setting is easy to check with the air and power off. Pull the clutch peg into the disc
and then rotate the clutch assembly by hand to check the V lines up perfectly with the
magazine in both positions.

5.94 Button Deflector

The Mk 22 is fitted with a deflector that enters the V to place the button in the correct
position prior to wrapping. This deflector nose must be set so that it does not bind on the
edges of the V as it enters. There should be 2.5mm gap between the end of the
deflector and the bottom of the V. This can be set on the bracket that the cylinder piston
engages on.

5.95 Start Switch

The height of the start switch must be adjusted to suit the diameter of the buttons being
wrapped. The start switch must be triggered 1mm before the button reaches the bottom
of the V in the disc.

Loosen and
make
adjustment to
suit button
diameter

5.96 Input test

The input test can be accessed by pressing the program button then repeatedly
pressing the screen until the IO test screen appears. Pressing the program button will
access the input list screen. Pressing the screen will skip through the other inputs.

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MK 22 step by step setting sequence

1. Disc face to face alignment - the magazine front face must be set so that it is 0.1mm in
front of the front face of the disc. The magazine is clamped in position with the 2 x M4
screws on each side of it however two locating plates mounted under the top frame
plate determine the position. To adjust the magazine position these need loosening (2
x m4 screws). Once the magazine is set these can be retightened for future location if
the magazine is removed.
2. Disk rotation – using the 2 hexagon head stop screws ensure that the V in disc is
perfectly aligned when rotated in both directions.
3. Button deflector – adjust the position of this so that it moves into the V without causing
any rotation of the disc when the disc is at both stops. This nose must travel exactly to
within 2.5mm from the bottom of the V. This is adjusted on the cylinder piston bracket.
4. Hooks – with the hook bracket up and the hooks extended adjust the position of the
main bracket (rod end) so that the back face of the hook is level with the back face of
the disc. With the hook open the height can be adjusted by adjusting the cylinder
position.
5. Thread tube – set this so that when both hooks are extended its nose passes inside
the open hooks but does not touch them or the face of the disc.
6. Heating fork – Set this so there is approximately 0.1mm gap between it and the rear
face of the disc (2 x M4 screw). The height should be adjusted so the top edge of the
fork leg is level with the lower edge of the V. The bonding position should be set so
that there is 1mm of gap at the bottom of the V to ensure some pressure is maintained
on the shank (adjust 2 nuts on the fork moving cylinder).
7. Magazine feed nose – this needs to be set so that the smallest diameter button will
activate the start switch when this is in its upper position. Slide a small button into the
magazine and, with the air off, push it down with the nose. This nose should stop
exactly at the point the switch has been activated by the button. If any adjustment is
needed this is done by adjusting the rod eye on the end of the up/down cylinder. Once
this is done then the nose can be slid to its top position where it should be opened to
allow more buttons to fall through. This open position can be adjusted by moving the
cam plate up or down. The nose should be clear of the front plate by 1mm to prevent
scraping and this can be adjusted with the hexagon M4 stop screw.

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6 Pneumatics
The machine is equipped with state of the art pneumatics which should prove to be
extremely reliable under normal conditions. To achieve this reliability the supply to the
machine should be a minimum of 5 bar. and a maximum of 10 bar. This air supply should
be relatively free of moisture. A filter regulator is mounted inside the machine which will
drain off a certain amount of excess moisture. Note – the filter cannot drain large amounts
of water and using air supply that is too wet will damage the machine.

6.1 Valves
The MK22 is fitted with 10 spring solenoid valves. They are mounted inside the machine
to the right hand side. As viewed from the front of the machine the valves functions are as
follows :

Valve 10 = left hook

Valve 9 = right hook
Valve 8 = hook up / down
Valve 7 = thread up blower
Valve 6 = heater in
Valve 5 = heater clamp
Valve 4 = clutch engage
Valve 3 = disc turn
Valve 2 = deflector nose
Valve 1 (closest to the front of the machine) = magazine feed

Each valve can be manually overridden by switching the plastic cover on the valve to the
left to reveal A B then pressing the blue button on the specific valve (ensure that the
electrical power is switched off when carrying out this test).

6.2 Air Pressure Control

The main air pressure is pre-set in the factory to 5 bar. This can be checked by viewing
the pressure gauge on the back of the machine. If it is incorrect then first turn off the
electrical power to the machine and leave it until the heating element has cooled down.
Remove the top machine cover and locate the pressure regulator. Lift up the black plastic
knob and turn it until the 5 bar is showing on the gauge. Inside the machine is a second
pressure regulator with controls the power of the magazine button feed. This should be set
at the lowest pressure required to feed the button into the start position.

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7 Electric’s

7.1 Supply Voltage

The supply voltage should be between 100 and 240 volts (50-60Hz) single phase. The
machine is equipped with a high quality in line filter to reduce any effect from electrical
spikes. This filter however cannot cope with extreme surges therefore the supply to the
machine should be relatively “clean”. It is also important that the ground is connected.

7.2 Reed Switches

Seal cylinder

So that the thread is bonded for the exact amount of time that is programmed, a reed
switch is fitted to the seal cylinder. This switch should be positioned on the cylinder so
that it switches at the end of its stroke (red LED lit).

Hook down

A reed switch is fitted at the lower end of the pneumatic cylinder which moves the hook
holder up and down. This switch gives the signal to the controller to open the hooks so that
the thread is ejected. It should be mounted so that the red LED lights when the hooks reach
there bottom position.

Hook up

A reed switch is fitted at the upper end of the pneumatic cylinder which moves the hook
holder up and down. The switch should be mounted onto the cylinder so that the red LED
lights up when the hooks are in the top position.

Clockwise disc rotation

A reed switch is fitted to the extended end of the rotating cylinder to signal when the disc
has reached its furthest clockwise position. It is important that this reed switch is set to
signal within 1mm of the end of the cylinder stroke so that the ‘V’ on the disc is in the
correct position before the thread clamp enters the ‘V’.

Anticlockwise disc rotation

A reed switch is fitted to the retracted end (closest to the right of the machine) of the
rotating cylinder to signal when the disc has returned to its home position to collect the
next button.

Deflector

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To signal when the deflector is in position a reed switch is mounted on the cylinder which
should light up when the deflector comes within 2mm of its left hand position.

Clutch nose

When the clutch nose is out (towards the front of machine) the reed switch should be lit.

7.3 Fuse
The main voltage fuse is situated under a flap in the filter (where the power lead plugs into
the machine). The rating of this fuse is 2 amp.

7.4 Heating Element

The heating element has a life of approximately one year. This can be less if the machine
is run for 2 or 3 shifts per day or the power is left on overnight. To change the element turn
off the power to the machine and allow it to cool (10 minutes). Remove the machine covers
to gain access to the element. Loosen the screws in the terminal block that hold the
element harness and cut of the tie wraps that secure it. With all of the securing tie wraps
removed slide out the heating element. Reverse this procedure to fit a new element.

7.5 Thermal Sensor

A thermal sensor is fastened to the insulated heating fork holder. This sensor is constantly
checked by the control system to ensure that the temperature of the heating element
remains above the recommended sealing temperature. If it requires changing then first
turn off the power and wait for the element to cool for at least 10 minutes. Then remove
the right hand front cover to gain access to the fork assembly. Loosen the screws in the
terminal block that hold the switch harness and cut of the tie wraps that secure it. Unscrew
the sensor from the insulator and remove it. Replace it with a new assembly and reverse
the procedure for reassembly.

7.91 Installing New Software

New versions of software are developed to provide improvements to existing features, new
features or correction of software errors. These from time to time can be installed by the
local dealer.

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8 Trouble Digest

Fault Cause Solution

Machine is not running No electrical power to machine. Check supply and main fuse.
when button presses start
switch Faulty power supply. Check 24v power supply.

Faulty start switch. Check start switch via. Input

check.
Faulty motor or motor supply. Check 24v motor supply and
then motor.
Jammed gearbox, belt etc. Check for free spinning of
mechanism
Faulty photocell. Check photocell and its
connections.

Hooks are not catching Motor stopping position incorrect Check flag settings (section 5)
thread
Hooks damaged or set
incorrectly. Check hook settings (section 5)

Thread breaks during Thread supply not free. Check cone and routing of
wrapping. thread.
Sharp edges on the tube rim or Remove any sharp edges and
hooks. polish.
Tension too high. Reduce tension.

Thread not caught by the Stopping position of thread tube Adjust the flag (section 5)
hooks at the end of the incorrect.
cycle
Hooks not clamping the thread Check hook condition and
correctly. setting (section 5)

Waste thread not ejecting Clean hooks, check down switch

position and venturi performance
/setting (section 5)

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Fault Cause Solution

Thread not bonding. Heating fork setting incorrect. Check setting and readjust (section
5).
Heating fork dirty or worn. Clean fork/replace if worn.

Hook assembly travelling down Readjust (section 5).

too quickly.

Thread wrapping Thread supply not free. Check cone and routing of thread.
tension not
satisfactory or button Shank too short causing Increase length of shank on button
not wrapped. wrapping to be around the sewing machine and check
button rather than shank. stretcher and thread clamp. Ensure
that the garment is resting on the
table rather than hanging.

Tails left on the shank Hook not clamping thread Reset or replace hook. (section 5).
effectively.

Hook assembly down speed Adjust flow controls.

incorrect.

Heating fork set too far from Adjust fork position (section 5).
disc.

Heating fork not hot enough Increase temperature

Bonding time too short Increase bonding time

Shirt dragged into the Shanks too short
machine Magazine feed nose coming
down too low
Magazine feed nose too much
pressure
Increase shank length to 2.5mm
Adjust so it just presses button onto
start switch
Decrease air pressure to cylinder –
regulator above valves

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Error Messages – MK.22

Error Cause Parts or settings to check

No.
1 No signal from Photocell, photocell wiring, belt, pulleys, free running of motor.
photocell
2 No signal from Sensor, sensor wiring, heating element, element wiring.
temperature sensor
3 No signal from seal Function and position of the reed switch (LED should be ‘on’
cylinder reed switch when the fork is to the left), wiring, free movement of seal
mechanism, flag setting, setting of top flow control on the , air
supply.
4 No signal from hook up Reed switch at top of hook up cylinder, wiring, free movement of
reed switch hook cylinder, setting of hook assembly flow control, air supply.
6 Not receiving the hook The reed switch at the rear end of the hook assembly cylinder and
holder down signal it’s wiring, free movement of the hook assembly, setting on hook
assembly top flow control, air supply.
7 hook assembly down Position of the down reed switch, the wiring of the reed switch,
reed switch is closed free movement of the assembly, air supply.
when it should not be
8 seal cylinder switch is The reed switch and it’s wiring, the free movement of the seal
on when it should be off assembly, setting on the seal cylinder lower flow control.
9 Thread tube not The free running of the thread into the machine, free movement of
reaching rest position the thread tube, motor and wiring, pulley wheels and belt.
10 Touch screen fault Make sure nothing is touching the screen, wiring or circuit board
fault
11 Start lever jammed Free movement of the start switch lever, setting of the start switch,
down start switch wiring.
14 Thread tube jammed The free running of the thread into the machine, free movement of
the thread tube, motor and wiring, pulley wheels and belt.
17 Motor jammed during Free running of centre tube. Ensure tension device or thread tube
first revolution are not touching anything. Motor should be free
19 Motor jam while Free running of centre tube. Ensure tension device or thread tube
wrapping short shank are not touching anything. Motor should be free
20 Motor jam while Free running of centre tube. Ensure tension device or thread tube
decelerating are not touching anything.
21 Motor jam when either Check thread tube is not touching the hooks when they are out.
hook is set Hooks may be loose or their top position may be too low (adjust on
main cylinder). Thread tube may need bending out.
22 Motor jammed at the Free running of the centre shaft. Check that the hooks do not
time the heating fork touch the thread tube. Check that the speed restrictors are present
moves to button in the air tubes to the heating fork cylinder.
23 Motor jammed Free running of centre tube. Ensure tension device or thread tube
are not touching anything. Motor should be free
24 Rotate cylinder Disc stuck in clockwise rotation position
25 Rotate cylinder Disc stuck in anticlockwise rotation position
26 Deflector jam The deflector is not able to move into disc freely. Adjust it’s
position so it does not foul against edge of V.
27 Deflector stuck in Check deflector adjustment.
28 Clutch nose jam Check deflector not touching edge of V, free movement of nose

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9.1 Main Chassis Assembly

ITEM PART NO. DESCRIPTION QTY ITEM PART NO. DESCRIPTION QTY
1 135432 Cover RH 1 9 135431 Rear cover 1
2 135500 Frame 1 10 135919 Trunnion 16 1
3 135751 Magnet 2 11 134672 Disc rotate cylinder 1
4 135644 Magnet bracket 2 12 10025 Flow control out 4
5 135327 Front cover 1 13 102327 Rod end bearing 6 1
6 135433 Cover LH 1 14 109710 Trunnion 1
7 135430 Top cover 1 15 134673 Magazine feed cylinder 1
8 135761 Cone holder 1 16 102325 Rod end bearing 4 1

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9.2 Deflector and Fork Assembly

ITEM PART NO. DESCRIPTION QTY ITEM PART NO. DESCRIPTION QTY
1 135700 Fork main bracket 1 13 135756 Insulator nut plate 1
2 134520 Linear double bearing 1 14 10025 Flow control out 2
3 135707 Fork moving bracket 1 15 133530 Cylinder – heating fork 1
4 135706 Fork intermediate bracket 1 16 134205 Reed switch 2
5 109815 Clevis assembly 1 17 135305 Deflector fork main bracket 1
6 109729 Barb elbow 4 18 134521 Linear bearing double 1
7 133535 Thread clamp cylinder 1 19 134675 Deflector cylinder 1
8 133277 Temperature harness 1 20 135103 Deflector cylinder bracket 1
9 135928 Heating fork insulator 1 21 135904 Deflector 1
10 135776 Heating element 1 22 135102 Deflector moving bracket 1
11 135927 Heating fork assembly 1 23 133169 Nut – M5 1
12 135712 Insulator spacer 1 24 133178 Shoulder nut – M5 1

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9.3 Disc Assembly

ITEM PART NO. DESCRIPTION QTY ITEM PART NO. DESCRIPTION QTY
1 135124 Bearing assembly 2 7 134674 Clutch nose cylinder 1
2 135416 Rear spacer 1 8 135413 Clutch nose guide 1
3 135551 Shaft clamp 1 9 135409 Clutch nose 1
4 135125 Disc shaft 1 10 135407 Clutch assembly 1
5 135115 Spider assembly 1 11 135410 Disc engage cam assembly 1
6 135902 Disc 1 12 135550 Cam spacer 1

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9.4 Thread Detector / Start Switch / Disc Stop

ITEM PART NO. DESCRIPTION QTY ITEM PART NO. DESCRIPTION QTY
1 135656 Thread tension assembly 1 6 109882 Start switch harness 1
2 109315 Photocell 1 7 135531 Clutch stop plate assembly 1
3 135607 Start switch lever 1 8 134141 Entry nipple bracket 1
4 135606 Start switch plate 1 9 102150 Entry nipple 1
5 135658 Start switch bracket 1

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9.5 Front Shield and Chute

ITEM PART NO. DESCRIPTION QTY ITEM PART NO. DESCRIPTION QTY
1 135163 Front plate bracket 1 4 135162 Button chute 1
2 135746 Mounting bracket spacer 1 5 135139 Button chute bracket 1
3 135908 Front plate assembly 1 6 135906 Disc cover plate 1

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9.6 Wrapping Head Assembly

ITEM PART NO. DESCRIPTION QTY ITEM PART NO. DESCRIPTION QTY
1 109722 Motor pulley 1 9 102350 Photocell 1
2 109725 Belt 1 10 109543 Front bearing assembly 1
3 134516 Motor bracket 1 11 109618 Flag 1
4 109624 Motor 1 12 101750 Pulley wheel - small 1
5 134131 Carriage main bracket 1 13 109541 Rear bearing assembly 1
6 134263 Centre tube 1 14 102155 Nipple fitting 1
7 135931 Thread tube 1 15 109729 Barb elbow 1
8 135800 Thread tube clamp asm 1

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9.7 Hook Assembly

ITEM PART NO. DESCRIPTION QTY ITEM PART NO. DESCRIPTION QTY
1 135913 Cylinder bracket 1 12 135803 Pin post 2
2 109790 Trunnion 6 1 13 135808 Hook LH 1
3 10025 Flow control 2 14 135802 Hook RH 1
4 109768 Main hook cylinder 1 15 135801 Hook moving bracket 1
5 102035 Reed switch 2 16 135806 Venturi bracket 1
6 135805 Rod end bracket 1 17 133534 Venturi clamp 1
7 102370 Bronze bush 6 2 18 134629 Venturi LH 1
8 135804 Hook fixed bracket 1 19 134621 Venturi RH 1
9 135925 Pivot pin 1 20 102327 Rod end 6 1
10 10000 Straight fitting 4 21 102220 Switch Band - 16 2
11 134676 Hook cylinder 2

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9.8 Magazine Tower – T version

ITEM PART NO. DESCRIPTION QTY ITEM PART NO. DESCRIPTION QTY
1 135661 Plate 2 18 135471 Button nose moving bracket 1
2 135671 Shank gauge 1 19 135472 Button nose swinging bracket 1
3 135663 Wing nut 2 20 135475 Spacer 1
4 135668 Nut plate RH 1 21 135464 Switch bracket 1
5 135665 Wing plate RH 1 22 135603 Switch 1
6 135670 Magazine tower frame 1 23 135679 Plate 1
7 135672 Button guide RH 1 24 135681 Magazine back plate 1
8 135673 Button guide LH 1 25 135677 Magazine side RH 1
9 135674 Front plate RH 1 26 135936 Bracket 1
10 135676 Front plate LH 1 27 135935 Bracket 1
11 135666 Wing plate LH 1 28 135458 Linear bearing bracket 1
12 135667 Nut plate LH 1 29 135474 Button pusher LH 1
13 135678 Magazine side LH 1 30 135771 Button pusher RH 1
14 135601 Linear bearing 1 31 135662 Plate 1
15 135760 Linear drive arm 1 32 135680 Plate 1
16 135602 Bearing 10 1 33 135153 Switch arm (plastic) 1
17 101391 Spring 1

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9.9 Tower – S version

ITEM PART NO. DESCRIPTION QTY ITEM PART NO. DESCRIPTION QTY
1 135651 Tower RH cover 1 4 135652 Tower LH cover 1
2 135661 Plate 2 5 135654 Tower back plate 1
3 135650 Tower frame 1

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9.10 Electronic and Pneumatic Components

ITEM PART NO. DESCRIPTION QTY ITEM PART NO. DESCRIPTION QTY
1 134502 Program switch 1 8 134161-BFM Control board 1
2 109926 Din rail 10 stn 1 9 134197 Manifold harness 1
3 109918 Air manifold assembly 10 stn 1 10 103917 Switch unit - mains 1
4 102452 Power supply 1 11 10097 Modular regulator 1
5 133654 Display harness 1 12 10056 Finger valve 1
6 134500 Switch display 1 13 10095 Filter regulator 1
7 135359 Control board bracket 1

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