HENGCHANG MACHINERY OPERATION AND MAINTENANCE

ATTENTION

ATTENTION 1 :
Before operate the quilting machine,please read this operation and maintenance manual
And please remain and keep this operation and maintenance at the quilter machine for quick
reference of your operator

ATTENTION 2 :
Computer must be electrified for 8-10 hours each 30 days if the machine have been stopped
for an long time.Otherwise,all data saved in computer will be lost, then computer will be
unavailable.

ATTENTION 3 :
Make sure all electric should be grounded .

ATTENTION 4 :
Operator should be well trained ,Machine’s Maintenance and Adjustment should be operated
by experienced engineer.

ATTENTION 5 :
Damage Check:
When machine arrived your factory ,Please inspect the shipping containers ,record exterior
Damage and report it to shipping company .

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CONTENTS

ATTENTION .................................................................................................................................................................. 1
CONTENTS ................................................................................................................................................................... 2
FORWARD ..................................................................................................................................................................... 3
COMANY INTRODUCTION ....................................................................................................................................... 4
Chapter 1 Installation ................................................................................................................................................... 5
ⅠTechnical Data(MM)........................................................................................................................................... 5
Ⅱ Site Preparation:................................................................................................................................................. 5
Ⅲ Power Requirements .......................................................................................................................................... 6
Ⅳ Test/Commissioning Machine: .......................................................................................................................... 6
Ⅴ Thread broken detector: ..................................................................................................................................... 6
Ⅵ How to choose good-quality thread ................................................................................................................... 6
Ⅶ How to do When Stitch Missing or jumping ..................................................................................................... 7
Ⅷ Machine Maintenance ........................................................................................................................................ 7
Ⅸ Fabric Loading Figure ....................................................................................................................................... 8
Chapter 2 Computer Screen and Function ................................................................................................................... 9
2-1 Computer Screen ........................................................................................................................................... 9
2-2 Drawing ....................................................................................................................................................... 13
2-2-1 Drawing............................................................................................................................................ 13
2-2-2 Draw Straight Line ........................................................................................................................... 15
2-2-3 Draw Round-arc ............................................................................................................................... 15
2-2-4 Curve Drawing ................................................................................................................................. 16
2-2-5 Circumrotate Moving ....................................................................................................................... 16
2-2-6 Drawing TACK&JUMP ................................................................................................................... 17
2-2-7 Save Pattern...................................................................................................................................... 18
2-2-8 Start Quilt ......................................................................................................................................... 18
2-3 Modify Pattern............................................................................................................................................. 18
Chapter 3 Machine Function introduction ................................................................................................................. 20
Chapter 4 Troubleshooting ........................................................................................................................................ 27
Chapter 5 Protective Function (Panasonic servo) ...................................................................................................... 29
Chapter 6 Troubleshooting and Fault information (Transducer) ............................................................................... 35
Chapter 7 Wiring Diagram ........................................................................................................................................ 38
7-1 Quilting machine signal input/output diagram ............................................................................................ 38
7-2 Quilting machine power supply diagram..................................................................................................... 39
7-3 CPU DIAGRAM ......................................................................................................................................... 40
7-4 Transducer Parameter & Panasonic Driver Parameter ................................................................................ 41
7-5 Electrical Connector diagram ...................................................................................................................... 42
Chapter 8 Spare Parts................................................................................................................................................. 43

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FORWARD

The purpose of this operation and maintenance is to provide instructions for Newest High-speed Computerized
shuttle less Multi-Needle Quilting machine manufactured

Detailed procedures are supplied wherever required, where no specific direction is necessary, standard
procedures should be used.

We reserve the right for OPERATION AND MAINTENACE ,any changes in OPERATION AND
MAINTENACE will not be specially informed .

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COMANY INTRODUCTION

Ⅰ. General Introduction

We specialize in manufacturing computerized quilting machine with more than 15 year‘s experience. All
machines adopt American‘s advanced technology and design, Thus our machines are more highly production
rate and efficiency, saving cost ad power consumption ,occupying less space and having longer life spans and
many other advantages, All long, our company has continuously import foreign advanced technology,
combining it with our own technology to produce generation of new machines ,All criterions always constant
heighten, Our products have sold all over the world: south-east Asia, American, Middle East, Europe, etc. We
are grateful to our customers for their support ad favor, we will keep innovating and working hard in order to
meet their needs and adapt to their cooperation with high-quality products, effective management and sincere
after service.

Ⅱ. Products Specification：

● No contact point thread breaking detector, more reliable.

● Computer controlled adjustable presser board lifting mechanism, enable it to quilt a broad range of material
thicknesses.
● No needle rod design, more durable, reliable and stable
● Self error probing system, detects machine problems and displays error messages onto the computer screen
● Brand new quilting machine software control system, allows more precise and stable quilting operations
● Machine is able to run up to 1200 RPM using thinner needle(140/22)
● Computer controlled automatic looper tracing system
● Stable and reliable hook transmission mechanism
● Titled body design, easy to operate and maintain
● Able to quilt pattern in pattern and multiple pattern designs

Ⅲ. After Service
As we know deeply after-service is of top importance. We will provide one-stop after services and
promise to sort all problems out with high speed; moreover, we could help our customer to draw new patterns
according to their different requirements. We will make every effort to supply our good service.

CUSTOMER SATISFACTION IS OUR GOAL,

INNOVATION IS OUR PERMANENT GARRANTEE.

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Chapter 1 Installation

ⅠTechnical Data(MM)
Paramete
Function Model High-speed Computerized Chain Stitch Quilting Machine
r
Main Size(L*W*H) 5100*1500*2000（mm）
Weight 4500kg
X Movement 450mm
Quilt Width 2450mm
Rotation Speed 600-1200RPM
Quilt speed 80-230m/h

Needle type 130/21 140/22 160/23 180/24

Needle range 76.2 ,76.2, 152.4

Needle space 25.4mm

Voltage 220v /380v

Stitch Size 2-7mm

Power 7KW

Quilt thickness ≤80mm

Ⅱ Site Preparation:

Computerized Quilting machine requires no extraordinary site preparation, the working place should be clean, level,
and well lighted .and requires space for operator movement and materials handling operations.

Fig. 1

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Ⅲ Power Requirements

The Chain Stitch Quilter requires phase 380/220V 50HZ/60HZ 3 PHASE dedicated power-line. This line is
connected to the electrical cabinet which supplies the machine. Separate ground-wires must be installed

Ⅳ Test/Commissioning Machine:

Connect machine with power , display will enter into working screen(fig 4),move mouse to choose

pattern ,then click ,and press ―START‖，if machine worked stable and without abnormal noise. It

means machine run in good condition. Otherwise please check electrical wires and relevant installation.

Ⅴ Thread broken detector:

If upper thread or down thread break, Thread Broken Detector give signal to computer, machine stop auto
(main-shaft will run several circles for inertia), please go to check thread and necessary operation.

If you do not need this function, please go to

and put OFF.
Thread broken detector is an independent function; please put it according to thread quantity.

Ⅵ How to choose good-quality thread

Thread Specification
Upper-thread Nylon thread(150D/3 -250D/3)
Diameter 0.3mm
Tensile strength >2.5kg/diameter0.3mm
Retractility （length of thread 500mm） <10mm
Bottom-thread Mixed cotton-thread
Diameter 0.25mm
Tensile strength >2kg/diameter 0.25mm
Retractility （length of thread 500mm） <5mm

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Ⅶ How to do When Stitch Missing or jumping

Malfunction Problem Solution

1.easy-break thread 1.Choose the best quality thread

2.Thread-pull wrong
3.Thread-dish too tight
easy-broken
4.Thread blocked in the middle
thread
5.Pinhole of the looper unsmooth
6..adjust the framework for winding 5.professional to adjust the framework
thread unwell
1.The interspace between the needle
and the pinhole is too large
2.Needle wrong position
3.The direction of the eyelet wrong
Thread 4.The retractility of the thread bigger
jumping 5.The looper‘s position forward or
backward
6.Spreader in wrong position/distorted
7.Looper distorted
8.The transmission distortion
2.Pull thread according to the correct
thread pulling
3.Adjust the thread-dish
4.Replace the new looper
for winding thread
1．2．3．5 Adjust needles and looper
dully .
4.Replace thread with small retractility
6.Reference to the right setting of
plectrum
7.Change the hook
8.Adjust transmission by professional
expert

Ⅷ Machine Maintenance
1.Computer should be kept in clean place ,the cleaner where you put computer ,the longer the computer could
worked ,if you find dust in the electrical board,please ask experienced electrical-engineer to clean it by blower.
2. Equipment movement parts(leading shaft,screw shaft) should be add oil each 5-10days in order to keep
lubricant and decrease abrasion, good quality lubricant is required.
3.Machine should be cleaned each day after machine worked full day

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Ⅸ Fabric Loading Figure

After installation and commissioning, then loading fabric and start to quilt
Fig 2

Fig 3 Fabric Loading

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Chapter 2 Computer Screen and Function

2-1 Computer Screen

Fig. 4
【EDIT】Return to edit or edit the present pattern

【SAVE】Save the setting data (every adjustment if you made ,you must press【SAVE】
or what you reset is unavailable )

【B.STEP】Back step number when repair

【TEST】Enter into diagnostic test page for sensor(2-1-1)

【NEEDLE UP】Needle return to Upper position

【RESET】Machine return to 0 and continue quilt

【FORWARD】Roller forward, new material will pull into roller when machine commissioning/test

【BACKWARD】Roller Backward, new material will pull out of roller

【LEFT MOVE】Carriage travel will move to left side

【RIGHT MOVE】Carriage travel will move to right side

【PRM:】 This icon show rotation speed, when machine start, value will be 11-12

Pattern size which showed pattern in computer ( Bigger/ smaller)

【BREAK ON】 When machine stop , please keep brake on if you need to turn hand-wheel

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【PARA.SET】Enter into parameter setting(2-1-1)

【DES.】Setting the quilting length

【STATUS】It showed machine present status

【BACK】It is to adjust start/end back stitch when quilt TACK & JUMP

【LONG】It control the length for upper thread after thread cutting

【THIN】Set quilting material‘s thickness

【X】When quilt simple pattern ,if X is not on the position ,then adjust this button ‗+‘or ‗-‘

【Y】When quilt simple pattern,if Y is not on the position,then adjust this button ‗+‘or‗-‘

【GX】It is to adjust X space between start/end when quilt TACK&JUMP

【GY】It is to adjust Y space between start/end when quilt TACK&JUMP

【STEP】It is to adjust the length of back stitch when you quilt TACK&JUMP

【ANGLE】It is to adjust the angle when edit the pattern

【P】It is to change between pattern in pattern, pattern out of pattern

【SPEED】 It is change machine working speed through ‗+‘ or ‗-‘, after this change, press ―【SAVE】 ‖ to save
what you changed.
【 M】Count the length for quilted material

【THREAD】if this option is enabled,thread breaking test will start.The machine wil stop when the

thread broke.
【NEEDLE】if this option is enabled, the needle will go to the high position.
【PLATE】Timing handle-wheel slowly according to fig 9 ,speed measuring plate will turn,，When Magnet aim
at speed-measuring magnetic head through speed-measuring magnetic-hole, this button will be ‗ ‘，
when speed-measuring plate shield magnet, this button will be ‗ ‘。
【ZERO】if this option is enabled, the needle will go to the low position.

Press‗↓‘ to choose pattern you want.

NOTE：2-1-1【TEST】 explanation：

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※1 When press ―START‖ ,‗□‘ should be ‗ ‘;or you need to check the following data

A: connector and relevant circuit; B:start,stop and relevant circuit

※2 Check thread detector work or not，when shield photoelectric sensor ,it is ‗ ‘

※3

When needle is in the upper position, upper position sensor will give signal to computer, this button will be

‗ ‘

※4 When machine back to resetting magnetic-head,

magnetic head will give resetting signal to computer ,this button will be ‗ ‘。

※5 When air pressure work normal‗ ‘，if press down thread loosing electromagnetism button,

electromagnetism left magnetic head ,this button will be ‗□‘。

※6 Timing handle-wheel slowly according to fig 9 ,speed measuring plate will turn,，When
Magnet aim at speed-measuring magnetic head through speed-measuring magnetic-hole, this button will
be ‗ ‘，when speed-measuring plate shield magnet, this button will be ‗□‘。

※7 Needle is in the upper position , when you press ― ‖，cylinder for upper thread

loosing ,down thread loosing and thread cutting will work to test air cylinder

※8 It is to keep main shaft brake on

※9 It is to keep main shaft brake off in an fixed place

※10 EXIT this Diagnostic test 。

NOTE：2-1-2 explanation：

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※1 When finished TACK&JUMP, machine will pull fabric, the speed for pulling fabric

※2 After the first pulling fabric and thread cutting ,then machine will pull fabric to second

TACK& JUMP, it is the speed for go to the second one, higher the value is ,the quicker the speed will be

※3

Adjust the sensitivity for thread broken detector ,the higher this value is ,the lower sensitivity will be .

※4 It is show needle space

※5 It is show needle space between the 2 and 3 row。

※6 Thread broken detector on/ off。

※7 It is adjust triangle position。

※8 It is adjust hook position。

※9 Slight adjustment of the Down position

※10 The stability of the machine working, the data setting should be ―0‖

※11 The speed when the machine stop

※12 The power when the machine stop

※13 after your choice , then press OK and EXIT

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2-2 Drawing

2-2-1 Drawing

Fig 5

New built pattern

Open saved pattern

Save pattern

Save pattern to another pattern file

Draw straight line

Draw curve

Empty

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Curve edit

Empty

Full clearance

Circumvolve

Display smaller

Display bigger

Grids size
Copy pattern

Set TACK&JUMP start position

Full move pattern position

Enlarge or smaller pattern size

Return to quilt screen

Full-symmetry

Upright-direction symmetry

Horizontal-direction symmetry

Central symmetry

Positive symmetry

Opposite symmetry

Close symmetry

Partial symmetry

Partial upright-direction symmetry

Partial horizontal-direction symmetry

Partial central symmetry

Partial positive symmetry

Partial opposite symmetry

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Partial close symmetry

XY modify function
※where no specific direction is necessary, left key is certain key for draw start position.

Certain draw start position is for X Y（0，0）position:

When Cursor enter into Fig 7, press ― ‖，cursor move to drawing district, click ,then it will be the
new pattern‘s start position

Move start position

。
Fig 6

2-2-2 Draw Straight Line

Press ― ―，then click one point as straight line end point , after this straight line is certain , continue
next point and etc .

Straight line end point

Fig. 7

Right key means delete the last line you draw.

2-2-3 Draw Round-arc

Press ― ―,then click one point as round-arc end point ,click mouse to move round-arc ‗s
position ,then round arc is certain
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Round-arc end point

。
Fig.8
Right key means delete the last round-arc you draw

2-2-4 Curve Drawing

Press ― ‖ and, click line end point to modify and change round arc size

Line end point

Fig 9

After modify

Fig 10

2-2-5 Circumrotate Moving

Click ― ‖ , choose line end point and move mouse to circumrotate

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Line end point

Fig 11

Circumrotate

Fig 12

2-2-6 Drawing TACK&JUMP

Click ― ‖，then move mouse to drawing district to decide start position(fig 14),click ― ‖ ,move
mouse to drawing district and click mouse continuously till pattern drawing finished(fig15-fig 18),then

click to certain pattern quilting(Fig 19)

Fig 13 Fig 14

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Fig 15 Fig 16

Fig 17 Fig 18
2-2-7 Save Pattern

Click ― ‖, goes to and enter file name into here for sure.

2-2-8 Start Quilt

Click ― ‖and turn return to quilt screen

2-3 Modify Pattern

When fabric loaded and choose pattern ,then press ―START‖ button in machine, machine will reset auto and

start quilt, if you find pattern in the fabric is not on the X position ,then adjust this button

‗+‘or ‗-‘ to change fabric‘s X position, if Y is not on the position, then adjust this
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button ‗+‘or‗-‘ to change fabric‘s Y position

Length will be 6 inch(if 6 inch)

＞ 6 inch ,please adjust Y-
＜ 6 inch ,please adjust Y+
X+— Angle tight
X— Angle separate

When quilt elastic fabric with

TACK&JUMP, quilting fabric will
have some differences ,then

adjustment to 、

、 、

is necessary to keep quilt pattern

in good condition.

GX：When quilt TACK & JUMP/ bigger span pattern ,then adjust GX is necessary .
Just as quilt TACK&JUMP and PATTERN IN PATTERN,
pattern will have some differences in transverse ,then

please adjust value；if in vertical differences,

then please adjust value。

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Chapter 3 Machine Function introduction

Fig.19 Fabric Loading

Fig.20

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Flywheel

Dial Plate

Dial Index

Fig21

Brake clutch

Fig.22 Dial handwheel & Clutch (The Value is O when Needle is in upper Position

Note:1,Dial Plate will be O when needle is in upper position

2, If clutch move hardly after the machine operated for an long time, please adjust Clutch
space.

Thread Clip

Thread broken detector

Note: when thread break, the ball inside detector

Fig23 Upper-thread Setting lose its tensity and work forward, it make the
sensor react and send thread broken signal to
computer .If you do not need this Function,please
go to
and put OFF .

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Fig.24 Bottom Thread Setting

Needle-top guide line

Needle Screw

Needle-ruler

Fig.25 Needle setting lacing

Thread cutting looper

Looper Shaft

Fig.26 Looper

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Connecting rod of looper shaft

Looper bar Eccentric

Fig.27

Speed-measuring Magnetic head

Speed-measuring plate

Note: the Method to measure speed:

When Magnet aim at magnetic head through

Fig.28 magnetic-hole,check ,it will be ‗ √ ‘。

Carriage shaft

Carriage-travel protection switch

Fig.29 Note: When Carriage come to protection switch, machine stop. Please drag strap X
Belt by hand till Carriage in the middle position, After, switch on machine

power and machine ,machine will reset and start quilt

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Electromagnetism-valve

Air pressure adjustor

Fig 30

Upper Position magnetic-head

Note: when needle is in the upper position,

Fig.31
‗√‘ will be showed

Thread clip

Thread loosen cylinder

Fig 32

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Quilt start Button

Quilt stop button

Emergency Stop
(Switch off power)
Fig.33

Machine run light

Power switch

Electricity ON

Electricity OFF

Down Switch

Upper Pos Switch

Protect switch

Triangle switch
Hook Switch
Fig.34

X Driver

Y Driver

Solid switch (control brake)

Solid switch (control thread broken detector)

Air valve board driver

Thread broken detector board(power transition)

Fig 35
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Power Box (Driver)

Power box
(Magnetic head, Infrared sensor)

Power box (Brake)

Power Box(Supply CPU power)

` Fig 36

IO Connector

USB
Mouse
Display jack

Power connector

Fig 37

Inverter

Data display

Fig 38

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Chapter 4 Troubleshooting

No. Problem Cause Solution

When press RUN,Run light

1、machine has no power input 1,connect machine‘s power
is off, no noise with Run
1 2、Run Button connect unwell 2,check electric circuit
connector, and computer
3、Air Switch off 3、keep air switch ON
display is off
Run Light is ON, computer
display have no signal,
1、computer has no power input 1、 Connect power
when pressed ―Quilt start
2 2、computer problem 2、 Change computer
Button‖ machine do not
3、Solid switch broken 3、 Change solid switch
work.

When you press RUN,RUN 1、 Carriage travel-block come to 1、 strap in X motor, then
light is on, after your photoelectricity protection carriage travel-block left
3 hand left this button, switch photoelectricity protection
RUN light off 2、 Emergency switch locked switch
immediately 2、 Keep emergency switch ON
1、 Mouse broken or mouse
Mouse is in the screen of 1、 Change an new mouse or
connect unwell with computer
4 display, but you can not connect mouse again
2、 Mouse line turnoff
move mouse. 2、 Check mouse line

1、the problem with control circuit1、 Check control circuit or

or connector change connector
2、the wires with Inverter and IO 2、 Check wires between Io
card break off or connect unwell card and inverter
Display work normal ,the 3、Inverter parameter lost 3、 Set inverter parameter
5
main shaft do not working 4、Inverter broken 4、 Change an new inverter
5、Main motor broken or connect 5、 Check main motor‘s circuit
unwell 6、 Switch on air pressure and
6、No air pressure or do not find air check air pressure sensor
pressure work or not
1、 Keep ―thread detector on‖
1、 Display ―thread detector on‖is
2、 Open thread detector
―thread detector off ‖
switch, change new
machine still work When 2、 Photoelectricity sensor ‗s
photoelectricity and check
Thread broken ,Thread broken
6 circuit with photoelectricity
broken detector is out of 3、 Photoelectricity in main board
3、 change photoelectricity in
work broken
mainboard
4、 Relay problem
4、 change relay
5、 Solid switch broken
5、 change solid switch

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1、 Thread broken sensor short

1、 Check sensor circuit
circuit
7 Start machine ,Machine run 2、 Reinstall delay time for
2、 Delay time for Thread broken is
several circles ,then stop thread broken
wrong
3、 Thread clip should be tight
3、 Thread loosen
1、 The signal for speed measuring 1、 Check circuit and position
Computer works do not send to computer where the speed measuring
8 normal ,but X.Y do not 2、 X Motor do not find resetting magnet head is
work signal 2、 Check IO and X motor
3、 Computer problem 3、 Change computer
1、 Thread with bad quality
2、 Something block between 1、 Change thread
Thread from thread bobbin to 2、 Pull thread again
9 Thread is easy broken
thread clip 3、 Loose thread clip
3、 Thread clip is too tight 4、 Change loop and spreader
4、 Looper and spreader have bur
1、 Thread do not put in thread clip
2、 When quilt,loose thread 1、 Change thread
When quilt ―tack & cylinder do not work 2、 Adjust thread clip
10
jump‖thread is easy broken 3、 Electromagnetism-valve 3、 Readjust machine‘s frame
disconnect 4、 Change spreader
4、 Air amplifier problem

1、 Thread with bad quality 1、 Change thread

2、 Upper thread clip loosen 2、 Adjust upper thread clip
11 When quilt, stitch missing
3、 Space between looper and 3、 Readjust space between
spread is too small looper and spread

1、 Readjust frame to pull

1、 Frame to Pull fabric tighten is
fabric tighten
loosen
2、 Readjust space between
12 Pattern distortion 2、 No fabric in presser roller
presser roller
3、 X 、 Y 、 GX 、 GY ‗s value
3、 Readjust X、Y、GX、GY‘s
incorrect
value
1、 Cylinder for thread cut do not 1、 Change amplifier and
work relevant photoelectric
2、 Air press is not enough 2、 Make air press higher
Thread can not cut when
13 3、 Cylinder movement is not 3、 Make cylinder movement
quilt tack and jump
enough higher.
4、 Upper thread loosen 4、 Tighten upper thread.
5、 Amplifier break 5、 Change amplifier
1、Check upper pos magnetic
Open machine, main axis head
14 1、Can not find upper pos signal
move, but X,Y do not work 2、Check wires.

Open machine, X,Y

1 、 No power with Main board
15 move,but main axis do not 1、Change battery
battery
work.

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Chapter 5 Protective Function (Panasonic servo)

What are the protective functions ?
♣ The MINAS driver have various protective functions, when one of the protections is activated, the motor trips
according to the timing chart shown in ―Error Handling‖ in appendix. and the servo alarm output (ALM) is
turned off.
♣ Actions to be taken after trip events
After a trip even,the LED touch panel displays an alarm code no. and no servo-ON occurs.
Any trip status is cleared by keeping A-CLR(Alarm clear input) on for at least 120 ms after A-CLR off
The overload protection can be cleared by A-CLR at least 10 seconds after the occurrence of the event, if the
control power connection between r and t is opened .the time limiting operation is cleared .
The alarms mentioned above can also be cleared with the LED touch panel,see Alarm clear modes in appendix
The alarms mentioned above can also be cleared by using PANATERM
Notes: protections marked with can not be cleared with A-CLR(alarm clear input)they should be cleared by
turning the power off,removing the causes ,and then turning the power on again .

protective functions:causes and corrections

Protection Warn Reason Solution

The P-N voltage of the control power
Under
converter is lower than the specified
voltage
11 value.Or the control voltage is too low
control
due to an instantaneous outage or
power
shortage of power capacity
The line voltage is larger than the
specified acceptable range，so that the
P-n voltage of the converter is larger
than the specified value，or the line
voltage was raised by a condensive
load or UPS(uninterruptible power
Over
supply)
voltage 12
① The internal regenerative discharge
error
resistor is disconnected
② External regenerative discharge
resistor is not suitable than
regenerative energy cannot
be absorbed.
③ The driver (circuit) failed.
Measure the P-N voltage to check whether
voltage is correct or not, modify the
control voltage to an acceptable
value .and/or increase the power capacity.
Measure voltages (betweenL1, L2,
L3)remove the causes, feed a power of
correct voltage
◆Measure the P-B1resistance of driver
using a circuit tester, if it read “∞”
，the
connection is broken， replace the driver，
insert an external regenerative discharge
resistor between the P and B2 terminals。
① Use resistor having the specified
resistance for specified Watt
② Replace with a new driver(that is
working correctly for another axis)

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The P-N voltage of the main power
converter is lower than the specified
value during Servo-ON.
① The main power voltage is too
Under
low，instantaneous outage occurs .
voltage
13 The power source is small. Main
main
power is turned off .or the main
power
power is not fed.
② Too small power source: the line
voltage dropped due to the inrush
current at power on.
The current flowing in the converter is
larger than the specified value
① The driver failed(due to defective
circuits or IGBT parts)
② Motor wires (U,V,and W) are
shorted.
Over ③ Motor wires(U,V and W) are
current 14 grounded
error ④ Motor burned
⑤ Poor connection of motor wires
⑥ The relay for the dynamic brake is
melted and stuck due to the
frequent Servo-ON/OFF
⑦ The motor is not compatible with
the driver
The radiator is heated up to exceed the
limit temperature. The power elements
of the driver are overheated. overload
*Overheat
15
error
30/47
OPERATION AND MAINTENANCE
Measure terminal-to-terminal
voltages(between L1,L2and L3)
Increase capacity of the main power or
replace it with a larger one or remove the
causes of the failure of the magnetic
contact ， and then restart the power
source.
Increase capacity of the main power.
Correct phase(L1,L2and L3)connections
of the main power. if the main power is
single-phase 100V.use L1and L3
Check the timing of power-on (for both
the main power and control power)
① Disconnect the motor wires, and enter
Servo-O,if this trouble happens
immediately, replace the driver with a
new one(that is working correctly)
② Check if the U>V and W wires are
shorted at the connections, reconnect
them, if necessary.
③ Measure the insulation resistance
between U/V/W and earth wire. If the
resistance is not correct. Replace the
motor with a new one.
④ Measure the resistance between U.V
and W. if they are unbalanced replace
the motor with a new one
⑤ Check if the U/V and W connector
pins are firmly secured with
screws .loosened pins should be fixed
firmly
⑥ Replace the driver with a new one ,Do
not start or stop the motor by entering
Servo-ON or OFF
⑦ Check the capacity of the motor and
driver on the nameplate .if the motor
is not compatible with the driver;
replace it with a correct one.
Check the ambient temperature and
cooling conditions, check the load rate.
Make the environment under which the
driver operates .reduce the load.
HENGCHANG MACHINERY
Over load protection is activated via
the specified time limiting operation
when the intergration of a torque
command exceeds the specified
overload level caused by a long
operation with a torque that exceeds
the specified torque limit。
① Long operation with more load
and torque than the rating
② Vibration or hunting due to
incorrect gains, cause vibration
overload 16
and/or abnormal sound
③ Motor wires connected wrong or
broken
④ The machine is hit against a heavy
thing, or suddenly becomes heavy
in operation, the machine is
entangled
⑤ The electromagnetic brake is ON
⑥ In a system of multiple drivers,
some motors are wired incorrectly
to other axis
The regenerative energy is larger than
the capacity of the regenerative
discharge resistor
① When the load inertia is too large,
the converter voltage increases,
Regenerati
due to the large energy
ve 18
regenerated during deceleration,
discharge
and increase more due to the
shortage of energy consumption
by the regenerative discharge
resistor.
*encoder
No A-and B- phase is detected .the 11
A/B-phase 20
–wire encoder failed
error Correct the encoder wiring per the wiring
Due to no communication between the diagram, correct the connection of the
*encoder
encoder and driver, the detective pins.
communica 21
function for broken encoder wires is
tion error
activated.
31/47
OPERATION AND MAINTENANCE
Monitor the torque (current wave) using
an oscilloscope to check whether the
torque is surging or not, check the load
factor and overload alarm messages.
① Increase the capacity of the driver and
motor, lengthen the ramp time of
acceleration/deceleration, reduce the
motor load
② Readjust the gains.
③ Correct the motor wiring per the
wiring diagrams, replace cables
④ Free the main of any tangle, reduce
the motor load
⑤ Measure the voltage at the brake
wiring connections, turn off the brake
⑥ Correct the motor and encoder wiring
to eliminate the mismatching between
the motors。
Check the load rate of the regenerative
resistor in the monitor mode, the driver
should not be used with continuous
regenerative braking.
① Check the operation pattern(using the
velocity monitor).check the load rate
of the regenerative resistor and the
over-regeneration alarm on display
increase the capacity of the driver and
motor, increase the deceleration time,
use an external regenerative resistor,
check the connection wire between
B1 and B2 terminals
② Check the operation patterns(using
the velocity monitor)check the load
rate of the regenerative resistor and
HENGCHANG MACHINERY OPERATION AND MAINTENANCE

Make sure that the power of the encoder is

11 the connection between the 11-wire 5VDC±5%（4.75-5.25V） ，especially when
*encoder encoder and driver is broken ,the the wire length is long, it is important to
connection 22 encoder rotates higher than the meet this requirement ,you should not
error specified rate when control power is bundle the encoder wires and motor wires
on together, connect the shield to FG see the
encoder wiring diagram
Encoder The encoder sends an erroneous data
communica mainly due to noises. The encoder is
23 See above item 22
tion data connected correctly, though the data is
error not correct
Check whether the motor operates per the
position command pulse or not, see the
torque monitor to check if the output
The position error pulse is larger
torque is saturated, readjust the gains,
Position thanPr63（position error limit），the
24 maximize the value of Pr5E （ torque
error motor operation does not respond to
limit set-up）correct the encoder wiring
the commands.
per the wiring diagram, increase the
acceleration and deceleration time, reduce
the load and velocity.
When the driver of the full-closed Check the connection between the motor
version is under the full-closed and and load. Check the connection between
hybrid control with an external the external encoder and driver. Correct
Hybrid encoder, the load position detected by the values of the external scale numerator
25
error the external encoder and the motor and denominator regarding parameters
position detected by the motor Pr74、Pr75、Pr76 and Pr77，increase the
encoder are beyond the limit specified value of Pr73,increase the value of Pr71
by Pr73（hybrid error limit） （hybrid switching time） 。
Decrease the target speed （ command
values ）， decrease the value of Pr50
（velocity command input gain）,adjust
The motor velocity exceeds the the scale ratio so that the frequency of the
Over-speed 26
specified limit。 command pulse is 500 kpps or less,if an
overshoot occurs, readjust the gains.
correct the encoder wiring per the wiring
diagram
The command pulse is larger than Reduce the multiplication factor by
Command 500kpps at the entrance of the position adjusting the values of Pr46 and Pr4B.and
pulse sealer 27 error counter, the scale ratios set by then adjust the scale ratios so than the
error Pr46 and Pr4B（numerator of 1st to 4th command pulse frequency is 500kpps or
command scale）are not correct. less。
When Pr76(scale error
invalidation)=0,and the driver is
External
28 operated under the full-closed and Check the reason why CN1、F33 is OFF。
scale error
hybrid control with an external
encoder, the scale error input is OFF

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HENGCHANG MACHINERY OPERATION AND MAINTENANCE

Check that the motor operates per the

position command pulse, see the torque
External
monitor to check that the output torque
scale The value of the position error counter
29 does not get saturated, readjust the gains.
disconnecti is over227（134217728）
maximize the value of Pr5E（torque limit
on error
set-up）correct the encoder wiring per the
wiring diagram.
*external
Check the power supply for the external
scale The external scales is disconnected, or
35 scale, correct the wiring and SIG
disconnecti the scale fails
connections per the wiring diagram。
on error
Set all the parameters again, if this error
*EEPROM The data contained in the parameter occurs frequently, the driver may have
Parameter 36 storage area of the EEPROM is been broken, replace the driver with a new
error broken, so erroneous data is retrieved. one. Return the old driver to the sales
agent for repair.
*EEPROM The driver may have been broken, replace
The check code of the EEPROM is
check code 37 the driver with a new one. Return the old
broken, so erroneous data is retrieved.
error driver to the sales agent for repair.
Check the switches, wires and power
supply that constitute the circuits. Check
Over travel Both the CW and CCW over-travel
38 that the control power (12 to 24DC)can be
inhibit limits are not active。
established without delay. Check the value
of Pr04,correct the wiring, if necessary.
Check the voltage of the battery，connect
Absolute to the battery，and then clear the encoder
system 40 The power of the encoder is out. using the absolute encoder clear mode
down error contained in the auxiliary function(see
details of operation in appendix)
Absolute
The data of the multi-turn counter of Limit the movable range to 32767（15
encoder
41 the encoder exceeds the specified bits） ，revolutions(15bits) from the initial
counter
limit。 position，adjust the value of Pr0B。
overflow
Absolute Connect the power to the encoder and
The encoder rotates faster than the
encoder then make sure that the encoder voltage is
42 specified rate when it is
over speed 5V（±5%）correct the SIG connections，
battery-powered。
error if necessary.
*absolute
encoder
The encoder detects an error of the
single-turn 44
single-turn counter.
counter
The motor may be broken, replace the
error
motor with a new one. Return the old
*absolute
motor to the sales agent for repair.
encoder
The encoder detects an error of the
multi-turn 45
multi-turn counter
counter
error
*absolute 47 The encoder detects an internal status Take measures to keep the motor away
33/47
HENGCHANG MACHINERY OPERATION AND MAINTENANCE

encoder error，after the control power on ,the from rotating until the driver outputs
status error encoder rotates faster than the S-RDY, take measures to keep the motor
specified rate away from rotating until the driver
outputs S-RDY.
When an 11-wire encoder is used ,Pr
Full close Set the value of Pr02 to 0、1、2、3、4 or
97 02(control mode selection) is set to
selection 5。
7,8 or 9 (―full-close‖ control)
The control circuit operates Turn off the power and turn it on again, if
*other
incorrectly due to large noises or any the error can not be eliminated. The motor
error
other reasons。 and/or driver may be broken, disconnect
the power supply of these equipments,
The driver‘s self-diagnosing function
*other and replace them with new ones. Return
is activated, because an error happens
error the old equipment to the sales agent for
in the driver。
repair.
※ Routine maintenance and inspections are essential for proper and satisfactory operation of the driver
and motor
Notes to maintenance /inspections personnel
（1）power-on/off operations should be done by the operators themselves。
（2）for a while after power off, the internal circuits is kept charged at higher voltage, inspections should be
done a while(about 10 minutes)。After the power is turned off and the LED lamp on the panel is extinguished.
（3）do not take insulation resistance measures because the driver gets damaged.
Inspection items and cycles
normal (correct) operating conditions：
ambient temperature：30℃（annual average）load factor：max.80%
operating hours：max. 20 hours per day

Daily and periodical inspections should be done over the following instructions：

Type cycles Inspection items

☆ambient temperature, humidity, dust, particles, foreign

matters, etc.
☆abnormal sound and vibration
☆Main circuit voltage
Daily
daily ☆odor
inspection
☆lint or other foreign matters in the ventilation openings
☆cleanliness of the operation board
☆damaged circuits
☆loosened connections and improper pin positions
☆foreign matters caught in the machine(motor load)
Periodical Every ☆loosened screws
inspection day ☆signs of overheat
☆burned terminals
note：if the actual operating conditions differ from things mentioned above, the inspection cycles may
change accordingly。
34/47
HENGCHANG MACHINERY OPERATION AND MAINTENANCE

Chapter 6 Troubleshooting and Fault information (Transducer)

The AC drive has a comprehensive fault diagnostic system that includes several different alarms and fault
messages, once a fault is detected, the corresponding protective functions will be activated. The following faults
are displayed as shown on the AC drive digital keypad display, the four most recent faults can be read on the
digital keypad display.
Fault Fault descriptions Corrective actions
1.check whether the motors horsepower corresponds to the
AC drive output power
2.check the wiring connections between the AC drive and
motor for possible short circuits
The AC drive detects an abnormal 3.increase the acceleration time
increase in current IGBT protection 4.check for possible excessive loading conditions at the
motor
5.if there are any abnormal conditions when operating the
AC drive after short-circuit being removed .it should be1sent
back to manufacturer
1.check whether the input voltage falls within the rated AC
drive input voltage
2.check for possible voltage transients
The AC drive detects that the DC but
3.bus over-voltage many also be caused by motor
voltage has exceeded its maximum
regeneration, either increase the decel time or add an optional
allowable value
braking resistor
4.check whether the required braking power is within the
specified limits
1,ensure that the ambient temperature falls within the
specified temperature range
The AC drive temperature sensor 2. Make sure that the ventilation holes are not obstructed
detects excessive heat. 3.Remove any foreign objects on the heatsinks and check for
possible dirty heat sink fins
4,provide enough spacing for adequate ventilation

The Ac drive detects that the DC bus Check whether the input voltage falls within the rated AC
voltage has fallen drive‘s input voltage.

The AC drive detects excessive drive

output current. Note: the AC drive can
withstand up to 150% of the rated
current for a maximum of 60 seconds.
Internal electronic overload trip
Motor overload. Check the parameter
setting
1.check whether the motor is overloaded
2. Reduce torque compensation setting as set in Pr.7-0.2.
3.increase the AC drive‘s output capacity
1. Check for possible motor overload
2. Check electronic thermal overload setting.
3. Increase motor capacity
4.reduce the current level so that the drive outputcurrent does
not exceed the value set by the motor rated current Pr.7.00
1.Reduce the motor load
2.Adjust the over-torque detection setting to an appropriate
setting）

35/47
HENGCHANG MACHINERY OPERATION AND MAINTENANCE

Hardware protection failure Return to the factory

1.when the external input terminal ―bb‖ is active, the AC
External base block. AC drive out put drive output will be turned off
is turned off. 2.disable this connection and the AC drive will begin to work
again
Over-current during acceleration
1,check for possible poor insulation at the output line
1. short circuit at motor output
2.Decrease the torque boost setting in Pr.7-0.2
2. torque boost too high
3.increase the acceleration time
3. acceleration time too short
4.replace the AC drive with one that has a higher output
4. AC drive out put capacity is too
capacity(next HP size)
small
Over-current during deceleration:
1.check for possible poor insulation at the output line
1. short-circuit at motor output
2.increase the deceleration time
2. deceleration time too short
3.replace with the AC drive with one that has a higher output
3. AC drive output capacity is too
capacity(next HP size)
small
Over-current during steady state
operation 1.check for possible poor insulation at the output line
1. short-circuit at motor output 2.check for possible motor stall
2. sudden increase in motor loading 3.replace the AC drive with one that has a higher output
3. AC drive output capacity is too capacity(next HP size)
small
1, When external terminal EF-GND is closed, the put will be
The external terminal EF-GND goes
turned off (Under N.O. E.F.)
from OFF to ON.
2. Press ―RESET‖ after fault has been cleared.
Emergency stop When multi function
input terminals(MI1 to MI6)are set to
Press ―RESET‖ after fault has been cleared.
emergency stop, AC drive stops any
output
1. return to the factory
Internal memory IC can not be read
2. check the EEPROM on the control board
1. return to the factory
Internal memory IC can not be read
2. reset drive to factory defaults

Drive‘s internal circuitry abnormal Return to the factory

Ground fault: the AC drive output is
abnormal. When the output terminal is
grounded (short circuit current is 50%
Ground fault:
more than the AC drive rated current),
1,check whether the IGBT power module is damaged
the AC drive power module may be
2.check for possible poor insulation at the output line
damaged. The short circuit protection
is provided for AC drive protection, not
user protection.

Auto accel/decel failure Don‘t use the function of auto acceleration/deceleration

1. Check the connection between the AC drive and computer

Communication error for loose wires.
2. Check if the communication protocol is properly set.
36/47
HENGCHANG MACHINERY OPERATION AND MAINTENANCE

Software protection failure Return to the factory

1.check both parameter settings and wiring of

AnLEr: analog feedback error or ACI
Analog/PC(Pr.10-00)
open circuit
2.check for possible fault between system reaction time
PGE rr: PG feed back signal error
and the feedback signal detection time (Pr.10-08)
Check power source input if all 3 input phases are connected
Phase loss
without loose contacts.
EF when preliminary count value 1check counter trigger signal
attained 2,check Pr.03-09,Pr.03-11 setting
1,checkcabling between drive and motor
Auto tuning error
2,retry again
1,check load current
Under current
2,check Pr.06-12 to Pr.06-15 setting

37/47
HENGCHANG MACHINERY OPERATION AND MAINTENANCE

Chapter 7 Wiring Diagram

7-1 Quilting machine signal input/output diagram

38/47
HENGCHANG MACHINERY OPERATION AND MAINTENANCE

7-2 Quilting machine power supply diagram

39/47
HENGCHANG MACHINERY OPERATION AND MAINTENANCE

7-3 CPU DIAGRAM

40/47
HENGCHANG MACHINERY OPERATION AND MAINTENANCE

7-4 Transducer Parameter & Panasonic Driver Parameter

PANASONIC DRIVER PARAMETER

Transducer Parameter
（MDDKT5540E）

01-07-100 05-05-47.5 PR*0.00 0

01-08-02 05-06-50 0.02 1

01-09-1.5 05-07-50 0.03 10

01-10-1.0 05-08-50 0.05 1 EX-Factory : 0

Anticlockwise
01-11-1.0 05-09-50 0.06 0 Rotation :1

01-12-0.1 05-10-50 0.08 X:800 Y:832

02-00-01 05-11-50 0.11 125

02-01-01 05-12-50

02-04-01 05-13-50

04-06-03 05-14-50

04-07-07 07-02-09

05-00-5.0 08-00-10

05-01-5.0 08-02-1.0

05-02-40.6 08-03-0.5

05-03-43 00-02-08(Locked)

05-04-45.4

41/47
HENGCHANG MACHINERY OPERATION AND MAINTENANCE

7-5 Electrical Connector diagram

42/47
HENGCHANG MACHINERY OPERATION AND MAINTENANCE

Chapter 8 Spare Parts

No Parts Name Specification Parts Picture Note

1 Sliding arm

2 Fulcrum bearing base

Connecting rod of the looper

3 With screw
shaft

Connecting rod of the looper

4 Without screw
shaft

5 Speed plate

6 Bearing 51204

7 Oscillating bearing of thread cut Left side

8 Oscillating bearing of thread cut Right side

9 Sliding arm of thread cut cylinder

10 Fulcrum connecting rod

11 Bearing of thread cut cylinder

12 Bearing 1202

13 Cylinder 50*50

14 Sliding rod of looper shaft

15 Retainer eccentric wheel

16 Eccentric wheel C

17 Eccentric wheel M14

Left side/Right
18 Fulcrum base
side
43/47
HENGCHANG MACHINERY OPERATION AND MAINTENANCE

19 Moving shaft

20 Looper shaft eccentric wheel

fine
21 Eccentric wheel cover A M18
thread

22 Connecting rod

23 Oscillating bearing of retainer Left side

24 Oscillating bearing of retainer Right side

25 Bearing NAP206

26 Bearing UCPA204

27 Pressure relief valve

28 Magnetic valve 12V 2位

fine
29 Double-ended screw M18
thread

30 Belt 1148

31 Connecting rod of looper shaft New

32 Support base 12 寸

With
33 Roll support base Left side
hole

34 Roll support base Right side

35 Ball screw shaft

36 Connecting bearing

37 Connecting rod of retainer rack

38 Oscillating bearing M8

39 Fulcrum rod M8

40 Bearing

41 Oscillating bearing M18 New

44/47
HENGCHANG MACHINERY OPERATION AND MAINTENANCE

42 Needle row New

43 Air cylinder 63*100

44 Bearing ∮28

45 Bearing base of material loading Long

46 Bearing base of material loading Short

Bearing base of second roll

47
sliding
Bearing base of second roll
48
sliding

49 Adjustable gear 1

50 Adjustable gear 2

51 Adjustable gear 3

52 Adjustable gear 4

53 Chain gear with 14 tooth

54 Belt 720H-8M-28

55 Belt 720H-8M-25

56 Belt 760H-8M-55

57 Retainer transmission base

58 Bearing 1515F

59 Belt pulley L:55mm

60 Belt pulley L:30mm

The clamping plate of Synchronous

61
Belt

62 Sliding rod New

Sliding rod of press plate

63 New
(Sliding rod C )

64 Locating bearing bushing New

45/47
HENGCHANG MACHINERY OPERATION AND MAINTENANCE

65 Bearing bushing New

Sliding rod of press plate

66 New
(Sliding rod B)

67 Needle row arm New

68 Press plate arm New

69 Bearing New

70 Locating arm bearing

71 motor

72 Manual valve

73 Air lever of Back cover

74 Air lever of front cover

75 Retainer rack support

76 Bearing SALF206

77 Bearing SAFA206

78 Bearing UCF205

79 Bearing UCF206

80 Bearing NAP207

81 Air cylinder drive board New

82 magnetic head(for resetting)

magnetic head(for Needle

83
position)

84 Thread detector (light blue)

85 Long Retainer

86 Short Retainer

87 Retainer rack base 1

46/47
HENGCHANG MACHINERY OPERATION AND MAINTENANCE

88 Retainer rack base 2

89 Retainer rack washer

90 Thread tension

91 Needle

92 Thread cutting looper

93 Retainer rack cushion

47/47