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AC Servo Motor series

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1. If an output signal has been sent twice in the OUTPUTOO OUTPUT 15 output pin the same signal will appear two different output pins Ex if OUTPUTOO 0 amp OUTPUTOS 0 then B T signal is output from both OUTPUTOO amp OUTPUTOS pin x When setting up other functions apart from the function numbers listed above the pertinent output pin functions are disregarded Roller Lift Solenoid Presser Foot Lift solenoid Back Tack solenoid Roller Lift Switch NOTUSED m Caution If the specific items of the parameter are changed carelessly they could break down or damage the machine so the user must be well trained before using it 55 56 50 INPUTOO Button A 1 0 51 INPUTO1 Button B 11 _ 8 INPUTD MsihSWik 27 58 PUTOQAsihSwih INPUT04 3 4 stitch Switch Lo l 86 05 7 56 INPUTO6 Left Sol Switch amp O 6 Output port changing function Write the function number 58 INPUTIO PresserFootlit o on the output PIN you want 89 PUTM ComtrSwih 12 91 after refering to 6 INPUTIZ PU i2schSwichSgna 20 16 17 66 INPUTZ2 PedalTimSigna TC x Input PIN function amp Actual Hardware Output Name No Actual Hardware Output Name Button A Switch 100 invButton A Switch But
2. SunStar 20 SUNSTAR ELECTRIC CO LTD Qo 10 2 Control box side rw A D Caution 2 WARNING Hazardous voltage will cause injury Be sure to wait at least 360 seconds before opening this cover after turn off main switch and unplug power cord US 20 9lol AAS AWS S 0 AAS HA zo E Su 36022 ASAI 2 Specification FORTUNA AC SERVO SERIES 4 MODEL POWER V 5o eotz Current MAX 5 0A IP 40 SERIAL NO SUNSTAR ELECTRIC 11 INSTALLATION 1 Attaching controller to table D As in the figure attach control box to the lower right of the table with 15mm fixing screws The underside of the table front part Right table leg Area where control box is to be attached 2 Attaching pedal unit
3. 5 8CH 8DH O O 5 m 25 5 TI e 91 5 5 EE Control Total 40 5 I 2 gt zE Data Field ist Explanation Cmd Field On Hole Set C2H ion cH Set Dir CCW Set CCW direction Set Speed Motor Run with given Speed C4H 0 5000 som 205 Set SpdByPed Make Motor Run with Speed given by pedal CH 778 TO Up Stop InSod 0 50 a Up Edge Decel in Speed at Up Edge stop 0 500 spml 25 DaccDn Edge Decel in Speed Dn Edge stop CBH 0 500 spml 25 Move Up Edge Move Up Edge with given Speed not stop 0 500 spml 25 Move DnEdge Move to Dn Edge with given Speed not stop CDH 0 500 spml 25 Pos Stop Up Up Stop after sewing given stitch with given Speed CEH 0 5000 som 0 255 stitch 2050 Pos Stop Dn Dn Stop afte sewing given stitch with given Speed CFH 0 5000 som 0 255 stitch 205 Pos Dacc Up Dacc Dn Edge after sewing given stitch with given Speed DOH 0 5000 som 0 500 spml 0 255 stitch 20spm 2spm Pos Dace Dn Up Edge sewing given stitch with given Speed D1H 0 5000 som 0 500 spml 0 255 stitch 205 2spm L Move Stop Move given distance wit
4. 80 Program Unit Mechanism Assembly No Ref No Parts No Note Name of Parts 13 007 A SE50 02 002A S E50 11 0025 5050 zi Cable for P U Box S 3 Front Cover for P U P U AA ow TEE Screw for Cover ST2 9X L8 AW ST2 9x L8 91 200 5 50 P U Bracket KM 23007 P U KM 23008 06 001C SE50 91 001 C SE50 Screw for P U 16 P U 16 Screw for P U Bracket 3 16 n 28 D 6 H 3 L 11 P U 23A 395 16 n 28 D 6 H 3 1 1 1 CO P i Series IV cable 82 Ref No Name of Parts Parts No Note 1 04 0000 5 E50 11 011A SF55 Pedal Base Pedal Unit Assembly OH Assembly No ag 11 1000 4701 10 0285 5 53 Pedal Board E 4 wei Unie MEL xr MLA yJ 5 13 007A SE50 Cable for Pedal Unit 918 E 6 08 015C 3701 Cord Push E 7 10 016A SC53 Spring Housing E 8 10 024P SC53 Spring Guide A E 9 10 025P SC53 Spring Guide B E 10 10 019G SC53 E 11 10 020G SC53 K 12 E 13 10 029P SC53 10 030P SC53 Stopper for Pressure Spring B K 14 E 15 E 16 10 0218 8C53 Pressure Control Screw MAXLIO E 17 10 031W SC53 E 18 10 031S SC53 E 19 11 01
5. 20 8 Program unit part names method of use ss 21 9 Simple operation unit part names and method use 41 10 Fortuna series 4 full function software method of use 46 11 Breakdown and troubleshooting 33 TO 12 How to place for controller gt T1 13 Blockdiagam 72 x Parts Rook e 4 4 4 4 22 T3 SAFETY INSTRUCTION Be sure to read and keep in mind the following instructions before you install and use the FORTUNA SERVO MOTOR 1 Use and Purpose This product 1s designed manufactured and sold as an industrial sewing machine It should not be used for other than industrial purpose 2 Working Environment D Power Source tis desirable that voltage of the power source be kept within the range of 10 of the rated voltage t is desirable that frequency of the power source be kept within the rage of 10 of the rated frequency 50 60 Hz The SERVO MOTOR can be expected to work normaly only in case the foregoing things are kept 2 Electromagnetic Noise t is desirable that those equipments causing strong electromagnetic field or high frequency not use the same electrical outlet as this on and stay away from it 3 Temperature and Humidity Keep the ambient temperature above 5 degrees and below 40 degrees Centigrade Never use it outdoors and avoid direct ray of light Keep it away from an hot o
6. 3 Programming the Start B T Sewing Conditions with Button B This button is used when the user wants to prevent threads from loosening at the end of the sewing work If the user presses this button in sequence the location on the lights will change as shown in the figures below This button offers the following three functions When sewing starts B T sewing can be When sewing starts B T sewing can be When sewing starts B T sewing does not Y D operated with the button operated with the button Use the C D button to program the number of B T stitches in the 4 digit displayer Caution Be aware that if the end B T stitch number is set to 0 in the 4 digit displayer the user will be unable to carry out start B T sewing 4 Programming the Needle Plate Position when Sewing Stops with Button C When you turn the power on one of needle plate s up stop and down stop lights in the simple operation unit will always be on If you press the button you can select the stopping location If the machine stops while sewing the If the machine stops while sewing the needle plate makes an up stop needle plate makes a down stop o0 42 5 Programming the Presser Foot lift Location when Sewing Stops with the Button D When you turn the power on one of presser foot lift s up stop and down stop lights in the simple operation unit will always be on If you press the button you c
7. The pattern function sewing speed will be the programmed speed value set in each pattern mode is not erased when the power is turned off Therefore if you want to use the same pattern again press the same mode again to use it However if the program is initialized all the formerly programmed information will be erased and the user must reset the information again 2 Method of use function Screen showing thef programming of first press the button and select the pattern sewing function stitch numbers for each side b Select the you want and the light will go on the pattern you selected c If you press the button the screen will change and you can use the stitches of P HB nt each side of the pattern you chose to program the value Method to program the value of each pattern side gt Q Method by using buttons nm nputting directly the number of stitch the user wants by using the buttons C and D This method is used when the user already knows the length of the stitches he she is choosing Method using the pedal movement P When the AUTO light is off the machine This is a function used when the user does not know the stitch length and sews stops when the pedal is released while directly to check the number of stitches for the pattern he she wishes to program If sewing mE the user presses on the pedal after the programming screen comes o
8. gt 010 1 For at most use with easiness please certainly read this manual before starting use 2 Keep this manual in safe place for reference when the machine breaks down SUNSTAR MACHINERY 00 TD 1 Thank you for purchasing our product Based on the rich expertise experience accumulated in industrial sewing machine production SUNSTAR will manufacture industrial sewing machines which deliver more diverse functions high performance powerful operation enhanced durability and more sophisticated design to meet a number of user s needs Please read this user s manual thoroughly before using the machine Make sure to properly use the machine to enjoy its full performance The specifications of the machine are subject to change aimed to enhance product performance without prior notice 5 product is designed manufactured and sold as an industrial sewing machine It should not be used for other than industrial purpose SUNSTAR MACHINERY CO LTD 5 1 Safetyinstruction es 6 2 Precautions before use 3 o on nmn 9 Locating and using parts of the controller box 10 A Installation 12 5 Wiring and grounding o o e e e e 17 6 Connection the earth wire of the sewing machine and motor 20 7 Things to be checked after installation
9. 255 20 2000 10spm When doing an aging test the value is equal to the running time The A24 used in PNEUMATIC must be 1 100ms 4 1020 The Solenoid operation time When doing an aging test the value 4 102 NA e is equal to the thread trimming time 10 Tension release operation time The A24 used in PNEUMATIC must be 1 200ms Tension release time In CAM type the used A24 must be 0 In CAM type the tension release is the value of the moving CAM angle 255 0 255 Waiting time for the next operation after thread trimming This is the delaying time to carry out the next operation after thread trimming is finished Wiper operation time Wiper Solenoid operating time 48ms 4 1020 4ms 4 Waiting time after wiper operation presser foot lift etc 40ms 4 1020 4ms 5 Automatic presser foot lift delaying time 100ms 4 1020 4ms Automatic presser foot lift maintaining time 300x0 1sec 5 1000 0 5sec After programmed time the presser foot lift is automatically released Automatic presser foot lift drop waiting time for next operation The delaying time or the time that the foot presser lift is maintained 100ms 4 1020 4ms the pedal is started until the presser foot lift drops and the sewing machine is started 4 0 1 1 lift selection Selection for automatic foot presser lift after thread trimming 0 2step backward thread trimming 0 1 2 1 1 step backward thread trimming Sele
10. Fixing Rubber for Resistor 559 10 021M SW66 C 6 13 005A SE50 Resistor Connect C 7 06 007 A SE50 Transformer C 8 06 001 C SES0 Screw L8 C 9 06 008A S E50 Display Panel C 10 06 003 5 50 C 11 06 004B SE50 2713 03 0000 5 E50 C 14 06 005C SE50 C 16 08 002M SW67 C 17 01 0000 5 E50 C 18 10 021M SW66 19 07 0045 5 55 20 01 0035 2070 21 06 005B SE50 22 06 002A SE50 24 06 114 5 50 C 25 10 003M P TOI 26 91 001 5 50 27 06 006 5 50 28 06 007 5 50 29 11 0025 5050 2 30 13 001A SE50 C 30 1 13 100A SE50 C 30 2 13 101A SE50 31 Sticker for Display Panel Sticker for Display Panel B DRV Driver Board Screw for DRV Driver Board M3xL6 Ege aul 4 3 16 Screw for Encorder Cover MAXLIO TAYA 2 0 Screw 116 Guide Rubber for Cable Front Cover for Control Box Front Cover for Control Box Screw Control Box Cover MAX L8 ON OFF Switch Cable Cover A Cable Cover B Screw for Cable Cover ST2 9X L8 Power Source Cable 1 1 220V Power Source Cable 1 3 220V Power Source Cable 1 1 110V 13 002A S E50 C 32 13 003 5 50 11 0025 5050 Power Source Cable 2 7 99 34 01 0038 B TOl C 35 06 0015 5 50 01 025 5 50 Principle Sticker Model Sticker Ww Gappad 1500 125 25 x 20
11. 28 Needle bars automaticstopatthehighestpostion _ 0 Ob 90 When using an angle 2needle select the semi automatic comer operation 70 04 t selection of semiautomatic Speed when selecting a semi automatic corner 200spm 20 2000 10spm 31 32 After selecting the left needle the first sewing stitch 3 stitches 0 255 1 stitch parameter used only when used after selecting number 30 33 After selecting the left needle the second sewing stitch 3 stitches 0 255 1 stitch parameter used only when used after selecting number 30 34 After selecting the right needle the first sewing stitch 3 stitches 0 255 1 stitch parameter used only when used after selecting number 30 1 35 After selecting the right needle the second sewing stitch 3 stitches 0 255 1 stitch parameter used only when used after selecting number 30 6 Maintaining time for the left right needle solenoid 450 x0 1sec 50 1000 5sec After the programmed time the solenoid is automatically released 7 Setgrease check function 0 1 0 Not used 1 Used 8 Set grease check time 750 hour 0 9999 1 hour 9 Stopping function during AUTO mode and while pedal is neutral 0 1 does not stop 1 stops 0 Selection of type of N stitch Sensor 0 10 active high 1 active low 1 The number of stitches done after the N stitch Sensor has finished sensing 3 stitches 0 255 1 stitch After sensing it will
12. Wait for 100 ms T R sol off Wait for 5 ms W P sol on on Wait for 100 ms Wiper solenoid off Wait for 5 ms End of Sequence Code Comm Data field number Explanation 0 HEN um EM m p NN CO o0 Operates Presser Foot Solenoid by Lefting Up function of Automatic Presser Foot after Trimming being set to 18 1 As every command field is displayed close to itis distinguishable from Data Field x All Data Fields are displayed easily enough to distinguish them from others differently from S II and there s no necessity of transforming the number and conversing the unit 68 we oni or o NO 009 000v 100 300 006 9501 10J 0067 95 eee ALL add ad uas ES EE TT pr 20 No NO oot oat 0 foor 100 05046 OWOLEZ IN 90022 ONILLAS UNN 4 9G ON 0 2148 IPPON Aq S9po2 JO 1511 9 69 Breakdown and Troubleshooting x If the machine breaks down while using the servo motor due to an unforseen change in the machine the error indicators mentioned below
13. The figures above show each representative sewing condition And there may be some differences according to the conditions of the sewing machine and it is normal that two types of conditions occur at the same time 33 2 Start End stitch number correction method The method to correct B T stitch numbers may differ according to the user However it is basically done in the following order A When the machine sews one less or one more stitch than the programmed number of stitches Initial screen 8 First fully check the B T sewing condition Commence sewing and check the current sewing condition Refer to the figure above 3333 92090799 b If you have checked the sewing condition first correct the stitch number that differs by one or more stitches to the programmed stitch number Correction method for stitch numbers with more than one stitch difference Program range 6 stitches 6 stitches e Program unit 1 stitch Method to apply correct stitch number program using buttons A B C and D Side A programmed value 3 programmed stitch number 3 actual stitch number sewn on side Side B programmed value 3 programmed stitch number 3 actual stitch number sewn on side Side C programmed value stitch number 3 actual stitch number sewn on side Side D programmed value 3 programmed stitch number 3 actual stitch number sewn on s
14. 2 At this point press button to change the display to UP Press button again to go back to the initial display of 3333 bt Press again to change to bc as explained in 1 The display will change by pressing button 3333 2090700 Bobbin counter The value will go down from the set value during sewing Initial value 0 Set range 0 9999 How to set use button This value will go up in proportion to the reduction ratio of bc bobbin counter Use this value to get the initial value of bc bobbin counter Initial value 0 Set range 0 9999 Set manual increase decrease function with C D button Back tack function that is shown in the initial display Caution x Pay caution when using button and button designed to perform special functions for bobbin counter e button Clear Presser Press button when is shown on the display Then the buzzer will go off and the current value will be stored as indicated and will change to the value of bobbin counter button Store counter value Press Q button when bc or UP is shown on the display The current indicated value will be stored as value of bobbin counter b Detailed functions of bobbin counter D When you start new sewing work you must re set the value of bobbin counter Refer to the following if you do not know your re set value First move to UP display and use button to cha
15. 2 Program Unit Method of Use 1 4 Digit Displayer and 2 Digit Displayer Functions and Method of Use 4 Digit Displayer and 2 Digit Displayer Functions nitializing screen 1 When you turn the power on you will see a screen as shown in the figure The 4 digit displayer shows the start and end B T sewing and the 2 digit displayer shows the current abbreviation for the letters or numbers shown in 3333 the 4 digit displayer bt the abbreviation for back tack Q 2 9 6 CF Example of error detection 2 The 4 digit displayer shows the error number for each type of error ER discovered and also shows the programmed value after it has been programmed The 2 digit displayer shows the number of the parameter Example of selection of number 2 item in Group A specific item s content or name which is shown in the 4 digit displayer 20090700 Caution The 4 digit displayer and 2 digit displayer show the current condition Therefore the user should always check it before using the machine 21 B Method of Use 4 Digit Displayer and 2 Digit Displayer a Method to change the start and end B T stitch numbers In order to change the start B T stitch numbers which is programmed when you first purchase this machine you must use the buttons If you want to change the end stitch numbers you must use the 9 buttons The program range is from 0 to 9 Ex How the screen looks w
16. D As in the figure attach pedal unit bracket to the underside of table with 15mm fixing screws 2 Attach pedal unit to the fixing holes on one side of pedal unit bracket 3 Pedal unit bracket should be fixed to the area where the bar linked to the pedal that is to be attached to table leg becomes vertical The area where pedal unit bracket is attached depends on where the pedal is 12 3 Installing and adjusting knee lifter solenoid Solenoid bracket A 1 For Sunstar KM 2300 Sewing Machine D Assemble Ornamental panel of knee lifter solenoid on the back of KM 2300 body 2 Attach knee lifter solenoid on bracket A Grounding Cable 3 Attach the bracket A fixed on the knee lifter solenoid 4 After attaching crank on the solenoid shaft connect to the Solenoid Cover machine 5 Put cover over solenoid KM 2300 Back 6 Connect grounding cable 4 Installing Position detector Synchronizer and adjusting Film 1 Installing Position detector KM 2300Series SC 7300Series D Synchronizer is attached on the machine upon shipment 2 When changing and fixing synchronizer see the manual 2 Setting needle bar up down stop position with using program unite KM
17. Option 2 Connector ontion2 Pedal Connector v Fortuna Pedal Connector AC Power switch Servo Series 4 Encoder Connector ORTA Motor Power Connector P U Connector Encoder Optioni Position Detector Connector Option 1 Connector A B Button Connector Solenoids Connector Option 3 SunStar SUNSTAR ELECTRIC CO LTD 20 Control box front Economic Control box back Economic Type Control box grounding part SS amp EE AC Power Input Power Cable Option 2 Connector Fortuna Pedal Connector _____ ____ Encoder Connector L Motor Power Connector 77 Synchro P U Connector Option Simple Controller Board __ Position Detector Connector Option 1 Connector Button Connector Solenoids Connector
18. Roller lift Switch Sequence Contro 0 64 0 64 0 64 0 64 0 64 0 64 0 64 0 64 0 64 0 64 0 64 0 64 0 64 0 64 Le 3 Orn ee ewe MEN om mmm FX eu 0 5 Inr ME o DET OE SEX lt N Caution Every the conditional Branch is made to the appropriate number when it is on No False When makingthe sequence program please check and use its function because the wrong sequence program can cause the mechanical trouble and the physical damage 6 5 Examples of the Function of Thread Trimming Sequence Yamato Three needle Trimming 1 Timing of Thread Trimming Sequence Needle T T T R W P 2 Flow Chart of Tread Trimming Sequence amp Program Code Flow chart wait for 5ms sol on l wait for 100ms l T R sol off wait 5 15 W P sol on wait for 100ms W P sol off wait for 5ms End of Seguence field 2nd asane Stop after moving to needle of upstop 200 at200spm Wait for 5 ms Lr __ Thread Trimming solenoid On la Wait for 100 ms o n Wait for 5 ms T R sol on
19. When the machine stops while sewing the When the machine stops while sewing the e presser foot lift stops at the top 5 presser foot lift stops at the bottom Caution If the user uses the automatic up stop function of the presser foot lift when the sewing machine stops while sewing it may cause damage to it because it has been left up for an unnecessarily long time Be aware that to prevent the foot presser solenoid from being damaged it is programmed to automatically come down when a certain amount of time passes 7 Method of Use Automatic Thread Trimmer and Wiper Selection Buttons These buttons offer the function of automatic trimming and wiping after sewing By pressing these buttons in sequence the user can use one of the following three functions The light shows the function that is currently being used 26 Automatic trimmer and oQ Only automatic trimmer 90 Both automatic trimmer and wiper do not operate function is operate wiper operate 8 How to use product counter and bobbin counter Product and bobbin counters are functionalities available for Fortuna Series IV option type D How to set product counter and bobbin counter A Set clear product counter and bobbin counter using the button in the program unit Repeatedly press the button in the program unit to change the status of the lamp and functions as below p yp When product counter and bobbin counter are not used W
20. a gt Internal E a a TA n Q a tc a gt a Membrane Switch FCZ42P e 72 5 Motor Mechanism 11 Control Box Mechanism Full Function 72 C Control Box Mechanism Economic Type 74 D Program Unit Mechanism 16 Pedal Mechanism 78 e Remarks Please let us get the additional details according to the itemized list below for the better service when ordering spare parts for SunStar motors Order for spare parts for servo motor 1 Serial number 2 Type of control box amp model name 3 Electric specification Phase Volt Hz 4 Machines model name Motor Mechanism lt 2 gt LL LP S e gt lt CO o EN 76 Assembly Ref No Parts No Note Name of Parts y No ooa SEn ene 06 009 5 50 Resistor 06 001 B SE50 B 4 06 002B 5 E50 Fixing Rubber for Resistor 5 10 021 5 66 6 13 005A SE50 Resistor Connect B 7 06 007 A SE50 Transformer B 8 06 001C SE50 Transformer Screw L6 EAA 4 16 B 16 08 002M SW 0606 B 17 01 0000 5 E50 B 18
21. convenient pattern for straight sewing at constant speed for a definite length The sides can be set from 0 to 999 stitches convenient pattern for repetitive 3 sided sewing Each side can be set from 0 to 999 stitches A convenient pattern for 4 sided sewing Each side can be set from 0 to 999 stitches Used often in square sewing convenient pattern when forward backward sewing is needed continually forward backward sewing is possible 9 times Also each side can be set from 0 to 999 stitches This pattern 15 used for continuous work on back tags of leather belt rings convenient pattern when the user wants to make many sided patterns The user can make patterns of up to 20 sides Each side can be set from 0 999 stitches 4 Method of Use Chain function pattern linking function First press the button and select the pattern sewing function Next press the button CHP ee Hn f you press the button the screen will change as the figure shows on the right You can change O mi of chains with buttons Q 9 Q If you want to program the number of chains in the pattern you want use buttons and to go to the item you want and press the pattern button After programming the chain numbers as explained above press the button and the change of value will be saved Then press the button to come out from the chain programming screen If you operate the programmed sewing work the pattern with th
22. 38 End Back Tack D stitch correction value 0040 6 6 Selection for maintaining reverse solenoid movement when thread trimming 0 01 1 reverse direction maintained Programming count condition i O counter used program whether or not automatic counter will be operated 1 automatic counter after thread trimming When automatically counting select Up Down count after thread m trimming thread trimming function must be enabled 0 DOWN COUNT buzzer rings sewing is allowed n 1 buzzer rings sewing is not allowed 37 When count in completeded the next operation is programmed 0 1 2 you press the Prog Key setup is cancelled 2 No buzzer ring sewing is allowed ee ee CLEAR PRESET 39 1 Items No 30 33 These are the items that make the number of stitches match when back tack number of stitches do not match Solenoid Duty Ratio The power that holds and maintains the solenoid Solenoid initial full on time The time it takes to pull the solenoid to the maximum in the outset Caution If the specific items of the parameter are changed carelessly they could break down or damage the machine so the user must be well trained before using it Checks operation of T R solenoid 4 C U Cc zx U e Checks operation of left solenoid OUTPUTOS matching the number of
23. Initial value 0 1 exact number of stitches function enabled If this function is used reverse sewing will no operate naturally 52 The speed of the first stitch during This item selects the speed of the initial reverse stitch when user has selected the exact B T exact performance number of stitches function in the B T operation 20 1000rpm Initial value 200rpm H Method to select buttons A B functions Name of function Method of use and explanation The function of button A can be one of the following four operations according to their set up value 0 If user presses A button while sewing B T sewing is operated while user keeps on pressing it 1 If user presses the A button while sewing B T sewing is operated If user stops sewing and presses A button once the needle plate is lifted If user presses it once more the needle plate is dropped 2 f user presses the A button while sewing B T sewing is operated while user keeps on pressing it If user stops sewing and presses button once the needle plate is lifted If user presses it twice consecutively the needle plate is dropped 3 If user presses A button while sewing B T sewing is operated while user keeps on pressing it When user stops sewing and presses the A button 1 2 stitch speed is operated The function of button A can be one of the following four operations according to their set up value 0 This item has the function of inserting deleting
24. Target speed If this speed is reached or passed a signal saying 1000spm 40 9960 40spm Target speed has been reached will appear M NN As an interior Port it is alloted and used in the GROUP Default is auxiliary 1 Delay start Delay start time duration setup 3 1x 100 ms Setup of needle bar s stop at the lowest position after trimming when the pedal is pressed Setup of the duration of needle bar s stop at the lowest position after trimming when the pedal pressed O disabled 1 enabled 70 100 100 250 1 ms Caution If the specific items of the parameter are changed carelessly they could break down or damage the machine so the user must be well trained before using it I co 50 2 Group B Parameter All types of output Full on Time PWM Duty checking input output operations sewing machine models and thread trimming sequence programming These are functions not used by general users and must be regulated by an A S technician ms 6 LetSolnoidintalFulOnTime ForTwiNeede 10005 a00 4ms _ AwirSoenodiialFulOnTme 4100 ____ _ 9 Left LED inital FullOnTime For TwinNeede moms 4100 4ms _ O Bobbin counter Disable Beers BH 30 Start Back Tack A number of stitches correction vale 000 66 QO05S ih 31 Start Back Tack B number of stitches correction vale 000 6 6 0 05 Stitch 32 End Back Tack stitch correction value 0040 6 6
25. on Time PWM Duty time set up method all types of solenoids LED and signals Item No B 1 B 28 E Full an Time n Off Type of wave that has a certain amount of Full on Time and 50 duty This figure explains the Full on Time and PWM Duty This figure shows the wave type graph where the machine maintains the power ON for a certain amount of time and when that Full on Time passes changes itself to a PWM signal with a certain duty In other words the certain amount of time that each device starts operating until they become completely the output wave type maintains itself On and when it maintains itself operating the output becomes the duty PWM wave type to maintain operation B B T stitch correction set up method Name of function Method of use and explanation mie This item has the function of correcting the B T sewing stitch that has not been shaped well and Start B T B side stitch correction value you can change the value of sides A B C D programmed value in the beginning B 32 End B T C side stitch correction value A 3 B 3 C 4 D 4 End B T D side stitch correction value d e f the stitch correction values is changed using the program unit the item value will automatically change Reversely if you change the programmed value of the items above the stitch correction values will also automatically change Detailed correction principles and methods of use are the same as the program unit
26. phase 200V 240V Switch Main Board Protective Earth EARTH 3 Three phase 200V 240V Switch Main Board PE Protective Earth EARTH Be sure to connect Protective Earth 2 Specification of electric current in wiring of power plug Be sure to use wiring materials which can stand electric current of higher than 15A 17 3 Names and Explanation of external connector in control box D Solenoid Connector 5566 16P 2 Basic switch connector 5566 8P Pin Number Pin Number 1 9 Back Tack solenoid 5 13 Left needle control 1 5 Manual Back tack 3 7 Knee lifter solenoid switch 2 10 knee lifter solenoid solenoid i button 4 8 Safety Switch 3 11 Trimming solenoid 6 14 Right needle control ly owl 4 12 Wiper solenoid solenoid 2 6 Back tack Insert Delete 7 15 Thread release solenoid Button 8 16 Auxiliary solenoid 3 Switch and lamp connector 5566 14P 4 Extension connector 5566 20P Pin Number Pin Number 1 10 9 i 2 9 4 4 1 2 9 10 12 V 13 Output 12 Left switch LED 10 3 4 3 8 GND 14 Output 13 Right switch LED 28 11 12 19 20 VCC 5 15 Output 14 Left switch 12 1 4 Right switch 13 Switch CNT 13 18 Extension Port 16 Output 15 VCC 5 14 Switch HALF 18 External Input 01 4 Changing solenoid supply voltage Basic setting values upon shipment J19 Xx It i
27. programmed corrected value 01 00 the length of the 1st stitch sewn in side D xt When the stitch comes out less than one stitch longer the last stitch of sides and B and the first stitch of sides C and D Side A program value Currently programmed correction value _00 00 When the stitch length comes out short Side C program value currently programmed correction value the length of the extra part of the stitch sewn on side C Side D program value Currently programmed correction value the length of the extra part of the stitch sewn on side D Caution The shadowed part is the currently saved correct value After programming press the button and save the programmed value Ex When the Start End B T stitch length is shorter than the programmed stitch length by around half a stitch a In the initial screen press the button and then also press the button b The screen will then go to the stitch number correction screen Using the Q buttons you can change the length of each side A B C and D in this screen If you have finished programming the new correction values to sidesA B C and D press the button and save the corrected value If you press the button you will return to the initial screen A 00 30 B 00 30 00 40 D 00 40 00 50 B 00 50 C 00 75 D 00 75 d Commence sewing and check the B T sewing condition e If the co
28. s stitch correction method Please refer to the program unit method of use of start end B T stitch correction method C Counter function method of use Name of function Method of use and explanation Counter condition set up When using automatic counter after trimming select increasing decreasing counter For detailed method of use and explanation of counter function refer to the After counter operation is over select the automatic erasing operation After counter operation is over set up the next operation Program unit s counter set up button method of use Caution lf the specific items of the parameter are changed carelessly they could break down or damage the machine so the user must be well trained before using it 3 Group C Parameter Specifics Method of Use and Explanation Pedal acceleration deceleration curve slow starting speed input output port change related parameter x These are functions not used by general users and should be regulated by an A S technician Pedal stroke step by step section and speed set up method Name of function Method of use and explanation pedal forward first step section pedal forward second step section After dividing the pedal stroke to 64 steps the pedal stroke s pedal forward third step section acceleration deceleration curve changes according to which stroke step is programmed from pedal forward steps 1 through pedal forward fourth step section pedal forwar
29. the command code and set up the data value according to the command code In other words the given sewing speed is the first data and the given stitch numbers is the second data and both of these form the data field Depending on the command code there can exist a data field or exist three data in the data field 64 4 Thread Trimming Sequence Program Code List Category Explanation Cmd Field Data Field 151 3r B T Solenoid On T R Solenoid Left Solenoid Right Solenoid AUX Solenoid Left LED Right LED Needle Up Signal Needle Down Signal Motor Runing Signal Reaching Target Speed Signal Motor Trimming Signal Motor End Tacking Signal Emergency Stop Signal On Roller Lift Solenoid Output Hemming Device Output Port Pedal Forward Step1 Signal B T Solenoid 98H P F Solenoid 99H T T Solenoid 9AH W P Solenoid 9BH T R Solenoid 9CH Left Solenoid 9DH Right Solenoid 9EH AUX Solenoid 9FH Left LED AOH Right LED Off A1H Needle Up Signal A2H Needle Down Signal Motor Runing Signal Reaching Target Speed Signal Motor Trimming Signal A6H Motor End Tacking Signal Emergency Stop Signal A8H Roller Lift Solenoid 9 Hemming Device Outout Pedal Forward Step1 Signal of Delay by 1 ms unit M NENNEN Delay by 2 ms unit u Time Delay NEN Delay by 4 ms unit B2H 6 5 85 86 87H 88H 5555 zi SE
30. the solenoid being tested press the 1stitch iL key and check Checks operation of right solenoid OUTPUTOG Checks operation of Aux solenoid OUTPUTO7 the condition of the movement Checks operation of Left LED solenoid OUTPUT10 Along with the output it will say or off Checks operation of Right LED solenoid OUTPUT11 Checks operation of needle when signal notifies up stop OUTPUT12 OUTPUT13 OO 51 Checks operation of needle when signal notifies down stop Checks operation of signal notifying motor running OUTPUT14 Checks operation signal notifying target speed has been reached 15 Select Thread trimming sequence a mn The default is set to 0 If you wish to input another sequence apart from the thread trimming sequence provided in the system input the newly composed sequence number Refer to the sequence composition method Thread trimming sequence data writing function 1 Selecting sewing machine model write the number that fits the sewing machine model provided in the full function manual 56 thread trimming sequence in the pertinent machine is copied 0 127 if you want to correct the thread trimming sequence change the contents of item B 55 However be aware that if you initialize the parameter the newly programmed changes will disappear and 59 non order made 75 118 order made Refer to attached material t
31. to move the needle bar to the desired position The screen displays changing position of needle bar 8 When the needle bar moves to the desired position save the position b p p y pressing key Then the screen automatically returns to the initial screen with a buzzer Caution Returning to the initial screen by pressing button without pressing button will not save reset values 2 Setting needle bar up down stop position by using simple controller board front OP D Turn on the up stop icon lamp by pressing needle bar up down stop button on the simple controller board to set needle bar up stop position 2 When the up stop lamp turns on press E button while pressing needle bar up down stop button Then as in the figure right the numbers that tell the current position of needle bar will be displayed 3 The operator turns the pulley forward manually to move the needle bar to the desired position The screen displays changing position of needle bar 4 When the needle bar moves to the desired position save the position by pressing key Then the screen automatically returns to the initial screen with a buzzer Caution Returning to the initial screen by pressing E button without pressing button will not save reset values 14 5 set needle bar down stop position press needle bar up down stop button of simple controller board to make on the icon lamp of needle bar up
32. 10 021M SW66 B 20 06 003C SE50 06 005B SE50 B 23 06 005A SE50 B 24 06 114A SE50 B 25 06 004C SE50 B 26 91 001A SE50 B 27 06 006B SE50 B 28 06 007B SE50 B 29 11 0025 5050 B 30 1 13 100A SE50 B 30 2 13 101A S E50 B 31 13 002 5 50 B 32 13 003A SE50 B 33 11 0025 5050 B 34 01 0035 1 B 35 GP 011331 00 B 36 13 006 5 50 37 01 025B SE50 Stud for DRV Driver Board M3 L5 L10 BE AHE M3 L5 L10 DRV Driver Board Screw for DRV Driver Board M3XL6 Screw for Bridge Diode 115 Guide Rubber for Cable Front Cover for Control Box WA AW Rear Cover for Control Box T 2 Front Cover for Control Box Screw for Control Box Cover MAXLI10 ON OFF Switch Cable Cover A Cable Cover B Screw for Cable Cover ST2 9 18 Power Source Cable 1 3 220V Power Source Cable 1 1 110 m Sapo Power Source Cable 2 Servo Motor Output Cable Screw for Control Box ST5 5 115 Principle Sticker Model Sticker Option Cable Gappad 1500 125 25 x 20 gt LP gt lt o lt gt c O O 78 Assembly Ref No Parts No Note Name of Parts No 06 009 5 50 Resistor 06 001 B SE50 C 4 06 002B 5 E50
33. 2300Series SC 7300Series Fortuna Series IV allows a user set up down stop position by using program unite without changing setting of synchronizer D Setting needle bar up down stop with using optional program unite D Turn on the down stop icon lamp by pressing needle bar up down stop button on the program unit to set needle bar down stop position 2 When the up stop lamp on press needle bar up down stop button with pressing the button After that as in the figure letter showing information on the setting target and number pointing the current position will blink 3 Turn the pulley forward manually to move the needle bar to the desired position The screen displays changing position of needle bar When the needle bar moves to the desired position save the position b p p y pressing key Then the screen automatically returns to the initial screen with a buzzer Caution Returning to the initial screen by pressing button without pressing button will not save reset values 13 5 Furthermore turn on the down stop icon lamp by pressing needle bar up down stop button on the program unit to set needle bar down stop position 6 When the down stop lamp turns on press button while pressing needle bar up down stop button Then as in the figure right the information on what 18 to be set and the numbers that tell the current position of needle bar will be shown 7 Turn the pulley forward manually
34. 2C 3701 Bushing for Pedal Control Lever ZEZ sg E 20 10 017A SC53 Pedal Control Lever Es gu E 21 10 025A SC53 Shaft for Pedal Control Lever ame 22 23 24 03 0048 5 M59 10 024P 3701 10 024W SC53 Screw for Pedal Control Lever M5 X L6 Flat Washer for Pedal Shaft 98 Fixing Pin for Pedal Control Lever 94x L10 zu 38 4x110 p du sd SBA 08 E 25 10 026A SC53 Base for Pedal Magnet amp Film HS u4ge amp BS Wola E 26 10 027C SC53 27 03 004S SM5S AS AERLE we M5xLo E 28 10 018G SC53 Tension Spring for Pedal Aza E 29 10 033C SF55 Rubber Cap for Pedal Base sj lt XH E 30 91 003 5 50 Pedal Control Rod Assembly L300xL300 s AA xx 1300 L300 E 31 07 027S SE55 Pedal Screw M5 X L10 su M5x L10 E 32 04 001 A S E50 Pedal Bracket aya E 33 E 34 04 001C SE50 Screw for Pedal Bracket ST5 5 X L15 duAHST55xLI15 E 000023 Edge Sensor Box Ass Edge Sensor YA lt E Pedal Magnet Base Screw for Pedal Magnet amp Film M5 x L6 E
35. 3 00 Sequence ending code 5 Now the user can change the sequence function according to his objectives but the remember that the program size cannot exceed 64 bytes Also you can set up several short sequences and then use the sequences you want by using item No B 54 When you setting this up each sequence must always have a starting and ending code Refer to sequence code list Caution f you dont press the button after changing the parameter item set up value the set up value will not be saved so use caution when using it e f the specific items of the parameter are changed carelessly they could cause breakdown or damage the machine Therefore the user must be well trained before using it 62 B Thread Trimming Sequence Selection Function Method of Use Item No B 54 D This function is used when the user wants to use other sequences apart from the sequences that are basically provided If you want to use this function first enter Item No 54 in parameter Group B Then you will see the screen shown in the figure 2 The starting value is set to 0 If you change this number to a value in the sequence of Item No B 55 you can now use the extra programmed sequence Use buttons Ex if you want to use the fourth sequence and change the sequence set up 3 The user can use Item No B 55 to save and use several frequently used sequences whenever he needs them Caution e f yo
36. LF lt Fortuna Series 4 gt 37 38 C Edge Sensor Program Setting y 4 p Turn the power on while pressing simultaneously is displayed with a beep sound and then disappears 2 Programs should be modified after trimming is completed O 3 Press first and then press O simultaneously Then the program modification mode appears as shown in the right figure 4 Use to set the code number at 52 Use to change the value from 2 the default value to 12 and then press to save the new value 5 When the program setting is done press to turn off the blinking lamp and use the sewing machine D Edge Sensor Setting D First make sure that there is no fabric below the sensor and set the operating mode of the rear side of the sensor at L ON 5 Press on the P U and check if the LED is blinking 3 Check if the STB yellow LED is turned on when there 15 a fabric below the sensor If the STB yellow LED is not turned on switch the operating mode to Operating D ON and begin the setting depending on types of fabric 5 Adjust the volume of SENS to make OPL red turned off while fabric is below the sensor and make OPL red turned on when it is removed it doesn t matter whether the STB LED 15 turned on or not 6 Check whether a signal alarm is issued in line with the presence of fabric under the sensor E Use of the Edge Sensor D Pre
37. Trimming Sequence Function Related Parameter Method of Use and Explanations Economic A Changing the Trimming Sequence with the Simplified Operation Panel When changing the thread trimming sequence by using the simplified operation panel the method is a bit different from when changing other parameters Check the following manual and make the changes in a correct manner lt S VI Simplified Operation Panel 63 How to Operate Display Remarks Press E Prg button and A button simultaneously Then the screen for changing parameters appears Program Enable Parameter B 01 2 Press B button and it moves to the parameter B group Use A button and B button to move to the No 55 trimming sequence of the B group Parameter B 55 Press C button when b 55 is displayed Then SEQ blinks on the screen Sequence 80 Trimming sequence start command Press C button once again and the screen displays the starting location number of trimming sequence starting location number of trimming sequence has changed from 80 to 81 Press button and B button to change the location number of the current trimming sequence ex When is pressed 80 is changed to 81 When C button or D button is pressed the trimming sequence location number increases or decreases The screen displays the values stored in the NE 88 the 83 command is stored in the second trimm
38. ammed value and forgets the original program contents Cun tait Oh ee Method of initializing Turn the power on by simultaneously pressing the buttons in the figure above which are the start B T button end B T button needle plate up down stop button Caution e f you initialize all the changes made by the user are changed to the original values programmed when the machine was delivered from the factory therefore only change the value if absolutely necessary After initializing rotate the machine for 1000RPM or more for approximately 5 seconds You must make the machine remember the location of the FILM 2 Sewing Machine Up Down Stop Location Automatic Recalling Function When first purchasing the controller if the user steps on the pedal for 5 seconds and runs the motor before beginning the sewing work the machine will automatically remember the sewing machine s up down stop location However when using a synchronizer this step is not necessary 3 Method of Use and Functions of the Program Unit and the General Control Box s Simple Operation Box When there 1s a program unit P U use it to program or change all the functions of the machine When there is no program unit use the general control box operation panel to program or change all the functions of the machine For detailed information on the method of use of program units and simple operation panel refer to th
39. an select the stopping location If the machine stops while sewing the If the machine stops while sewing the presser foot lift makes an up stop presser foot lift makes a down stop 6 Programming the Automatic Thread Trimmer and Wiper Movements with the Button E Pro This button programs the automatic trimmer and wiper after sewing If the user presses this button in sequence the location on the lights will change as shown in the figures below This button offers the following three functions Both the automatic trimmer and wiper are operating Automatic trimmer and wiper are not Only the automatic trimmer is operating operating 7 Programming the Start and End B T Stitches Press the appropriate button for 0 5 seconds for the place you wish to program the new Initial Screen B T stitch value The light will blink in that place Programming buttons for number of start B T stitches buttons A B Programming buttons for number of end B T stitches buttons D QTf the number is blinking you can change the programmed value by pressing the appropriate button Ex If you press the A button for 0 5 seconds the first number in the screen will blink 3 If programming is completed press the same button for 0 5 seconds once more and you will return to the initial screen Ex Changing the value of A B C D from 3 3 3 3 to 4 4 4 4 Caution Be aware that if you don press the
40. away from noise sources such as high power strip frequency equipments and welding machines gt 7 Avoid electrical shock when servicing the controller box Wait for 6 8 When an error message sppears on the digital display minutes before opening the cover after turning off the power take a note of the Er code and then turn on and off before resuming operation Contact the local dealer if message persists on the display Er 9 Clean it every two or three weeks so that no dirt or a dirty 10 When replacing the fuse use a standard item opening the substance may be piled up cover as shown in the diagram eben en eade Oe 2 9 E 250V 15A 65TL 31 8mm 250V 15A 65TL 31 8mm O 250V 1A 50T 20mm 250V 6 3A 50T 20mm 11 Make the length of the cable connected with an outside parts like stand up pedal as short as possible 3 LOCATING AND USING PARTS OF THE CONTROLLER BOX 1 Front and back of control box Control box front Full Option Type Control box back Full Option Type Control box grounding part SSS 60 69 e AC Power Input Power Cable
41. bject like a stove Keep the ambient humidity above 30 and below 95 4 Never use it near gases and explosives 5 Do not use it at a spot located 1 000m or higer above sea level 6 Keep the storage temperature higher than 25 degrees below zero and lower than 55 degrees Centigrade when not in use 3 Installation Follow the instruction carefully when installing it D Be sure to start installing it after pulling the power plug off the outlet 2 Fix the cable so that it may not move and do not allow the moving parts like belts to be interfered with Keep distance of at least 25mm from them 3 Be sure to have the Controller and the sewing Machine grounded 4 Be sure that the voltage of power source fits the specification of the Controller before the power is on 5 Be sure to use Safety Extra Low Voltage when an extra item or an accessory 15 fitted into the Controller 4 Disassembly D Indisassembling it be sure to wait at least 360 seconds before taking any action after pulling the plug off the power source after turning it off 2 When pulling off the plug from the power source be sure to hole the plug itself instead of the wire connected to the plug Gunstar gt 5 Service and Maintenance 1 Make sure that service and maintenance are carried out by a skilled technician 2 Never try to operate with the Motor and the Controller open 3 When inserting a thread into or touching the machine be sure to turn th
42. button for 0 5 seconds the screen will not return to the B T stitch programming screen but will remain in the sewing conditions program change items 1 4 functions section 43 44 8 Sewing Speed and Rotating Direction Programming Method D If you press the E Prg button for 0 5 seconds you will see the screen that enables you to change the sewing speed If you press the same button again for 0 5 seconds you will see the screen that enables you to change the rotating direction If you press the button one more time you will return to the initial screen Initial screen Speed programming screen Rotating direction programming screen Initial screen 2 If you want to change the sewing speed press the E Prg button After seeing the speed programming screen press buttons A and B to program the speed you want Caution Be aware that if you don t press the button for 0 5 seconds the screen will not return to the B T programming screen but will remain in the sewing conditions programming screen Items 1 4 functions 9 Method to Change Parameter Specific Items lt parameter specific item initial screen D To change the parameter s detailed items press the E Prg and A buttons simultaneously and return to the parameter detailed item s initial screen lt Initial screen for group gt Initial screen for group 2 If you see the PrEn screen select a parameter group using buttons A D 5 01 A but
43. ction for pedal thread trimming position 2 thread trimming at neutral position The maximum sewing speed for the KM 1060BL 7 presser foot lift 2000spm 200 2000 10spm with mutual crossing quantity of 4 8 7 0 mm Delaying time for complete release of KM 1060BL 7 B T Solenoid 4 1020ms Select to operate 2 start B T 4115 4 1020 1 N 18 9 1 NO gt gt Choose between 1 or 2 Select to operate 2 end B T Choose between 1 or 2 IC Caution If the specific items of the parameter are changed carelessly they could cause breakdown or damage the machine Therefore the user must be well trained before using it 47 48 OENE di 0 1 2 0 CAM type machine 24 ae ii b id Ls 1 thread trimming after up stop selection according to sewing machine type 2 thread trimming after low stop 0 1 25 Whether or not to use default sequence when A24 1 0 B 55 exclusive sequence is used This is a sequence determined on A9 A10 value 1 default sequence is used 26 Selection of B T Solenoid operation position 0 1 0 lower position 1 upper position program P1xx P2xx P3xx in order 27 Setting the maximum sewing speed of the machine according to Less than P1xx 3500 spm presser foot lift height of the KM 1060BL sewing machine Less than P2xx 3000 spm Less than P3xx 2500 spm More than P3xx A20 spm
44. d fifth step section sewing speed during pedal forward first step 440rpm sewing speed during pedal forward second step 920rpm The pedal stroke s acceleration deceleration curve changes sewing speed during pedal forward third step 4000rpm according to how the pedal forward step by step sewing speed set up is done sewing speed during pedal forward fourth step 5480 sewing speed during pedal forward fifth step 9960rpm B Slow start sewing method of use this function allows to start the sewing slowly and the user can set up the following specific items Name of function Method of use and explanation gt Tm These items help you choose at which point you can apply slow start If you want to apply it after thread trimming set item No C 11 value to 1 If you want to apply it after when you start sewing after stopping set item No C 12 to 1 If both 12 Slow Start after sewing machine stops these items are set to 0 the slow starting function will not operate When using the slow start function this item gives you the option of maintaining C 13 When Slow Starting change Slow starting speed the same starting speed or setting up a new speed If you want to set up a new speed use items No C 14 C 18 and set up a new speed When Slow Starting the operation speed of beginning stitch f When the item 13 set up value is 1 the slow start beginning wn values When Slow Starting the o
45. e blinking light is the current work being done and the pattern with the light on continuously is the next programmed pattern Caution After programming the chain function and pressing the button the set up value is saved f you change the pattern program while sewing it will sew with the new programmed pattern f the last chain pattern is finished it will automatically go to the first sewing pattern 1 the user presses the when using the pattern sewing function the Q light will go on and the machine will automatically sew the programmed pattern section even if the user releases the pedal 31 32 11 Method of Use Constant Speed Sewing AUTO Selection Button This button is used to choose the sewing speed It offers two functions according to where the light turns on When the light is blinking When the light is off f the user presses on the pedal the The machine will sew according to the machine will sew at the programmed amount of pressure given to the pedal sewing speed by the user Caution This button works in a different way when using the pattern function Please refer to section 10 12 Method of Use Sewing Speed Program Changing Button A Method to Check Sewing Speed If you want to check the current programmed sewing speed you must press the 14000 SE button If you briefly press the Q button button once the screen shown on your right will appear briefly and
46. e explanation in the last section 4 Function Parameter OR Group A General functions of the sewing machine 5 Group All types of output Full on Time PWM Duty checking input output operations sewing machine models and thread trimming sequence programming 3 Group C Pedal acceleration deceleration curve slow starting speed and input output port change related parameters Group D All types of gain parameter related motor control If the specific items of the parameter are changed carelessly they could cause breakdown or damage the machine Therefore the user must be well trained before using it 46 2 Fortuna Series 4 Full Function Software Specific Parameters 1 Group A Parameter General functions of sewing machine Minimum speed of pedal limit of sewing machine s minimum speed 200spm 20 510 Maximum speed of pedal limit of sewing machine s maximum speed 4000spm 40 9960 Thread trimmer speed Sewing machine speed from beginning to end of thread trimming when using CAM type Program Unit 1 stitch speed Key s performance speed 100spm Lifting of needle plate with button A dropping speed performance speed 300spm Step 25 40spm 300spm 20 510 25 20 51 20 51 25 25 Pedal degree of acceleration Pedal Curve 255 When the maximum speed is put in 255 steps 2 200 spn Thread trimming operation time
47. e power off and step down from the platform 4 Be sure to use standard products specified for replacement of parts 6 Other Safety Instructions 1 Tack care not to let your fingers touch any moving parts including belts 2 In case of remodelling or fitting of additional device be sure to follow safety standards and do not ever try to go ahead based on your own judgments 3 Do not try to operate with the safety device removed 4 Take care not to let water or coffee or something like those admitted into the Controller or the Motor 5 Never drop the Controller or the Motor to the ground The instructions presented above are for the safer and more proper operation of the Fortuna Servo Motor Ignoring such instructions could cause damage to the machine or physical injury of the user Please follow all the instructions when operating the machine PRECAUTIONS BEFORE USE 1 Do not turn on the power while stepping on the pedal 2 Turn off the power when leaving the servomotor overnight 3 off the power when servicing the servomotor or changing 4 Be sure to keep the servomotor securely grouned the needle 4 g 5 8 si 5 dj 8 3 le pm 1 5 Do not connect multiple servomotor power plugs to the same 6 Install the servomotor
48. ecure the selected group If the user changes the programmed value from the parameter specifics carelessly the user may cause break down or physical damage to the machine The user must therefore be well trained before changing the parameter group 2 Method of Use 1 Stitch Button Function D When necessary make 1 stitches by pressing the 1 stitch button 2 When the needle plate makes a down stop shortly press the 1 stitch button once and the needle plate will make an up stop And when the needle plate makes an up stop shortly press the 1 stitch button once and the needle plate will make a down stop Caution Be aware that if you are continuously pressing the 1 button the machine will keep on moving at the 1 stitch speed 22 3 Method of Use Start B T Button This button is used when the user wants to prevent threads from loosening at the end of the sewing work If the user presses this button in sequence the location on the lights will change This button offers the following three functions When sewing starts B T When sewing starts B T sewing is on with sewing is operated with DO e sewing does not operate button button Using the A B buttons in the 4 digit displayer the user can program the B T number of stitches he she wants Caution Be aware that if the start B T stitch is set to 0 in the 4 digit displayer the start B T sewing is imposs
49. en there is no signal from encoders R S T the connector the machine manually and 129 Er When the motor is overloaded check the machine load Check the location sensor cable 130 Er When there is no signal from the location sensor and connector 1 131 When there is an electric current overflow the motor Check the motor cable and the connector and problems with the connector Turn the power off and on again 12 133 Er When theelectric current overflow of the IPM stops em before using it 70 Gunsitar gt HOW TO PLACE FOR CONTROLLER 948550 11 2 18 a Sub classification according the details of the medal b Distinction of the SunStar models from others m Economic Type Full Option Type Sunstar KM 2300 Series 235A B 250 SunStar SC 7300 Series Chain Stitch UJ 1Phase 110 V 1Phase 220 V 8Phase 220 V OREDER S4AC50 2AF refers to SERIESA 1Phase 220V FULL FUNCTION CONTROL BOX for normal drop feed 71 13 BLOCK DIAGRAM SCN 7P P1 P2 P3 J14 2 DRIVER BOARD MAIN BOARD J6 B11B XH 41 J1 J12 J7 J12 5559 20 5557 14 555746 ae JE Servo Motor N with Encoder e
50. es listed above the pertinent output pin functions are disregarded Output Signal Level Collective Reverse Function 0 signa Collective Reverse selection Input Signal Level Collective Reverse Function 00 om signal Collective Reverse selection E NOT USED NOT USED Caution If the specific items of the parameter are changed carelessly they could break down or damage the machine so the user must be well trained before using it 4 Group D Parameter All types of gain parameter related motor control These are functions not used by general users and must be regulated by an A S technician The set value which listed below may show difference depends on motor LC a Dem oem Pme 9 L NC 8 N IA Positioning D gain Kpd3 1800 0 5000 Caution If the specific items of the parameter are changed carelessly they could break down or damage the machine so the user must be well trained before using it When you start tuning with the default values the parameter values above will be adjusted to the load level and the set value will differ from the default value E EN E EN E ES EN 57 3 Method of Use and Explanations for Specific Items of the Parameter 1 Method of Use and Explanations for Specific Items of the Group A Parameter General fu
51. es to be made after edge sensing will be made provided that the number of stitches to be made after edge sensing should be bigger than the number of stitches defined for the concerned line of a pattern F Edge Sensor Deactivation D Press to turn off the edge sensor Then the edge sensor is deactivated 39 40 Edge Sensor Program Modification D Programs should be modified only after trimming is conducted O 2 Press first and then press simultaneously p y Then the program modification mode is displayed as shown in the right figure 3 Use B 9 to enter the code number to be modified and use O to enter the desired value Press to save the new value 4 When the modification 1s completed press to turn off the blinking lamp and then use the sewing machine Caution When the sewing machine is initiated all stored data are returned to the default values 5 The edge sensor related programs are located in Group and the code numbers and descriptions are displayed as below Description Remarks 1 stitch Select types of fabric sensor Set the number of stitches to be made after sensing the fabric edge 40 spm Set the speed of sewing after sensing the fabric edge 0 use of pedal 1 constant speed constant speed related to A42 When using patterns trimming is automatically conducted after the set number of stitches is made Si
52. ge related parameter x These are functions not used by general users and must be regulated by an after sales service engineer 6 Seving seed alin sep where Mem 4999 _ speed alsin he step where pedalmavestaward Xs 4290 dem _ 9 Sewing speed asin he 4 step where pedal movestoward 4 90 _ Sewing speed value in the 5 step where pedal moves forward 9960spm 40 9960 Select slow start after thread trimming 11 After performing thread trimming start the next sewing work slowly 01 1 selection Select slow start after sewing machine stops 12 After performing sewing machine stops start the next sewing work slowly 01 1 selection 1 Use 14 18 value 13 When starting slowly select sewing speed change 0 1 Use default value D Lm NOT USED Automatic scaling to the speed curve selected by each set mode 29 Mode 0 Use a curve based on the set values from C 1 to C 10 Mode 1 Scaling to the speed set at 2 Mode 2 Scaling to the speed set using the Speed Up Dn key xt Items No 1 5 Equal division of pedal stroke in 64 steps The speed curve of the pedal stroke changes according to how many steps are set up for the divided pedal stroke of each forward pedal step Used when adjusting pedal Sensor Pedal Stroke x No 20 If a synchronizer signal comes but the next synchronizer signal does not come wi
53. h given Speed D2H 0 500 spm 0 357 deg SodinPos Make motor given Speedin given Position D3H 0 5000 som 0 357 deg 20spm Random Stop Stop randomly D4H EE WaitDn Edge Waituntil Dn Edge detected Chk Pos Check the posiiton passed amp branchto the address EAH 0 35 deg 0 64 address Chk Up Edge Check Uo Edge detected amp branch to the address E5H 0 64 Wait Pos1 When position aleady passed return EOH 0 357 deg When position aleady passed wat next position Wait Pos2 0 357 deg and then return Walt Up Edge Wait until Up Edge detected 2 Position Speed Check address Chk Dn Edge Check Dn Edge detected amp branch to the address E6H 0 64 address Uo Edge Clea Up Edge FG mak UpEdge not detected E H Dn Edge Clea Dn Edge FG mak DnEdge not detected E8H 0 5000 som Walt Speed Wait until motor speedis target speed 20spm 0 357 deg 0 64 address Check if motor speed is target speed amp Chk Speed branchto the address 66 Data Field Explanation Cmd Field Tm Pot No Switch en ich Right Solenoid Switch Pressor Foot Lift Switch utton 1 2 switch on P U Box Timming Disable Switch Wait until Rolla hit Sw the port oer signal deteded N AUTO Switc Pedal Start m Pedal Pressor Foot Input Pedal Thread Trimming Input Input Port Check 0 64 address WaitPort m tch De Check the address
54. he movement to item EZ Item 41 the number of stitches it will sew after it senses the edge 0 225 after sensing the machine will sew as many stitches as it has been programmed to sew Item 42 the sewing speed after it senses the edge of material 20 2000RPM this item sets up the speed of the stitches set to be sewn after it senses the edge 3 After sensing the edge of sewing material and the machine has sewn the number of stitches at the programmed speed the user needs to select item 43 to change the operation 0 to stop after sewing the programmed stitch numbers 1 to operate automatic thread trimming function after sewing the programmed stitch numbers 29 10 Method of Use Pattern Work Selection Button A Method to Set Up the Pattern Work Function This function is used when you need to continuously work on a sewing material If the light goes on after pressing the button you can use the pattern sewing function B Method of Use of Pattern Sewing Specific Functions D Cautionary words when using the pattern function Before using the pattern function finish the trimming work and turn on the pattern switch light If the user presses the pattern switch twice when he she is not using the pattern function the light will go off and he she will be able to go back to normal sewing However if the pattern mode has not been completely finished the pattern light will not go off
55. he thread trimming sequence will change to that of SunStar 235 250 Independent operation of trimming sequence 1 independent operation Presser foot lift solenoid slowing down time 1 resser foot lift solenoid slowing PA ime aes 2 510ms T Applied only when it is full on condition Presser foot lift solenoid slowing down time 2 30 2 510ms 2ms Applied only when it is PWM Items No 40 53 functions that check if solenoid and other output signals are working properly Select No 55 and press the Enter key Along with the buzzer sound you will see the words Seq 55 appear on the screen Thread trimming sequence composition permitting condition is now possible You can program a thread trimming sequence to a maximum of 64 bytes For thread trimming sequence program method refer to attached material 0 64 O operation after trimmin oh 3 Caution If the specific items of the parameter are changed carelessly they could break down or damage the machine so the user must be well trained before using it 52 8 Checks the signal input INPUTO4 3 4 stitch Switch Checks the signal input INPUTO5 4 4 stitch Switch 806 _ 70 Checks the signal input INPUTOG Left Switch Checks the signal input INPUTO7 Right Switch Checks the signal input INPUT10 Manual presser foot lift Switch Along with the input it will say on or Checks the signal inpu
56. hen changing both start and end B T stitch numbers to 4 b Method to check or change the specifics of the parameter D Press the button and as you press it also press the O button Then you p p you can either check or change the programming items for the parameter of group A A group group group group 9 Users should turn the machine off to select B C or D group While pressing the button turn the power switch on The screen will be changed to the initial screen after showing the PrEn message Then the users can select B C or D group by pressing B C or D button while holding program button 2 You can move to the parameter item you want with the ana buttons The parameter item number will appear in the 2 digit displayer and the wanted value will appear in the 4 digit displayer Ex Screen showing the maximum speed limit preset in the item 2 of group 3 After using the 9 increase button and decrease button to choose the value you want press the Enter button and save the value you chose Ex Reducing the maximum sewing speed limit from 4000RPM to 3000RPM After saving press the button and go back to the initial screen Caution Be aware that if you don t press after changing the programmed value for the parameter item the value will not be saved When the B C or D group selection is completed users should turn off the machine first and restart to s
57. hen the lamp is off 2 When product is set When the lamp is on 3 When 15 set When the lamp is flashing X To use the counter function set the detailed functions under parameter B Group 2 How to use detailed functions of product counter and bobbin counter A How to use the detailed functions of product counter To use the counter function set the detailed functions beforehand D To use the product counter function first set the value of the parameter group B item 35 as desired e 0 Set the external counter switch on 1 Set the automatic counter on after trimming xX As the default value is set 0 the counter will not run if there is no external counter switch 2 Set the parameter to select the type of product counter 1 Up counter 0 Down Counter The default value is set at 1 QQ The current amount 3 Press the counter button to set the counter function Press the button to check and set the detailed data of the counter The current counter amount The remaining amount 90 The progress tn Total target amount Default 100 The remaining amount x Press button repeatedly to see the above detailed data in order The user may set up the current counter amount Cn and the total target amount tn as desired 20099700 The progress 45 After the total target amount is set u
58. ible 4 Method of use End B T Button This button is used when the user wants to prevent threads from loosening at the end of the sewing work If the user presses this button in sequence the location on the lights will change This button offers the following three functions When sewing ends B T When sewing ends B T sewing can be operated sewing can be operated When sewing ends B T with o with the sewing does not operate C button button Using the C D buttons in the 4 digit displayer the user can program the B T number of stitches he wants Caution Be aware that if the end stitch is set to 0 in the 4 digit displayer the start B T sewing is impossible 5 Method of Use The Needle Plate Position Selection Button When the Sewing Machine Stops When the user turns the power on one of the up stop or down stop lights in the program unit panel needle plate is always left on The user can change the stop location by pressing the button When machine stops while sewing the When machine stops while sewing the needle plate makes an up stop needle plate makes a down stop 23 24 6 Method of Use The Presser Foot lift Location Selection Button When the Sewing Machine Stops When the user turns the power on one of the up stop or down stop lights in the program unit panel pressser foot lift is always left on The user can change the stop location by pressing the button
59. ide D After programming press the and buttons simultaneously Ex When there is one less Start or End B T stitch sewn a In the initial screen use buttons to change it from 3333 to 4444 b After programming it to 4 4 4 4 press the button Then press the 1 2 stitch button You will see the letters bt C and the buzzer will ring three times and the screen will automatically return to the initial screen c The changed initial screen will continue to display the wanted programmed value of 3 3 3 3 d Recommence sewing and check the corrected stitch number e If the corrected sewing condition continues to show more than one stitch difference repeat steps a d and make corrections x The example above is an explanation of when one B T stitch number comes less than one When there is more than one stitch is added or missing you can correct the stitch number as explained above Caution The stitch number correction value program range is between 6 stitches to 6 stitches You cannot see the currently applied correction value on the initial screen If you want to see the currently applied correction value press the button and then the Q button and either check the programmed value of each side or check items 30 side A s correction value 31 side B s correction value 32 side C s correction value and 33 side D s correction value from Group B of the parameter If each side s correc
60. ing location concerned sequence location ex When C is pressed the screen displays 83 the value which is in the second trimming sequence location Trimming sequence 15 stored When the trimming sequence change is complete following the above procedure press E Prg button to store the sequence Notice Please make sure that in case of a simplified operation panel the location value of the current trimming sequence is not shown Please make sure that in case of a simplified operation panel the functions of the buttons A B C D E are a bit different from those when they are used in other context n order to exit the trimming sequence change mode press E Then all the changed values will be stored If you want to make several changes press one time after all changes are made to save the changed values 3 Basic Structure of Thread Trimming Sequence Program Code A The thread trimming sequence program code is basically composed of the command field and data field which comes according to the command field The size of the program cannot exceed 64 bytes 2 I Explanation of function field Needle plate up stop after sewing given stitch numbers at given speed 0 5000 rpm 20rpm 0 255 stitch PosStopUp B The table above is an example of the program code structure If you want to use the function Needle plate up stop after sewing given stitches at given speed you must first select
61. inv P F Solenoid with duty T T Solenoid 102 inv T T Solenoid with duty W P Solenoid 103 inv W P Solenoid with duty T R Solenoid 104 inv T R Solenoid with duty Left Solenoid 105 Left Solenoid ith duly Right Solenoid 106 inv Right Solenoid ith duty AUX Solenoid 107 inv AUX Solenoid ith duty Left LED 108 inv Left LED ith duty Right LED 109 inv Right LED ith duty Needle Up stop notifying signal 110 inv Needle Up Stopped ith duly Needle Down stop notifying signal 111 inv Needle Down Stopped ith duty Sewing machine running notifying signal 112 inv Motor Running with duty Target speed notifying signal 113 inv Target Speed with duty Trimming notifying signal 114 inv Trimming without duty End Back Tack notifying signal 115 inv End Back Tack without duty Emergency stop notifiying signal without duty 116 inv Emergency Stopped without duty A signal appears when the motor stops for any error A signal appears when the motor stops for any error Roller Lift Solenoid without duty 117 inv Roller Lift Solenoid without duty Hemming Device Output without duty 118 inv Hemming Device Output without duty First step forward pedal notifying signal without duty 119 inv Pedal Start without duty Low signal without duty 201 High signal without duty A
62. ion use A B C D buttons c Save the programmed value press the E Prg and B buttons simultaneously You will go to the bt C screen The buzzer will sound three times and you will return to the initial screen 2 When making corrections of less than one stitch use items 30 33 of parameter Group B and will correct to stage 0 05 For detailed B T stitch number correction method refer to the section 13 of the Program Unit manual 11 Method of Use of the Inertia Tuning Function T lt Inertia tuning initial screen The inertia tuning function is to find the motor s gain value that match the weights 3 inertia Press buttons E Prg and D simultaneously to return to the initial screen of the inertia tuning Initial screen 2 If the initial screen comes on press the pedal until you hear the buzzer ring During inertia tuning the sewing machine will operate and stop 10 times 3 If the inertia tuning is completed the buzzer will ring and the initial screen will come on at the same time Caution Inertia tuning is carried out only when the controller is attached to the sewing machine for the first time and when the sewing machine is unable to accelerate or decelerate quickly 45 Fortuna Series 4 Full Function Software Method of Use 1 Basic Functions of the Fortuna Series 4 Full Function Software 1 Initializing This function is used when the user randomly changes the parameter s progr
63. ion of end back tack performance condition 0 1 1 exact stitch performance Change between and switch wih butons Aor B during sewing 0 on i SdedwihtutonB 0 Only operates 1 Lift and drop needle plate with one movement 2 Lift needle plate with one movement Drop needle plate with two movements 3 Slow performance when stopped 1 2 stitch speed 1 B T work completion 2 B T exact stitch performance gt Selection of button A function 0 B T delete insertion 1 Lift and drop needle plate with one movement 2 Slow performance when stopped 1 2 stitch speed 3 Only B T operates 0 current sewing speed 1 initial reverse speed Selection of Button B function 56 Selection of speed during manual back tack during sewing OD Go N N Reverse rotation distance when selecting reverse rotation after thread trimming 20degree 0 250 When machine stops fix pulley When machine stops fix the motor by force 1 0 0 0 1 selection of reverse direction 0 0 01 1 fix when machine stops Power to fix the A number 62 Pulley 40 10 100 1 0 Distance recovered after fixing A number 62 Pulley and rotating it by force 20degree 10 100 1 1 1 1 E p T 1 1 1 clockwise 65 Select the motor rotating direction 0 counterclockwise 1 25 0 1
64. k down or damage the machine so the user must be well trained before using it 58 F Pre stitch function method of use and explanation Item No Name of function Method of use and explanation The pre stitch function is a function that programs the machine to sew a certain amount of stitches before A47 Selection of pre stitch function commencing the actual sewing work 0 disable 1 enable oet pre stitching stitch number This item sets the number of stitches when using the pre stitch function 0 255 stitches Initial value 3 stitches A49 Sat ores speed This item sets the sewing speed when using the pre stitch function did 20 2000rpm Initial value 2000rpm G Method to select beginning ending reverse sewing conditions Name of function Method of use and explanation The start B T function can be one of the following three operations according to their set up value 0 If user releases pedal during B T operation sewing stops 1 If user releases pedal during B T operation sewing stops after finishing work 2 The exact amount of stitches is operated notwithstanding the number of stitch corrections However if this function is used B T will no operate naturally Selection of start B T conditions Initial value 1 This item selects whether or not to use the end B T s exact number of stitches function operation Selection of end B T conditions 0 exact number of stitches function disabled
65. m 07 91 Distance between up stop low stop M the standard is the pulley s normal direction rotation 92 Programming the upper stop location the standard is the pulley s normal direction rotation 0 359 1degree Not valid for model 5 1 93 Programming the low stop location the standard is the pulley s normal direction rotation 0 359 1degree Not valid for model S III 94 Index pulse occurring position 0 359 1degree the standard is the pulley s normal direction rotation MEMBRE Turn the pulley manually and stop it in the position you want 95 CAM type thread release solenoid operation position 0 359 1degree Turn the pulley manually and stop it in the position you want CAM type thread release solenoid release position 0 359 1degree mmo 97 CAM type thread trimming solenoid operation position 0 359 1degree semmmeermasepanme CAM type thread trimming solenoid release position Turn the pulley manually and stop it in the position the user wants Manual and automatic set up of solenoid operation 1 0 1 set up release position in CAM type thread trimming 1 automatic set up Caution If the specific items of the parameter are changed carelessly they could break down or damage the machine so the user must be well trained before using it 53 54 3 Group C Parameter Pedal acceleration deceleration curve slow starting speed and input output port chan
66. matically return to the initial screen Caution Inertia tuning can only be carried out when the controller is attached to the sewing machine for the first time and when the sewing machine does not accelerate or decelerate quickly 15 Sewing machine head open error and safety switch error DSewing machine head open error function is available for KM 2300 series When the sewing machine head is lifted during sewing or with the power switch on oPEn Er will show with a buzzer sound and sewing will stop oPEn will appear When th hine head is lifted with env The error indication will disappear when the machine head is put back to its original the power switch on position and sewing may begin o oPEn Er will appear 2 When the machine head is lifted PP f the error message remains even after putting the machine head to its original position during sewing turn the power off first and turn it back on to continue sewing When oPEn Er message appears even when the machine head is in its original position EM be sure to check the following 9 a pace Check the switch attached under the right side of the machine head original position Check the set value of parameter The value of must be set at 20 2 Safety switch error function is available for SC 7300 series The error message will show when the blade does not retu
67. mple Operation Unit Part Names and Method of Use 1 Names of Each Part in the Simple Operation Unit Simple operation unit is attached in the front of the control box and used when there is no program unit panel 2 Simple Program Unit Method of Use 1 Initializing This function is used when the user randomly corrects the programmed value and forgets the initial programmed value Turn the power on by simultaneously pressing the buttons A and B C Caution When you initialize you change all the original values that the sewing machine had when it was manufactured in the factory Initialize only when absolutely necessary When initializing you must run the motor for more than 5 seconds at the speed of 1000RPM in order to make the synchronizer to work properly 41 2 Programming the Start B T Sewing Conditions with Button A This button is used when the user wants to prevent threads from loosening at the end of the sewing work If the user presses this button in sequence the location on the lights will change as shown in the figures below This button offers the following three functions JN When sewing starts B T sewing does not with the button Use the A B button to program the number of B T stitches in the 4 digit displayer Caution Be aware that if the end B T stitch number is set to 0 in the 4 digit displayer the user will be unable to operate start B T sewing
68. n the pedal can Ae LL will finish sewing the pattern section program the number of stitches by using the accelerating and decelerating even if user releases pedal while characteristics through the pedal s sensors The standard for choosing the number sewing of stitches here is slower than the normal sewing speed and the programmed pattern sewing speed Method using the A button and 1 2 stitch button This function is used when the user needs to make small adjustments at the end of the pattern work It allows the user to check and program the pattern length while he she sews at a slow speed or sews half stitches d After programming is finished press the button and save the set up value Then press the button After the stitch numbers of each side disappear from the screen you can start sewing with the programmed value in the pattern sewing function The pattern sewing speed is constant because it sews at a programmed speed not by the acceleration or deceleration of the pedal If you press the pedal after pressing the Q button and see the light blink sewing will continue until it is finished even if you release the pedal Caution After setting each side of the stitches the user must press the button to save the programmed value When the pattern has more than one side the pattern work only operates for the number of stitches programmed for each side 30 3 Specific items of each pattern
69. nctions of sewing machine A Minimum maximum sewing speed limit set up method and thread trimming speed set up method Name of function Method of use and explanation 1 Minimum sewing This item allows user to set up the minimum sewing speed limit or the minimum sewing speed speed limit set up given whenthe pedal is pressed 20 510rpm Initial value 200rpm Maximum sewing This item allows user to set up the maximum sewing speed limit or the maximum sewing speed limit set up speed given when the pedal is pressed 40 9960rpm Initial value 4000rpm Thread trimming speed set up This item allows the user to set up the thread trimming speed when the thread trimming function is operating after sewing Set up method of zstitch speed by program unit P U and needle plate lift drop by button Name of function Method of use and explanation Sanmameihod ord This item allows user to set up the 1 stitch speed by program unit P U and hence sets up the ud ae nit P U L5 stitch operating speed However if set up to a rapid speed many stitches may be UP sewn after pressing the button Set up the speed of lift drop This item allows user to set up the speed of lift drop of the needle plate with button A of needle plate with button A However if set to a rapid speed many stitches may be sewn after pressing the button C Start B T sewing speed and end B T sewing speed set up method Name of function Method of use and explanati
70. nge the value to Replace old lower thread with the new The amount of the lower thread must be consistent Begin sewing The more you sew the higher the value of UP will be Continue sewing until you run out of the lower thread When there is no lower thread left during sewing press button to store the counted value Before storing subtract 10 20 from the counted value to account for the value counted after the lower thread had run out 2 When the bobbin counter setting is complete move to bc display Then you will see the value you stored on UP display 3 The value of bc bobbin count decreases gradually when sewing begins after completing set up Caution x Before using the bobbin counter function move to bc display or initial display If you start working from display the value of counter will go up 27 28 c When bobbin counter is complete D Replace old lower thread with the new one Start sewing and the value of bc Bobbin counter will go down gradually 2 Take note that the buzzer will go off when the value goes down below 20 This is to warn that there 1s little lower thread left 3 Continue sewing till the value of bobbin counter hits 0 Then sewing will stop buzzer will go off and the display will start to flash 4 When sewing stops after counting is complete use the following method to return Press to change to the au
71. on This item allows user to set up the start B T speed If the speed is changed the stitch A 7 Start B T speed set up P P P 9 correction value also has to be set again This item allows user to set up the end B T speed If the speed is changed the stitch A 8 End B T speed set up correction value also has to be set again D Selection method of thread trimming location with pedal Name of function Method of use and explanation You can change the thread trimming operation through pedal position by making the following changes to the set up values Start speed set up 0 When the pedal position is backward 2 gear operate thread trimming Starting set up value 1 When pedal position is backward 1 gear operate thread trimming 2 When pedal position is neutral operate thread trimming E Edge Sensor method of use Item Name of function Method of use and explanation The set up method changes according to the set up parts of edge sensor Selection of edge sensor type 0 When edge is sensed and using high output sensor 1 When edge is sensed and using low output sensor edge sensor sensing a programmed amount of stitches when edge is sensed after edge sensor sensing a programmed amount of stitches when edge is sensed select N stitch mode even when other sensor signals are inputted in the edge sensor port Caution If the specific items of the parameter are changed carelessly they could brea
72. peration speed of third stitch ihe specific chance he valise When Slow Starting the operation speed of fourth stitch 1 400 2 400 3 640 4 1000 5 1680rpm When Slow Starting the operation speed of fifth stitch C Motor maximum speed limit set up method Item No Name of function Method of use and explanation This function allows you to limit the maximum motor speed and the starting value is C 19 Set up motor maximum speed limit set to 3000 rpm C 14 C 15 C 16 C 17 18 C Caution If the specific items of the parameter are changed carelessly they could break down or damage the machine so the user must be well trained before using it 61 4 Thread Trimming Sequence Function Method of Use Items no 54 55 56 of Group Thread trimming sequence function characteristics thread trimming sequence is a user programming function of PLC control type used for thread trimming or when a special simple repetitive function is required The user composes the thread trimming sequence he wants and can program the machine or motor s operation during thread trimming When necessary the user can change it to exclusive mode and can program all types of special operations The program size is 64 bytes so compose the program within this size limit The program code is composed of the command field and the data field The thread trimming related parameters a
73. re items No 54 55 56 from Group B This item that provides the function of thread trimming sequence selection which allows the user to select and use the sequence from item No B 55 This item provides the function of allowing the user to select other company sewing machine models and makes automatic changes in the thread trimming sequence that fit the selected sewing machine This item provides the function of allowing the user to compose the thread trimming sequence himself 1 Thread Trimming Sequence Function Related Parameter Method of Use and Explanations Full Option A Thread Trimming Sequence Data Input Function Item No B 55 D This function allows the user to compose the thread trimming sequence himself In order to do this the user must first enter parameter Group B 2 If the screen changes go to the specific items and choose item No 55 from Group B Then the user will see the letter Seq blink Use buttons Q Q If you press the button where it says Seq 55 you can now choose the thread trimming sequence In the figure you can see the command 80 which indicates the sequence start The command 7017 is a number within the sequence 01 64 of the 80 command 4 If you use buttons Q increase the numbers you can see the sequence that was set up in the start Their contents are explained below 01 08 Sequence starting code 02 F3 General sequence 0
74. rn to its original position during trimming D When the error appears during SF22 Er will appear sewing Check if the blade of the sewing machine has returned to its original position If SF22 Er message appears after you turn the power on and begin sewing be sure to 2 When the error appears immediately i S check the following Check the safety switch attached on the back of the sewing machine Check the set value of parameter The value of must be set at 111 36 16 How to Use the Edge Sensor Fabric Edge Sensor A Applicable Fortuna Model D Fortuna Series 3 Full Function Type using the switch and lamp connector port 2 Fortuna Series 4 Full Option Type using the switch and lamp connector port B Installation D Install the edge sensor bracket on the head of the sewing machine as in the figures below 2 Attach the edge sensor to the installed edge sensor bracket EDGE SENSOR Upside of sewing machine table KM 235 250 gt KM 750 790 gt 3 Install the edge sensor box ass y which is connected to the edge sensor on the table 4 Link the edge sensor connector to the switch and lamp or option 1 connector Pin Number 116418413211 1 2 7 GND 9 4 4 Left switch LED 10 3 4 Right switch LED 11 24 Left switch 12 1 4 Right switch 13 Switch CNT VCC 5 V 14 Switch HA
75. rrected sewing condition still shows differences between the programmed value the repeat steps a d and continue correction Caution If each side s corrected value has been corrected to the minimum or maximum value limit between 6 stitches to 6 stitches and the sewing condition is still not correct reduce the B T sewing speed Generally you can correct for when there is more than one stitch difference with item A However with item B you can correct when there is either more or less than one stitch difference Make sure to press the button and save the programmed value when you finish programming sides A B C and D s new correction value 35 14 Method of Use Inertia Tuning Function lt Inertia tuning initial screen 1 The inertia tuning function enables the machine to save the gain value of the motor 5 5 that matches the loaded inertia If you simultaneously press buttons and you will see the inertia tuning screen Then you will see the words TUNE blinking EHRE EN 2 When the screen changes you must press the pedal until the buzzer rings If you A 6 release the pedal before the buzzer rings the inertia tuning won t be completed Initial screen Therefore you must press on the pedal until the buzzer rings When doing inertia tuning the sewing machine will operate and stop 10 times 3333 3 When inertia tuning is completed the buzzer will ring and it will auto
76. s for a good operation of solenoid when AC input voltage changes D Setting values of solenoid supply voltage against input voltage input voltage 220V series Solenoid with the rating current of 30V Solenoid with the rating current of 24V Input Voltage Setting Values Input Voltage Setting Values Solenoid with rating current of 30V Solenoid with rating current of 24V Input Voltage Setting Values Input Voltage Setting Values Less than 100V 2 Setting values of supplied voltage to solenoid against input voltage Input voltage 1 10V 3 Setting supplied voltage ze n xo Ta D 5 19 Method As in the figure connect grounding conductors green or green yellow that link the machine and the controller Check if grounding part of power is connected to the grounding conductors Failure to ground the motor can cause abnormal operations such as overspeed rotation or unwanted Caution stitching THINGS TO BE CHECKED AFTER INSTALLATION 1 Before the power is on D Make sure that the incoming voltage is in accordance with that shown in the name plate of the Control box 2 Check whether the following connectors are connected 3 Check to see the fixing nuts for pulley are tightly fastened 4 Check whether
77. se and to set the movements Set value of B 37 0 When work is finished the buzzer will go off and sewing may begin 1 When work is finished the buzzer will go off and sewing may begin only when the button is pressed o 9 2 When work is finished the buzzer will not go off and sewing may begin Total target amount Set value of B 38 gt 0 Noreturning to automatic initial value when counting is complete 1 Returning to automatic initial value when counting is complete 20099700 Caution When B 38 is set at 70 the value will keep on going up down even when counting is complete The user will need to re set the value of Cn to restart 25 B How to use the detailed functions of bobbin counter Bobbin counter is designed to check the remaining amount of the lower thread a To use the counter set detailed functions beforehand D To use the bobbin counter function first set the value of the parameter Group B item 39 0 Bobbin counter function not used 1 Bobbin counter function used The default value is set at O At this point the bobbin counter will not start even when the counter button in the program unit is set at bobbin counter function b Detailed functions of bobbin counter D Select the bobbin counter function by pressing button to get the lamp flashing Press button and the display will change as shown in the right bc stands for bobbin counter
78. sew the programmed number of stitches and stop 42 N stitch sewing speed 1000spm 20 2000 10spm 3 Selection of One Touch function replaced by AUTO Key function 1 Auto Mode Used in the sewing mode that uses the auto function Selection of One Touch function replaced by AUTO sewing mode programming 1 One Shot Mode qe If there is no thread trimming signal when selected sewing will continue even if user releases pedal One Shot sewing speed When using AUTO function it is programmed with the speed Up Dn Key 2000spm 40 9960 40spm qe 0 1 0 1 6 N stitch sewing mode selection sewing mode that inputs a sensor signal 0 1 in the edge sensor port and uses it as an edge sensor 1 N stitch Mode 7 Selection of pre stitch function When selected it will perform only 1 selection the programmed stitches before the actual sewing work starts Pre stitch number of stitches 3 stitches 0 255 1 stitch Pre stitch speed 2000spm 20 2000 10spm Caution If the specific items of the parameter are changed carelessly they could break down or damage the machine so the user must be well trained before using it qe 48 49 1 Selection of start B T operating conditions 0 stop function selected 50 0 if pedal is released during back tack it will stop 1 if pedal is released during back tack the work will still be completed 2 it will perform the exact amount of back tack stitches It 51 Select
79. ss to turn on the lamp 2 During sewing while the lamp is on if the sewing needle comes near to the edge of fabric some 2cm between the needle and the edge of fabric a beep sound is issued and the sewing stops 3 Move the pedal to the neutral position and press it again Then the sewing 15 resumed according to the number of stitches previously set under Prog Group on the the number of stitches to be made after sensing the fabric edge and the sewing speed previously set under No 42 Note The default number of stitches to be made after edge sensing is three stitches and can be adjusted to 64 stitches at the maximum depending on user choice The sewing speed can be set at the range of 24 to 2040spm The default speed is 200spm If the pedal is pressed continuously the sewing machine will repeat the same function as described above 4 When a trimming is programmed to be conducted after the low speed sewing 15 completed the backtack sewing will be performed according to the number of backtack stitches defined on the P U followed by trimming Note Press to turn the lamp off in order to change the number of stitches to be made after sensing the fabric edge while working on pattern See the below to modify the program 6 If the edge sensor detects the fabric edge before the set number of stitches is finished during sewing the unfinished number of stitches will be ignored Only the number of stitch
80. stop 6 When the down stop lamp on press needle bar up down stop button C with pressing E button After that number pointing the current needle bar position will blink 7 Turn the pulley forward manually to move the needle bar to the desired position The screen displays changing position of needle bar When the needle bar moves to the desired position save the position by pressing C key Then the screen automatically returns to the initial screen with a buzzer Caution Returning to the initial screen by pressing button without pressing button will not save reset values Caution The names of buttons on simple controller board are as follows D A Button switch Switch for initial Reverse 2 B Button switch Switch for end reverse 2 C Button switch Switch for needle bar up down stop when the machine Stops D Button switch Switch for automatic presser foot ascending when the machine stops 5 E Button switch Switch for program 15 6 Installing program unit D As in the figure below attach program unit bracket to program unit with three fixing screws As in the figure attach the bracket with program unit to the head of machine firmly with two fixing screws 7 SunStar machine installed with program unit WIRING AND GROUNDING 1 Specification of the power plug 1 Single phase 100V 120V Switch Main Board Protective Earth EARTH 2 Single
81. t INPUT1 1 Counter Switch Le Checks the signal input INPUT12 PU 1 2 stitch Button Checks the signal input INPUT13 Safety Switch ID Checks the signal input INPUT14 Edge Sensor Checks the signal input INPUT15 Thread trimming not allowed T2 73 Checks the signal input INPUT20 First step for pedal going forward 7 i 79 2 e 7 EN Crede tepengan ncreases by each rotation of the sewing machine 1 increases when sewing machine Checks the synchronizer signal rotates clockwise 2 decreases when sewing machine 81 Checks the signal from encoder A B rotates in counterclockwise 1 When sewing machine is rotating clockwise 1011001105010 011001101 8 Checks the signal from encoder R S T 2 When sewing machine is rotating counterclockwise 101 001 gt 0115 010 110 gt 100 101 Items No 60 76 functions that check individual normal movement Items No 77 79 functions that check each analog input normal movement Item No 80 function that checks whether the synchronizer signal is working properly Item No 81 function that checks whether the encoder is working properly Item No 82 function that checks whether the encoder R S T is working properly Caution If the specific items of the parameter are changed carelessly they could break down or damage the machine so the user must be well trained before using it
82. ted value has been corrected to the minimum or maximum value limit between 6 stitches to 6 stitches and the sewing condition is still not correct reduce the B T sewing speed Generally you can correct in the manner mentioned above when there is more than one stitch difference And you can correct when there is less than one stitch difference with the item mentioned in the next page 34 B When the machine sews less than a stitch more or less than the one programmed Initial screen 8 If there are still problems with the B T sewing condition even after correcting the stitch numbers for more than one stitch difference based on item A refer to figure B and 3333 check the sewing condition again A O QQ b Look at the sewing condition and make the correction as follows Program range for making stitch corrections for less than one stitch Prog Auto 6 stitches 6 stitches Program unit 0 05 stitches Corrections are done by dividing one stitch into 20 parts nitial program A 00 30 B 00 30 C 00 40 D 00 40 Correct stitch number application method use C and D buttons for programming When the stitch length comes out short the third stitch of sides and B the Ist stitch of sides C and D 01 00 the length of the 3rd stitch sewn in side B Side C program value Currently programmed corrected value 01 00 the length of the 1st stitch sewn in side Side D program value Currently
83. the B T sewing when user presses the B button If the user presses the B button where there is no B T sewing section B T sewing is inserted and when it is pressed where there is a B T sewing section B T sewing is deleted If user presses the B button once the needle plate is lifted and if user presses it once more it is dropped 2 When user stops sewing and presses the B button 1 2 stitch speed is operated while user presses it 3 When sewing B T sewing is operated while user presses B button Selection of button A function Initial value 2 Selection of button B function Initial value 0 Method of use of motor rotating direction selection function Name of function Method of use and explanation This item sets up the set up value according to the motor s rotating direction Selecting the motor s rotating accion 0 clockwise rotation 1 counterclockwise rotation Initial value 1525 Caution If the specific items of the parameter are changed carelessly they could break down or damage the machine so the user must be well trained before using it 59 60 2 Group B Parameter Specific Method of Use and Explanation All types of output Full on Time PWM Duty checking the input output movements sewing machine models and thread trimming sequence programming These are functions not used by general users and should be regulated by an A S technician A All types of output Full
84. the sewing machines are right kinds Chain Stitch S M Lock Stitch S M 5 Check the rated voltage for Solenoid Refer to How to change the electric voltage supplied for Solenoid 2 After the power is on D Check whether the program unit is working 2 Check the direction of rotation of the Sewing Machine n case the direction of rotation is not right action shall be taken to change set it right referring to the methods of changing the program and the list of changing functions 65 in Group 3 Check to see whether there are abnormal heat smell or noise nearby n case there are turn the power off and call our regional office 20 Program Unit Part Names and Method of Use 1 Program unit part names Button to Select Presser Foot lift 2 Digit Displayer Start B T Selection Button Location When Machine Stops End B T Selection Button Thread trimmer and Wiper Selection 4 Digit Displayer Button to Select Needle Plate Location When Machine Stops Button to Change the Sewing Speed Installation Sun Stas SUNSTAR ELECTRIC CO LTD 990000 00 90 E e e e e e e Zc ap 124 4 CLP QUOS Chaff Qe 1 2 Stitch Button Pattern Work Selection Button Constant Sewing Speed Selection Button Button for Program Change Button for Counter Use after Counter Programming Button to Save Program Changes Button to use Edge Sensor Selection after Edge Sensor Programming Pattern Work Connecting Button
85. then return to the initial screen Q 9Q o 9Q x The speed on the screen is the limit of the maximum sewing speed Caution The maximum speed and minimum speed limits can be changed by changing the parameter s specific items B Sewing Speed Changing Method D When you want to change the sewing speed you can see the screen that shows the 3933 current sewing speed by pressing the Q button or button A 5 D 2 If you see the current speed on the screen you can change speed by using the Q 9000 button before going back to the initial screen When you press the buttons twice in sequence The sewing speed increases decreases 9 99 by 40RPM When you keep pressing the button The sewing speed increases decreases rapidly 3000 Caution aware that if you don t press the Q Or button the screen will automatically go back to the initial screen The maximum speed and minimum speed limits can be changed by changing the parameter s specific items 13 Start and End Backtack Stitch Correction Method Since backtack stitches may vary according to the type of sewing machine use the following stitch correction method adjust the stitch fast and clean users should check the stitch condition before commencing the correction D Classification according to backtack sewing condition The backtack sewing condition can be classified as follo
86. thin the sensing time an error message will appear No 21 If a speed instruction was sent to the motor but the motor does not reach the value of the speed instruction an error message will appear Caution If the specific items of the parameter are changed carelessly they could break down or damage the machine so the user must be well trained before using it This item is operated by the factory only so general users and A S technicians should not use it s 2 33 W P Solenoid Low Active 3 T R Solenoid Low Active 34 OUTPUT04 OUTPUTO5 Left Solenoid Low Active Output port changing function OUTPUTOS Right Solenoid LowActve 6 write the function number the output PIN you want to OUTPUTO7 AUX Solenoid Low Active change after referring to the 38 OUTPUT10 Left LED High Active 5 table below A 35 36 39 11 Right LED High Active 40 12 Needle upper stop notifying signal High Active 41 OUTPUT13 Needle lower stop notifying signal High Active 42 14 Signal notifying motor is running High Active 43 OUTPUT15 Signal notifying target has been reached High Active x Output PIN function Function No H W type actual output name Function No H W type actual output name B T Solenoid 100 inv B T Solenoid with duty P F Solenoid 101
87. tomatically stored value of bc AUTO CLEAR PRESET Caution To use the bobbin counter function first set B Group 39 to 1 x Use Q button to change the display to set clear the value of bobbin counter during sewing button is used to set the value of bobbin counter on display or to return to the default value Press A button to clear the current value and recall the stored counter value x Wind the lower thread with consistency to ensure the proper use of bobbin counter functions Counter functions may work differently depending on lower thread and sewing conditions 9 Method of Use Sewing Material Edge Sensor Selection Button A Method of Use Edge Sensor Function After programming the edge sensing function in the sewing material from the parameter specific items press the button If the light goes on you can start using the edje sensor function B Method of Use of Sewing Material Edge Sensor s Specific Functions The sewing material edge sensor selection button has a function that enables the machine to stop when it senses the end of a sewing material If you want to operate a particular function you must program a few specific items D User must change item programmed value according to the characteristic of the installed sensor 0 When edge sensing 5V output Active High should be the initial value 1 When edge sensing OV output Active Low 2 After sensing you can set up t
88. ton A group B button B group J Initial screen for group Initial screen for group D gt Cbutton C group D button D group 3 After selecting the group you want use buttons A and B to select the specific item you want Ex Select No 2 item of Group A Limiting the maximum sewing speed If you selected the specific item you wanted press button C The value you selected will then appear on the screen Ex The current maximum sewing speed 4000RPM 5 Using the buttons A and B change the current programmed value to another value Change the maximum sewing speed from 4000RPM to 3000RPM 6 If you completed your selection press the C to save the value you chose 7 You can change other specific items of the parameter in the same manner Caution aware that if you changed the specific items of the parameter and didn t press the C button the changed value will not be saved f you change the parameter specific items carelessly this may cause breakdown or physical damage to the machine Therefore the user must be well trained before changing items in the parameter group 10 Start and End B T Stitch Number Correction Method D Corrections in the initial screen are the same as those in item 13 of the program unit manual Correcting method for when the B T number differs by one stitch a Check the present sewing condition b Change the value of the part that needs correct
89. ton B Switch 101 inv Button B Switch 1 4 stitch Switch 102 inv1 4stitch Switch 2 4 stitch Switch 103 inv 2 4 stitch Switch 3 4 stitch Switch 104 inv 3 4 stitch Switch 4 4 stitch Switch 105 inv4 4stitch Switch Left Solenoid Switch 106 inv Left Solenoid Switch Right Solenoid Switch 107 inv Right Solenoid Switch Presser Foot Lift Switch 108 inv Presser Foot Lift Switch Counter Switch 109 inv Counter Switch Program Unit 1 2 stitch Switch 110 inv Program Unit 1 2 stitch Switch Safety Switch 111 inv Safety Switch Edge Sensor Signal 112 invEdge Sensor Signal Thread Trimmer Signal 113 inv Trimming Disabled Signal Roller Lift Switch 114 inv Roller Lift Switch N_AUTO Switch 115 invN_AUTO Switch Pedal Start Signal 116 inv Pedal Start Signal Pedal Presser Foot Lift Signal 117 invPedal Presser Foot Lift Signal Pedal Thread Trimming Signal 118 inv Pedal Thread Trimming Signal Extemal Signal 119 invExtemal Signal Machine Head Open Switch 120 invMachine Head Open Switch Co Nl O gt x Caution When any inputs PIN No INPUTOO INPUT22 are overlapped it works as the OR circuit Ex if INPUTOO 0 amp INPUTO1 0 then it is recognized as button A INPUTOO x The hardware of input switches and sensors are done with a point of contact Active High input as the standard x When setting up other functions numbers apart from the on
90. u don t press the button after changing the parameter item set up value the set up value will not be saved so use caution when using it e the specific items of the parameter are changed carelessly they could cause breakdown or damage the machine Therefore the user must be well trained before using it C Thread Trimming Sequence Automatic Change According to Sewing Machine Model Selection Item No B 56 D This function allows automatic change of thread trimming sequence when user attaches the controller to a sewing machine other than the one being currently used If you want to use this function first enter Item No 56 in parameter Group B You will see then the screen shown in the figure 2 you press the button after changing the set up value to fit the new sewing machine model number the matching thread trimming sequence is duplicated lt Refer to the sewing machine list Ex when using the SunStar KM 790BL 7 sewing machine 3 The duplicated thread trimming sequence can be check in the Item No B 55 and if you want to change the contents you can do so using Item No B 55 Caution f you don t press the button after changing the parameter item set up value the set up value will not be saved so use caution when using it e the specific items of the parameter are changed carelessly they could cause breakdown or damage the machine Therefore the user must be well trained before using it 2 Thread
91. will appear in the displayer of the program unit or simple program unit according to the self checking function of the machine The machine will then stop along with the sound of a warning buzzer When an error indicator appears follow the solution steps described below and resume work If the problem is not solved after taking these measures contact a company branch office Order 209 Cause of breakdown Troubleshooting indicator SF22 Er Safety switch error 00000000 switch error Check Check safety switch cable and connector switch cable and connector FA PU26 Er Trouble with program unit connection Check program unit cable and connector Check the simple program unit cable and connector PU27Er Trouble with simple program unit connection 60 E This error sign is seen when the user connects the power off and on the location sensor while the power is still on again before using it This error sign is seen when the user the user the power off and on A removes the location sensor while the power is still on again before using it 126 E This error sign is seen when the motor s rotor magnet Check the condition of the motor s and stator coil s electric current flow does not match This error sign appears when the direction encoders Check the encoder cable and 5 and the direction of A B do not match the connector Check the encoder cable 128 Er Wh
92. ws When A 3 stitches B 3 stitches C 3 stitches D 3 stitches A When one more or less stitch than the set stitch number is sewn Sewing condition where few backtack Sewing condition where more Classification Correct backtack sewing condition stitches are sewn backtack stitches are sewn 1 A 1 4 Al 84 A 1 2W W Start backtack Sewing condition 1 When sides A and B each have When sides A and B each have 3 When sides A and B each have one less stitch sewn stitches correctly sewn one more stitch sewn End backtack 1 Sewing condition le p When sides C and D each have When sides C and D each have 3 When sides C and D each have one less stitch sewn stitches correctly sewn one more stitch sewn B When one more or one less stitch is sewn than the programmed stitch number Classification Correct B T sewing condition comes out shorter A Start backtack Sewing condition When the length of the last three stitches When sides A and B have 3 When sides A and B each have 3 stitches in sides A and B have been sewn short stitches correctly sewn and a half stitch or less than one stitch sewn End backtack Sewing condition When the sides of C and D have 3 stitches When the sides of C and D each have 3 stitches When the length of the first stitch in sides C and D have been sewn short correctly sewn and a half stitch or less than one stitch sewn Caution

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