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1. 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 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 Por Cause of breakdown Troubleshooting indicator 1 SF22 Er Safety switch error e Check safety switch cable and connector PU26 Er Trouble with program unit connection e Check program unit cable and connector Check the simple program unit cable and connector 2 PU27 Er Trouble with simple program unit connection This error sign is seen when the user connects Turn the power off and on 60 Er d of TE the location sensor while the power is still on again before using it This error sign is seen when the user the user Turn the power off and on 61 Er el PON removes the location sensor while the power is still on again before using it This error sign is seen when the motor s rotor magnet Check the condition of the motor s 126 Er and stator coil s electric current flow does not match This error sign appears when the direction of encoders
2. said C 5 10 002S SW66 SrewFoPedalPCB 5Asy C 09 2268 3701 SorewForSoenoidTransomer Ass Y CY 10 012M PT10 StudeForc4 Ay C 8 07 0048 SM55 ScewForEnodrCoer AS C 9 15 0228 1000 ScrewForEncoderCover Ay C 0 10 008C SES55 Sike Man d O CH 10 024A SE55 ContolBoxLef Side Cover KANSAI o SSS o C Q 10 034A SE55 ControlBoxLeftSide Cover YAMATO Et C 8 10 044A SE5S ControlBoxLeftSide Cover SIRUBA o J 1 CM 10 064A SE55 ControlBoxLeftSide Cover KINGTEX J 1 OC 10 046A SE55 Control Box Left Side Cover DINO Thread Trimming Machine 4 Connector Other Company Type KANSAI OCO a o CW 91 013A SE 55 Comector Other Company Type YAMATO Et C 8 91 008A SES55 Connector Other Company Type SIRUBA 4 CM 91 032A SE 55 Comedo OherComanyTyp KNGTEX 1 J CM 91 046A SE 55 Connector Other Company Type DINO Thread Trimming Machine 1 1 Connector Other Company Type EE ME MEE 79 OJO C5 C5 CD OOOO 69 ON CO oo ola n2 o O c0 ojojojojojojojojojojojojojojofojojojolo Sls SHS RI E SB S E S S S S S S E S S S on D PEDAL ACCESSORIES I 1 x l 100 I lg A d I mi ie A ee SP wile E tene 19 2 NCAA SS LU JS os ea Q m I
3. 1 D 8 02 001A SM5C Earth Cale For Auto Knee Lifting Solenoid 1 Plug For Auto Knee Lifting Solenoid Low l Tube For Cable 1 D 8 25 006A 3200 KneeforCable 1 o DM 18 021A 5607 BalJong Rgh A 18 0158 5607 Nt DfoD54 1 1 O Ball Joint connecting Rod A o O D 5 Nut R For D 54 E ME EN 18 020A 5607 Baldont Le o 1 y O D 57 18 011B 5607 Solenoid Shaft Connecting Rod Solenoid 1 1 18 0198 5607 NutForD57 to y O D EA 000 02 3 EdgeSensor Box Assy A A hJ D 1 4 81 E SYNCHRONIZER E 1 O oh LL O Se LU N F i Sr q ul NM LLI D Y AA LS om T Lu Y EM LLI My n LAST LU j SN LU 82 ET 11 0000 SE55 SpoueAmb WMas a E 15 3014 9000 Syren Base KS 3 Es 16 8024 9000 Syetvorzer Shah kas 1 4 16 0068 5C53 SmhoueCoe Mas 3 Es 12 0115 SC58 SmhmmimU 1 ES 12 0125 SC53 syrer Am DON 1 Er t2 0168 SES5 abe ForDn Comer ES 11 006C SC53 Fed Bushing For Sycron 3 ES 11 0075 SC53 SwwFoSphwzetim 3 E 11 008W SCS3 WerrSmwneerim asi En 11 0095 SC53 SwwFaPbSewrAsemby 1 Em 11 024P 3701 RiPnGst SO a L 1 I DI Is Il I mure 71 o lt Ci 16 0085 2000 Screw For Sync
4. Am inv Target Speed with duty Trimming notifying signal End Back Tack notifying signal Emergency stop notifiying signal without duty signal appears when the motor stops for any error 114 115 116 inv Trimming without duty inv End Back Tack without duty inv Emergency Stopped without duty A signal appears when the motor stops for any error Roller Lift Solenoid without duty Hemming Device Output without duty First step forward pedal notifying signal without duty Low signal without duty 117 118 119 201 inv Roller Lift Solenoid without duty inv Hemming Device Output without duty inv Pedal Start without duty High signal without duty gt x If an output signal has been sent twice in the OUTPUTOO OUTPUT15 output pin the same signal will appear in two different output pins Ex if OUTPUTOO 0 4 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 x Roller Lift Solenoid Presser Foot Lift solenoid Back Tack solenoid Roller Lift Switch NOTUSED O 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 50 INPUTOO Button A 0 0 0 0 0 0 0 0 0 951 I
5. 2 Thread 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 dm ue i NOR AEE cee a e mo EA eee HE PE l y J 17 qty gt lt hy Vi Yu Y v q 2 2 Res y lt S Ill Simplified Operation Panel 62 How to Operate Display Remarks Press E Prg button and A button simultaneously Then the screen for changing parameters appears 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 Program Enable e Parameter B 01 Parameter B 55 e Sequence Press C button when b 55 is displayed Then SEQ blinks on the screen 80 Trimming sequence start command Press C button once again and the screen displays the starting location number of trimming sequence The starting location number of trimming sequence has changed from 80 to 81 Press A button and B button to change the location number of the current trimming sequence ex When A is pressed 80 is changed to 81 When C button or D button is pressed the trimming sequence location number increases or
6. Caution e f you don t press the Ens 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 C Thread Trimming Sequence Automatic Change According to Sewing Machine Model Selection 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 If you press the Enter button after changing the set up value to fit the new sewing machine model number the matching thread trimming sequence is duplicated X 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 e 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 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
7. m USER S MANUAL 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 1 Thank you for purchasing our product Based on the rich expertise and 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 This 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 DAS Certification Scope of Quality Approval The following Company SUNSTAR ELECTRIC CO LTD The Company has been approved for the following scope of operation Manufacture Sale and Servicing of Motors and Controllers for Sewing Machines and Embroidery Machines Scope of approval NACE 19 Electrical and optical equipment Date of Certificate Issue 26 November 2003 Certificate Valid until 26 November 2006 Certifi
8. oao l o ESEC SE ro l o l l I DIA V m l gt lt p an E mz I 76 Name of Parts Assay No B1 10 1000 SE55 tPhsetlVCotoBox CCC B2 10 0000 SES55 1 Phase220VControlBox 3 Phase 220VContolBox O Z O 1 B 3 01 0000 SE55 PowrBordAsy LA i1 sy B 3 1 11 007B SE55 CableForPowerImput 1 B 3 2 09 003A SC51 BridgeDiode3510 2 B4 02 0000 SE55 CPUBadAsy J JJ Jhihsy O B 4 1 10 009A SF55 IPM PM2CSJ60 M isyp B5 30 0000 SE55 SIPUBDASy sd B 9 1 1300 3A SESS BUBX 5 US O 4 B 5 2 30 002A SE55 MemraeSwkh 1 B 5 3 20 010A SE55 PUComedoCabeSEO3 CT B5 4 30 001M SE55 ScrewForPUBx 5Nsy LES TTT ASSESS Guida 10 112A SE55 ConrlBoFontCoer a Horis 17107 O O O NES GER B 9 10 008A SE55 SolnoidTransfomerS3 0 1 0 0644 E55 Combi Score a AE 10 005A SE55 ConlBoRghtSdeCoer CC D 001A SESS Comont 1 10 009C SE55 NamePanelSticker 0 1 BM 01 003S BTO01 WamngPaelSikr a B 15 10 003C SE55 CableRubberGuide a y Bier MOTOR HEUT A A rn BAT 10 011C SE55 OptonStcker 0 1 B 8 12 005B SE55 Assistance Signal Cable S
9. 16 Locate detector synchronizer SY Position magnetic Up Position magnetic down Sewing machine 2 How to adjust the magnet of the location detector D Assemble the detector in order following the pictures Locate detector synchronizer 2 Once assembling is completed power the controller on and step on the pedal At this time make sure that the needle moves up and down Stop the needle at a desired location by moving the magnet back and forth along the location where the needle stops The highest position of take up lever Normal rotation Normal rotation direction direction Y Locate detector 2mm turning around synchronizer from the lowest position of needle bar 3 How to adjust a location detector in case of a reverse rotation sewing machine It is the same as that used for the normal rotation direction The highest position of take up lever Reverse rotation Reverse rotation direction direction tl V Locate detector 2mm turning around synchronizer from the lowest position of needle bar Note After adjusting a location detector rotate the motor by stepping on the pedal for 3 5 seconds so that a controller can remember the location 17 6 Mounting the Program Unit P U 1 SunStar KM 235 Sewing Machine First attach the P U bracket to the P U using three fixing screws and a supporting bolt with nut attached on it as shown in the figure Second securely a
10. Pressure Spring For Thread Trimming to D 2 10 025P SC53 SpngGude B 4 D3 10 024P SC53 SpringGuide A 1 DM 10 0318 SC53 ScewForSpringHousng o Z o Z o o 20sy D5 10 016A SC53 SpngHousng 1 4 D 10 0218 SC53 PressureControlScrewForSpring Assy o 20sy DM 18 0168 5607 NutForD 4 DB 20 106C 6100 StickerForautoKneeLifingSolenid tis 1 D 18 029C 5607 Guide Bushing for Cabe 1 o D 9 91 001A 3701 BetCoer B 1 o 1 D3 91 101A SA53 BetCovr NewTyp h o 1 D 9 91 004C SA53 SNBetGude 1 D 8 09 0318 3701 ScrewForBetGude to DM 07 0278 3701 ScrewForBetCover A 2 D 5 01 1358 1701 ScrewForBeltCover B _ 2 D 91 0298 1000 SrewFrPUBx By DM 01 039W 1701 SpingWasherForPIUbxBraket gt gt gt 20sy 91 0308 1000 SceewForP UBoxBracket 208sy D 9 91 100A SE55 BrcetForPIUBx pt oo D H 91 200A SE55 BracketFor2s0P UBox 1 DM 18 1078 9000 AutoKneelifterSoenodCase sis 1 oo D 4 18 108B 9000 AutoKnee Lifter Solenoid Cover ss 1 D 8 18 109B 9000 FixingPlateForStroke 1 1 DM 18 023R 5607 RubberWasher 0 OS 4 D 6 17 017C 3000 StopperRubber 1 o DM 01 134C 1701 ScewForD4 T 26sy DW 12 015M 2350 CablForAuoKneelifingSoenid
11. Program range 6 stitches 6 stitches 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 A Side B programmed value 3 programmed stitch number 3 actual stitch number sewn on side B Side C programmed value 3 programmed stitch number 3 actual stitch number sewn on side C Side D programmed value 3 programmed stitch number 3 actual stitch number sewn on side D Prog and GD buttons simultaneously Ex When there is one less Start or End B T stitch sewn button You will see the letters bt C and the men will ring three times and the screen automatically return to the initial screen c The changed initial screen will continue to display the wanted B T 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 X When there is more than one stitch is added or missing you can correct the stitch number as explained above Caution x 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
12. This function is used when the user randomly changes the parameter s programmed value and forgets the original program contents SUNSTAR ELECTRIC CO LTD 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 e 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 is 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 3 For detailed information on the method of use of program units and
13. 111 ON ON DOWN DOWN ON ON SUNSTAR 42 111 OFF OFF UP DOWN ON ON OHR 40 11 OFF OFF UP DOWN ON ON OHER 49 11 OFF OFF UP DOWN ON ON OTER 38 11 OFF OFF UP DOWN ON ON OHR 3 111 OFF OFF UP DOWN ON ON OVER 4 111 OFF OFF UP DOWN ON ON OmER 38 11 ON ON DOWN DOWN ON ON SUNSTAR 43 60 ON ON DOWN DOWN ON ON SUNSTAR 41 80 ON ON DOWN DOWN ON ON SUNSTAR 44 90 ON ON DOWN DOWN ON ON OTER 44 90 ON ON DOWN DOWN ON ON OHER 44 80 ON ON DOWN DOWN ON ON OHER 55 80 OFF OFF UP DOWN ON ON OHR 3 11 ON ON DOWN DOWN ON ON OHER 36 111 OFF OFF UP DOWN ON ON OTER oO 11 ON ON DOWN DOWN ON ON OHER 42 111 OFF OFF UP DOWN ON ON OTHER 42 11 ON ON DOWN DOWN ON ON SUNSTAR 43 60 OFF OFF UP DOWN ON ON X 42 111 OFF OFF UP DOWN ON ON X 11 ON ON DOWN DOWN ON ON SUNSTAR 42 80 ON ON DOWN DOWN ON ON SUNSTAR 42 111 ON ON DOWN DOWN ON ON SUNSTAR 42 111 ON ON DOWN DOWN ON ON SUNSTAR 42 111 ON ON DOWN DOWN ON ON SUNSTAR 55 80 ON ON DOWN DOWN ON ON SUNSTAR 42 111 OFF OFF UP DOWN ON ON X Z ttf OFF OFF UP DOWN ON ON X 39 11 OFF OFF UP DOWN ON ON X 42 tff OFF OFF UP DOWN ON ON X 3 amp tff ON ON DOWN DOWN ON ON SUNSTAR 55 60 ON ON DOWN DOWN ON ON 11 or or UP DOWN ON ON X Z tf
14. i hi pon i i I O A NT A Le ree Sg e ape eder eT FEG ecce cisci cuc Sess ipee E t4 l Pod RES i i r Re A A A A A i D hire a i I E a d Sac Y y Lal I l l SRI l Pd eni NES Iss l Ld O m I l l l pg i I oT pl RESTO Q 1 e I umm co SER P gt eo I l es A E C Emp GES I l l Y co I aT i l EET i gt l M 2 l Lo ce I oq Ja E Lo O Si to es E cata I i I A r i E I Po gt E e D I I po 155 I Q I Lo d A met em I oo l IR O EUM Pe Dep Mes 2i A e uc ee M rm M Ss y A i p i i FoS a Sick ae ey O AA p 4 I I l l I I I T M I I E a Nu ie se aq ees pes mde E TE di cy Il a TE oe Lo I i I T Q pg nt QO nA i o EX I T I M s L 7 I A l l I I 1 E A cete UI RE uM is leo GG HR p l Es I e r reia teri poteri a xd A PAS RT DA AE De I I ii Sem i 11 mMm c po verd lm I I I EN CD II o II oo I s I a l jo Em p u lau leq eq Rem i oi Bb l ll l 1 1 I l l i T E EA PESE L 4 ME Ma i i e n A AREA EE A i i I I II a I I Es I E I H l I i I q Adr l s l AS 7 ADAN AIN RRE SE QE qe ct 4 Low l I LO I Q l I FR l l I e Escuche E op PROTON E Ne tm O e aan o E E A TAA aee DS NR Se ee Es a Po ce in FE 14h eS SS a E A a eR I BLD ae Ee c MU CIT g Ie l RS l De co l Ai O
15. message Then the users can select B C or D group by pressing B C or D button while holding program Pros button 2 You can move to the parameter item you want with the O and Q 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 A group 3 After using the Q increase button and Q 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 4 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 e When the B C or D group selection is completed users should turn off the machine first and restart to secure the selected group e 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 44 stitches by pressing the 1 stitch button 2 When the needle plate makes a down stop shortly press the 5 stitch D button once and the needle plate will make an up stop And when the needle
16. select a parameter group using buttons A D e A button A group B button B group Initial screen for group C Initial screen for group D gt e C button 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 4 If you selected the specific item you wanted press button The value you selected will then appear on the screen Ex The current maximum sewing speed 400RPM 5 Using the buttons and B change the current programmed value to another value Ex Change the maximum sewing speed from 4000RPM to gt 3000RPM 43 If you completed your selection press the C to save the value you chose 7 You can change other specific 1tems of the parameter in the same manner Caution e Be 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 e 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 t
17. 1 2 121 step backward thread trimming 2 thread trimming at neutral position co Selection for pedal thread trimming position The maximum sewing speed for the KM 1060BL 7 presser foot lift with mutual crossing quantity of 4 8 9 7 0 mm Delaying time for complete release of KM 1060BL 7 B T Solenoid 200ms Select to operate 2 start B T JR A E 2000spm 200 2000 10spm No 4 1020ms 4ms No No NO NO 0 1 Choose between 1 or 2 Select to operate 2 end B T ADR RE Ne 0 1 Choose between 1 or 2 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 46 0 1 2 0 CAM type machine 24 Selection of thread trimming conditions 1 thread trimming after up stop selection according to sewing machine type 2 thread trimming after low stop 25 Whether or not to use default sequence when A24 1 0 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 gt P3xx in order Less than P1xx 3500 spm No Setting the maximum sewing speed of the machine according to 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 1
18. Select with button B 0 Only B T 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 NO Change between B T and switch with buttons A or B during sewing Selection of button A function 0 B T delete insertion Selection of Button B function 56 Selection of speed during manual back tack during sewing 0 NOT USED Thread Trimming Sequence Selection of SunStar Chain Stitch Machine 1 0 9 Thread Trimming Sequence Selection of other Company chain Stitch Machine 0 0 0 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 p E oo 1 OO IN 1 i 1 1 1 Selection of reverse rotation after trimming 1 selection of reverse direction 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 fix when machine stops 1 1 1 1 Co Power to fix the A number 62 Pulley 40 10 100 11 Distance recovered after fixing A number 62 Pulley and rotating it by force 20degree 10 100 S 1 pa T 1 0 1 clockwise 65 Select the motor rotating direction rn a aeae O counterclockwise Target speed If this speed is reached or passed a sig
19. Time PWM Duty time set up method all types of solenoids LED and signals Item No B 1 B 28 le Ja Full an Time On 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 ES AA TAS 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 The 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 id 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 s stitch corr
20. Trimmer and Wiper Movements with the Button Efes 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 C 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 LA B Programming buttons for number of end B T stitches buttons C D 2 If the number is blinking you can change the programmed value by pressing the lt When the button Anes been pressed for 0 3 seconds appropriate button dada 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 t press the 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 8 S
21. 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 B T 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 I 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 When the machine stops while sewing the When the machine stops while sewing the presser foot lift stops at the top presser foot lift stops at the bottom LU 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 ti
22. e Check the encoder cable and TERI R S T and the direction of A B do not match the connector e Check the encoder cable and 128 E nd the connector When there is no signal from encoders R S T Turn the machine manually and When the motor is overloaded check the machine load 129 Er e Check the location sensor cable and connector 14 131 E When there is an electric current overflow in 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 e before using it 10 130 Er When there is no signal from the location sensor 70 HOW TO PLACE FOR CONTROLLER S3AC55 a Sub classification according the details of the medal b Distinction of the SunStar models from others F FULL Function TYPE E Economic TYPE A SunStar KM 235A B 250A B 7 250BH 7 250AU 7 506 7 530 7 350 7A B B SunStar KM 750 7 750BL 7 857 7 867 7 560 7 967 7 957 7 650BL 7 640BL 7 967B 7 757 7 757BL 7 1060BL 7 C SunStar KM 790 7 790BL 7 797BL 7 797 7 890 7 D SunStar SC 7300 Series Chain Stitch 1 142110V x Only control box is classified 2 14220V by applied voltage and motor 3 34220V is used in all voltages OREDER Ex S3SAC55 2AF refers to SERIES3 1 Phase 220V FULL FUNCTION CONTROL BOX for normal drop feed 71 FORTUNA SERIES 3 BLOCK DIAGRAM PO IR nen a SWITCH LR 12V 1 Solen
23. given Speed D1H 0 5000 som 0 500 spml 0 255 stitch 20spm 2spm Move given distance with given Speed D2H 0 500 spm som 0 357 deg SpdinPos Make motor given Speedin given Position D3H 0 5000 spm 0 357 deg 20som Wait Pos When position aleady passed return EOH 0 357 deg When position aleady passed wat next position Wait Pos2 E1H 0 357 deg and then return Wait Up Edge Wait until Up Edge detected E H Wait Dn Edge Wait until Dn Edge detected ES Chk Pos Check the posiiton passed amp branch to the address E4H 0 357 deg 0 64 address Position Chk Up Edge Check Up Edge detected amp branch to the address E5H 0 64 address Speed Check Chk Dn Edge Check Dn Edge detected amp branch to the address E6H 0 64 address Cl Up Edge Clea Up Edge FG mark UpEdge not detected E H Clr Dn Edge Clea Dn Edge FG mark DnEdge not detected E8H 0 5000 som Wait Speed Wait until motor speedis target speed E9H 20spm Check if motor speed is target speed amp Chk Speed H 0 357 deg 0 64 address branchto the address a 6 C1 Category Explanation Switch ene ich Right Solenoid Switch Pressor Foot Lift Switch ath Wait until signal detected Pedal Start mi E ich isa o sca Check the due e ae address Input Port Check WaitPort Sequence SUPE Sequence Control End of the sequence Caution Every the conditional Branch is made to the appropriate n
24. o C 5 8 10 002B SES559 DisplayPanelMembane a o 002 BS ESS Comerc Weg C 55 11 001B SE5959 ConolerCabe SE00 a o NENNEN 10 212A SE 55 ControlBoxFrontCoverEconomicType a o C 8 10 113A SES55 ControlBoxRearCove at o C9 10 008A SES55 SoenidTanfomerS o C 10 10 004A SE55 ControlBoxLeftSideCover a o CH 10 005A SES55 ContolBoxRightSideCover o C 2 10 007A SE55 ControlBoxHolder gt 1 C 8 10 009C SES55 NamePadSike a CM 10 0038 8B8T01 WamingPanelSioker a o Gt 10 003C SE55 CableRubberGudeC a o Ser MOTOR INPUT a FEER C 7 10 011C SE55 OptionSitker a o C 8 11 005B SE55 Assistance Signal Cabe at o CW 11 008B SES5 CableForMotorQuputSE0H a Y Cm 11 006B SE55 Solenoid Connection Cable SE 009 a C 2 11 004B SE55 CabeFoDCPowrSEQ y 2 12 003B SE55 SolenoidCableSE 006 J 1 J C 5 09 007A HB1O CemetRessordOWi609 a C 11 015B SE55 RessantCometorSEO7 o C 8 1 10 002S8 SW66 ScewForPedaP CB S do Jo CH 10 003M PTO1 SctewContolBoxCver ans Ca 10 003M PTO1 SerewForc7 As Cy 10 003M PTO1 SrwFrC8 2 3A C 3 10 003M PTO1 SrwFrCHO 5 5 5 5 AAsy C j 09 0398 3701 SmwFrCH2 sy C 8B 10 012M PT10 SudeFals As CA 10 0025 SW66 SrewFoPedalPCB
25. 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 the command code CE H 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 63 4 Thread Trimming Sequence Program Code List casal BTSoenoid OR RR oo PF Solenoid E E To VTSdmd O 8H WPSdeod On 8H J T R Solenoid On 8 amp H J Jj LeftSolemoid On 8H po RgwSoeod o On 8H AUX Solenoid On 8H Left LED On 8H X RR RgtiED A NeedeUpSgnal n On 8H Needle Down Signal On 8H I Motor Runing Signal On 8DH y o ReachingTaretSpeedSigal ON EHP Motor Trimming Signal ON 8H J Motor End Tacking Signal On 90H pM Emergency Stop Signal AP Roller Lift Solenoid On 8H po poo Output Hemming Device Output On 9H poo Port Pedal Forward Step Signal On O M EX BH o TUM mFSmd 1 Of 9 O TTSoenid o AJ Of 9M J 4 2 BH
26. selection of semi automatic Speed when selecting a semi automatic corner 200spm 20 2000 10spm parameter used only when used after selecting number 30 e lh 8 Needle bar s automatic stop at the highest position 9 Pedal analog filtering difference 15 When using an angle 2 needle select the semi automatic corner operation 1 200 0 1 2 After selecting the left needle the first sewing stitch 3 stitches 0 255 1 stitch parameter used only when used after selecting number 30 3 After selecting the left needle the second sewing stitch 3 stitches parameter used only when used after selecting number 30 4 After selecting the right needle the first sewing stitch 3 stitches parameter used only when used after selecting number 30 5 After selecting the right needle the second sewing stitch 3 stitches parameter used only when used after selecting number 30 6 Maintaining time for the left right needle solenoid 450 x0 1sec After the programmed time the solenoid is automatically released NOT USED NOT USED Stopping function during AUTO mode and while pedal is neutral 1 0 1 0 does not stop 1 stops 0 active high 1 active low 1 stitch 0 255 1 stitch 0 255 1 stitch 0 255 1 stitch 50 1000 0 5sec Co Oo 9 40 Selection of type of N stitch Sensor The number of stitches done after the N stitch Sensor has finished sensing 3 stitches 0 255 After sensing it will sew the programmed number of stitches and stop ods 3 Sel
27. uti Edi 91 201A SES T Power Source For Sash soc uti Emo 91 201A SES3 Power Source For Sue Bocey uti E 46 3 91 101A SE51 Power Source For Switch Box 1 110V 1 Ass y EA 91 008C 1701 5 Ass y 83
28. will change to that of SunStar 235 250 Refer to attached material O operation after trimming Independent operation of trimming sequence 0 1 1 independent operation P foot lift sol 1 resser foot lift solenoid slowing down time aims dietis Applied only when it is full on condition Presser foot lift solenoid slowing down time 2 H R Sl 30ms 2 510ms Applied only when it is PWM x Items No 40 53 functions that check if solenoid and other output signals are working properly x Select Item 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 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 FOR Checks the signal input INPUTOO Button A Checks the signal input INPUTO1 Button B Checks the signal input INPUTO2 1 4 stitch Switch 63 Checks the signal input INPUTO3 2 4 stitch Switch Checks the signal input INPUT04 3 4 stitch Switch Checks the signal input INPUTO5 4 4 stitch Switch 70 aN ASA AS Checks the signal input INPUT06 Left Switch Checks the signal input INPUTO7 Right Switch Checks the signal
29. 0 9 f 4800 300 1600 16001 0 0 10 1 6000 200 1600 1600 1 0 fo m 6000 290 1600 1600 2 o 109 11 6000 200 1600 1600 1 0 10 M 4480 200 1600 1600 1 0 104 11 3000 180 800 80 0 1 106 2 4000 200 1600 1600 0 1 mm 2 2400 200 1600 1600 0 1 M8 2 4000 300 1600 160017 1 1 15 12 4000 300 1700 1700 o 1 fel 2 4480 200 1600 1600 1 0 104 11 2000 200 s so o 1 te 2 4000 200 1600 1600 1 1 0 8 tf 4000 200 1600 1000 1 0 88 11 2400 180 800 so o 1 38 e 3520 230 1600 1600 0 1 2 2400 180 800 80 o 1 2 400 200 1600 1600 1 o 128 11 5000 200 1600 1600 1 O 14 m 2400 180 amp 0 so o 1 f 2 4000 300 1700 1700 o 1 oO gt 400 200 1600 16001 1 0 125 tf PROGRAM UNIT SETTING NEEDLE ON ON DOWN DOWN ON ON SUNSTAR 42 111 ON ON DOWN DOWN ON ON SUNSTAR 42 111 ON ON DOWN DOWN ON ON SUNSTAR 42 80 ON ON DOWN DOWN ON ON SUNSTAR 42 80 ON ON DOWN DOWN ON ON SUNSTAR 42 80 ON ON DOWN DOWN ON ON SUNSTAR 42 80 OFF OFF UP DOWN ON ON OHR 3e 11 OFF OFF UP DOWN ON ON OTHER 38 111 OFF OFF UP DOWN ON ON OTER NON 111 ON ON DOWN DOWN ON ON OHER 42 111 OFF OFF UP DOWN ON ON OTER 43 11 ON ON DOWN DOWN ON ON SUNSTAR 42
30. 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 is completed the backtack sewing will be performed according to the number of backtack stitches defined on the P U followed by trimming Note a Press to tum 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 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 stitches 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 O 1 Press to turn off the edge sensor Then the edge sensor is deactivated G Edge Sensor Program Modification D Programs should be modified only after trimming is conducted me 2 Press first and then press A simultaneously Then the program modification mode is displayed as shown in the right figure 3 Use O to enter the code number to be modified and use O t
31. ACSS LXLI 016 Single Cav TOYOTA LS2 AD341 102 ingle CAM S3AC55 LIAL 052 w ses 05 DUKOPPZI MMQ ELEC Solenoid Chain AIR Solenoid stitch AIR Solenoid AIR Solenoid SAC A 034 KM967B 7 Roller HIGH Post back tack S3AC55 L AL 086 S3ACS5 LIXC 035 S3ACS5 LIXL 038 32 S3AC55 OX0 04 S3ACS5 LIXC 042 S3ACS5 LJAL 048 S3ACB5 LIDE 49A S3ACB5 IDE 40B o 050 KM 506 KM 530 7 0 00 41 S365 DACI 058 KM SQACSS LAD 054 O KM B08 7 O S3JACBS LAD 05 KM 857 7kKM 8807 O S3AC55 OAD 066 O O KB S3AC55 ODE 57A SC 7300 for tinsel trimming Table A TYPE S3AC55 LIDE 57B SC 7300 for tinsel trimming Table B TYPE SSACSS LIDE 588 S3ACB5 DIAC 059 SAS AE 060 E na Waist Band Device for Homan Sewing Machin S3ACS5 LIDE 061 SC 7310 left blade Table A TYPE E A2 A8 A7 A8 AZ A65 B56 C52 400 300 1700 1700 o 1 o5 2 4000 300 1700 1700 0 1 2 2400 180 800 80 o 1 38 2 2400 180 800 80 o 1 2 6000 200 1600 100 1 0 8 11 6000 200 1600 1600 1 0 88 11 1720 230 1600 1600 0 0 amp 2 4000 230 1600 1600 0 1 88 2 400 200 1600 100 1 0 88 111 3000 230 100 100 o 1 8 2 400 230 1600 1600 0 1 9 2 2600 300 1600 1600 0 1 2 5400 200 1600 1600 1
32. Anchor Bolt fasten the bottom nut tightly so that the motor is securely fixed 12 Belt Guide Fixing 3 Mounting and adjusting the foot lift solenoid 1 SunStar KM 235 Model 1 Attach the main power switch first since the power switch is located normally in between the solenoid brackets 2 By referring to the figure on the right and the mounting instructions enclosed in the packaging box locate the insertion surface of the oil pan and then attach the foot lift solenoid Solenoid No Applicable Models SPF 2 KM 235A B 2 SunStar KM 250 Model 1 First assemble a panel for the attachment of presser foot solenoid on the back of KM 250 2 Attach the presser foot solenoid to a bracket A 3 Attach the bracket A with the presser foot solenoid to the panel above 4 Attch a crank to a solenoid shaft and then connect it to a sewing machine 5 Place a cover on the solenoid 3 SunStar Special specification models The same mounting procedure for KM 235 model is applicable for other models listed below No Do TT IS KW 750BL7 DO EI ZA mao S4 Rus SPF 4 SPF 6 KM 957 7 KM 967 7 SPF 8 KM 757 7 7 SPF 9 4 Adjusting the stroke Gap of the automatic foot lift solenoid 1 Check point Check to make sure that the stroke adjusting screw is located at the center of the solenoid axis 1 e the solenoid should be assembled in parallel with the bottom surface of the table If the solen
33. CH fT LefiSolemoid CY RightSolenoid CY FH pbetLED RAR G RgwiED YA Needle Up Signal o o 0Of MH A mpj MH MotorRuningSignal OL MH j Reaching Target Speed Signal AH MotorTrimmingSignal Of AH NH j Emergency Stop Signal Of AH Roler LiftSolenod o 0Of MAH A29 Jl HemmingDeviceOutout J MH ABH Delybytimsjurt is mpm UBRO To BH Dd NN RR EE ToS 0 Data Field Pu ond Muros PP S Ld SMDrCW iewat ARA Set Speed Make Motor Run with given Speed C4H 0 5000 spm 20som H pop S SET en TEE Lm 0 50 pm som E Bem Decel in Speed at Dn Edge not stop CBH 0 500 spm 2som s Move to Up Edge with given Speed not stop 0 500 spml 2som Move to Dn Edge with given Speed not stop CDH 0 500 spm 2spm Pos Stop Up Up Stop after seving given stitch with given Speed CEH 0 5000 som 0 255 stitch o 20spm Pos Stop Dn Dn Stop after sewing given stitch with given Speed CFH 0 5000 spm 0 255 stitch eme 20spm Pos Dacc Up Dacc Dn Edge after sewing given stitch with given Speed DOH 0 5000 som 0 500 spml 0 255 stitch 20som som Pos Dacc Dn Dacc Up Edge afte sewing given stitch with
34. E 008 Z O Z Z4 1 89 11 008B SE55 CableForMotor Output SE 011 Ca 820 11 006B SE55 Solenoid Connection Cable SE 009 eC Cs 8 21 11 004B SE55 CabeFrDCPowrSEQ7 1 Bx 12 0026 sE55 SoomdGateSE06 CSE B9 12 013B SE55 OptionSwitchConnectorCableSEO14 1 o 824 11 014B SES55 Right amp LeftSwitch Connector Cable SE 015 CT 1 825 09 007A HB 0 CementResistor 40W1602 1 1 B 26 11 015B SE55 ResstantCometorSEOI7 Z 4 B 26 1 10 0028 SW696 SeewFoPedlP CB 1 8 27 10 003M PT01 SctewControlBoxCover 4s y B 9 10 003M PTO1 SorewForB7_ sy B30 10 003M PTO1 ScrewForB8 J 20sy o 8 31 10 003M PTO1 SrewFrB10 ash B 32 09 0398 3701 SiewFrBi 4Asy 833 10 012M PT10 StudeForB 3 asp y BM 10 002S SW66 ScewFoPedalPCB sy O 8 35 10 002S SW66 SrewForPedalPCB sy o 8 36 09 226S 3701 SeewForSoenidTansome Z 4Msy y o Bar 10 012M PT1O StudeForB4 50sy o 8 38 07 0048 SM55 ScrewForEncoderCove 1 1 das B 39 15 022S 1000 ScrewForEncoderCover sc o deasy y O B 40 10 008C SE55 Sike Main 0 0 0 4 BM 10 024A SE55 ControlBoxleftSi
35. Mode 0 Use a curve based on the set values from C 1 to C 10 Mode 1 Scaling to the speed set at A 2 Mode 2 Scaling to the speed set using the Speed Up Dn key x 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 DO DIDIDNDIDIDIDINDID OD sts 1 1 1 1 2 co Pedal Stroke x No 20 If a synchronizer signal comes but the next synchronizer signal does not come within the sensing time an error message will appear x 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 5 Co 54 x This item is operated by the factory only so general users and A S technicians should not use it NO 1 OUTPUTO5 OUTPUTO6 ENG GG oe OE ee eno EE change after referring to the 0 3 7 8 9 OUTPUT14 OUTPUT15 3 3 3 3 OUTPUTO3 OUTPUTO4 3 3 3 3 4 OUTPUT10 Function m A ol aA Left Solenoid Right Solenoid jr SS SS mm AS x A Output PIN function Function No Oo H W type actual output name B T Solenoid P F Sol
36. NPUTOT Button B s G i AAE 2 58 INPUTOS 2 4 sich Sito o 3 INPUTO4 3 4 stitch Switch X3 86 INPUTOS 4 4 Sith S 5 56 INPUTOS Left Sol Site amp Output port changing function Write the function number 58 NPUTiO PreserFooL Swih 8 the output PIN you want 59 INPUT11 CounterSwihy o to change after refering to 60 INPUTI2 PUUT2stibhSwichSina dO fnetable below 16 17 66 INPUT22 Pedal Trim Signa TC x B Input PIN function Actual Hardware Output Name No Actual Hardware Output Name Button A Switch 100 inv Button A Switch Button B Switch 101 inv Button B Switch 1 4 stitch Switch 102 inv 1 4 stitch 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 inv 4 4 stitch Switch Let Solenoid Swich 108 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 invProgram Unit 1 2 stitch Switch Safety Switch 111 inv Safety Switch Edge Sensor Signal 112 inv Edge Sensor Signal Thread Trimmer Signal 113 inv Trimming Disabled Signal Roller Lift Switch 114 inv Roller Lift Switch N AUTO Sh 115 Pedal Start Signal 116 inv Pedal Start Signal Pedal Presser Foot Lift Signal 117 inv Pedal Presser Foot Lift Signal Pedal Thread Trimming Signal 118 inv Pedal Thread Trimming Signal Exte
37. Source e t is desirable that voltage of the power source be kept within the range of 10 of the rated voltage e It 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 e 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 e Never use it outdoors and avoid direct ray of light e Keep it away from an hot object like a stove e 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 the Motor and the sewing Machine grounded 4 Be sure that the voltage of power source fits the specification of
38. ammed pattern section even if the user releases the pedal 11 Method of Use Constant Speed Sewing AUTO Selection Button This button 1s 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 e The machine will sew according to the machine will sew at the programmed YY amount of pressure given to the pedal by sewing speed um 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 button If you briefly press the A button g button once the screen shown on your right will appear briefly and then return to the initial screen 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 current sewing speed by pressing the A button or g button 2 If you see the current speed on the screen you can change the speed by using the A and g button before going back to the initial screen When you press the buttons twice in seque
39. cate Number K01 1714 Authorized Sf DA du cc Date 03 December 2003 DAS CERTIFICATION Ltd Company Number 3384526 i 6 diera sari Crich Lane DAS tada Belper Certification Derbyshire DES6 1 HG ISO 9001 2000 Telephone amp Fax 44 0 1773 828586 Approval UKAS QUALITY MANAGEMENT CONTENTS 1 Safety instruction es 6 2 Precautions before use o o o on nmn 8 3 Locating and using parts of the controller box 10 A Installation e e e 11 5 Wiring and grounding I I BR 20 6 Connection the earth wire of the sewing machine and motor 23 7 Things to be checked after installation 23 8 Program unit part names and method of use 24 9 Simple operation unit part names and method of use 40 10 Fortuna series 3 full function software method of use 45 11 Breakdown and troubleshooting s 70 12 How to place for controller eee T1 13 Blockdiagam o t nt ng n ng 72 x Parts BOOK cc 4 4 4 4 22 T3 SAFETY INSTRUCTION Be sure to read and keep in mind the following instructions before you install and use thr 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
40. ch numbers for each side b Select the pattern you want and the light will go on the pattern you selected c If you press the Prog button the screen will change and you can use the stitches of H H E each side of the pattern you chose to program the value 79 6 309 Gop AD lt Method to program the value of each pattern side gt e Method by using the Q O buttons Inputting directly the number of stitch the user wants by using the buttons C and D H O ui This method is used when the user already knows the length of the stitches he she AlelcloMXelTF is choosing Method using the pedal movement When the AUTO light is off the machine This is a function used when the user does not know the stitch length and sews dera Her pena rs eS Wile directly to check the number of stitches for the pattern he she wishes to program If When the AUTO light is on the machine the user presses on the pedal after the programming screen comes on the pedal can will finish sewing the pattern section even if program the number of stitches by using the accelerating and decelerating user releases pedal while sewing characteristics through the pedal s sensors The standard for choosing the number 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 allo
41. could break down or damage the machine so the user must be well trained before using it m seurgmaciepteysze o ie 91 Distance between up stop low stop iul 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 S III 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 v the standard is the pulley s normal direction rotation E RR Tum 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 10 Es O ommo 97 CAM type thread trimming solenoid operation position 0 359 1degree IEA AO mm 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 O manual 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 3 Group C Parameter Pedal acceleration decelerati
42. deCover KANSAL CE B 2 10 034A SE55 ConlBoxletSdeCover YAMTO Z pa 8 43 10 044A SES55 ControlBoxLeft Side Cover SIRUBA a y B 44 10 064A SE55 ConrlBoLekSideCover KINGTEX a DSO EAS SESS Cone Boxe Se Cover DNO Thread Timing Machine 1 O B 6 91 031A SE55 Connector Other Company Type KANSAI 1 8 47 91 013A SE55 Connector OtherCompanyType YAMATO A 548 91 008A E55 Comectr Ofer Company Type SRUBA 31 Connector Other Company Type KINGTEX i EE 17 C CONTROL BOX Economic TYPE i co is Ana 3 O C 7 SS 43 oe q C 48 me Hm I o ES M ea Em RE n I o I I I N I O Yd ON q Foods io OC 4 ES E IAS I pm Deo l i T ITO l E ONP 1 1 U o Dial I J O d I mom REP CPC C45 o C50 78 C93 50 1000 SE55 1 PhasetOVContolBox___ pt C2 50 0000 SE55 1 Phase220VControlBox 3Phase220VContolBox 1 C 8 01 0000 SE55 PowrBordAsy Ay CM 11 007B SE55 CabeFoPowerlpt 1d C 32 09 003A SC51 BridgeDiode3510 o PR C 4 07 0000 SES55 CPUBadAsy 3 iAsy Cut 10 009A SF55 IPM PM2CSJ60 Ay C 5 03 0000 SE55 SIIOPBadAsy fAsy C51 03 1000 SE55 SIIOPPCBAsy a C 5 2 10 006A SE55 ContolBoxDispayPanel do
43. decreases The screen displays the values stored in the concerned sequence location ex When C is pressed the screen displays 83 the value which is in the second trimming sequence location In case where Model 88 the 83 command is stored in the second trimming location Trimming sequence is 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 In order to exit the trimming sequence change mode press E Then all the changed values will be stored e If you want to make several changes press E 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 i i ed 8 FE mu SE 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
44. earlier Tighten the adjusted film with the fixing screw Setting Position Fixing Nut Fixing Nut Sensor Calibration Line Film Adjusting Line i Sensor Housin a e eh Up Film Adjustment The highest position x position of needle bar of take up lever Down Film Adjustment 3 Adjustion the films of reverse rotation sewing machines For reverse rotation sewing machines the film adjusting lines located at right edge of the UP and DOWN film should be matched to the center line of the sensor Setting Position Fixing Nut Fixing Nut Sensor Calibration Line Film Adjusting Line Reverse Rotation Sensor Housing Down Film Adjustment 2m tuming around Up Film Adjustment The highest position from the lowest of take up lever position of needle bar Caution After adjustment the film of the position detector be sure to rotate the motor for 3 5 seconds by pedalling so that the Controller may remember location of the film 15 9 How to equip and adjust a built in location detector synchronizer 1 How to equip the built in location detector synchronizer In case of a SunStar thread trimmer When a built in location detector synchronizer for the sewing machine with the SunStar thread trimmer is equipped all that the users need to do is to simply adjust the location of magnetic for detection according to their needs Position magnetic up Locate detector Sewing machine synchronizer Position magnetic down
45. ection method Please refer to the program unit method of use of start end B T stitch correction method C Counter function method of use Item No Name of function Method of use and explanation B B5 Counter condition setup condition set Counter condition setup E using automatic counter after trimming select increasing decreasing counter For detailed method of use and explanation of counter function refer to the program unit s counter set up button method of use B37 After counter operation is over set up the next operation counter After counter operation is over set up the next operation is over set up the next operation EE counter operation is over select the automatic ue erasing operation 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 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 A Pedal stroke step by step section and speed set up method Name of function omg Method of use and explanation o 15 After dividing the pedal stroke to 64 steps the pedal stroke s 31 acceleration deceleration curve changes according to which 40 52 stroke st
46. ection of One Touch function replaced by AUTO Key function Used in the sewing mode that uses the auto function Selection of One Touch function replaced by AUTO sewing mode programming If there is no thread trimming signal when selected sewing will continue even if user releases pedal 2005p N stitch sewing mode selection a sewing mode that inputs a sensor signal 47 Selection of pre stitch function When selected it will perform only the programmed stitches before the actual sewing work starts Pre stitch number of stitches 3 stitches Pre stitch speed 2000spm 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 b 20 2000 10spm 0 1 1 Auto Mode E 0 1 1 One Shot Mode 45 6 40 9960 40spm 0 1 1 N stitch Mode E RA I A C2 Co Co de oo Se j DD DD Y N 0 1 1 selection 48 49 0 255 20 2000 1 stitch 10spm 4 WJ 48 Selection of start B T operating conditions 0 B T stop function selected 0 if pedal is released during back tack it will stop 1 B T work completion al e 1 if pedal is released during back tack the work will still be completed 2 B T exact stitch performance 2 it will perform the exact amount of back tack stitches 51 Selection of end back tack performance condition 0 1 1 exact stitch performance Blond 200spm f spm 1
47. ed 1 buzzer rings sewing is not allowed 0 1 2 Co l When count in completeded the next operation is programmed you press the Prog Key set up is cancelled 2 No buzzer ring sewing is allowed 1 AUTO CLEAR PRESET 0 1 ams 6 Let Solenoid ital Ful On Time For Twin Needle ims 4 1020 ams e Aviary Solenoid inal FullOn Time i0ms 4 1020 ams O Let LED initial Fur On Time For Twin Need i0ms alo ams ams ams Winer Solenoid Duty Rat Tension Release Solenoid Duty Ratio Left Solenoid Duty Ratio For Twin Needle Signal notifying target speed reached Duty Ratio L9 NUUED O E SS 30 Star Back Tack A numberof stiches conection value 0080 66 06h Start Back Tack B number of stitches correction value 0030 66 005Stiteh 82 End Back Tack stth coection value ow O08kh End Back Tack D stitch correction value 0040 66 005Stiteh 0 i reverse direction maintained Bl Ea 38 When count is completed select the counter auto clear preset 39 NOT USED x Items No 30 33 These are the items that make the number of stitches match when back tack number of stitches do not match x 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 mu
48. ed set up method Name of function Method of use and explanation 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 J 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 B T speed set up 0 When the pedal position is backward 2 gear operate thread trimming Starting set up value e 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 No 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 O When edge is sensed and using high output sensor e 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 pa
49. ending counter Down counter X The initial value is programmed to be 1 3 Program the counter function by pressing the counter button If you press the Current work quantity button you can check and program the specific information Cn Current count quantity tu En rn Current remaining quantity NOOO OC e Production rate tn Quantity of total programmed work Initial value 100 lt Remaining work quantity gt xIf you press the button continously you can see the specific information mentioned above in order The user can set up the current count quantity Cn and the 100 n quantity of total programmed work tn 3 ED CI 09 CDG 4 After the total work quantity has been done you can program items or pm B 37 item programmed value roduction rate 0 programming that enables sewing when the buzzer rings after work is done programming that enables sewing when the buzzer rings after work is done but pmi E only after the user presses the button 7965963063 Oa 2 programming that enables sewing after work is done even when the buzzer doesnt ring Total programmed work quantity lt B 38 item programmed value 0 After count is over it does not automatically change to the initial programmed value After count is over it automatically changes to the initial programmed value J WU Ww Yu Caution If the user programs item B 38 to 0 even after the count is over it will continue to i
50. enoid T T Solenoid W P Solenoid MEM OUTPUTOO B T Solenoid Low Active O Fixed EN OUTPUTO P F Solenoid Low Active 1 Fixed OUTPUTO T T Solenoid Low Active 2 W P Solenoid Low Active 3 T R Solenoid Low Active 4 Low Active 5 Low Active Left LED High Active B ESI omui nein Signal notifying motor is running High Active 3 Signal notifying target has been reached High Active 13 Function No 100 101 102 103 x Output port changing function write the function number on table below 1 1 1 1 H W type actual output name inv B T Solenoid with duty inv P F Solenoid With duty inv T T Solenoid with duty inv W P Solenoid with duty T R Solenoid 104 inv T R Solenoid with duty Left Solenoid Right Solenoid AUX Solenoid 105 106 107 inv Left Solenoid with duty inv Right Solenoid ith duty inv AUX Solenoid ith duty gt Q0 NI OD 01 AI Go PO Left LED 108 pm A inv Left LED ith duty Right LED Needle Up stop notifying signal Needle Down stop notifying signal Sewing machine running notifying signal 109 110 111 112 inv Right LED ith duty inv Needle Up Stopped ith duty inv Needle Down Stopped ith duty inv Motor Running with duty gt Target speed notifying signal 113
51. ep is programmed from pedal forward steps 1 through pedal forward fourth step section pedal forward 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 2 3 4 5 6 F 8 9 speed set up is done sewing speed during pedal forward fourth step 5480rpm 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 enel These items help you choose at which point you can apply slow start If you P rcu 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 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 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 MN When Slow Starting the operation speed of beginning stitch y f ll ll When the item N
52. eplacing the fuse use a standard item opening the 12 Make the length of the cable connected with an outside parts cover as shown in the diagram like stand up pedal as short as possible 250V 6 3A 250V 6 3A LOCATING AND USING PARTS OF THE CONTROLLER BOX 1 Left and right side of control box Control box left side Control box right side FER Y Motor Power Cable Encoder Connector Green AC Power switch Standard Solenoid Connector ju Switch and Lamp BUE E Connector for Position Sensor Black OPTION Foot lift Solenoid Green Right lit Solenoid Blue dee mu onnector Ite Tension release and Auxiliary solenoid White 2 Rear panel 1 Caution WARNING a i 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 Tet MRO Soh LAE VO MAS au sl Je AAA T YO Bs g M 0113 81 LIM 36022 e pun 2 Motor 3 AC INPUT INSTALLATION 1 Mounting your Servo Motor on the table 1 Make sure that the holes are bored on the table as shown in the figure Belt Hole 41 Cable Hole 2 Insert three motor fixing bolts through the three holes on the table Attach the motor base padded with vibration proof rubber and slide flat and spring washers over the bolt stems and then fasten the bolts with nuts Motor Fixing Bolts Motor Fixi
53. ewing Speed and Rotating Direction Programming Method OD If you press the Efu 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 Fes button After seeing the speed programming screen press buttons A and B to program the speed you want 3 If you want to program the rotating direction press the Fes button to see the rotating direction programming screen then press buttons A and B_ to change the rotation to the direction you want reverse direction dir 0 normal direction dir 1 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 parameter specific item initial screen D To change the parameter s detailed items press the Fhe and A buttons simultaneously and return to the parameter detailed item s initial screen lt Initial screen for group A gt Initial screen for group B 2 If you see the PrEn screen
54. f 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 on the P U and check if the LED is blinking 3 Check if the STB yellow LED is turned on when there is a fabric below the sensor 4 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 is turned on or not 6 Check whether a signal alarm is issued in line with the presence of fabric under the sensor 37 38 E Use of the Edge Sensor O 1 Press 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 is resumed according to the number of stitches previously set under Prog Group A on the P U 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
55. gram 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 FA and B C Caution e 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 e 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 40 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 i AN When sewing starts B T sewing does not p button operate with the withthe 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 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 locati
56. he present sewing condition b Change the value of the part that needs correction use A B buttons c Save the programmed value press the Ef 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 x 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 i bn TEN nertia tuning initial screen DThe inertia tuning function is to find the motor s gain value that match the weights inertia Press buttons Fs and D simultaneously to return to the initial screen of the inertia tuning lt 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 44 FORTUNA SERIES 3 FULL FUNCTION SOFTWARE METHOD OF USE 1 Basic Functions of the Fortuna Series 3 Full Function Software 1 Initializing
57. hen the stitch length comes out short the third stitch of sides A and B the Ist stitch of sides C and D Side A program value Currently programmed corrected value 01 00 the length of the 3rd stitch sewn in side A Side B program value Currently 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 gt the last stitch of sides A and B and the first stitch of sides C and D Side A program value currently programmed correction value the length of the extra part of the stitch sewn on side A 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 b The screen will then go to the stitch number correction screen Using the O O buttons you can change the length of each side A B C and D in this screen button and save the corrected value If you press the reg button you will return to the initial screen A 00 30 B 00 30 C 00 40 D 00 40 A 00 50 B 00 50 C 00 75 D 00 75 d Commence sewing and check the B T sewing condition e If the corrected sewing condition still shows differences between the programmed value the repeat steps a d and continue correction Caution x If each side s corrected value has been corrected to
58. hronizer Cover 16 01089 2000 Screw For Synchronizer Shaft Ass y 09 0428 37041 Screw For Cable Holder 16 007B SC53 P C B Holder Plate 12 0000 SE 5 5 Synchronizer Assembly Special Type 1 7000 SE 5 5 Synchronizer Assembly Other Company Type S S S C Do 71 o lt 15 026M 1000 BandClip For Cable 16 30 1A S C 51 Synchronizer Base Special Type 06 303A SC5 1 Synchronizer Shaft Other Company Type 06 008B SC 53 Synchronizer Cover Other Company Type 12 105C SC51 LockNut For Photo Sensor Assembly 16 303A 90 0 0 Synchronizer Shaft Special Type 1 102C SC51 Stopper For Bearing 1 S 1 009S SC 53 Lock Screw For Photo Sensor Assembly 06 009B SC53 ynchronizer Base Other Company Type 16 015A 2000 Bearing 60012 1 104C SC51 onnection Plate For Synchronizer 1 105 C C51 Lock Rubber For Synchronizer 1 BID sedi END El ll emn ie is 2 eii laa ise a st lt 1 1 1 11 011C SC53 onnection Bushing For Synchronizer Other Company Type 11 012S SC 5 3 Screw A For E 34 11 32 n 28 11 013S 8SC 53 Screw B For E 34 5 16 n 24 1 1 1 1 1 1 2 2 2 2 101C SC51 Fixing Plate For Cable 2 2 2 j 16 003B 5600 ynchronizer Cover 560 i SEE 1 S 16 010S 2000 ScrewForE 34 1 S 103C SC51 topper Bushing For Bearing TUE 2 Eu 12 1040 8051 ScrewForBeaingSoper O ai E amp 91 007A 8T0 1 Peca ContolRodAssemby O
59. input INPUT10 Manual presser foot lift Switch Along with the input it will say on or off Checks the signal input INPUT11 Counter Switch EN Checks the signal input INPUT12 PU 1 2 stitch Button Checks the signal input INPUT13 Safety Switch mM Checks the signal input INPUT14 Edge Sensor EN Checks the signal input INPUT15 Thread trimming not allowed T2 T3 Checks the signal input INPUT20 First step for pedal going forward E 2 ao Checks the pedal analog output 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 101100110010 011 001 101 8 Checks the signal from encoder R S T 2 When sewing machine is rotating counterclockwise 101 001 501150105 110 100 101 w Norse x Items No 60 76 functions that check individual normal movement x Items No 77 79 functions that check each analog input normal movement x Item No 80 function that checks whether the synchronizer signal is working properly x Item No 81 function that checks whether the encoder A B is working properly x 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
60. itch is sewn than the programmed stitch number 1 VE Start backtack Sewing condition When the length of the last three stitches When sides A and B have 3 When sides 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 length of the first stitch in sides When the sides of C and D have 3 stitches When the sides of C and D each have 3 stitches C and D have been sewn short correctly sewn and a half stitch or less than one stitch sewn Caution 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 2 Start End B T stitch number correction method x 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 E lt lnitial screen a First fully check the B T sewing condition Commence sewing and check the current sewing condition Refer to the figure above 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 x Correction method for stitch numbers with more than one stitch difference
61. k Solenoid 4 8 GND VDC 2 6 Thread Cutting Solenoid DC 46V or DC 32V Tension Release Solenoid 3 7 Wiper Solenoid 9 10 Button B to insert delete the back tack operation 11 12 Button for manual back tack operation 2 Foot lift solenoid 5 Switch and lamp Used in twin needle sewing machine Connector Color Green Shape of pin No of pin Foot Lift Solenoid Switch Foot Lift Solenoid 4 4 N C 9 3 4 N C O 2 4 N C 3 Right Left solenoid Used in twin needle sewing machine 1 4 NC 2 N C Connector Color Blue Right Needle Control Solenoid Left Needle Control Solenoid 4 How to change the electric voltage supplied for solenoid The factory installed setting is J2 x This is to make the movement of solenoid smooth in times of fluctuation in the incoming electric voltage D Set Value for electric voltage supplied for 220V series for Solenoid against the incoming voltage For 30V regular Solenoid For 24V regular Solenoid Incoming Voltage Set Value Incoming Voltage Set Value Below 210V Below 180V Above 230V Above 190V 21 22 2 Set Value for electric voltage suplied for 110V series for Solenoid against the incoming voltage For 30V regular Solenoid Incoming Voltage Set Value 3 Setting of pin For 24V regular Solenoid Method Connect the motor and sewing machine using the ground wire green green yellow as shown in the figure Make sure tha
62. lerate or decelerate quickly 35 36 15 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 KM 750 790 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 Shape of pin No of pin 4 4 N C 9 3 4 N C 9 2 4 N C 51 4 N C 2 N C lt Fortuna Series 3 gt C Edge Sensor Program Setting y Y O a p Turn the power on while pressing Pres simultaneously PrEn is displayed with a beep sound and then disappears 2 Programs should be modified after trimming is completed n 3 Press first and then press O simultaneously Then the program modification mode appears as shown in the right figure 4 Use B to set the code number at 52 Use D to change the value from 2 the default value to 12 and then press Enter to save the new value 0 5 When the program setting is done press Pres to turn of
63. mal Signal 119 inv External Signal AJ OND Z O i NI O1 BO PO O 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 INPUTO1 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 ones listed above the pertinent output pin functions are disregarded 7S Oupa Serato Coleco Reese Ecion ACI 9 ostiis sim A ted SipalLevelColedve Revese Furcin o sad Em wrnug O O o wwe BE BE BER 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 4 Group D Parameter All types of gain parameter related motor control x These are functions not used by general users and must be regulated by an A S technician 1 speed P gain Kvp 2 speed D gain Kvd 9 o3 3 location P gain Kpp 200 4 location D gain Kpd 7 s E E A o 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 3 Method of Use and Explanations for Specific Items of the Parameter 1 Method of Use and Explanation
64. me 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 Automatic trimmer and wiper Only automatic trimmer Both automatic trimmer and do not operate function is operate wiper operate 8 Method of Use Counter Program Button A Count Function Program Method After enabling the count function in the parameter specific items go back to the initial screen Press the count button If the light goes on the user can use the count function B Method of Use Count Specific Functions The count button is a button programmed to check the production quantity In order to operate the functions you want the user needs to program a few specific items D This is a function that checks the production quantity If you want to use this function first program the value what you want in the parameter Ex Item no 35 in Group B 0 Program the outer counter switch 1 Program the automatic count after thread trimming x The initial value is programmed to be 0 When there is no outer counter switch the count function does not operate 27 2 Program the parameter item and you can select the type of production quantity counter e Ascending counter Up counter Desc
65. nal saying 1000spm 40 9960 Target speed has been reached will appear As an interior Port it is alloted and used in the C GROUP Default is auxiliary Delay start setup Delay start time duration setup 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 normal start 0 1 Delay start 3 250 1 x 100 ms o O disabled 1 enabled 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 OD O O Oo O1 O O1 Ol al 01 01 NO C1 gt Co 67 3 70 10 Em 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 x These are functions not used by general users and must be regulated by an A S technician Selection for maintaining reverse solenoid movement when thread trimming C Only B T 0 1 1 reverse direction maintained Programming count condition program whether or not automatic counter will be operated When automatically counting select Up Down count after thread trimming thread trimming function must be enabled 0 1 O counter used 1 automatic counter after thread trimming 1 Up COUNT OD 1 0 1 0 DOWN COUNT 0 buzzer rings sewing is allow
66. nce The sewing speed increases decreases by 40RPM When you keep pressing the button The sewing speed increases decreases rapidly Caution Be aware that if you don t press the A or Ug 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 31 32 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 To adjust the stitch fast and clean users should check the stitch condition before commencing the correction D Classification according to backtack sewing condition x The backtack sewing condition can be classified as follows 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 Classification enn ene WAOE TEN DACAR Correct backtack sewing condition stitches are sewn 1 all Be 2W Start backtack Sewing condition i 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 l End backtack C A Sewing condition V lo 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 st
67. ncrease or decrease Therefore if the user wants to initialize it he she must reset the Cn value 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 1 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 the movement to item ESIS ERA Item A 41 the number of stitches it will sew after it senses the edge e 0 225 after sensing the machine will sew as many stitches as it has been programmed to sew Item A 42 the sewing speed after it senses the edge of material e 20 2000RPM this item sets up the speed of the stitches set to be sewn after it senses the edge 28 3 After sensing the edge of sewing material and the machine has sewn the number of stitches at the programmed speed the user
68. needs to select item A 43 to change the operation 0 to stop after sewing the programmed stitch numbers to operate automatic thread trimming function after sewing the programmed stitch numbers 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 f 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 The pattern function sewing speed will be the programmed speed The 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 a first press the button and select the pattern sewing function stit
69. neral sequence 03 00 gt 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 x Refer to sequence code list Caution e f you dont press the Ens 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 61 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 the Q o 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
70. ng Bolts 3ea Em 4 Te L Vibration Proof rubber Flat Waser Controller Box E 0 NES CH EB A B C E Motor Fixing Bolts 3ea 3 Make sure that the center of motor pulley 1s matched to that of the sewing machine before tightening the motor fixing bolts and nuts 11 2 Assembling the belt cover and adjusting the belt tension 1 Belt cover assembling procedure 1 Upon the completion of the motor mounting bring the two Controller Box pulleys of motor and sewing machine closer to each other by pulling back the sewing machine You can then mount the belt easily as shown in the figure 2 Place the belt cover B making sure that the belt cover does not contact the belt and then fasten the cover with the fixing screw Belt Cover Fixing Screw 2 Adjusting the belt tension DOptimum Tension Level The optimum tention level is achieved when the belt is pushed by 5 10mm when the top surface portion of the belt at about 30 50mm above the tabletip is pressed by a finger with a force of 1 kgm sec or 1 Newton 2 Adjusting the Tension Level If the tension level is out of the optimum range adjust the tension as follows First loosen both the upper and lower nuts for the anchor bolt letting the belt be Upper Nut for the Anchor Bolt stretched by the motor weight itself Second tighten the upper nut only to the extent that the motor does not move Third Lower Nut for the
71. nserting deleting 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 e 1 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 direcion e 0 clockwise rotation e 1 counterclockwise rotation Initial value Exe MES 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 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 x These are functions not used by general users and should be regulated by an A S technician A All types of output Full on
72. o C 13 set up value is 1 the slow start beginning A values When Slow Starting the operation speed of third stitch eones NN When Slow Starting the operation speed of fourth stitch e 1 400rpm 2 400rpm 3 640rpm 4 1000rpm 5 1680rpm When Slow Starting the operation speed of fifth stitch C Motor maximum speed limit set up method Name of function Method of use and explanation C 12 C 13 C 14 C 15 C 16 C 17 18 set to 3000 rpm Set up motor maximum speed limit This function allows you to limit the maximum motor speed and the starting value is 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 Thread Trimming Sequence Function Method of Use Items no 54 55 56 of Group B x Thread trimming sequence function characteristics The 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 e 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
73. o enter the desired value Press to save the new value e 4 When the modification is 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 A and the code numbers and descriptions are displayed as below Description Remarks Select types of fabric sensor Set the number of stitches to be made after 0 64 1 stitch sensing the fabric edge Set the speed of sewing after sensing the 24 MAX SPM 40 spm fabric edge O use of pedal 1 constant speed constant speed related to A42 x When using patterns trimming is automatically conducted after the set number of stitches is made 39 SIMPLE OPERATION UNIT PART NAMES AND METHOD OF USE 1 Names of Each Part in the Simple Operation Unit x Simple operation unit is attached in the front of the control box and used when there is no program unit panel EE Thread Trimming and Wiper Programming Displayer 4 Digit Display er Button Switch for Program Changes Start B T Programming Displayer Presser Foot lift Up Stop and Down Stop Programming Displayer A Button Switch D Button Switch i Needle Plate Up Stop and Down Stop Programming Displayer B Button Switch E SERES SEER C Button Switch End B T Programming Dis player 2 Simple Pro
74. oid SOLENOID Transfomer Servo Motor CPU BOARD with Encoder FRONT BOARD O SYNCHRO CEMENT RESISROR 13 BLOCK DIAGRAM 72 MANUAL CODE NO SIK 001 04 PARTS BOOK Motor PRIS Roly LL 70 B Control Box FULL Function TYPE 72 Tw C Control Box Economic TYPE 74 D Pedal Accessories 16 E SYNCNroni Zer LLL 18 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 x Order for spare parts for servo motor 1 Serial number 2 Type of control box amp mode name 3 Electric specification Phase Volt 4 Machines s model name P4 Se ee at co E iM eec c al is ea ee ai 14 ss q a e s Go qi iue sep c T A 2 a e cett SM pool x l I p po d gt In c I 3 a gi c pe 4 Rem aS S CET per eel NEN E e E 4 A Rc x Jc c PE EI I po I I l 1 I MEE Lo RE Lo i 4 LO Au Cu Gai l e l 1 C l pol el eMe ec ete e c eR SEE ER J E eee A MOTOR PARTS 74 m sooo suse won ME RN e or ooooswss mem 3 M eror sms re 1 o M rorooro SESs eewemee BEEN o As weserssass cmerumg EE o M onee sess IO 3 O a wersreiwemtams CS m DEE Semp 3 m reri ire ECT 1 m Werk cass mmme SS m 040045 SMS
75. oid is not in paralle make an adjustment so that the screw is in parallel with the center of the solenoid axis using the connection link fixing screw 2 Adjusting Procedure The verical travel distance of the presser foot can be adjusted by the stroke adjusting screw First Loosen the two fixing screws and adjsut the vertical stroke using the stroke adjusting screw loosening and tightening the stroke adjusting screw will decrease and increase the verical stroke of the presser foot respectively After the adjustment fasten the fixing screw tightly Oil Pan Insertion Surface Mounting Position 4 for Automatic Foot Lift Solenoid Belt Holes x Specification viewed from the table bottom Solenoid Bracket A Cover for Foot Lift Solenoid x KM 250 Rear Panel Oil Pan Insertion Surface Mounting Position 4 for Automatic Foot Lift Solenoid Belt Holes Specification viewed from the table bottom Connection Link Fixing Screw Oil Pan Solenoid Axis Fixing Nuts 18 4 Mounting the position sensor Synchronizer and setting the film 1 Mounting the position sensor Synchronizer 1 SunStar thread cutting sewing machine All SunStar thread cutting sewing machines are equipped Ser with a position sensor Users therefore are required to the E Adjusted left and right adjust the film position if necessary as shown in the figure Synchro shaft Photo INTERRUPT COVER P C B Holde
76. on curve slow starting speed and input output port change related parameter x These are functions not used by general users and must be regulated by an after sales service engineer No Step 1 sep section where pedal movesfoward o 08 2 sep section where pedal moves omar 6 os Zsiep secion where pedal moves omad J S 0 64 64 4 step section where pedal moves forward 064 5 step section where pedal moves forward 1 Sewing speed value in the 1 step where pedal moves forward 440spm 40 9960 40spm Jt Sewing speed value in the 2 step where pedal moves forward 920spm 40 9960 40spm Sewing speed value in the 3 step where pedal moves forward 4000spm 40 9960 40spm Sewing speed value in the 4 step where pedal moves forward 5480spm 40 9960 40spm Sewing speed value in the 5 step where pedal moves forward 9960spm 40 9960 40spm 0 1 0 1 0 1 1 2 Select slow start after thread trimming After performing thread trimming start the next sewing work slowly 12 Select slow start after sewing machine stops After performing sewing machine stops start the next sewing work slowly secu e 11 1 selection 1 Use C14 C18 value 13 When starting slowly select sewing speed change dae 0 0 0 0 0 0 0 0 ppm 40 8950 40spm 40spm 40spm 40spm 40spm zor 05sec 05sec ams ams m 1 8 NOTUSED E AN Automatic scaling to the speed curve selected by each set mode ES
77. on on the lights will change as shown in the figures below This button offers the following three functions When sewing starts B T sewing does not AN 7 D H operate with the 7 button with the button When sewing starts B T sewing can be operated When sewing starts B T sewing can be operated 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 FE 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 needle If the machine stops while sewing the needle plate makes an up stop plate makes a down stop mM 41 42 5 Programming the Presser Foot lift Location when Sewing Stops with the Button B 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 can 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 E g Es ES 6 Programming the Automatic Thread
78. ontinuous work on back tags of leather belt rings A 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 If you press the button the screen will change as the figure shows on the right You can change the number of chains with buttons O f 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 the 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 e If you change the pattern program while sewing it will sew with the new programmed pattern e f the last chain pattern is finished it will automatically go to the first sewing pattern x If the user presses the when using the pattern sewing function the CD light will go on and the machine will automatically sew the progr
79. p IA I I REESE Q I I I LA I mf I I I p I HERR A EDEL BES keer SEE RUE ORA RENSE UN E O tes REE ak ca REE PRS E E A KR ES El pers 80 Name of Parts Assay No Di 06 0000 SE55 PeddUntAsemby o Asyl D 2 06 1000 SE55 PedlBDAsy gt 14 o D 3 12 009B SE55 Cable For Pedal Input SE 003 1 o D 3 1 11 017B SE55 CabeForPedalGroundng 1 D 4 11 011A SF55 PedalBase 1 D 5 06 001C SE55 PubberCapForPedalUnt isis 1 oo D 6 06 001M SE55 Scew Se 5XOCR y 4AAsy D 7 10 033C SF55 RuberCapForPedalBse O Psy D 8 10 0288 SC53 ScrewForPedalP C BSet 2 oo D 8 1 10 002S SW66 ScrewForP C BSet 4 D 9 10 107A SC53 PeddConllevr A D 10 10 026A SC53 PedalMagetHoder Cs i 4 o Dt 10 027C SC53 PeddMamt Dt 03 0048 SM5S Fixing Bolt For Pedal Magnet amp filmBase o 26sy D 3 10 024W SC523 ParalelWasherForPedalShat CE 1 D 14 11 012C 3701 BushingForPedalContolLeverShat 1 Dt 11 012C 3701 BushingForPedalContolLeverShat CE D i6 10 018G SC53 TenminSpingFoPedl 1 1 DT 03 0048 SM5S Fixing Bolt For Pedal Control Lever ss 1 o Stopper B For Pressure Spring ME GE MEE D i9 10 029P SC53 Stopper A ForPressureSpring 1 D 0 10 019G SC53 Pressure Spring For Presser Fo Cis 1 o DM 10 020G SC53
80. plate makes an up stop shortly press the 1 stitch D button once and the needle plate will make a down stop Caution Be aware that if you are continuously pressing the 1 C button the machine will keep on moving at the 14 stitch 40 speed 25 26 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 operated with sewing is operated with When sewing starts B T the as sewing does not operate PD XE 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 impossible 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 the TR with the bed sewing does not operate 5 AN f A MOY NE button button Using the C D
81. r 2 All other sewing machines including other manufacturers brands First attach the position sensor mounting adapter to the upper shaft of the sewing machine Second attach the position sensor fixing plate to the body of the sewing machine as shown below in the figure Third secure the position sensor to the adapter with the fixing SCICWS Sewing machine Screw A TYPE SM 11 32n 28 Adapter Screw B TYPE SM 5 16n 24 Sewing Machine Position Sensor Fixing Plate Type A Position Sensor IR 9090055 oGQO Cable 5 0598 90 olo DE mp 7 aug A N a Position Sensor Fixing Plate Type B Nylon Cable Tie U Fixing Bolt for Position Sensor Fixing Plate 14 2 Adjusting the film of the position sensor D Assemble the films and position sensor in the order as shown in the figure Position Sensor Shaft Film Fixing Screw 2 Upon the completion of the assembling position the needle shaft tight at the rising point from the lowest needle position by manually rotating the pulley Loosen the film fixing screw and adjust the DOWN film so that the film adjsting line and the sensor housing calibration line are matched Tighten the film fixing screw just to the extent that the film can not be rotated Likewise position the thread take up at the highest position Loosen the film fixing screw and adjust the UP film as shown in the figure while using caution not to move the DOWN film which is already adjusted
82. r solenoid off Wait for 5 ms W P sol on v wait for 100ms v W P sol off wait for 5ms 9 NEM End of Sequence x Operates Presser Foot Solenoid by Lefting Up function of Automatic Presser Foot after Trimming being set to A18 1 x As every command field is displayed close to it is 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 End of Seguence EL eo oo 67 O 00 6 List of Codes by Machine Model able to choose from No 56 of GROUP B ORDER NO Model Name TYPE of Sewing TT NND Sewing Machine GSP Code Sub Code S3ACSS S3AC55 A KM 2508 7 A KM 750 7 KM750BL 7 KM 757BL 7 KM 757 7 KM 650 7 A KM 560 7 3AC55 L A 005 KM 957 7 6 S3ACSS L AL 006 S3ACS5 XCI 007 8 S3AC55 OX0 008 Stitch AR Solenoid UNION 34700 YAMATO VC2700 SIRUBAUTP UTA 9 S3ACSS DXH OO MaerUtsD1370 S3ACS5 LIXE 013 SS
83. rameter are changed carelessly they could break down or damage the machine so the user must be well trained before using it o 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 A 47 Selection of pre stitch function commencing the actual sewing work 0 disable 1 enable Set pre stitching stitch number This item sets the number of stitches when using the pre stitch function 0 255 stitches Initial value 3 stitches A 49 e oen seed This item sets the sewing speed when using the pre stitch function i id 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 O 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 e 0 exact number of s
84. related parameters are items No 54 55 56 from Group B Function 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 A Thread Trimming Sequence Data Input Function Item No B 55 1 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 3 If you press the Enter 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 01 is a number within the sequence 01 64 of the 80 command 4 If you use buttons O Q to 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 e 02 F3 gt Ge
85. rogram and the list of changing functions N 65 in Group A 4 Check to see whether there are abnormal heat smell or noise nearby In case there are turn the power off and call our regional office 23 PROGRAM UNIT PART NAMES AND METHOD OF USE 1 Program unit part names Start B T Selection Button End B T Selection Button 2 Digit Displayer Button to Select Needle Plate Location When Machine Stops a code Button to Select Presser Foot lift Location When Machine Stops 4 Digit Displayer Thread trimmer and Wiper Selection Button to Change the Sewing Speed Installation Pattern Work Connecting Button Constant Sewing Speed Selection Button Pattern Work Selection Button 1 2 Stitch Button Button for Program Change Button for Counter Use after Counter Programming Button to use Edge Sensor Selection after Edge Sensor Programming Button to Save Program Changes 2 Program Unit Method of Use 1 4 Digit Displayer and 2 Digit Displayer Functions and Method of Use A 4 Digit Displayer and 2 Digit Displayer Functions lt Initializing screen D 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 the 4 digit displayer bt the abbreviation for back tack 6 3 9 6 EYF lt Example of e
86. rror detection gt 2 The 4 digit displayer shows the error number for each type of error discovered and also shows the programmed value after it has been 29 GJ X9 E LF programmed The 2 digit displayer shows the number of the parameter lt Example of selection of number 2 item in Group A gt specific item s content or name which is shown in the 4 digit displayer Caution The 4 digit displayer and 2 digit displayer show the current condition Therefore the user should always check it before using the machine 24 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 Q O buttons If you want to change the end B T stitch numbers you must use the Q O buttons The program range is from 0 to 9 Ex How the screen looks when 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 Q button Then you can either check or change the programming items for the parameter of group A A group Q 5 group Q3 C group Q9 D group i O X Users should tum the machine off to select B C or D group While pressing the Pros button turn the power switch on The screen will be changed to the initial screen after showing the PrEn
87. s for Specific Items of the Group A Parameter General functions 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 A 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 B Set up method of stitch speed by program unit P U and needle plate lift drop by button A Name of function Method of use and explanation This item allows user to set up the stitch speed by program unit P U and hence sets up the Set up method of stitch operating speed However if set up to a rapid speed many stitches may be stitch speed by program unit P U 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 spe
88. simple operation panel refer to the explanation in the last section 4 Function Parameter D Group A General functions of the sewing machine 2 Group B 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 x 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 45 2 Fortuna Series 3 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 GD Keys performance speed 100spm Lifting of needle plate with button A dropping speed L s performance speed 300spm Step 2spm 40spm 300spm 20 510 2spm E 20 51 20 51 2spm 2spm al Pedal degree of acceleration Pedal Curve When the maximum speed is put in 255 steps 7 Start Back Tack Speed 1700spm 20 2000 10spm End Back Tack Speed 1700
89. spm Thread trimming operation time 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 41020 Pe 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 3 Wiper operation time Wiper Solenoid operating time 48ms 4 Waiting time after wiper operation presser foot lift etc 40ms 5 Automatic presser foot lift delaying time 100ms Automatic presser foot lift maintaining time 300 x0 1sec After programmed time the presser foot lift is automatically released 4ms 4 1020 4 1020 4ms 4 102 4ms 4 102 4ms i 5 1000 0 5sec 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 18 Selection for automatic foot presser lift after thread trimming 0 1 1 lift selection 0 step backward thread trimming 0
90. st be well trained before using it 49 50 pr Checks PAA of T R solenoid OUTPUTO04 x After matching the number of the solenoid being tested press the 1stitch iL key and check the condition of the movement Checks EPOD of Left LED solenoid OUTPUT10 Along with the output it will say on or off Checks operation of needle when signal notifies down stop OUTPUT13 Al A A A lA lAs lAs lA lA mm nm Checks operation of signal notifying motor running OUTPUT A I lt x Checks operation signal notifying target speed has been reached OUTPUT15 Select Thread trimming sequence 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 Thread trimming sequence data writing function sequence data writing Thread trimming sequence data writing function Selecting sewing machine model write the number that fits the sewing machine model provided in the full function manual thread trimming sequence in the pertinent machine is copied if you want to correct the thread trimming sequence change non order made the contents of item B 55 x However be aware that if you initialize 75 118 the parameter the newly programmed changes will disappear and order made the thread trimming sequence
91. swor ET aw rocooso sEss hm 1 9m wesssssass temmg 1 A os oors SM5S ES ET O Am os ooo sess mows CS COM DADES EEN ET mo reres tooo EN ET O m 97055 SMES mme SC am eere sors EE O BEEN EEN am eoor soss mser CS m ooe sess mows 1 am rera suss mowe CS sy E OOO m os oors swss sworo MC E ICON AECE LISA ES ET MO 1 o E 4 CO 9m LECCE mB 3 75 B CONTROL BOX FULL Function TYPE em ea zs c cp EDI SCC IRE hsm Suc FE REE HEE asi ss ccc 2 M dr MN a ad a a Es DE E M l i I E I a Al Ud N im Da i I1 Op I co wo l iS muse e ea a l c HON d ER Narr NN LO iq d pg l co Ee H E SE s l a EGNE I co 1 E I OTA 1 X OE xeu im ER IDA let m OE i ch pese rs AS 4 EES ba eee ae pg I I l z2 I 5 I I bsd I Si pl oo l A MEE pa Si is o lt l A aa 0 0 tol y O EI l 2451 In A I LO I LO I ch K rer qe a hie 1 010 Im FEE ice a i c Rs ST in ies ceo m ea I o I I la I kk fare EE AE PRA A r I a I l 1 I Laso ai Ee A c ee Tros ts O A El I I A I l I I fe l i o LM I i I I E CON Pra I1 I l I Y l I c l puc Rm A l e I I l l zm ar B WD a a O Ns Q ns P ogee CO l pies o o SEU te ea a AL e I e 3 ur I Mg
92. t the factory connected ground wire between the controller box and motor is securely in place Caution Failure to ground the motor can cause abnormal operations such as overspeed rotation or unwanted stitching Ground Wire Green 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 Connector for incoming AC power source Connector for motor power Connector for motor encoder Connector for pedal Connector for position detector Connector for others option knee lift program unit etc 3 Check to see whether the belts are in touch with the wiring 4 Check the tensile strength of the belts 5 Check to see the fixing nuts for pulley are tightly fastened 6 Check whether the sewing machines are right kinds Chain Stitch S M Lock Stitch S M 7 Check the rated voltage for Solenoid Refer to How to change the electric voltage supplied for Solenoid 2 After the power is on 1 Check whether the lamp for the position detector is on Except in the case of built in position detector 2 Check whether the program unit is working 3 Check the direction of rotation of the Sewing Machine In case the direction of rotation is not right action shall be taken to change set it right referring to the methods of changing the p
93. the Controller before the power is on 5 Be sure to use Safety Extra Low Voltage when an extra item or an accessory is 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 CSunstar 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 the 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 x The instructions presented above are for the safer and more proper operation of the Fortuna Servo Motor Ignoring such instructions co
94. the currently applied correction value press the Pros button and then the C3 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 x 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 x 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 33 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 D B and check the sewing condition again b Look at the sewing condition and make the correction as follows x 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 Initial 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 gt lt W
95. 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 x 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 14 Method of Use Inertia Tuning Function D The inertia tuning function enables the machine to save the gain value of the motor lt Inertia tuning initial screen that matches the loaded inertia If you simultaneously press buttons X w you will see the inertia tuning screen Then you will see the words TUNE blinking LAE 2 When the screen changes you must press the pedal until the buzzer rings If you n9 6 9 Cop Od release the pedal before the buzzer rings the inertia tuning won t be completed i lt Initial screen gt 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 hr 3 When inertia tuning is completed the buzzer will ring and it will automatically return LY ED CI D CDG 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 acce
96. titches function disabled Initial value 0 1 exact number of stitches function enabled If this function is used reverse sewing will no operate naturally A 50 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 e 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 e 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 A button once the needle plate is lifted If user presses it twice consecutively the needle plate is dropped e 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 O This item has the function of i
97. ttach the P U to the head of the sewing machine using two fixing screws and washers keeping a 3 4mm distance between the bottom surface of the nut and the base of the supporting bolt 2 Other SunStar thread machine First attach the P U bracket to the P U using the four fixing screws Second attach the P U to the main body of the sewing machine using the three bracket fixing screws as shown in the figure Program Unit Program Unit P U Bracket P U Bracket Fixing Screw 3 SunStar Caution Fix the cable using the cable tie so that cable is not in the way of the belt 18 7 An example of installing the SunStar sewing machine 19 WIRING AND GROUNDING 1 Specification of the power plug 1 Single phase 100V 120V Switch Box Control Box ER Protective Earth EARTHV 2 Single phase 200V 240V Switch Box 16 Control Box QD AC 220V EARTHV 3 Three phase 200V 240V Switch Box 36 Control Box AC 220V PE Protective Earth EARTHV 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 20 3 Name and description on the outside connector of control box D Standard solenoid connector 4 Tension release and auxiliary solenoid Shape of pin No of pin Connector Color White AOS A 10009 Auxiliary Solenoid 1 5 Back Tac
98. uld 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 Turn off the power when servicing the servomotor or changing 4 Be sure to keep the servomotor securely grouned the needle 5 Do not connect multiple servomotor power plugs to the same 6 Install the servomotor away from noise sources such as high power strip frequency equipments and welding machines 7 Avoid electrical shock when servicing the controller box Wait for 6 8 When an error message Er 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 Er message persists on the display 9 Adjust the belt tension to the optimum level 10 Clean it every two or three weeks so that no dirt or a dirty substance may be piled up Belt tension adjustment should be performed after the motor is mounted on the table First loosen both the upper and lower anchoring bolts CD The belt tension will then be adjusted by the weight of servo motor itself Fasten both anchoring bolts 11 When r
99. umber when it is on No False e When makingthe sequence program please check and use its function because the wrong sequence program can cause the 66 mechanical trouble and the physical damage Cmd Field mdi A _ an pa m nidi pa 7E s ami a 5 midi aS A E SR a 4 pu E malo ro FOH FIH F2H F3H 80H 00H Data Field 1st O Input Pot No 0 Port N 0 64 Address 0 64 address 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 0 64 0 64 0 64 0 64 0 64 5 Examples of the Function of Thread Trimming Sequence O Yamato Three needle Trimming D Timing of Thread Trimming Sequence Needle T T T R W P 2 Flow Chart of Tread Trimming Sequence amp Program Code errar Code Comm Data field tai ados number field 2nd ocu 0 a CR O re OA A AE Stop after moving to needle of upstop 29 at200spm aitor ms MEN E oe Wait for 100 ms I NN NN START of Sequence Needle Up Stop with 200spm walt for 5ms T T sol on wait for 100ms T T sol off wait for 5ms Wait for 5 ms off T R sol on off T R sol on mE NEN p EN NN EN MEN mm EN wait for 100ms Wait for 100 ms AAA Na NEN NN WM REN INN mm E EE T R sol MEN NEN MM REN MEM NEN m ME d T R sol off wait for 5ms Wait for 5 ms W P sol on on Wait for 100 ms Wipe
100. ws the user to check and program the pattern length while he she sews at a slow speed or sews half stitches 29 30 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 e 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 C3 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 e When the pattern has more than one side the pattern work only operates for the number of stitches programmed for each side 3 Specific items of each pattern A convenient pattern for straight sewing at constant speed for a definite length The sides can be set from 0 to 999 stitches A 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 O to 999 stitches Used often in square sewing A 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 is used for c

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