MANUAL
Chenille Automatic
Embroidery Machine

MME-051020

SUNSTAR PRECISION CO., LTD.
1. THIS IS AN INSTRUCTION FOR SAFE USE OF
AUTOMATIC
EMBROIDERY MACHINES. READ THOROUGHLY BEFORE USE.
2. CONTENTS IN THIS I...
Contents

1. MACHINE TYPES AND SPECIFICATIONS ...............................................................................
Contents

10. ERROR DISPLAY AND TROUBLESHOOTING ...................................................................... 47
...
01

MACHINE TYPES AND SPECIFICATIONS

1.1) MACHINE TYPES

SWF / CA - 6 9 06 - 120
Y-Stroke

Series

No. of Heads

No. of C...
02

SAFETY RULES

2.1) SAFETY INDICATIONS
The following set of safety rules categorized as CAUTION , WARNING , and DANGER ...
2.2) MACHINE DELIVERY
Warning mark

Description
ONLY TRAINED AND EXPERIENCED PERSONS, FAMILIAR WITH THE
RELEVANT SAFETY IN...
2.3) MACHINE INSTALLATION
2.3.1) Machine malfunctions or physical damages may occur due to
condition of the installation e...
2.5) REPAIR
2.5.1) Only SWF-trained and designated engineers should perform repair
work.
1) Turn OFF the power before clea...
03

PRODUCT FEATURES

3.1) CHENILLE HOOKED NEEDLE’S RETURN TO THE ORIGIN
- The hooked needle of the chenille embroidery ma...
3.15) AUTOMATIC TRIMMING DEVICE
- The automatic trimming device is performed according to the design and the machine set-u...
04

MACHINE INSTALLATION AND PRECAUTIONS

Meet the conditions described in the manual when installing the machine. Failure...
4.2) ELECTRICITY INSTALLATION ENVIRONMENT

Check if the input voltage of the machine corresponds with the voltage supply b...
Until the height difference between the four adjusting bolts becomes 10mm, use the spacer by
holding it against the lower ...
05

NOTICES RELATED TO OPERATION

5.1) SAFETY LABEL TYPES
Have a full understanding of the labels attached to the machine ...
5.2) LOCATION OF SAFETY LABELS
WARNING
Injury may be caused by moving
needle.
Ensure that the machine is in a
stop conditi...
06

NAMES OF MACHINE PARTS

A. Machine Body

F1. Arm 1

J. Upper thread holder

N. X-axis driving system

B. Table

F2. Ar...
07

ACCESSORIES AND THEIR ASSEMBLY

7.1) STAND
1) Stand assembly (chenille)

Thread holding bar
Thread holding bar

Suppor...
08

FUNCTIONS OF EACH PART AND MACHINE OPERATION

8.1) BASIC OPERATION
8.1.1) Power on
1)
2)
3)
4)

Plug in the power cord...
8.1.2) For starting embroidery and stopping the machine
You can use START and STOP switches during machine operation in th...
4) For backward non-stitching during embroidery work stop
Same as START/STOP during embroidery work stop

NOTE

1) “Inchin...
3) Forward Frame Movement While the Embroidery Work is Stopped
Bar Switch Operation

Frame Movement

Push it to the right ...
8.1.4) Change switch function of chenille head
1) On/off switch function
Chenille head’s work can be adjusted by changing ...
- The needle bar can be fixed at one position using the lamp-off function in order to disable specific heads.

NOTE

The u...
8.1.6) Needle pause clutch function (jump)
When the manual jump clutch lever is pushed
backward, the machine is back to no...
8.1.8) Chenille threading and tension adjustment
1) Chenille threading
– Place the thread at the chenille head following t...
2) Adjustment of chenille head’ thread tension
s
– Loop stitch
Adjust the tension adjusting device to make each thread ten...
4) Upper threading of regular head

Upper thread stand

Upper thread
(from the upper
thread stand)
Sub thread adjuster
Thr...
5) Threading the tension adjuster of regular head
Threading the sub tension adjuster

Threading the thread detector roller...
6) Upper Thread Tension Adjustment
Thread tension adjustment is critical for producing high quality of the embroidery. A b...
7) Take-up spring adjustment
– Functions
Difference in the length of the upper thread pulled by the take-up lever and by t...
8.1.9) LOWER THREADING AND TENSION
ADJUSTMENT
1) Lower threading
– Use cotton yarn (80# ~ 120#) for your lower
thread.
– L...
8.1.10) BOBBIN WINDER
1) Bobbin winding
– Insert the bobbin onto the shaft ① and manually wind the thread 5-6 times around...
3) Adjusting the bobbin winding condition
– If the thread is not parallel to the bobbin,
adjust the body of the thread gui...
8.1.11) Things to consider when using an Floppy Disk or a USB memory stick
When handling this input/output device, the fol...
8.1.15) Return to stop position in unexpected blackouts
Your SWF embroidery machine automatically returns to the previous ...
2) Regular head (SA-Series)
- Inadequate selection of thread and needle may result in thread breaks, skipped stitches, as ...
– Make adjustments to let the cross-section of
the needle meet with the screw, and push the
needle inside until the very e...
– When inserting the needle, make sure that
the groove of the needle is facing front.
– End tip of the needle should be in...
Looper

Looper

(Looper Stitch)

(Chain Stitch)

8.2.5) Relationship between needle and hook
– Adjusting timing between ne...
8.2.6) Adjusting gap between needle and
hook point
Hook point

– Gap between the hook point and the needle
The distance be...
8.2.9) Different loop shapes
Shape of the loop varies by the type of thread or fabric. Unstable shape of the loop may resu...
In normal hook timing, the hook should be in the (C) range.

CAUTION

(B)
Groove of the hook

(C)
(A)

8.3) THREAD BREAK D...
8.3.2) Disassembling the thread detector
You will need to disassemble the thread-break detector unit when you to have to c...
09

NOTICE

EMBROIDERY METHODS

For more information on how to use the chenille embroidery machine, please refer to the
ch...
10

ERROR DISPLAY AND TROUBLESHOOTING

10.1) MAIN SHAFT MOTOR
No.

Error

Description

Troubleshooting

100

Main shaft st...
10.3) COLOR CHANGE
No.

Error

300

Needle bar position

Description
Needle bar doesn’come to
t
correct position when chan...
10.6) FLOPPY DISK
No.

Error

Description

Troubleshooting

600

No disk

No disk in the drive

Insert the disk in the dri...
10.7) MEMORY
No.

Error

Description

Troubleshooting

700

No embroidery data in the
memory

No embroidery data in the
me...
11

CONTROL BOX

11.1) MAIN CONTROL BOX
11.1.1) Inside the Control Box

①

②

① SMPS power
② Power for Jump Motor, picker ...
11.1.2) Outside the Control Box

①
②

① Terminal for tape reader and winder
② Fuse for tape reader and winder

52
11.2) MAIN SHAFT & X-Y MOTOR DRIVE (SANYO)
①
②
③
④

X-axis driver
Y-axis driver
Trimmer driver
Joint board

①
②

④

③

53
11.3) LIST OF ERRORS AND CAUSES IN MAIN SHAFT DRIVER & X,Y SERVO
MOTOR DRIVERS
DISPLAY

ERROR

CAUSE

Excess current

Erro...
12

MAINTENANCE AND INSPECTION

12.1) CHECK POINTS FOR REGULAR INSPECTION

CAUTION

1) Make sure that the power is turned ...
12.2.1) Cleaning method and cleaning cycle for machine parts

Types

No.

Names

Reference Fig.

Cleaning cycle

1

Needle...
Types

Regular
head

No.

Names

3

Around the movable
blade and the fixed
blade

Reference Fig.

Cleaning cycle

Movable
...
12.3) OIL SUPPLY

1) Make sure to turn the power OFF during oil supply.
2) SWF is not responsible for machine damages or w...
[Regular head]

Head

③
③

③

⑤

②

②

⑤

③
Oil hole ③
Arm
④
④

Raceway ①

※ Oil can’ be automatically supplied to
③,④. Ma...
3) Oil wick-based oil supply
When supplying oil, fill up the oil until the oil wets the felt inside the oil tank.
– Oil su...
12.3.2) Grease supply

Make sure of turning the power off when supplying grease.

CAUTION

1) Locations to be Supplied wit...
2) Use high-quality mineral-base lithium grease
No.

Grease Supplied Area

Frequency

Location

1

Inside the arm
Take-up ...
3) Use lithium - Type grease (JIS No. 2)
(Brand Name : Albania No. 2)
No.

Grease Supplied Area

Frequency

1

Head drive ...
5) Greasing the X, Y drive guide rail
– Disassemble the frame from the table.
– Unscrew the stainless cover and remove it....
12.3.3) Drive belt tension

Turn OFF the main power when inspecting drive belt tension.

CAUTION

Too weak or too tight te...
13

ADJUSTING MAJOR PARTS OF THE MACHINE

Turn OFF the main power when adjusting the machine.

DANGER

13.1) ADJUSTING THE...
13.1.3) Needle locating position adjustment
1) Needle locating position height adjustment
– Set the chenille head’ main sh...
13.2.2) Adjusting Space between Movable Blade and Hook
To adjust a space between the movable blade and the hook, remove or...
13.2.3) Adjusting Blade Tension
Make sure to check and adjust the cross-tension of the movable and the fixed blades after ...
13.2.4) Adjusting Trimmer Return Spring
1) Function
The trimmer return spring detects whether the movable blade has return...
⑥ Install the arm guard plate and go through ① and ② to complete.

CAUTION

If the upper thread holding unit does not func...
2) Adjusting picker volume
Adjust the eccentricity of the picker stopper so the
picker slightly touches the bobbin you’re ...
3) After adjustment, run the color change to check if the wiper functions well at each needle bar.

Driver link

Bracket s...
13.6) ADJUSTING LOW-NOISE PRESSER FOOT
1) Assembling the presser foot cam
– Position the main shaft angle 178°Put two asse...
2) Adjusting the height of the presser foot
– Check the relationship between the presser
foot, the needle, and the embroid...
13.8) CORRECT POSITION OF NEEDLE
1) Make sure to check the position of the needle – it may change during machine delivery ...
13.9) ADJUSTING HALF-TURN FILM FOR COLOR CHANGE
1) The machine will stop automatically if either of the needle position la...
13.11) NEEDLE BAR ADJUSTMENT
1) Adjusting the Lower Dead Stop of the Needle

You should be able to see half or the entire ...
13.12) JUMP MOTOR ADJUSTMENT
Adjust the position of the jump motor if you have to replace it or if you find errors in jump...
13.13) ADJUSTING DRIVE BELT TENSION
13.13.1) X, Y Timing Belt

CAUTION

1) Make sure to turn OFF the main power when adjus...
Timing belt
Adjusting nut

Tension
adjusting bolt

Tension base screws (2)

Tension
adjusting
axis
Tension base screws (2)...
13.14.2) Main Shaft Motor and Upper/Lower Shaft Belt
1) Adjusting tension on main shaft motor belt
– Tension on the timing...
13.14) ADJUSTING X, Y SCOPE LIMITS
1) Adjusting X scope limit
– Manually move the frame to a point, where the
right end of...
2) Adjusting Y scope limit
– Manually move the frame to a point, where the
rear end of the frame clip is 18.5mm from the
c...
4) Adjusting X scope limit when using odd or even number heads (SWF/SA-WB(X) SERIES)
– Set the needle bar stop clutch func...
14

TROUBLESHOOTING

Inspect/repair the machine by the guideline in machine failures.

CAUTION DANGER

Error Type

Cause

...
Error Type
Bad Color
Change

Cause

Inspection & Repair

Reference

① Incorrect position of needle
stop

■ Refer to user’ ...
Error Type

Cause

Inspection & Repair

■ Check the plate connection
and change the circuit board

① Bad SMPS for jump

■ ...
Error Type
Thread breaks

Cause

Inspection & Repair

Reference

① Stitch is too small/dense for
thread

■ Re-punch design...
Error Type
Thread breaks

Cause

Inspection & Repair

⑦ Bad thread (weak, uneven
thickness, poorly twisted,
old)

■ Change...
Error Type
Thread breaks

Cause

Inspection & Repair

Reference

⑫ Dent on thread path on
hook and bobbin case

■ Remove d...
Error Type
Skipped
Stitches

Cause

Inspection & Repair

Reference

① Bent needle

■ Change needle

② Inadequate needle si...
Error Type

Cause

Inspection & Repair

Reference
■ See 8.1.8) 6) (p.31)

■ Adjust tension

■ Clean main and sub tension
a...
Error Type

Cause

Inspection & Repair

① Excessive thread tension

■ Adjust tension

② Excessive pressure of
presser foot...
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  1. 1. MANUAL Chenille Automatic Embroidery Machine MME-051020 SUNSTAR PRECISION CO., LTD.
  2. 2. 1. THIS IS AN INSTRUCTION FOR SAFE USE OF AUTOMATIC EMBROIDERY MACHINES. READ THOROUGHLY BEFORE USE. 2. CONTENTS IN THIS INSTRUCTION MAY CHANGE, WITHOUT PRIOR NOTICE, FOR IMPROVEMENT OF MACHINE QUALITY AND THUS MAY NOT CORRESPOND TO THE MACHINE YOU PURCHASED. CONTACT YOUR SALES AGENT FOR INQUIRIES. 3. THIS IS DESIGNED AND MANUFACTURED AS AN INDUSTRIAL MACHINE. IT SHOULD NOT BE USED FOR OTHER THAN INDUSTRIAL PURPOSE.
  3. 3. Contents 1. MACHINE TYPES AND SPECIFICATIONS ................................................................................... 6 1.1) MACHINE TYPES ................................................................................................................................. 6 1.2) MODELS ................................................................................................................................................. 6 1.3) SPECIFICATIONS .................................................................................................................................. 6 1.4) PERIPHERALS ....................................................................................................................................... 6 2. SAFETY RULES ....................................................................................................................................... 7 2.1) SAFETY INDICATIONS ....................................................................................................................... 7 2.2) MACHINE DELIVERY ......................................................................................................................... 8 2.3) MACHINE INSTALLATION ................................................................................................................ 9 2.4) MACHINE OPERATION ....................................................................................................................... 9 2.5) REPAIR .................................................................................................................................................. 10 3. PRODUCT FEATURES ........................................................................................................................ 11 4. MACHINE INSTALLATION AND PRECAUTIONS ................................................................... 13 4.1) INSTALLATION CONDITION ........................................................................................................... 13 4.2) ELECTRICITY INSTALLATION ENVIRONMENT ....................................................................... 14 4.3) LEVELING THE MACHINE .............................................................................................................. 14 5. NOTICES RELATED TO OPERATION .......................................................................................... 16 5.1) SAFETY LABEL TYPES .................................................................................................................... 16 5.2) LOCATION OF SAFETY LABELS .................................................................................................... 17 6. NAMES OF MACHINE PARTS ......................................................................................................... 18 7. ACCESSORIES AND THEIR ASSEMBLY ................................................................................... 19 7.1) STAND ................................................................................................................................................... 19 7.2) OP BOX ................................................................................................................................................. 19 7.3) FLUORESCENT LIGHT ..................................................................................................................... 19 8. FUNCTIONS OF EACH PART AND MACHINE OPERATION ............................................. 20 8.1) BASIC OPERATION ............................................................................................................................ 20 8.2) NEEDLE-HOOK TIMING AND RELATED TIPS ............................................................................ 37 8.3) THREAD BREAK DETECTOR ASSEMBLY AND ITS FUNCTIONS ......................................... 44 9. EMBROIDERY METHODS ................................................................................................................. 46 4
  4. 4. Contents 10. ERROR DISPLAY AND TROUBLESHOOTING ...................................................................... 47 10.1) MAIN SHAFT MOTOR ..................................................................................................................... 47 10.2) X, Y-AXIS MOTORS ......................................................................................................................... 47 10.3) COLOR CHANGE .............................................................................................................................. 48 10.4) ENCODER .......................................................................................................................................... 48 10.5) REPETITION WORK ........................................................................................................................ 48 10.6) FLOPPY DISK .................................................................................................................................... 49 10.7) MEMORY ........................................................................................................................................... 50 10.8) CHENILLE HEAD ............................................................................................................................. 50 11. CONTROL BOX .................................................................................................................................... 51 11.1) MAIN CONTROL BOX ..................................................................................................................... 51 11.2) MAIN SHAFT & X-Y MOTOR DRIVE (SANYO) ......................................................................... 53 11.3) LIST OF ERRORS AND CAUSES IN MAIN SHAFT DRIVER & X,Y SERVO MOTOR DRIVERS ...................................................................................................... 54 12. MAINTENANCE AND INSPECTION ............................................................................................ 55 12.1) CHECK POINTS FOR REGULAR INSPECTION ......................................................................... 55 12.2) CLEANING ......................................................................................................................................... 55 12.3) OIL SUPPLY ....................................................................................................................................... 58 13. ADJUSTING MAJOR PARTS OF THE MACHINE ................................................................. 66 13.1) ADJUSTING THE CHENILLE HEAD ............................................................................................ 66 13.2) ADJUSTING THE TRIMMERS ....................................................................................................... 67 13.3) ADJUSTING THE UPPER THREAD HOLDING UNIT ............................................................... 70 13.4) PICKER ADJUSTMENT ................................................................................................................... 71 13.5) ADJUSTING UPPER THREAD HOLDER ..................................................................................... 72 13.6) ADJUSTING LOW-NOISE PRESSER FOOT ................................................................................. 74 13.7) RELATIONSHIP BETWEEN PRESSER FOOT AND NEEDLE .................................................. 75 13.8) CORRECT POSITION OF NEEDLE ............................................................................................... 76 13.9) ADJUSTING HALF-TURN FILM FOR COLOR CHANGE ......................................................... 77 13.10) ENCODER ADJUSTMENT ............................................................................................................ 77 13.11) NEEDLE BAR ADJUSTMENT ...................................................................................................... 78 13.12) JUMP MOTOR ADJUSTMENT ..................................................................................................... 79 13.13) ADJUSTING DRIVE BELT TENSION .......................................................................................... 80 13.14) ADJUSTING X, Y SCOPE LIMITS ............................................................................................... 83 14. TROUBLESHOOTING ....................................................................................................................... 86 5
  5. 5. 01 MACHINE TYPES AND SPECIFICATIONS 1.1) MACHINE TYPES SWF / CA - 6 9 06 - 120 Y-Stroke Series No. of Heads No. of Colors for Chenille Head No. of Needles for Standard Head 1.2) MODELS Machine Color Heads Head Interval (Pairs) Standard Chenille (mm) Emb. space (mm) All Head Board×Continuous Table Size (mm) SWF/CA-6906-120 6 9 6 480 1,200×480(230) 1,200×2,880 2,849×4,900 SWF/CA-6906-75 6 9 6 400 750×480(230) 750×2,880 1,955×4,900 SWF/CA-6912-75 12 9 6 500 750×500(230) 750×6,000 1,985×8,025 1.3) SPECIFICATIONS Stitch Length 0.1 ~ 12.7 (mm) Chenille Head Max. 600 rpm Standard Head Max. 1000 rpm Speed Main Motor AC Servo Motor X 2 X-Y Motor Pulse Motor X 2 / Servo Motor(12Head) Electricity 1-Phase:200V, 220V, 240V (50~60Hz) / 3-Phase(12Head) Power Consumption 1.0 Kw 1.4) PERIPHERALS Operation Box Standard Color Touch Screen Memory Capacity Standard 2,000,000 6
  6. 6. 02 SAFETY RULES 2.1) SAFETY INDICATIONS The following set of safety rules categorized as CAUTION , WARNING , and DANGER indicates possibilities of physical or property damages if not fully observed. No. Names Content CAUTION Users may be subject to physical or property damages if not fully observe the CAUTION. WARNING Users may be subject to death or severe damages if not fully observe the WARNING. CAUTION WARNING DANGER Users may be subject to death or severe damages and emergency if not fully observe the DANGER. DANGER 7
  7. 7. 2.2) MACHINE DELIVERY Warning mark Description ONLY TRAINED AND EXPERIENCED PERSONS, FAMILIAR WITH THE RELEVANT SAFETY INSTRUCTIONS, SHOULD HANDLE THE MACHINE. MAKE SURE TO FULLY OBSERVE THE FOLLOWING INSTRUCTIONS. 2.2.1) Delivery using a crane DANGER Max 40。 1) The crane used should be strong enough to lift the machine. The nylon rope used should also be durable enough to support the machine weight. 2) Please hang the nylon rope on the rope hangers on the right and left sides of the body. 3) When hanging a rope to the crane, the slant angle of the rope should not exceed 40° at the maximum. Nylon rope Make sure all persons and obstacles are out of the way of the moving machine. 2.2.2) Delivery using a forklift 1) Make sure that size and weight of the forklift is sufficient to support the machine. 2) Place the machine so that its center is on the fork arm. Lift the machine carefully from behind so that the machine does not tilt to either side. WARNING When unloading the machine from forklift or crane, make sure to maintain the weight balance in order to prevent injury or machine damages. 8
  8. 8. 2.3) MACHINE INSTALLATION 2.3.1) Machine malfunctions or physical damages may occur due to condition of the installation environment. Make sure to meet the following conditions. CAUTION 1) The foundation (floor) under the machine must be strong enough to support the weight of the machine (approximately 3.5 tons). 2) Air conditioning can eliminate dust and humidity, which may cause pollution and corrosion of the machine. Make sure your machine is regularly maintained. 3) Do not expose the machine to direct sunlight. (Long exposure to direct sunlight can fade the machine paint or deform the machine shape.) 4) Allow at least 50cm space on each side of the machine (right, left, rear) from the wall for convenient maintenance. 2.4) MACHINE OPERATION 2.4.1) The machine has CAUTION and WARNING labels on each risky parts. Pay careful attention to the labels and make sure to observe them during operation. WARNING 1) Read thoroughly and fully understand the manual before operating the machine. 2) Dress for safety. Long and unbound hair, jewelry such as necklaces, bracelets, and wide sleeves can get caught in the machine. Wear shoes with non-slip soles to prevent slip-off accidents. 3) Check the scope of machine operation to see if there is no problem. 4) Keep your hands or head away from the moving parts of the machine such as needle, hook, take-up lever, and pulley when the machine is in operation. 5) Do not remove the safety covers on the pulley or shaft when the machine is in operation for your safety. 6) Be sure the main power is turned off and the power switch is OFF before opening the cover of any electrical components such as control box. 7) Be sure the main switch is OFF before manually turning the main shaft. 8) Turn OFF the machine when you thread needles or inspect the finished embroidery. 9) Do not lean against the cradle or place your fingers near the pantograph guide grooves. You may hurt your fingers when the frame moves. 10) The machine noise may exceed 85db when it runs at the maximum speed. 9
  9. 9. 2.5) REPAIR 2.5.1) Only SWF-trained and designated engineers should perform repair work. 1) Turn OFF the power before cleaning or repair. Wait for 4 minutes so the machine electricity is completely discharged. CAUTION DANGER It takes approximately 10 minutes after turning off the main switch before the electricity is fully discharged from main shafts and the X/Y drive box. 2) Do not change the settings or any parts on the machine without consulting with SWF. Machine changes without consultation with SWF may cause risks to your safety when you operate the machine. DANGER 3) Use only official SWF parts when repairing your machine or replacing parts. 4) Re-install all safety covers when you are finished with the repair. 10
  10. 10. 03 PRODUCT FEATURES 3.1) CHENILLE HOOKED NEEDLE’S RETURN TO THE ORIGIN - The hooked needle of the chenille embroidery machine can be automatically returned to the origin. 3.2) CHENILLE LOOPER’S RETURN TO THE ORIGIN - The looper of the chenille embroidery machine can be automatically returned to the origin. " 3.3) 10.4 LCD MONITOR - The operating panel is equipped with the 10.4 LCD monitor, which shows all information related to " embroidery work at a glance. 3.4) EXPANDED MEMORY - You can store maximum 100 designs and maximum 2 million stitches. 3.5) MIRROR IMAGE CONVERSION - You can turn the design from 0° 359° 1° also mirror the design (reverse in the X direction). to by and 3.6) ENLARGING AND REDUCING DESIGN - You can reduce or enlarge the design from 50% to 200% by 1% along the X, Y axis. 3.7) AUTOMATIC SELECTION OF NEEDLE BAR - You can select the order of the needle bars up to the 99th bar. 3.8) GENERAL REPETITION WORK - The same design can be repeated up to 99 times along the X, Y axis. 3.9) SPECIAL REPETITION WORK - Several designs can be repeated up to 64 times at different angles and directions. 3.10) AUTOMATIC OFFSET - The frame automatically returns to the offset point when the embroidery is finished, making it easier for you to switch the frames. You can select AUTOMATIC OFFSET at PARAMETER SELECT MODE to move the frame automatically to the desired point, making it easier to do appliqués and to switch the frames. 3.11) MANUAL OFFSET - You can manually move the frame to the pre-selected point to do appliqués or change the frame during embroidery work. The frame can be moved back to its original place by simply pressing certain buttons. 3.12) RETURN TO START - The frame can be moved back to the start point of the design during the embroidery. 3.13) NON-STITCHING - The frame and the needle bar can move backward and forward by the units of 1, 100, 1000, and 10000 stitches and by color without stitching. 3.14) FRAME BACKWARD - When the thread breaks or runs out of track, you can move the frame back to the starting point of the design in the units of one to ten stitches. 11
  11. 11. 3.15) AUTOMATIC TRIMMING DEVICE - The automatic trimming device is performed according to the design and the machine set-up in order to enhance work productivity and quality of the finished product. 3.16) AUTOMATIC DETECTION OF UPPER AND LOWER THREAD BREAKS - The machine detects when the upper thread breaks or the lower thread is out of the needle and automatically stops the machine. 3.17) FRAME CENTER - The machine moves to the center of the frame. This is easier if the design starting point is in the center. 3.18) AUTOMATIC RETURN TO STOP POINT IN UNEXPECTED BLACKOUT - When the power fails unexpectedly, the frame moves back to the exact point where the stitching stopped. This helps reduce the number of defects. ″ 3.19) 3.5″ FLOPPY DRIVE (EMBEDDED) - A 3.5″ floppy drive is embedded in the operation panel for you to read or store designs. (Both 2DD and 2HD disks can be used.) 3.20) EDITING - You can delete, change, or insert stitch data and function codes (jump, finish, trimming). 3.21) LANGUAGE SELECTION - You can select the language among Korean, English, Spanish, German, Dutch, Italian, Indian, Chinese, and Turkish. 3.22) The screen will indicate the cause of any machine stops. 3.23) The screen indicates RPM data. 3.24) FRAME MOVEMENT SPEED - You can adjust the frame speed to high, medium, or low. 3.25) The screen indicates the memory available for use. 3.26) You can use 2-binary and 3-binary tape codes. 3.24) OTHER BRAND CODES - The machine can automatically read designs of various formats stored in the floppy disk. [ Readable Format ] 1. SST 4. FMC, FDR 2. DST, DSB, DSZ 5. ZSK 3. TAP 7. EXP 6. 10O 12
  12. 12. 04 MACHINE INSTALLATION AND PRECAUTIONS Meet the conditions described in the manual when installing the machine. Failure to follow the directions may result in unexpected machine malfunctions. CAUTION 4.1) INSTALLATION CONDITION 4.1.1) Temperatures 1) When machine in operation: 0 ~ 40℃ (32 ~ 104℉) 2) When machine is idle: -25 ~ 55℃ (-13 ~ 131℉) 4.1.2) Humidity 1) relative humidity : 45~85% 1) Do not let moisture drops on the machine. 2) Provide air conditioning to control humidity and to prevent dust and corrosion. CAUTION 4.1.3) Grounding Ensure the electricity is properly grounded. Ensure properly grounding of the machine to avoid the possibility of electric shock. Use three-wire grounding (grounding resistance below 100 ohms). DANGER 4.1.4) Surrounding environment Close any doors or windows near the machine to prevent direct sunlight, dust, and humidity. 4.1.5) Place of installation Foundation (floor) under the machine must be sufficiently strong and flat concrete to support the weight of the machine. 4.1.6) Industrial environment classification Installation and use of the machine must be performed in an industrial area. (SWF machines should be used in Class A environment) 13
  13. 13. 4.2) ELECTRICITY INSTALLATION ENVIRONMENT Check if the input voltage of the machine corresponds with the voltage supply before installing or operating the machine. WARNING 4.2.1) Input voltage (to be adjusted at installation) 200V, 220V, 240V(50~60Hz) / 3-Phase (12 Head) 4.2.2) Allowed voltage range Within 10% of the voltage set 4.2.3) Electric capacity and power consumption 1.0 KW 4.2.4) Insulation resistance Over 10M ohms (measured with 500V insulation tester) 1) Make sure to check the voltage supply where the machine will be installed. 2) Install the cable away from the operator’s work space to prevent accident or injury. WARNING 4.3) LEVELING THE MACHINE The machine must be accurately leveled (especially front-back) to prevent machine from deformation or needle from moving out of position. CAUTION 4.3.1) Leveling the device 1) leveling - Use the adjusting bolts installed at the four stands to level the machine (front, rear, left, and right). Use a level gauge. Adjusting bolts Stand Level gauge 14 Level base
  14. 14. Until the height difference between the four adjusting bolts becomes 10mm, use the spacer by holding it against the lower balancing base. CAUTION 2) Locations of level gauge – Place the level gauges at the locations as in the figure below to maintain the balance of the machine. Level Gauge Level Gauge Do not place the level gauges on the square pipes and the table for maintaining the balance of the machine. CAUTION 3) Leveling fixation – When the left and right balancing is completed, turn the supporting bolt of the frame until it reaches the level base and loosen it by turning in the reverse way by a 1/4 circle. – When the supporting bolt adjustment is completed, tightly fasten the nut for fixation. Supporting bolt Nut The supporting bolt at the center reduces the machine vibration and maintains its horizontal balance. CAUTION 15
  15. 15. 05 NOTICES RELATED TO OPERATION 5.1) SAFETY LABEL TYPES Have a full understanding of the labels attached to the machine to prevent any possible accidents. CAUTION WARNING Injury may be caused by moving needle. Ensure that the machine is in a stop condition before changing, threading or rethreading of needies or changing of needles. WARNING Fire or death may be caused by high voltage electric shock. Don’t open the cover except for service man assigned by SWF. When open the cover turn off power and wait for 6 minutes. WARNING Physical damage may be caused by interposition. While embroidery frame is running according to the direction of embroidery frame may be injured your hands by gap between fixed body and embroidery frame. WARNING Injury may be caused by winding. Be sure to turn off the power before cleaning, lubricating, adjusting or repairing. WARNING Physical damage may be caused by winding. Don’t put your hands near the needle bar & take-up lever while machine is running. WARNING Make sure that the power is turned off before conducting cleaning, oil supply, adjustments or repairs. Otherwise, you may hurt your hands. WARNING Physical damage may be caused by winding. Don’t put your hands near the arrow while the main shaft is rotating ※ NEEDLE Injury may be caused by moving needle. Ensure that the machine is in a stop condition before changing, threading or rethreading of needies or changing of needles. ※ HIGH VOLTAGE Fire or death may be caused by high voltage electric shock. Don’t open the cover except for service man assigned by SWF. When open the cover turn off power and wait for 6 minutes. ※ HAND Physical damage may be caused by interposition. While embroidery frame is running according to the direction of embroidery frame may be injured your hands by gap between fixed body and embroidery frame. ※ MACHINE MOVE Injury may be caused by winding. Be sure to turn off the power before cleaning, lubricating, adjusting or repairing. ※ MACHINE MOVE Physical damage may be caused by winding. Don’t put your hands near the needle bar & take-up lever while machine is running. ※ MACHINE MOVE Make sure that the power is turned off before conducting cleaning, oil supply, adjustments or repairs. Otherwise, you may hurt your hands. ※ MACHINE MOVE Physical damage may be caused by winding. Don’t put your hands near the arrow while the main shaft is rotating CAUTION Always use the thread guide when threading to enhance your productivity as shown in the figure. THREAD GUIDE WARNING ① Turn off the main power before rotating the main shaft by hand! ② Do not remove covers during operation! ③ Turn off the main power before opening electricity-related boxes! ※ Always use the thread guide when threading to enhance your productivity as shown in the figure. ① Turn off the main power before rotating the main shaft by hand! ② Do not remove covers during operation! ③ Turn off the main power before opening electricity-related boxes! 16
  16. 16. 5.2) LOCATION OF SAFETY LABELS WARNING Injury may be caused by moving needle. Ensure that the machine is in a stop condition before changing, threading or rethreading of needies or changing of needles. WARNING Physical damage may be caused by winding. Don’t put your hands near the needle bar & take-up lever while machine is running. WARNING Injury may be caused by winding. Be sure to turn off the power before cleaning, lubricating, adjusting or repairing. WARNING Make sure that the power is turned off before conducting cleaning, oil supply, adjustments or repairs. Otherwise, you may hurt your hands. WARNING Physical damage may be caused by interposition. While embroidery frame is running according to the direction of embroidery frame may be injured your hands by gap between fixed body and embroidery frame. [Front] WARNING Fire or death may be caused by high voltage electric shock. Don’t open the cover except for service man assigned by SWF. When open the cover turn off power and wait for 6 minutes. WARNING Injury may be caused by moving needle. Ensure that the machine is in a stop condition before changing, threading or rethreading of needies or changing of needles. WARNING Physical damage may be caused by winding. [Side] Don’t put your hands near the arrow while the main shaft is rotating [Back] 17
  17. 17. 06 NAMES OF MACHINE PARTS A. Machine Body F1. Arm 1 J. Upper thread holder N. X-axis driving system B. Table F2. Arm 1(chenille) K. Head O. Y-axis driving system C1. Thread stand G1. Arm 2 P. Bar switch C2. Thread stand(chenille) G2. Arm 2(chenille) L1. Thread tension adjustment board D. Main shaft drive motor H. Trimming drive box R. Controller box E1. Bed I1. Color change L2. Thread tension adjustment board(chenille) E2. Bed(chenille) I2. Color change(chenille) M. Sub controller box T. Thread release 18 Q. Embroidery frame S. Operation box
  18. 18. 07 ACCESSORIES AND THEIR ASSEMBLY 7.1) STAND 1) Stand assembly (chenille) Thread holding bar Thread holding bar Supporter 30 Supporter Spool plate Spool plate Bolts for supporter Bolts for supporter - Regular Head - - Chenille Head - 7.2) OP BOX - Rear - 7.3) FLUORESCENT LIGHT 19
  19. 19. 08 FUNCTIONS OF EACH PART AND MACHINE OPERATION 8.1) BASIC OPERATION 8.1.1) Power on 1) 2) 3) 4) Plug in the power cord of the embroidery machine. Turn on the power switch. Press the operation switch attached on the bar switch. When the main power switch is “OFF”, the power is not supplied, although the operation switch is turn “ON”. Power operation switch Main power switch NOTE ※ Power Switch ※ When the emergency switch develops errors, the power switch detects them and ensure that the machine remains turned off. This is designed to detect the breakdown of the emergency switch and prevent related accidents. 20
  20. 20. 8.1.2) For starting embroidery and stopping the machine You can use START and STOP switches during machine operation in the following cases. 1) For starting or stopping the embroidery work Switch Machine Operation Press START Machine starts and embroidery work begins. Hold START Machine “inching (see Note1)” until you release the START switch. Press STOP Machine stops. NOTE 1) Non-stitching (floating) function is not available in the initial menu. 2) To perform floating at the start of embroidery, press STOP switch. The machine will then go into STOP MODE. Select FLOAT and set the number of non-stitching desired in the sub menu. 2) For moving the frame backward during embroidery work stop Switch Machine Operation Press STOP Frame moves backward in selected frame movement units (see Note 2) Hold STOP Frame starts to move backward. If you release STOP before the machine goes 10 of the selected stitches, the machine will stop immediately (the machine moves in the selected frame movement units). If you release the switch after the machine traveled 10 of the selected stitches, the machine will continue to move back. Press STOP Press STOP again and the machine will stop moving backward. 3) For forward non-stitching during embroidery work stop Switch Machine Operation Press START Frame moves forward in selected frame movement units (see Note 2) Hold START Frame starts to move forward. If you release START before the machine goes 10 of the selected stitches, the machine will stop immediately (the machine moves in the selected frame movement units). If you release after the machine traveled 10 of the selected stitches, the machine will continue to move forward. Press STOP Press STOP again and the machine will stop moving forward. 21
  21. 21. 4) For backward non-stitching during embroidery work stop Same as START/STOP during embroidery work stop NOTE 1) “Inching” refers to low-speed embroidery at 100 rpm range, performed for stable stitching when the machine is re-started after stop. 2) “Frame movement unit” refers to the “BK STITCH UNIT” in “Parameter Set-Up”. You can select from 1 to 10 stitches (by 1 stitch). 8.1.3) Bar Switch operation CAUTION You cannot perform non-stitching (floating) at the start of the embroidery because the function is not in the start menu. To perform floating at the start, push the bar switch to left go into “ ” STOP MODE. Then select FLOAT” and select the number of non-stitches desired in the sub-menu. 1) Bar switch to start the embroidery work or stop the machine during operation BUTTON OPERATION MACHINE OPERATION Push to right Machine starts and embroidery work begins. Hold to right Machine “inches (see Note1)” until you release the button. Push to left Machine stops. 2) Backward Frame Movement While the Embroidery Work is Stopped Bar Switch Operation Frame Movement Push it to the left side once The embroidery frame moves backward by the feed unit (see Note2). Push it to the left side continuously The embroidery frame starts moving backward. If the bar switch is released before pushing it ten times, the machine will stop immediately. (The embroidery frame moves back by the feed unit (see Note2)). If the bar switch is released after pushing it more than 10 times in a row, the embroidery frame continues to move backward by the unit of 10 needles. Push it to the right side and release it When the embroidery frame continues to move backward, push the bar switch to the right side again to stop the backward movement of the frame NOTE 1) For Chenille Embroidery 1) When trying to move the frame backward, while embroidery work is suspended, trimming occurs first, and automatic backward movement of the frame follows next. 22
  22. 22. 3) Forward Frame Movement While the Embroidery Work is Stopped Bar Switch Operation Frame Movement Push it to the right side once The machine moves forward by the embroidery frame feed unit (see Note2). Push it to the right side continuously The machine starts moving forward. When the bar switch is released before the embroidery frame moves ten times, the frame is immediately stopped. When released after the embroidery frame moves forward 10 times or above in a row by the feed unit, the frame continues to move forward by the unit of 10 needles. Push it to the left side and release it While the embroidery frame continues to move forward, and the bar switch is pushed to the left again, the forward movement of the embroidery frame is stopped. 4) For backward non-stitching while the embroidery work is stopped Same as Bar Switch operation 5) Performing Work Other Than Embroidery If you want to perform a solenoid test, a thread break sensor test, or manual trimming, select the function and press START. Select function CAUTION NOTE Push Bar Switch to the right side 1) “Inching” refers to low-speed embroidery at a 100 rpm range, performed for stable stitching when the machine is re-started after stop. 2) “Frame movement unit parameter” refers to the “BK STITCH UNIT” in “SET-UP 1”. You can select from 1 to 10 stitches by 1 stitch. 1) For Chenille Embroidery 1) When trying to move the frame backward, while embroidery work is suspended, trimming occurs first, and automatic backward movement of the frame follows next. 23
  23. 23. 8.1.4) Change switch function of chenille head 1) On/off switch function Chenille head’s work can be adjusted by changing the position of the toggle switch. – Top When fixing the fabric or starting embroidery work, place the chenille head at the top position to prevent the chenille head from being stuck to the fabric or embroidery frame. – Normal operation (center) When the machine is in normal operation, place the toggle switch at the “Lamp On” position to make the lamp on. – Lamp off (bottom) The “Lamp Off” function can make certain chenille heads fixed to the needle bar to make them disabled temporarily. Top Center Bottom 8.1.5) Lamp on thread tension adjustment board 1) Switch – For normal operation, turn the toggle switch on to turn on the indicator lamp. – If the machine stopped after detecting a thread break, move the frame back to the location of the thread break using STOP button and restart the machine to pick up stitching (design edit). If you want to move the frame back for any reason when a thread break has NOT occurred, press the toggle twice (OFF and ON again). NOTE 24
  24. 24. - The needle bar can be fixed at one position using the lamp-off function in order to disable specific heads. NOTE The upper thread holding device fixes the thread on the heads, whose toggle switches are off, and the heads unused for the embroidery at the moment, thus preventing thread escape from the needle. 2) Thread Break Detector Lamp Lamp on a specific head will blink when thread break is detected at the head, while lamps on other heads will be turned off. You cannot turn the lamp on or off on the other heads using the toggle switch. ON Thread detecting roller OFF Thread-break detection off switch ON Lamp Toggle switch OFF Interference to the thread detector roller (due to foreign substances around the thread detector roller, etc.) can cause the thread break lamp to blink. CAUTION 3) Deletion of Thread-Break Detection Function Poor function of the thread detecting roller due to foreign substances around it may result in wrong and frequent detections, causing inefficiency of work. In this case, you can turn off the detecting function by turning on/off the toggle switch at the end of the thread tension adjustment board as shown in figure. This will turn off the detecting function on the head you are working with. 25
  25. 25. 8.1.6) Needle pause clutch function (jump) When the manual jump clutch lever is pushed backward, the machine is back to normal operation. If the lever is pulled forward to the user side, the needle bar does not operate. Manual jump clutch lever CAUTION 1) The trimmer and the take-up lever continue to move even when the needle bar is stopped by the clutch. Avoid any operations, i.e. threading the needle or changing thread. 2) Long-time operation of the needle bar with the clutch may damage the bar controller. 8.1.7) LED on color change box Needle position lamp on the color change box blinks at the using needle in operation. Needle set lamp on the box blinks when the needle reaches the center of the needle hole on the plate (the roller is on the straight line of the color change cam. See figure in below. The needle moves only when the both lamps blink – preventing machine errors from incorrect needle position or color change failure. Color change motor Needle set lamp Needle position lamp N/set LED Needle position lamp ON ON Head OFF OFF ON OFF ON ON Roller Needle plate Lamp and the curve of the color change cam If any of the two lamps are off, adjust the half-turn film. CAUTION 26
  26. 26. 8.1.8) Chenille threading and tension adjustment 1) Chenille threading – Place the thread at the chenille head following the order below: No. 1 thread tension adjusting device → No. 2 thread tension adjusting device → Thread take-up spring → Needle plate → Hooked needle To place the thread on the loop, thread the needle threading device and insert the device into the hole at the looper bottom. Push it up to the top of the looper and leave 3~4cm of thread as a remaining thread. Pass thread through a needle using a threader, and use the manual trimming and manual color change functions to ensure easier threading. CAUTION Needle Plate Main thread tension adjusting device No. 2 thread tension adjusting device No. 1 thread tension adjusting device Embroidery frame Threading device 3~4cm 27
  27. 27. 2) Adjustment of chenille head’ thread tension s – Loop stitch Adjust the tension adjusting device to make each thread tension adjusting device have some 20~30g of tension. – Chain stitch Adjust the tension of the main thread tension adjusting device to make the main thread tension adjusting device have some 40~50g of tension. (based on rayon #300) Thread tension should be re-adjusted depending on the fabric and thread types. CAUTION 3) Threading of the tension adjusting device NO. 1 & No. 2 Thread Tension Adjusting Device Main Thread Tension Adjusting Device Rotary tension disk Pass the thread between thread guide disk and through the thread guide plates hole of the thread adjusting device. Pass the thread between thread guide disk and through the thread take-up spring of the thread adjusting device. 28
  28. 28. 4) Upper threading of regular head Upper thread stand Upper thread (from the upper thread stand) Sub thread adjuster Thread tension adjustment board Thread detecting roller Tale-up Spring Stopper Take-up spring Rotary tension disk Main thread tension adjuster Upper thread guide Thread guide (upper) Take-up lever Thread guide (middle) Thread guide Upper thread holding Presser foot Needle 29
  29. 29. 5) Threading the tension adjuster of regular head Threading the sub tension adjuster Threading the thread detector roller Thread detector roller 1 time rotation Thread guide disk (through the center of shaft) Feed it between the thread guide plates and through the hole in the axis of the thread adjusting device. Wrap the thread around the detector roller one time. Threading the main tension adjuster Threading around the needle Upper thread holder plate 1.5 times rotation Rotary tension disk Feed the thread through upper thread holder plate in the upper thread holding. Thread the thread guide and needle. Fix the thread between the holder plate in the upper thread holding. Wrap the thread 1.5 times around the rotary tension disk (V-shaped groove.) 30
  30. 30. 6) Upper Thread Tension Adjustment Thread tension adjustment is critical for producing high quality of the embroidery. A balance of 2/3 upper thread and 1/3 lower thread generally indicates good tension. CAUTION 1) If tension is too weak The upper thread will loop, causing thread tangles or breaks. 2) If tension is too strong Puckering may occur as well as thread and needle breaks. – The upper thread tension is controlled by sub and main thread tension adjusters. Turn adjusting nut clockwise to increase the tension and counterclockwise to decrease the tension. – The sub thread adjuster should control about 2/3 of the upper thread tension. – The main tension adjuster should handle the other 1/3. – Set the tension of the sub thread adjuster so the upper thread flows smoothly through the rotary tension disks and into the rollers of the main tension adjuster. CAUTION Adjusting nut Sub thread adjuster 2/3 1/3 Main tension adjuster 1) If tension at the sub thread tension adjuster is too loose, the detector roller may not rotate well and make wrong detections. 2) After adjusting the tension, check if the upper thread tension is what can be pulled with little force of around 100-120g. 3) After adjusting the tension, pull the upper thread to see if the detector roller rotates well. 4) Adjust the tension constantly according to the type of thread and fabric used. 31
  31. 31. 7) Take-up spring adjustment – Functions Difference in the length of the upper thread pulled by the take-up lever and by the hook creates tension or looping. The take-up spring absorbs the leftover of the upper thread. Increase the tension or the stroke of the spring to form tight stitches on the embroidery. ○ × Correct position of the take-up spring Incorrect position of the take-up spring Gap between the take-up spring stopper and the spring (due to dust or foreign substances in the stopper) The take-up spring stopper touches the spring Stopper Take-up spring – Adjusting tension of the take-up spring You can adjust the tension of the take-up spring with its shaft. You can increase the spring tension by turning it clockwise, and decrease the tension by turning it counterclockwise. – To adjust the stroke of the take-up spring You can adjust the stroke of the spring by moving the take-up stopper to right or left. Thread tension adjusting stud 32
  32. 32. 8.1.9) LOWER THREADING AND TENSION ADJUSTMENT 1) Lower threading – Use cotton yarn (80# ~ 120#) for your lower thread. – Lower threading into the bobbin case Insert the bobbin into the bobbin case with the thread coming out from the case slot. Pull the thread through the thread guide. – To prevent lower thread tangles, trim the thread, leaving the length at 3-4cm, before inserting the bobbin into the hook. 3~4cm Lower thread holder Slot Screw Tension spring Bobbin Thread guide Make sure the bobbin rotates clockwise when you pull the thread holding the bobbin case in your left hand. CAUTION 2) Lower thread tension adjustment Adjust the tension of the lower thread using the bolt on the tension spring of the bobbin case. Turn the bolt clockwise to increase the tension and counterclockwise to decrease the tension. Bobbin case CAUTION To check if the lower thread tension is adequate, hold the thread from the bobbin and jiggle the bobbin case lightly up and down. The thread should come out from its own weight and the tension should be 25-35g. 33
  33. 33. 8.1.10) BOBBIN WINDER 1) Bobbin winding – Insert the bobbin onto the shaft ① and manually wind the thread 5-6 times around the bobbin. Press START button ② to wind the bobbin. – Bobbin winder will stop winding according to the embedded timer. But if you want to stop winding before the bobbin automatically stops, press STOP button ③. Knob ST AR T Thread tension adjustment screw ST OP Thread guide Thread guide screw Winding shaft Bobbin 2) Adjusting thread volume on the bobbin – Fill the bobbin 80% and make sure the thread is parallel to the bobbin as shown in the figure. 80% – Thread volume on the bobbin can be adjusted using a TIME dial. Set it at MAX to increase the volume. Knob decrease increase 1) Overfilling the bobbin may interfere with the smooth pull of the lower thread. 2) For normal bobbin, 80% fill will render around 80m of lower thread. CAUTION 34
  34. 34. 3) Adjusting the bobbin winding condition – If the thread is not parallel to the bobbin, adjust the body of the thread guide left and right. – Adjust the tension of the bobbin winding using the tension adjusting nut. Thread tension adjustment screw Thread guide screw Thread guide Winding the bobbin off-center or uneven as shown below can cause thread breaks, skipped stitches, or thread tangles. CAUTION Too tight tension of the bobbin winding can block smooth pulling of the thread and cause thread breaks or short tails. CAUTION 35
  35. 35. 8.1.11) Things to consider when using an Floppy Disk or a USB memory stick When handling this input/output device, the following instructions should be strictly observed. CAUTION 1) The floppy disk sold in the market can be used after formatting. But make sure of using a certified disk product. 2) In case of using a USB memory stick, its file system should be FAT 16. If it is FAT 32, the memory stick cannot be used. ▶ In case of using an FDD: – Place the FDD away from objects creating magnetism or magnets. ex) TV, radio, etc. – Keep the FDD away from heat, humidity, and direct sunlights. – Do not place heavy objects over the FDD. – Do not remove a diskette from the disk drive, while the disk formatting or the data input/output is conducted. – Do not leave the disk drive cover stay open. – If the writing prevention tap is on, data input to the FDD is impossible. – If one diskette is used for multiple reading and writing activities, the diskette may develop errors. – Produce a backup diskette to safely keep important data. ▶ In case of using an USB memory – While the input/output work is in progress, do not remove the USB memory from the USB port. 8.1.12) Floppy disk and USB memory inserting – Floppy disk inserting Press the arrow part to open the cover. Insert an FDD into the arrow direction. – USB inserting Insert the USB memory into the USB port. 8.1.13) Floppy disk and USB memory stick removal Press the exit button to remove the disk from the FDD. In case of an USB, close the input/output window and remove the USB memory. CAUTION Do not remove a floppy disk from the FDD in the middle of formatting or data input/output operation. Otherwise, the stored data might be deleted. 8.1.14) Operation related to embroidery design input/output Embroidery design can be imported to the OP Box from outside by using a floppy disk, USB memory, CF card or serial communications. Embroidery design output can be conducted by using a floppy disk and a USB memory. 36
  36. 36. 8.1.15) Return to stop position in unexpected blackouts Your SWF embroidery machine automatically returns to the previous position when the power comes back on after an unexpected blackout, thereby not affecting the quality of the embroidery. (See LCD Monitor User Manual) CAUTION Do not remove a floppy disk from the FDD in the middle of formatting or data input/output operation. Otherwise, the stored data might be deleted. 8.2) NEEDLE-HOOK TIMING AND RELATED TIPS 8.2.1) Needle 1) Chenille series (CA-Series) – Choose appropriate hooked needle in line with fabric and thread type. – If the hooked needle used is inappropriate, the loop is not properly made or the skipped loop might result. 2) Regular head (SA-Series) – It is very important to select the right needle for the type of thread and fabric used. – Inappropriate needles can cause bad embroidery, thread breaks, skipped stitches, etc. – For normal embroidery, use a DB×K5 needle. × DB×K5 needle has an eye twice larger than that of DB1 (used for normal stitching). × Use DB×K5 for normal embroidery. CAUTION 8.2.2) Relationship between needle and thread 1) Chenille series (CA-Series) – The table below shows the types of hooked needles and threads used for chenille. Hooked Needle Nipple Needle Plate Thread Chumetz Organ Diameter Inner Diameter Needle Plate Diameter (mm) Rayon Thread Thickness 75 11 0.75 1.0~1.2 1.2~1.3 120 90 14 0.9 1.1~1.3 1.4~1.6 300 100 16 1.0 1.2~1.4 1.6~1.8 300, 600 110 18 1.1 1.3~1.5 1.8~2.0 600, 900 – 19 1.2 1.4~1.6 1.9~2.1 900 – 21 1.3 1.5~1.7 2.0~2.2 900 and more 37
  37. 37. 2) Regular head (SA-Series) - Inadequate selection of thread and needle may result in thread breaks, skipped stitches, as well as in badquality embroidery. - Refer to the following table of threads and needles used for normal embroidery. Needle Size Thread Size US Japan Germany 0.25 9 65 0.27 10 70 0.29 11 75 0.32 12 80 0.34 13 85 0.36 14 Silk Nylon Rayon 70~80 100~120 130~150 70~100 50~60 90 80~100 100~130 100~130 36~40 CAUTION Cotton # 60~70 80~100 130~150 Needle and thread most commonly used in embroidery Thread : rayon yarn 120d/2. × Needle : DB×K5 #11 8.2.3) Changing the needle Screw for the needle bar clamp 1) Chenille series (CA-Series) – Completely remove the needle bar to replace a chenille series needle. – Loosen the screw for the needle bar clamp and completely separate the needle bar. – Loosen the needle fixing screw at the bottom of the needle bar and disassemble the existing needle. Needle fixing screw 38
  38. 38. – Make adjustments to let the cross-section of the needle meet with the screw, and push the needle inside until the very end. If the needle is not pushed throughly into the end of the hole, the needle might need to be readjusted. CAUTION 2) Regular head (SA-Series) – Make sure the needle is completely clear of the needle plate before changing it. If the needle is not clear of the plate, use the main shaft handle, manually turn the main shaft to put the needle in the right location for change. CAUTION 1) Turn OFF the machine according to the safety rules before turning the main shaft manually. 2) Immediately remove the main shaft handle afterward: it is dangerous to operate the machine with the handle inserted. Main shaft lever Needle OUT Needle IN Needle plate 39
  39. 39. – When inserting the needle, make sure that the groove of the needle is facing front. – End tip of the needle should be inserted completely into the needle bar. Needle insert hole Front groove of the needle – When using special threads, such as artificial silk, you might want to turn the groove of the needle to the right in order to minimize the thread breaks. If the needle is not inserted all the way to the top of the needle bar hole, timing of the machine will go off, causing broken needles and thread breaks. CAUTION 8.2.4) Relationship between needle and looper 1) Looper’s rotary angle The looper rotates clockwise and counter-clockwise at 250 degrees, and creates a loop by winding thread around the hooked needle. 2) Stitch types There are two types of stitches. – Loop Stitch The embroidery frame’s feed direction is same to the hooked needle’s direction. When the loop is created, the thread is automatically separated from the hooked needle. – Chain Stitch The embroidery frame’s feed direction is opposite to the hooked needle’s direction. When the loop is created, the thread is not separated to move to the next stitch. 40
  40. 40. Looper Looper (Looper Stitch) (Chain Stitch) 8.2.5) Relationship between needle and hook – Adjusting timing between needle and hook Default timing of the needle and the hook is set by the main shaft angle of 201°Relationship between the . needle and the hook varies as below. Top point of hook circumference Hook point Top edge of the needle eye Top edge of needle eye Hook point c Needle tip a b Lower dead stop of the needle a. At lower dead stop of the needle bar 2.3~3.7 mm b. At needle-hook timing 1.8~2.2 mm c. At needle-hook timing 0.5~1.5 mm – Adjusting allowance in the hook The hook can move right and left if there is an allowance in the lower shaft gear. Eliminate the allowance (gap) by turning the hook clockwise. Then adjust the timing. Allowance (gap) 41
  41. 41. 8.2.6) Adjusting gap between needle and hook point Hook point – Gap between the hook point and the needle The distance between the needle and the hook should be 0.1-0.3mm at their closest interface. – Thread skip Thread skip occurs due to thread looping or inadequate balance or gap between the needle and the hook. – Adjustment The closer the hook point is to the needle, the hook point will be inside the loop and threading will be more stable. 0.1~0.3mm 8.2.7) Functions of hooked needle 1) Hooked needle’s groove It creates loops by twisting the threads supplied by the looper. – Loop Stitch The hooked needle’s direction is same to the embroidery frame’s feed direction. After creating a loop, it exits from the loop and create the next loop. – Chain Stitch The hooked needle’s direction is opposite to the embroidery frame’s feed direction. This produces embroidery which is connected to each other. 8.2.8) Functions by needle shape Hole and groove of the needle vary by the size and type of the needle. – Front groove It protects the thread from the friction heat of the sewing (which can cause thread breaks). – Back groove It adjusts the hook timing according to the needle movement, thus preventing thread skips. CAUTION Front groove Needle eye Back groove 1) Prevention of looping is important for stitching. Adjust the hook point as close to the needle as possible to achieve the perfect thread position. 2) If embroidery state is not good, move the needle slightly to the right. 42
  42. 42. 8.2.9) Different loop shapes Shape of the loop varies by the type of thread or fabric. Unstable shape of the loop may result in skipped stitches. The following pictures show different shapes of loop formed by different types of thread. Hook point Hook point Cotton thread loop Synthetic thread loop 8.2.10) Relationship between the take-up lever and the hook Hook point timing is directly related to thread tension and thread breaks. The following pictures show the location of hook when the take-up lever starts to move up from the lower dead stop (main shaft rotation angle: 291° ). 1) Hook timing is fast (in the A range) The hook starts to take the thread from the takeup lever. Loop is small because the upper thread is pulled. Stitches are made but stitch tension is bad. Thread skips occur, where hook fails to go through the loop. Too small 2) Hook timing is slow (in the B range) The hook starts to take the loop before the takeup lever goes up. Thread skips don’t occur, but thread breaks occur, because the take-up lever moves faster than the thread coming off the hook. Too large 43
  43. 43. In normal hook timing, the hook should be in the (C) range. CAUTION (B) Groove of the hook (C) (A) 8.3) THREAD BREAK DETECTOR ASSEMBLY AND ITS FUNCTIONS 8.3.1) Functions 1) Chenille series The sensor attached to the looper base is used to detect thread breaks to prevent bad sewing. 2) Regular head The thread detector prevents bad embroidery by detecting breaks of the upper or the lower threads. The thread detection roller performs the detection. Wrong detection can occur if the thread detection roller does not rotate smoothly. CAUTION 44
  44. 44. 8.3.2) Disassembling the thread detector You will need to disassemble the thread-break detector unit when you to have to clean it for more smooth rotation. Remove the cover of the thread tension adjusting plate, separate the cables of the thread detection board, and unfasten the roller base bolts. The entire unit will be disassembled including the rollers and bush bearing. CAUTION 1) When assembling the thread detection roller, check between the sensor groove and the film on the thread detection board. 2) Thread detection may not work according to the location of the thread detection board. 3) You can adjust the location of the board using the board base bolts. Film Bush bearing Roller base screw Roller base Thread detector roller 45
  45. 45. 09 NOTICE EMBROIDERY METHODS For more information on how to use the chenille embroidery machine, please refer to the chenille operating manual and the SA-series touch screen manual, which were published by SunStar. 46
  46. 46. 10 ERROR DISPLAY AND TROUBLESHOOTING 10.1) MAIN SHAFT MOTOR No. Error Description Troubleshooting 100 Main shaft stop Main shaft doesn’stop at 100° t Adjust the main shaft at 100° using lever. 101 Main shaft motor drive Error in main shaft motor driver Turn the main switch off and on again. 102 Main shaft motor overload Thread tangles in the hook Error in needle bar controller Thread tangle in trimming Check hooks of all heads. Turn the switch off and on again. 103 Trimming return Trimming sensor doesn’return t when trimming Check for errors in the trimming system 104 START switch START is pressed when turning power on Check START – connector connection 105 STOP switch STOP is pressed when turning power on Check STOP – connector connection 107 Valve Valve is opened 108 Air pressure Air pressure is below standard (Sequin) 109 AC line Problems in the joint board Replace the joint board, etc. 10.2) X, Y-AXIS MOTORS No. Error Description Troubleshooting 200 (+X) frame limit Frame reaches +X limit Move the frame -X 201 (-X) frame limit Frame reaches -X limit Move the frame +X 202 (+Y) frame limit Frame reaches +Y limit Move the frame -Y 203 (-Y) frame limit Frame reaches -Y limit Move the frame +Y 204 X-axis driver Error in X-axis driver Turn the main switch off and on again 205 Y-axis driver Error in Y-axis driver Turn the main switch off and on again 206 Wiper return Wiper solenoid doesn’t return Repair the wiper mechanism 207 Trimmer return Trimmer motor doesn’t return Repair the trimmer mechanism 47
  47. 47. 10.3) COLOR CHANGE No. Error 300 Needle bar position Description Needle bar doesn’come to t correct position when changed Troubleshooting Move the needle bar manually. Check the load. Position it at the correct location. 10.4) ENCODER No. Error Description Troubleshooting 400 Main shaft encoder A Error in signal in main shaft encoder A Check encoder connection. Turn the main switch off and on again. 401 Main shaft encoder Z Error in signal in main shaft encoder Z Check encoder connection. Turn the main switch off and on again 10.5) REPETITION WORK No. 501 Error Repetition set-up Description Off the repetition limit (X set-up)×(Y set-up)>99 48 Troubleshooting Change the set-up to (X set-up)×(Y set-up)<99
  48. 48. 10.6) FLOPPY DISK No. Error Description Troubleshooting 600 No disk No disk in the drive Insert the disk in the drive 601 No sector in disk Disk is not formatted Disk is of different format Format or replace disk 602 No design in disk No design in the disk Replace disk 603 Remove protection tab Disk is write-protected Remove the protection tab 604 Damaged disk Disk is damaged Format or replace disk 605 No capacity No extra space in the disk Replace disk 606 Disk out of drive Disk is removed during use Insert disk and re-work 607 Bad sector in reading Bad sector in the disk Format or replace disk 608 Bad sector in writing Bad sector in the disk Format or replace disk 609 Unknown error Unknown error during use Format or replace disk 610 Disk error Unknown error during use Replace disk 611 ZSK design error 612 BARUDAN design error 613 Bad sector 614 OS installation error OS program file name doesn’ t exist or match OS program file name is swf_tb.bin. If the name reads swf.tb.exe, change it. 630 Error in input data Error in the data from tape reader Re-read from the tape reader 640 Failure to find the network device Network device is not connected Check connection of the network device 650 USB error USB drive is not ready Check if the USB file system is FAT16 49
  49. 49. 10.7) MEMORY No. Error Description Troubleshooting 700 No embroidery data in the memory No embroidery data in the memory Store data in memory via disk 701 Insufficient memory Unable to copy data to memory due to insufficient memory Delete unnecessary data 702 Memory full 100 memory rooms are full Delete unnecessary data 703 Design memory system Error in copy/delete between memories RESET or turn the main power off and on again. 704 Bad memory battery Run out of battery that keeps memory data during power off. Unstable storage of data, i.e. number of stitches, X/Y position, etc. Consult the nearest SWF for battery change (if battery outages are frequent, replace CPU board) 10.8) CHENILLE HEAD No. 900 Error Chenille main shaft motor’s stop position error Description Troubleshooting The error occurs, when the main shaft does not stop at the 35° direction. Use the main shaft revolving lever to adjust the main shaft stop angle. 50
  50. 50. 11 CONTROL BOX 11.1) MAIN CONTROL BOX 11.1.1) Inside the Control Box ① ② ① SMPS power ② Power for Jump Motor, picker & upper thread holder solenoid 51
  51. 51. 11.1.2) Outside the Control Box ① ② ① Terminal for tape reader and winder ② Fuse for tape reader and winder 52
  52. 52. 11.2) MAIN SHAFT & X-Y MOTOR DRIVE (SANYO) ① ② ③ ④ X-axis driver Y-axis driver Trimmer driver Joint board ① ② ④ ③ 53
  53. 53. 11.3) LIST OF ERRORS AND CAUSES IN MAIN SHAFT DRIVER & X,Y SERVO MOTOR DRIVERS DISPLAY ERROR CAUSE Excess current Error in driver or motor Overload Driver error or mechanical overload Driver overheated Error in driver Excess voltage Error in driver, error in power voltage Over speed Error in parameter set, error in motor Error in control power Error in power voltage, error in driver Error in sensor Driver error, wiring error, error in parameter set, error in motor, error in power voltage Power voltage drop Error in driver, error in power voltage Error in power voltage cable Driver error, wiring error Error in speed control Driver error, motor error, sub tuning, error in power voltage Excess variation Error in driver, error in parameter set, wiring error External overheat Error in driver, wiring error Sub processor error Error in driver Recovery error Error in driver, error in parameter set, mechanical error, error in wiring of recovery resistance terminal Memory error Driver error, error in parameter set Battery error (Only for absolute value encoder) Replace battery Error in driver, error in parameter set No. Light 54
  54. 54. 12 MAINTENANCE AND INSPECTION 12.1) CHECK POINTS FOR REGULAR INSPECTION CAUTION 1) Make sure that the power is turned off before checking or cleaning the machine. 2) Wait for some ten minutes after turning off the power for complete discharge, and then conduct checking or cleaning. 3) Make sure to turn OFF and STOP the machine when performing inspection. 12.1.1) Clean, oil, and grease the set parts of the machine on a regular basis. 12.1.2) Inspect tension of each driver belt. 12.1.3) Failure to perform regular inspections can cause the following. – – – – – Corrosion of P/C circuit board Damage to the semi-conductor on P/C circuit board Malfunction of the floppy disk drive Ill connection of the connector Abnormal wear-outs of machine parts due to insufficient oiling and greasing 12.2) CLEANING Use the air compressor to clean each part of the machine. CAUTION 1) Make sure that the power is turned off before checking or cleaning the machine. 2) Wait for some ten minutes after turning off the power for complete discharge, and then conduct checking or cleaning. 3) Properly adjust the frequency of cleaning depending on the usage conditions and nearby environments. If the machine is broken or develops mal-operation due to the negligence on regular checkup, SWF is not liable. CAUTION 55
  55. 55. 12.2.1) Cleaning method and cleaning cycle for machine parts Types No. Names Reference Fig. Cleaning cycle 1 Needle plate, Trimmer area, Thread holding area, Looper, Needle, Looper drive gear, Looper gear section 1~2 times in a week 2 Needle bar, Needle bar sleeve, Needle 1~2 times in a week Chenille series Hook 1 Around the hook Every day Regular head Guide rail to the take-up lever 2 Guide rail to the take-up lever of the head Once a week 56
  56. 56. Types Regular head No. Names 3 Around the movable blade and the fixed blade Reference Fig. Cleaning cycle Movable blade Lower thread holder Once in 3 days Fixed blade CAUTION 1) In order to prevent the loss of nipple connection studs, make sure to disassemble them before cleaning the machine. 2) When cleaning the chenille bed, make sure to clean the area between the looper base and the gear. 3) Use the trimming driving knob and a spanner for manual spinning for cleaning purpose. 4) Use the needle plate air gun to push inside dusts out by blowing wind. 5) To clean, remove the needle plate and pull the movable blade to the front (see picture). After the cleaning, assemble back in the reverse order. 57
  57. 57. 12.3) OIL SUPPLY 1) Make sure to turn the power OFF during oil supply. 2) SWF is not responsible for machine damages or wear-outs caused by insufficient oiling. CAUTION 12.3.1) Oil supply 1) Use the SWF-provided sewing machine oil (Spindle Oil) or ISO-level VG18. 2) Manually oiling Types No. Supplying Place Supply Frequency Reference Fig. 1 2 Needle motion lever, connection rod Around the nipple connecting bracket 1 Take the bobbin case out of the hook. Feed small amount of oil on the raceway. Once a week ① 2 Needle bar and needle bar shaft Once a week ② 3 Inside the arm Once a week ③, ④ 4 Regular head Needle bar, needle bar sleeve 3 Chenille Head Guide rail to the take-up lever _ 5jw Once a week ⑤ ① Once a week ② ③ [Chenille head] ① ③ ② 58
  58. 58. [Regular head] Head ③ ③ ③ ⑤ ② ② ⑤ ③ Oil hole ③ Arm ④ ④ Raceway ① ※ Oil can’ be automatically supplied to ③,④. Make sure of conducting manual oil supply to these areas once a week. CAUTION Bobbin case Hook 1) Excess oil may stain the thread and the fabric. 2) Run the machine without stitching for 2-3 minutes after oiling. 3) Excessive oiling in the hook may cause trimming errors and thread breaks. 59
  59. 59. 3) Oil wick-based oil supply When supplying oil, fill up the oil until the oil wets the felt inside the oil tank. – Oil supply position and supply frequency No. 1 Supplying Place Supply Frequency Within the arm a. Thread take-up moving lever pin b. Pressor foot driving pin c. Needle bar driving shaft Once per every two days 1) Use SunStar’s spindle oil or the oil with ISO viscosity level VG18. 2) Fill the oil until the height of the oil at the tank is between H(High) and L(Low). CAUTION 60
  60. 60. 12.3.2) Grease supply Make sure of turning the power off when supplying grease. CAUTION 1) Locations to be Supplied with Silicon Grease No. Grease Supplied Area Frequency Location 1 Inside the chenille arm Driving cam Location cam Gear 2~3 times a month ① ② ③ ④, ⑤ 2 Looper driving gear 2~3 times a month ⑥, ⑦ ① ④ ② ③ ⑤ ⑥ ⑦ 61
  61. 61. 2) Use high-quality mineral-base lithium grease No. Grease Supplied Area Frequency Location 1 Inside the arm Take-up lever drive cam Needle bar drive cam Needle bar controller Presser foot driver cam, take-up lever driver roller Once in 6 months ① ② ③ ④, ⑤ 2 Color change cam, color change-related gears Once in 6 months ⑥, ⑪ 3 Hook gear and lower gear in the rotary hook base Once in 6 months ⑦, ⑧ 4 Trimmer driver link and trimmer driver shaft bushing Once in 3 months ⑨ Regular greasing prevents machine noise and abnormal wear-out. CAUTION ④① ② ⑨ ⑤ Trimmer cam box ③ Color change cam box ⑦ ⑪ Half-turn ⑥ gear ⑧ Lower shaft Rotary hook base Motor gear Color change gear 62
  62. 62. 3) Use lithium - Type grease (JIS No. 2) (Brand Name : Albania No. 2) No. Grease Supplied Area Frequency 1 Head drive LM guide Once a month 2 X, Y drive guide rail Once a month Regular greasing prevents machine noise and abnormal wear-out. CAUTION 4) Greasing the head drive LM guide [Upper cover opened] Where to grease Where to grease 63
  63. 63. 5) Greasing the X, Y drive guide rail – Disassemble the frame from the table. – Unscrew the stainless cover and remove it. – Push the guide block farthest to the front of the machine. – Lift the timing belt with one hand and grease the entire guide rail. – Place the cover in the reverse order. [Layout of X, Y drive guide rail] Y-axis LM guide X-axis LM guide Stainless cover Frame [Zoom-in the guide rail layout] Where to grease Where to grease 64 Where to grease
  64. 64. 12.3.3) Drive belt tension Turn OFF the main power when inspecting drive belt tension. CAUTION Too weak or too tight tension on the drive belt may cause machine malfunction or damages (abnormal wearout of drive unit). Inspect the driver belt on a regular basis. No. Location for inspection Inspection cycle 1 Belt on main shaft motor Once in 3 months 2 Upper & lower shaft belt Once in 3 months 3 X-axis timing belt Once in 3 months 4 Y-axis timing belt Once in 3 months Inspection ① Belt tension ② Belt crack ③ Belt wear-out ④ Bearing damage ⑤ Wear-outs of rotating parts Reference Fig. ① Inspect the tension in the direction of the arrows in the picture below. CAUTION ① ① 12.3.4) Main shaft driving belt disassembl 1) Loosen the screws for the upper shaft coupling, the bearing socket, and the upper shaft pulley to disassemble the main shaft connected to the coupling. 2) Use the empty space to disassemble the main shaft driving belt. Upper shaft coupling Screw for the upper shaft pulley 65
  65. 65. 13 ADJUSTING MAJOR PARTS OF THE MACHINE Turn OFF the main power when adjusting the machine. DANGER 13.1) ADJUSTING THE CHENILLE HEAD See the operation manual to lower the needle to the lowest position, and conduct the adjustment of the chenille head. CAUTION 13.1.1) Nipple 1) Nipple height check – Turn off the machine power. – Set the chenille head’ main shaft angle at s 185° using the main shaft handle. by – When the angle is set at 185°check whether , the nipple and the needle plate are contacted. 2) Height adjustment – Loosen the fixing screw for the nipple and adjust the nipple to make it contacted with the needle plate. 185 Nipple fixing screw Nipple Needle plate 13.1.2) Needle 1) Needle height adjustment – Set the needle height at 1 from the operation panel. – Set the chenille head’ main shaft angle at s 35° using the main shaft handle. by – When the main shaft angle was 35°check , whether the distance between the end of the needle and the needle plate is 2mm. 35 Hooked needle 2mm 66 Needle plate
  66. 66. 13.1.3) Needle locating position adjustment 1) Needle locating position height adjustment – Set the chenille head’ main shaft angle at s 110° using the main shaft handle. by – Turn the nipple rotary gear when it is at the lowest position, and check whether the hooked needle hole is rotating at the center of the needle plate hole. 110 Nipple rotary gear Needle Needle plate hole 13.1.4) Pressor foot adjustment 1) Height check – Set the chenille head’s main shaft angle at 35° using the main shaft handle. by – Check whether the presser foot is properly fixing the embroidery fabric. 2) Height adjustment – Loosen the screw for the pressor foot holder and adjust the pressor foot to fix the embroidery fabric. 35 Presser foot Embrodery fabric Needle plate 13.2) ADJUSTING THE TRIMMERS 13.2.1) Adjusting the Position of Movable Blade The initial setting position of the moving mes means its starting position of motion and the basic position of determining trimming timing. 1) When adjusting the initial setting position of the moving mes, first of all check whether the moving mes is installed at the right position (The front end should be located at 2.5mm away from the fixed screw for the fixed mes.) If the position of the moving mes is inappropriate, the upper thread separation and the failure in cutting could result. 2) If the position of the moving mes is inappropriate, loosen the tightening screw for the crank, and manually move the moving mes for adjustment. When adjustment is completed, tightly fasten the crank tightening screw. . 2.5mm 67
  67. 67. 13.2.2) Adjusting Space between Movable Blade and Hook To adjust a space between the movable blade and the hook, remove or insert a spacer (t 0.1) between the blade base and the hook base. In the case of spacer removal, make sure to check if the hook does not interfere with the movable blade. Blade base Movable blade Spacer Hook holder Hook base 68 Fixed blade
  68. 68. 13.2.3) Adjusting Blade Tension Make sure to check and adjust the cross-tension of the movable and the fixed blades after replacement or repair. – Checking the cross tension Manually move the movable blade and cut the upper and the lower threads. Check the cross-section of the thread cut. – Adjusting the cross tension Adjust the cross tension using the tension adjusting bolts of the fixed blade. Manually move the movable blade and make adjustment to the point, where it crosses in parallel with the cutting line of the fixed blade from its entry point to its return point. NOTE Avoid excess cross-tension. Excess tension may cause errors or wear-out of the movable blade from overload at its entry or return point. By holding the thread fed from the bobbin case after trimming, the lower thread holder helps to make starting stitches after trimming. Regularly clean the thread debris around the lower thread holder for efficient functioning of the holder. CAUTION L-wrench Tension adjusting screw Movable blade Fixed blade Movable blade Crank screw Movable blade crank 69 Fixed blade
  69. 69. 13.2.4) Adjusting Trimmer Return Spring 1) Function The trimmer return spring detects whether the movable blade has returned to its correct position after trimming. If the blade has not returned, it stops the machine to prevent damages on the needle and the blade. 2) Adjustment Adjust the position of the sensor and the sensor unit so that the left edge “side A” of the sensor unit is at ( ) the center of the left sensor when the movable blade is in its correct position (see picture A of Figure.). Make sure that the sensor unit does not interfere with the operation of the sensor (see picture B of Figure.). Trimmer shaft Sensor Sensor fixing nut 1mm Trimmer return sensor device 2mm Sensor unit 13.3) ADJUSTING THE UPPER THREAD HOLDING UNIT 1) Checking the assembly of upper thread holding lever and upper thread holder plate ① Stroke of the upper thread holder driver plate in the upper thread holder base should be 1mm from the base when the upper thread holding solenoid is on. ② If the space is shorter than 1mm, adjust the position of the upper thread holding solenoid up and down so that the stroke of the plate is 1mm. ③ If the solenoid is not adjusted with the above measure, you must adjust the position of the upper thread holding lever. ④ To adjust the upper thread holding lever, remove the arm protection plate from the arm. Adjust the upper thread holding solenoid over the center, and unscrew the lever. Support the arm protection plate with a flat plate so the lever touches the flat plate. Fasten the screw of the upper thread holding lever. Make sure that the upper thread holding lever is touching the axis of the upper thread holding solenoid. ⑤ Check if the lever moves smoothly left and right when you manually operate it. 70
  70. 70. ⑥ Install the arm guard plate and go through ① and ② to complete. CAUTION If the upper thread holding unit does not function well, check if the upper thread holder driver plate of the unit moves smoothly when you manually move it. If not, adjust the position of the upper thread holding base. Upper thread holding solenoid ② Arm Guard Plate (R) Upper thread holder base Upper thread holding lever Upper thread holding lever screw Upper thread holder driver plate ① 1mm 13.4) PICKER ADJUSTMENT Incorrect position or volume of the picker may result in failures of separation of the upper and lower thread, trimming of both threads, and short upper thread after trimming. 1) Adjusting picker position Manually move the picker so it touches the bobbin. Unfasten the picker screw and adjust the tip of the picker. Correct picker position Picker Bobbin case Picker screw 71
  71. 71. 2) Adjusting picker volume Adjust the eccentricity of the picker stopper so the picker slightly touches the bobbin you’re your press it with your hand. Picker Picker stopper Picker stopper 13.5) ADJUSTING UPPER THREAD HOLDER 1) Adjusting Sensor Adjustment Rings Make the following adjustments if you find errors in the wiper return system. – Open the cover of the wiper motor. Of the two sensor adjustment rings, align the center of the sensor screw in the rear ring with the #1 carve point on the fixed block on the cam shaft. Align the center of the sensor screw in the front ring with the #2 carve point on the fixed block on the shaft. – Adjust so the wiper return sensor is 1-1.2mm from the upper head of the sensor screw. Make sure to check if the wiper return sensor turns on. Wiper return sensor #1 carve point Sensor screw (rear) Sensor adjustment ring Sensor screw (front) #2 carve point Fixed block on the cam shaft 2) If the wiper does not move well, unscrew the driver link and adjust the wiper lever up and down. Unfasten the bracket screw so there is less overload from upper thread holder bracket. Adjust and fasten the bracket back at the point where the wiper moves well. 72
  72. 72. 3) After adjustment, run the color change to check if the wiper functions well at each needle bar. Driver link Bracket screw Upper thread holder bracket 4) If there occurs a trimming or jump problem on a particular head during the embroidery, operate the wiper clutch to protect the embroidery and the wiper. - Press and turn the wiper clutch counterclockwise to operate the clutch. Press and turn it clockwise to stop the clutch operation Wiper clutch 73
  73. 73. 13.6) ADJUSTING LOW-NOISE PRESSER FOOT 1) Assembling the presser foot cam – Position the main shaft angle 178°Put two assembler pins (ф3) into the assembler hole (ф3) of the presser . foot driver cam as shown in figure and into the assembler hole of the take-up lever driver cam (ф3). – Adjust the position of the presser foot driver cam so that the assembler pins move freely left and right. Fasten three screws (M4×L35) snugly. CAUTION 1) The assembly pin must smoothly move left and right after the cam is fixed with 3 screws. 2) The assembler and the assembler pin are not for commercial sale. 3) Contact your SWF dealership if you must adjust the presser foot cam. Pin hole (ф3) Take-up lever driver cam Assembler pin(ф3) Presser foot drive cam Screws (3) Assembler holes 74
  74. 74. 2) Adjusting the height of the presser foot – Check the relationship between the presser foot, the needle, and the embroidery material. Turn the main shaft with the lever and position the needle bar at the lowest point (main shaft angle of 178° ). – Uncover the head and unscrew the presser foot so it moves up and down. Place a 1mm-thick gauge on the needle plate. Softly push the presser foot down onto the gauge and fix the screw snugly. Presser foot holder Screw Needle plate 1mm Presser foot 13.7) RELATIONSHIP BETWEEN PRESSER FOOT AND NEEDLE 1) Relationship between Presser Foot and Needle/ Embroidery Material For stable stitching, the presser foot must be pressing the embroidery material before the needle pierces into the material. The same is true for when the needle comes out of the material. Presser foot Embroidery material Needle OUT Needle IN Needle plate 2) When the Presser Foot is Too High – Needle In The left figure shows the presser foot fails to press the work material when the needle pierces into the fabric, causing an unstable needlework. – Needle Out The right figure shows the presser foot fails to press the work material when the needle comes out of the fabric. The embroidery material is lifted up along with the needle, making a gap between the fabric and the needle plate. This may cause thread breaks, skipped stitches, or unstable stitching. Needle Out Needle In 75
  75. 75. 13.8) CORRECT POSITION OF NEEDLE 1) Make sure to check the position of the needle – it may change during machine delivery or leveling. First check if the needle is bent. Then turn the main shaft lever to set the shaft at around 130°Position the needle at the . lower dead stop and check if the needle is at the center of the needle hole on the plate. Check the needle position on all heads. CAUTION 2) If the needle is not in the correct position, unscrew the brackets (2 screws) to adjust the head and the needle (see figure). Lever Bracket screws Head Needle plate Needle plate 76
  76. 76. 13.9) ADJUSTING HALF-TURN FILM FOR COLOR CHANGE 1) The machine will stop automatically if either of the needle position lamp or the needle set lamp blinks on the color change box. In this case, adjust the half-turn film as below. - When the needle comes to the center of the needle hole on the plate, adjust the position of the color change cam, using the manual knob, so that the roller is positioned at the center of the straight line of the cam as shown in figure. Open the half turn film cover and align the centers of the half turn sensor and the half turn film. Half-turn film Film screw Roller Half-turn sensor Color change motor Color change cam CAUTION ° Manual color change must be performed at the upper shaft angle of 100° . ° Manual adjustment at the upper shaft angles other than 100° may cause damage on the controller and the take-up unit. 13.10) ENCODER ADJUSTMENT Encoder base 1) Adjust the encoder as below if the needle bar stops at an incorrect position. – Unfasten the two screws on the upper shaft of the coupling connected to the encoder. – Manually fix the upper shaft angle at around 98° turning the main shaft lever. Adjust the by encoder as shown in figure. Tighten the coupling screws when FIX POS light turns red on the operation box. Encoder 77
  77. 77. 13.11) NEEDLE BAR ADJUSTMENT 1) Adjusting the Lower Dead Stop of the Needle You should be able to see half or the entire needle hole from the gauge in the bobbin case when the needle is at the lower dead stop. CAUTION Lower dead stop of the needle refers to the lowest point of the needle movement. It is important for timing of the needle and the rotary hook and must be adjusted precisely. Usually you don’have to t adjust it, but if the lower dead stop is not correct, follow the procedures below. – Turn the hand lever and set the angle of the upper shaft signal board at 178° . – Install the lower dead stop gauge (included in the SWF accessory kit). – Unscrew the needle bar holder and move the needle bar up and down. Fix the holder so that the needle bar softly touches the upper part of the gauge. Screw Needle bar holder Presser foot holder Lower dead stop gauge × Use ONLY DB×K5 #11 needle for the lower dead stop gauge. CAUTION 2) Adjusting the Highest Point of the Needle You have to adjust the highest point of the needle if you adjusted the lower dead stop. Unfasten the screw on the highest point stopper and set the upper shaft angle at 0°Attach the rubber cushion . and the highest point stopper to the head frame. Tighten the screw. Needle bar rubber cushion Highest point stopper L-wrench Needle bar holder 78
  78. 78. 13.12) JUMP MOTOR ADJUSTMENT Adjust the position of the jump motor if you have to replace it or if you find errors in jump. 1) Adjusting the standby position (adjusting the motor base) – Unscrew the motor base (3 screws). Adjust so the jump crank roller is 0.3mm from the jump driver unit as shown in figure. Fix the screws snugly. – If the distance is longer than 0.3mm, the jumps may be interfered. If the distance is shorter than 0.3mm, there may be noise. Jump crank roller 0.3mm Controller Motor base screws 2) Adjusting the manual jump clutch position – You can use the manual jump clutch lever to turn off the head mechanically. If the jump does not function well, check the assembly of the clutch. – First, check, in the standby position, if the center of the motor shaft is in straight line with the centers of the manual clutch pin and the carve point. Refer to the right figure. If not, unfasten the screws on the manual jump clutch, with the jump crank roller attached to the stopper, and align the clutch with the center of the carve point. Fasten the screws back. – Check if the clutch and the stopper are attached when you pull the clutch lever forward. If not, adjust the eccentricity of the stopper so it is completely attached to the clutch. CAUTION Clutch base Carve Stopper Manual jump clutch “A” side Stopper Manual jump clutch lever Manual jump clutch screw Center of the motor shaft 1) Make sure to run the manual jump clutch lever if you do not plan to use the head ON/OFF switch for long hours. “ ” 2) If A” side of the clutch does not touch the stopper when the jump clutch lever is operated, you will hear noises when you do electric jumps. 79
  79. 79. 13.13) ADJUSTING DRIVE BELT TENSION 13.13.1) X, Y Timing Belt CAUTION 1) Make sure to turn OFF the main power when adjusting the driver belt tension. 2) Driver belt tension may affect the quality of your embroidery or the machine performance. Only the SWF-trained engineer or professional engineers must adjust the belt tension. 1) X, Y Timing Belt – Push the frame plate to X or Y axis as shown in the below figure and pluck the middle of the belt to check the tension. – Tension should measure 5-6mm drop of belt for X and 7-8mm drop of belt for Y when you pluck the middle of the belt span with 2kg force. – To adjust the belt tension on the X axis, unfasten the tension base screws (2 screws) and turn the tension bolts. Turn clockwise to increase and counterclockwise to decrease the tension. – To adjust the belt tension on the Y axis, unfasten the tension base screws (2 screws) and tension adjustment shaft screw and turn the adjustment shaft. Turn clockwise to increase and counterclockwise to decrease the tension. CAUTION Belt Tension Adjuster Specifications (Sound-wave Adjuster) – Model: U-305 Series Sound-wave belt tension adjustment (standard type) – Manufacturer: UNITTA 2) X, Y Motor Timing Belt (see the below figure) – Adjust the tension on the X, Y motor timing belts so the sound wave tension adjustor measures 35-40kgf when you pluck the belts with your finger or a dull-ended tool. – Input data for U-305 Belt Tension Adjustor: Weight : 003.8 gf/m Width : 50.0/fR Span : 0112mm – To adjust the belt tension, unscrew the motor bracket and turn the tension adjustment bolt. 80
  80. 80. Timing belt Adjusting nut Tension adjusting bolt Tension base screws (2) Tension adjusting axis Tension base screws (2) Tension adjusting axis screw Motor bracket screw X, Y driver motor Tension adjusting bolt 81
  81. 81. 13.14.2) Main Shaft Motor and Upper/Lower Shaft Belt 1) Adjusting tension on main shaft motor belt – Tension on the timing belt of the main shaft motor should measure 2~3mm drop of belt when you pluck the middle of the belt span with 11kg force (see figure). – To adjust the belt tension, unfasten the motor bracket (5 screws) and turn the tension adjustment bolt. Fasten the bolts to increase and unfasten to decrease the tension. 2~3mm Check if the belt is properly arranged before adjust the tension. CAUTION 2) Adjusting tension on upper/lower shaft belt – The upper/lower shaft belt should spring back when you lightly press the belt on which the idler is installed. – To adjust the tension, unfasten the roller holder (one screw) and adjust the position of the roller front and back (see figure). Idler 82
  82. 82. 13.14) ADJUSTING X, Y SCOPE LIMITS 1) Adjusting X scope limit – Manually move the frame to a point, where the right end of the frame clip is 45.5mm from the center of the needle hole on the #1 bed (see figure) Center of the needle hole on #1 bed m .5m 18 45 .5m m – Adjust the origin detecting sensor on the left of the X-axis LM guide as shown in figure and fasten the sensor base. Sensor plate Origin detecting sensor Screw on the origin detecting sensor base – After adjusting the origin point on the X axis, turn on the main switch and press the X frame movement key on the operation box. When the frame reaches the limit of the X scope (interval between heads? ex. 330. 300. 275. 400 mm. See FRAME-X on the screen), turn off the machine. Fix the position of the limit sensor on the right of the LM guide as shown in figure. Sensor board limit sensor Limit base screw 83
  83. 83. 2) Adjusting Y scope limit – Manually move the frame to a point, where the rear end of the frame clip is 18.5mm from the center of the needle hole on the #1 bed (see figure). – Adjust the origin detecting sensor on the front of the Y-axis LM guide as shown in figure and fasten the sensor base. Origin detecting sensor Origin detecting sensor base screw – After adjusting the margin Y point, turn on the switch and move the Y frame using the key on the operation box, seeing the current position of Frame-Y on the operation box screen. When it reaches the Y limit, fix the limit sensor at the back of the LM guide on Y axis as shown in figure. Sensor board Limit sensor 3) After adjustment, turn on the power and select MACHINE MAINTENANCE in the main function menu and FRAME ORG in the sub menu to check if the scopes are correctly adjusted. 84
  84. 84. 4) Adjusting X scope limit when using odd or even number heads (SWF/SA-WB(X) SERIES) – Set the needle bar stop clutch function for the even number heads and the X scope will double. You can double the X scope of the SWF/SA-WB(X) Series to 480mm by using even/odd number heads, whereas the scope is 240mm when using all heads. CAUTION – X scope was factory adjusted for using all heads and you must adjust the scope when using odd/even heads. ※ Unfasten the limit switch on the right on the X axis and push it to the end of the axis. Move the frame to 480mm (see FRAME-X on the screen) and fix the limit switch as shown in figure. Limit sensor board Limit sensor 240mm Limit sensor base screw (X scope when using odd) 480mm (even number heads / X scope when using all heads) Turn OFF the lamp on the tension adjustment boards of the even number heads when using odd/even number heads. CAUTION Check if the limit sensor base is firmly fixed. The limit sensor must NOT move during embroidery work. CAUTION 85
  85. 85. 14 TROUBLESHOOTING Inspect/repair the machine by the guideline in machine failures. CAUTION DANGER Error Type Cause Inspection & Repair Reference ■ Adjust belt tension / change belt ■ Check power fuse in controller box and change ③ Failure to sense signals for needle position or 1 rotation ■ Run manual color change and check if signal lamps (needle set lamp & needle position lamp) blinks at correct needle position. Adjust the half-turn film. ■ See 8.1.7) (p.26) ④ Frame out of X or Y limit ■ Move frame back to within the limit ■ Check limit switch ■ See 13.14) (p.83) ⑤ Machine doesn’start with t bar switch Incorrect Stop Position ① Loose belt tension / belt damage ② Power fuse failure Operation failure ■ Check switch connection and connector related to bar switch ① Loose tension on main driver belt ■ Adjust belt tension ■ See 13.14.2) (p.82) ② Incorrect position of encoder or bad encoder ■ Adjust position or change encoder ■ See 13.10) (p.77) 86 ■ Check ① main driver belt ② X-Y timing belt
  86. 86. Error Type Bad Color Change Cause Inspection & Repair Reference ① Incorrect position of needle stop ■ Refer to user’ manual s ■ Set main shaft angle back at 100°if you , manually moved it for cleaning, inspection or repair. ② Failure to sense signals for needle position or 1 rotation ■ Run manual color change and check if signal lamps (needle set lamp & needle position lamp) blinks at correct needle position. Adjust the half-turn film. ■ See 8.1.7) (p.26) ③ Incorrect position of needle bar ■ Set it to the correct position ④ Incorrect position of take-up lever ■ Adjust so take-up lever is in line with the other levers in the stop position (upper shaft angle:100° ) ■ Adjusting position of take-up lever Unscrew the driver lever and adjust so it is in line with other levers on the take-up guide rail. Take-up lever driver screw Take-up driver ⑤ Color change and wiper motor Bad connection ■ Check connection 87
  87. 87. Error Type Cause Inspection & Repair ■ Check the plate connection and change the circuit board ① Bad SMPS for jump ■ Change jump SMPS in controller box ■ Check wiring and change jump motor ③ Bad connection ■ Check connection ④ Switch failure on tension adjusting board and bad circuit board Bad stitch ■ Disassemble the roller and clean the roller and bush bearing. ② Bad wiring for jump motor Bad jump motor Bad jump ① Failure of thread detecting roller ② Poor connection & quality of tension adjusting plate Poor detection of upper thread ■ Change switch and circuit board ① Bad table ■ Correct table ② Inadequate tension on X-Y belt ■ Adjust tension ③ Foreign substance in X-Y rail ■ Clean the rail ④ Failure of X/Y driver board ■ Change circuit board ⑤ Heavy load on frame ■ Reduce speed of main shaft 88 Reference
  88. 88. Error Type Thread breaks Cause Inspection & Repair Reference ① Stitch is too small/dense for thread ■ Re-punch design tape ② Frequent thread break in the same spot ■ Re-punch after checking design ■ Correct the stitches on operation box ③ Inadequate needle size for thread ■ Change needle ④ Needle damage (bent, dent, worn) ■ Change needle ⑤ Incorrect needle installation (height, direction, etc.) ■ Re-install needle ■ See 8.2.3) (p.38) ⑥ Dirty needle (adhesive, etc.) ■ Clean or change needle and hook ■ Use minimum adhesive for applique 89 ■ Check design ■ See 8.2.2) (p.37)
  89. 89. Error Type Thread breaks Cause Inspection & Repair ⑦ Bad thread (weak, uneven thickness, poorly twisted, old) ■ Change thread ⑧ Right-twisted thread Reference ■ Change to left-twisted thread Check selecting thread ※ Selecting thread ■ Select soft, tight, and stable thread with even thickness and left-twist ■ Z-twist: left ■ S-twist: right ⑨ Excessive thread tension ■ Adjust tension ■ See 8.1.8) (p.27) ⑩ Tension imbalance between upper and lower threads ■ Adjust tension ■ See 8.1.8) (p.27) ⑪ Excessive tension & stroke on take-up spring ■ Adjust tension and stroke ■ See 7) (p.39) 90
  90. 90. Error Type Thread breaks Cause Inspection & Repair Reference ⑫ Dent on thread path on hook and bobbin case ■ Remove dent or change the case ■ Check rotary hook ⑬ Narrow space between hook holder and groove for hook holder (on hook) ■ Adjust space ■ Set it at 0.5-0.7mm for smooth feeding of upper thread Hook holder mm 0.7 5~ 0. ⑭ Insufficient oil in hook ■ Oil the raceway of hook ⑮ Poor timing of needle and hook ■ Adjust timing ⒃ Incorrect lower dead stop ■ Adjust the lower dead stop ■ See 8.2.5) (p.41) ⒔ Dent on thread path ■ Check: ① Thread path in presser foot ② Around needle hole on needle plate ③ Thread guide on the head ④ Thread path in tension adjuster ⑤ Thread path in upper thread holding unit ■ See 13.8) (p.76) ⒕ Fabric moves on the frame ■ Fix the material firmly ⒖ Inadequate height of presser foot (does not press the work material) ■ Adjust height 91 ■ See 13.7) (p.75)
  91. 91. Error Type Skipped Stitches Cause Inspection & Repair Reference ① Bent needle ■ Change needle ② Inadequate needle size for thread ■ Use needle of adequate size ③ Incorrect installation of needle ■ Install needle correctly ④ Poor timing of needle and hook ■ Adjust needle-hook timing ■ See 8.2.5) (p.41) ⑤ Large gap between needle groove and hook point ■ Adjust space ■ See 13.17) (p.78) ⑥ Incorrect lower dead stop ■ Adjust lower dead stop ⑦ Damaged hook point ■ Use whetstone to adjust hook point or change hook ⑧ Thread feeding is interfered ■ Adjust thread tension ■ See 8.1.8) (p.27) ■ For lower thread, change bobbin or bobbin case ■ See 8.1.9) (p.33) ⑨ Inadequate thread ■ twist ■ elasticity ■ and flexibility ■ Select right thread for embroidery ⑩ Excessive tension or stroke on the take-up lever spring ■ Adjust stroke or tension ⑪ Fabric moves with needle – weak or damaged presser foot (spring) ■ Change presser foot spring ■ See 8.2.2 (p.37) 92 ■ See 8.1.8) 7) (p.27)
  92. 92. Error Type Cause Inspection & Repair Reference ■ See 8.1.8) 6) (p.31) ■ Adjust tension ■ Clean main and sub tension adjusters in the thread tension adjusting plate ③ Weak lower thread tension ■ Adjust tension ④ Uneven lower thread tension ■ Clean bobbin case and check tension on bobbin spring ⑤ Thread thickness ■ Change to quality thread ⑥ Poor timing of needle and hook ■ Adjust timing ■ See 8.2.5) (p.41) ⑦ Insufficient oil in hook Needle breaks ① Weak upper thread tension ② Uneven upper thread tension due to foreign substances Poor stitch tension ■ Use whetstone to adjust hook point or change hook ■ See 12.3) (p.58) ① Bent needle ■ Change needle ■ See 8.2.3) (p.38) ⑤ Needle touches the hook point ■ Space the needle and the hook point ■ See 8.2.6) (p.42) ⑥ Incorrect installation of needle ■ Correct the installation ■ See 8.2.3) (p.38) ⑦ Needle touches the needle hole on the plate ■ Check if needle plate is unscrewed ■ Adjust the position of the needle bar ■ See 13.8) (p.76) ■ See 8.1.8) 2) (p.33) ② Bad quality needle ③ Tip of the needle is worn or bent ④ Inadequate needle size 93
  93. 93. Error Type Cause Inspection & Repair ① Excessive thread tension ■ Adjust tension ② Excessive pressure of presser foot ■ Change presser foot spring ③ Needle failure – worn out/damaged needle tip needle is too large for thread ■ Change needle ④ Needle hole is too large for needle Puckering ■ Use adequate size of needle Reference ■ See 8.1.8) (p.27) ■ SWF needle holes are 2.0mm large. SWF/ specification for needle & thread are: Cotton : #50-70 Rayon : #75-120 needle : DB×K5 #9~#14 Trimming failure ① Short-circuit of trimming fuse ■ Check and change fuse in trimmer board ■ Check fuse spec in trimmer board 1) 3-phase: :250V 10A 2) 1-phase: :250V 10A ② Poor trimmer motor and connection ■ Check and change trimmer driver motor ③ Bad connection ■ Check connection ④ Red light on trimmer driver box ■ Address the error cause. Press RESET to turn the light green. 94

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