Beisler 100-54 User Manual

Automatic-Pocket-Piping-Machines

Series 100/54, 100/55, 100/56

© 1998-99 Beisler GmbH, Hösbach

Operating instructions

Version 1.1, 11-18-98 – GB

These operating instructions contain the following parts:

Part 1: Operating instructions (pages 1-xx)

adresses to the operator of the machine, that means the person
who works at and with the machine

Part 2: Mechanics manual (pages 2-xx)

is used for the putting into operation, adjustment,
troubleshooting and maintenance of the machine and adresses
to qualified staff only

Part 3: Technical manual (pages 3-xx)

contains information on the further adjustment, maintenance,
troubleshooting and repair of this machine and adresses to
especially trained and experienced staff only.

Please obtain all safety, warning and other hints and regulations in this
manual.

Part 1 Operating instructions

Hint

These operating instructions contain all information required for the operation
of the machine. It adresses to the operator of the machine, that is the person
that works at and with the machine. Please obtain all rules and regulations.

Contents Page

Part 1 Operating instructions ...................................................................................... 1-1

1 Security advice and warning hints ................................................................... 1-2

1.1 Classification........................................................................................................ 1-2

1.2 Range of validity .................................................................................................. 1-2

1.3 Authorized person ................................................................................................ 1-2

1.4 General security advice and warning hints ........................................................... 1-2

1.5 Copyright ............................................................................................................. 1-3

2 Preliminary remarks .......................................................................................... 1-4

2.1 Introduction .......................................................................................................... 1-4

2.2 Limitation of liability .............................................................................................. 1-4

2.3 Guarantee regulations ......................................................................................... 1-5

2.4 Use as agreed ..................................................................................................... 1-5

2.5 Description of the machine .................................................................................. 1-5

2.6 Main parts of the machine.................................................................................... 1-6

3 Security............................................................................................................... 1-7

3.1 Available security systems ................................................................................... 1-7

3.1.1 Program stop button ............................................................................................ 1-7

3.1.2 Mains /emergency stop button ............................................................................. 1-8

3.2 Security measures of the operator ....................................................................... 1-8

4 Operation of the machine .................................................................................. 1-9

4.1 Controls and indicators ........................................................................................ 1-9

4.1.1 Operating device ................................................................................................ 1-10

4.1.2 Insertion station.................................................................................................. 1-13

4.1.3 Mains / emergency stop button .......................................................................... 1-13

4.1.4 Foot pedal machine sequence ........................................................................... 1-13

4.1.5 Foot pedal vacuum ............................................................................................ 1-13

4.1.6 Foot pedal stacker ............................................................................................. 1-13

4.1.7 Piping slitting device .......................................................................................... 1-13

4.1.8 Take off roller ..................................................................................................... 1-14

4.1.9 Flap station with flap feeding device .................................................................. 1-14

4.1.10 Swing out insertion station ................................................................................. 1-14

4.1.11 Change folder and guiding head ........................................................................ 1-15

4.1.12 Change vylene roll ............................................................................................. 1-16

4.1.13 Empty the stacker .............................................................................................. 1-17

4.2 Operation ........................................................................................................... 1-17

4.2.1 Machine sequence ............................................................................................. 1-17

4.2.2 Program operation ............................................................................................. 1-17

4.2.3 Select a sewing program.................................................................................... 1-18

4.2.4 Enable/disable seams ........................................................................................ 1-18

4.2.5 Change seam length .......................................................................................... 1-18

4.2.6 Remove and add seams .................................................................................... 1-18

5 Required cleanings .......................................................................................... 1-20

1-1

1 Security advice and warning hints

1.1 Classification

Three different types of hints are used in this manual, which are indicated
with different symbols and signalling words:

DANGER

This indicates a possibly dangerous situation or action, which may cause
injuries to persons or severe damage to the machine.

ATTENTION

This indicates a situation or action, which may cause damage to the
machine.

Hint

This indicates hints for a better use and other helpful information or hints.

Please obey all rules and regulations.

1.2 Range of validity

This operating manual is valid for Pocket-Piping-Machines manufactured by
Beisler named ‘Universal-Pocket-Piping-Automaton 100/55/56’.

This operating manual is not valid for the sewing head applied in the
machine. Please refer to the operating manual of the sewing head delivered
with the machine, for which we don’t take any liability.

Further security advice (verbal and written) for this machine or the
components will not be repealed by this manual.

1.3 Authorized person

Danger

Danger might arise for persons, things and environment by inappropriate
operation of this machine. Installation and maintenance duties may only be
carried out by authorized staff.

Persons are regarded as authorized, who are able to recognize possible
danger and judge the assigned duties from their technical education and
experience.

1-2

1.4 General security advice and warning hints

Danger

Danger might arise for persons, things and environment by inappropriate
operation of this machine. Installation and maintenance duties may only be
carried out by authorized staff.

Danger

Danger of injuries in the range of the sewing head! Don’t grasp into the
affected area of the needle during the sewing process!

Danger

Before any operations at or with the machine (putting into operation,
operation, maintenance, repair, etc.) the person carrying out has to read and
understand this manual with each appendix completely.

Danger

Before carrying out maintenance or repair duties, the mains supply must be
cut off. Additionally pressure must be released from the pneu-matical system.

Attention

The machine will be destroyed by a connection to a wrong mains voltage!
See the section ‘Technical data’ before connecting the power supply.

1.5 Copyright

© 1998 Beisler GmbH, Hösbach

Pocket-Piping-Automaton

The Universal-Pocket-Piping-Machine 100/55/56 and this operating manual
with all parts are protected on copyright. Manufacture without license will be
prosecuted by law. All rights reserved on this operating manual, including
reproduction in any thinkable way, either by copying, printing, on any data
recording media or in translated form. Reproduction of this operating manual

- even in extracts - only with written approval by Beisler GmbH.

This operating manual contains a description of the product, but no promise
of certain qualities or results of use. The operating manual has been proved
before delivery. The Beisler GmbH takes the liability, that this operating
manual if free of errors reducing its value for the estimated use. The editors
don’t take liability for consecuting damage arising through application of the
operating manual. We are always thankful for hints and ideas.

The technical standard of the common delivery of product and operating
manual by the Beisler GmbH is decisive, if not other information is given.
Technical changes without prior notice are reserved, previous operating
manuals loose validity.

The general conditions of sales and delivery of the Beisler GmbH are valid.

Do you have questions or problems with installation or putting into operation?
Don’t hesitate to call us.

Beisler GmbH

Frohnradstr. 10 - D-63768 Hösbach
Tel: (+49) 6021 / 50 19 0
Fax: (+49) 6021 / 50 19 10

1-3

2 Preliminary remarks

2.1 Introduction

This operating manual adresses to the operator of the machine, that is the
person that works with the machine. It is not a technical manual. Please ask
questions exceeding the contents of this operating manual to our service
staff.

Attention

All service and maintenance duties at this Pocket-Piping-Machine may only
be carried out by qualified staff (qualified electrical employee or electro­technical instructed person according to IEC 364 and DIN EN 60204-1).
Machine operation may only be carried out by an instructed person, who had
read and understood this operating manual completely.

Attention

Any structural changes to the machine, either electrically, mechanically or
regarding the machine control, are suspect to the responsibility of the
machine owner.

The following documents are part of the documentation of the Universal­Pocket-Piping-Machine 100/55/56:

1. Electrical wiring plans

2. Parts list

Please check the documents delivered with the machine for completeness.

2.2 Limitation of liability

We guarantee the faultless functioning of our product in accordance with our
advertising, the product informations edited by the Beisler GmbH and this
manual. Further product-features are not guaranteed. We take no liability for
the economy and faultless function if the product is used for a different
purpose then that described in the chapter „Use as agreed“.

Compensation claims are generally impossible, except if intention or cul­pable negligence by the Beisler GmbH is proved, or if assured product­features are not provided. If this machine is used in environments, for which it
is not suited or which do not represent the technical standard, we are not
responsible for the consequences.

We don’t accept responsibility for damages at installations and systems in
the surroundings of this machine, which are caused by a fault of the product
or an error in this manual.

We are not responsible for the violation of patents and/or other rights of third
persons outside the Federal Republic of Germany.

We are not liable for damages, which result from improper operations
according to this manual. We are not liable for missed profit and for
consecuting damages due to non-regardance of security advices and
warning hints. We don’t accept liability for damages which resulted from the
use of tools and accessoires which are not delivered and/or approved by the
Beisler GmbH.

The prdocuts of the Beisler GmbH are designed for a long life. They
represent the standard of technique and science and were checked on all
functions individually before delivery. The electrical construction corresponds
to the current norms and regulations, particularly DIN 5713 / VDE 0113.
Beisler GmbH is doing product and market research for the further

1-4

development and permanent improvement of their products. In the case of
faults and/or technical trouble please contact the Beisler GmbH service staff.
We assure that suitable measures will be done immediately.

The Beisler GmbH guarantee regualtions are valid, which we will send to you
on demand.

2.3 Guarantee regulations

We guarantee the fault-free functioning of the Universal-Pocket-Piping­Machine 100/55/56 according to this operating manual except the tools for a
time range of six months after delivery. If the machine is used in double- or
triple-shift operation, the term of guarantee is reduced to three or two
months.

The term of guarantee starts with the date of delivery to the customer,
independant from the time of putting into operation. Guarantee will be
spoiled, if the machine isn’t installed and operated according to this operating
manual and the regulations given by the Beisler GmbH staff. A cost-free
repair is only possible, if all regulations considering storage, transportation
and putting into operations have been obeyed.

Customers and third persons may only mesh with the machine after getting a
written approval by the Beisler GmbH. The Beisler GmbH takes no
responsibility for injuries and damages arising from non-obeyance of this
stipulation. All warranty will be spoiled in this case.

The Beisler GmbH takes no responsibility for faults of the machine as
consequence of defective or functional faulty equipment in the surrounding of
the machine or by the use of accessoires, which were not delivered by the
Beisler GmbH.

The general conditions of sale and delivery of the Beisler GmbH are valid.

2.4 Use as agreed

The Universal-Pocket-Piping-Automaton 100/58 has been developed for the
piping of pockets and the sewing in of pocket bags.

Danger

This machine has been developed and build for a certain purpose. Adaptions
may influence security equipments negatively. We recommend to contact our
service staff in such a case.

2.5 Description of the machine

The Universal-Pocket-Piping-Automaton 100/58 allows the automatic piping
of pockets. The machine is equipped with a cutting device, a clamp
transportation system, a sewing head and a stacking system for the
produced pieces.

All components of the machine are mounted on a base frame made of
square steel pipes and controlled by an innovative micro-processor system.

Machine operation is achieved with an operation device. Here you can open
several control programs, define new programs and check all machine
components individually for maintenance and repair duties.

1-5

2.6 Main parts of the machine

100-55 100-56

A Spool rack

B Program-Stop-Button

C Operating device

D Sewing head

E Piping slitting device

F Insertion station

G Mains / Emergency-Stop switch

H Sewing motor

I Foot pedal vacuum (reset)

J Foot pedal machine sequence

K Foot pedal flap clamp

L Foot pedal stacker

M Vylene roll

N Working table

O Flap station

P Stacker

Q Clamp transportation

R Power distribution

The following chapters contain further information on the machine’s
components.

1-6

3 Security

The topic of this chapter is the security exclusively. Please see chapter 1 for
the general security advice and warning hints and the security and warning
hints in the other chapters of this operating manual.

3.1 Available security systems

Danger

Check all security systems daily for functioning and effectivity!

Danger

Changes to the machine may influence function and effectivity of the security
systems negatively!

100-55 100-56

A Program stop button

B Mains / emergency stop button

3.1.1 Program stop button

The program stop button is mounted in the right upper corner of the operation
device. After pressing, all movements and the sewing process will be
stopped immediately.

Before a re-start the program stop button must be turned to the right to be
unlocked. With the release, the reset will be triggered.

1-7

3.1.2 Mains /emergency stop button

The mains / emergency stop switch is mounted on the front side of the
machine, right-handed below the working plate. It can be used to cut-off the
power supply.

3.2 Security measures of the operator

The security systems of this machine work passively, that means that they
can only react on certain incidents. To achieve the required security for your
health and that of your collegues, active measures of the operator are
required.

Please obey the following general rules for the use of this machine:

1. Always work concetrated and avoid actions with a risk.

2. Don’t try to bridge existing security systems or to disable them in any way.

3. Check all security systems on function and effectivity before starting work.

4. Cut off the power supply before opening the switchbox.

5. Switch off the machine with the mains / emergency stop switch, before
executing cleaning and mainetenance duties.

1-8

4 Operation of the machine

Danger

This machine may only be operated by qualified staff, who had read and
understood this operating manual completely.

4.1 Controls and indicators

100-55 100-56

A Operating device

B Flap station

C Insertion station

D Piping slitting device

E Mains / Emergency-Stop switch

F Foot pedal vacuum (reset)

G Foot pedal machine sequence

H Foot pedal flap clamp

I Foot pedal stacker

1-9

4.1.1 Operating device

During production the machine can be operated with the operating device;
existing programs can be called and new programmed. You will find the
program stop button at the device.

A Slot for the Memory card

B Program stop button

C Display

D Ten key pad with P- and M-key

E Function keys

F Arrow and enter keys

The elements of the operating devices have the following occupations:

4.1.1.1 Slot for the Memory card

The Memory card is used as a backup memory for software and programs of
the machine. You can load programs to the Memory card or read them after a
possible data loss into the machine.

4.1.1.2 Program stop button

By pressing the program stop button, all movements of the machine will be
stopped immediately. To continue production, you have to turn the button to
the right and release it.

4.1.1.3 Display

1-10

All information required for the operation of the machine will be imaged in the
display. During normal production the display shows the following (see Pict.

6):

• the graphic on the left side images the mitre cut of the pocket; in the
shown example, the mitre cutter cuts the basic value 50 at the seam start
and 0.5 mm less at the end, that is the value 45

• the graphic to the right shows the seam or flap lenght of the pocket; the
value displayed above the flap (33.0) defines, how far the flap will be
pushed behind the needle, after the photocell has recognized the flap
(value for the seam start); the value displayed below the flap (40.0)
defines, how long the machine continues sewing, after the photocell has
recognized the end of the flap

• the most upper line shows the number of the selected program (M01) and
the seams assigned to this program (30, 31, 32 and 33); seams 30 and
32 are enabled (32 will be the next seam to be sewed), 31 and 33 are
disabled

• the name of the current seam is displayed to the right

• the square below contains the icons of the machine functions assigned to
the current seam

• below the square, the stock of bobbin thread (45 m) and the number of
produced parts (149) are displayed

4.1.1.4 Ten key pad with P- and M-key

Numerical inputs can be done using the ten key pad.

The letters displayed below the digits can be entered, after the function key
with the corresponding color indication has been pressed before.

The P-key is used in several steps of the machine programming.

Sewing programs can be selected after pressing the M-key.

4.1.1.5 Function keys – lower occupation

The function keys are occupied as follows

switches to the upper occupation of the function keys

Mitre knife correction; press this key once to change the mitre
knife position at the seam start; press F1 and the cursor stands

on the seam start; press twice to change the position at the
seam end; after pressing F1, enter the new value using the ten
key pad, which will be displayed in the left-handed graphic; 50 =
middle value; the higher the value, the more far the mitre knife
cuts to the outside
e.g. old value 50, new value 56 and the mitre knife cuts 0.6 mm
more to the outside
e.g. old value 50, new value 22, the mitre knife cuts 2.8 mm
more to the inside

1-11

Change pocket length; press F3 and enter the new value for the

length to be sewed; when producing with flap, this sets the
photo cell security length, too; e.g. security length 140 mm
allows the sewing of a flap length between 130 and 150 mm;
when producing flaps it is possible to disable the security length
by entering 999 here.

Sewing-over at seam start and end (only valid when sewing with
flap); press once to set the sewing-over at seam start, twice to

set it at seam end; enter the new value using the ten key pad
Seam start: the smaller the set value, the more the flap will be
sewed over; seam end: the bigger the set value, the more the
flap will be sewed over

Pick needle thread manually; after the first pressing, the main
clamp drives to end position, with the second pressing the

needle thread catcher will be enabled; it remains enabled, until
the key is released

Push vylene forward manually (option); after changing the

vylene roll, the vylene will be cut with a key pressure and then
be pushed in position (only available if vylene mode is enabled)

Pick up piping, with this function the piping strip can be picked

up manually

Reset key; use this key to reset the program sequence step by
step; sets the clamp into starting position

4.1.1.6 Function keys – upper occupation

The function keys are double occupied. Press F1 to switch to the upper key
occupation. The icons will be displayed in the lower line.

switches back to the lower key occupation

Switch middle knife on/off; the knife is switched off, until it will be
switched on here; together with the middle knife, the mitre knife
is switched off

Switch mitre knife on/off; it remains switched off, until it will be
switched on here

Switch stacker on/off; it remains switched off until it will be
switched on here

without function here

1-12

Sets counter to zero

Manual spooling; the sewing head runs with low revs, after a
second key press, it stops in the upper needle position

Attention

At machines with insertion station, the station must be swung out first (see
chapter 4.1.10); in any case, both threads must be removed from the needles
and the spools from the pickers.

Reset spool thread length; when removing a half-full and
inserting a full spool, you can display the whole thread length by
pressing this key

4.1.1.7 Arrow and Enter-keys

Use the arrow keys to move the flashing cursor between the different
sections of a display. Confirm inputs using the Enter key.

4.1.2 Insertion station

The parts to be manufactured are inserted at the insertion station. Use the
marking lamps to align the parts exactly.

4.1.3 Mains / emergency stop button

With the mains / emergency stop button, you can cut-off the power supply of
the machine.

4.1.4 Foot pedal machine sequence

Use this foot pedal to trigger the steps of the machine sequence (see further
below).

4.1.5 Foot pedal vacuum

Press this foot pedal to enable the vacuum. The parts inserted at the
insertion station are fixed by the vacuum which will be disabled automatically,
after the main clamp has picked up the parts.

4.1.6 Foot pedal stacker

Press the foot pedal stacker to open the stacker to be able to take out the
stacked parts.

4.1.7 Piping slitting device

This slits the piping at seam start and end before sewing the piping strip. It
can be switched from double-piping to strip with a hand grip:

1-13

If the black grip (1) stands at the front (closer to the operator), the piping
slitting device is set to double-piping. If the grip stands in the back (closer to
the sewing head), it is set to strip.

Use the tilt switch (2) to switch on/off the piping slitting device. If the switch is
in the upper position, the device is switched on, in the lower position, the
device is switched off.

4.1.8 Take off roller

After mitre cutting, the take off roller brings the fabrics into the desired
stacking position.

4.1.9 Flap station with flap feeding device

This swings the inserted flap (or the pocket pouch) under the clamp.

4.1.10 Swing out insertion station

1-14

100-55 100-56

For several reasons (e.g manual spooling) the insertion station must be
swung out to give access to the sewing head.

Grasp the insertion station as shown in the picture and pull it out of the
locking (A). When swinging in, be sure that the insertion station is inserted
completely into the locking.

Attention

The folder and the lamps of the crosshair attached to it are adjusted exactly
and are sensitive against violence. Therefore, swing the folder slowly and
without the use of power.

4.1.11 Change folder and guiding head

ATTENTION

Before changing folder and guiding head, the insertion station must be swung
out (see section 4.1.10).

Different folders and guiding heads are required for different pocket shapes
(e.g. single/double piping). Folder and guiding head can be changed in
seconds:

100-55 100-56

1. Loosen fixing screw (A) of the folder.

2. Take out the folder with a movement downwards and to the right.

1-15

3. Loosen the fixing screw (A) of the guiding head (B).

4. Pull the guiding head (B) downwards out of its locking (already happened
in the picture).

5. Mount guiding head and folder in reverse order.

4.1.12 Change vylene roll

The vylene roll is located below the working table and can be changed this
way:

1. Swing out the insertion station (see section 4.1.10).

2. Lift the insertion plate at its front and push it to the left.

3. Remove all vylene rests which are still in the machine.

4. Insert a new vylene roll.

5. Insert the vylene over the roll into the vylene guiding.

1-16

6. Press the key „F6“ repeatedly, until the vylene appears above the working
table.

7. Insert the insertion plate; be sure that the positioning pin is inserted into
the drillhole (see arrow int the first picture of section 4.1.12).

4.1.13 Empty the stacker

If the stacker placed at the left machine side is full, press the foot pedal of the
stacker. The stacker will be opened and the fabrics can be taken out. Re­lease the foot pedal to close the stacker.

4.2 Operation

4.2.1 Machine sequence

The production sequence is divided into several parts:

1. The machine sequence can start when the machine is in starting position.

2. Insert the fabrics to be sewed and align it exactly.

3. Press the foot pedal machine sequence and the clamp drives forward.

4. Press the foot pedal machine sequence, the main clamp will be lowered.

5. Press foot pedal machine sequence, the folder picks up the piping strip
automatically and lays it between the main clamps.

6. Press foot pedal flap clamp to close it.

7. Press foot pedal machine sequence, the flap clamp brings the pocket
pouch (or the flap) to the main clamp, where this will be closed
automatically.

8. Press foot pedal machine sequence, the clamp pushes the fabrics under
the sewing head and there it will be sewed; the mitre cutting will be
executed, the clamp opened and the sewed fabric will be stackered.

The operator can trigger each step with a short step on the foot pedal or
execute an automatic operation by keeping the foot pedal pressed.

Due to the programming, different machine sequences might occur.

4.2.2 Program operation

The machine is operated with programs, which can be selected by the
operator. A program is stored at a memory location (e.g. ‘M01’) and contains
one or several seams (max. number is six).

The selected program and the assigned seams are imaged in the upper line
of the display. The machine executes all enabled seams of a program
sequentially. An enabled seam is displayed inverted (white on black).

You can produce several pocket shapes and lengths sequentially, without
changing the sewing program. This allows to sew several pockets of a jacket
part.

1-17

The following operational actions are explained in this chapter:

• select a sewing program

• enable/disable seams

• change seam lengths

• change sewing programs

• create new sewing programs

• program new seams

4.2.3 Select a sewing program

The current sewing program is displayed in the upper line of the display. How
to select a program:

1. Press M-key.

2. Enter the number of the desired program using the ten key pad.

3. Press ENT-key.

4.2.4 Enable/disable seams

Seams are assigned to every sewing program. All enabled seams are sewed
sequentially. Enabled seams are displayed inverted (white on black).

If a seams shall be skipped, it must be disabled. How to enable/disable a
seam:

1. Move the cursor on the desired seam using the arrow keys.

2. Press the ENT-key to enable/disable the seam.

4.2.5 Change seam length

Several parameters of the current seam are imaged in the left half of the
display (e.g. seam length, mitre knife position). You can change these
settings individually using the function keys.

All changes executed with the function keys are stored for all seams with the
same number, even if they are used in different programs.

Further information are contained in the chapter ‘4.1.1.5 Function keys’.

4.2.6 Remove and add seams

You can add seams to and remove them from sewing programs:

4.2.6.1 Remove seams

1. Select the sewing program to be changed.

2. Press the P-key.

3. Press F1.

4. Move the cursor on the seam to be removed using the arrow keys.

5. Press the M-key.

6. Repeat steps 4. and 5. for all seams to be removed.

1-18

4.2.6.2 Add seams

1. Select the sewing program to be changed.

2. Press the P-key.

3. Press F1.

4. Use the arrow keys to move the cursor to the place, where you want to
add a seam.

5. Press the ENT-key.

6. Enter the number of the desired seam.

7. Repeat steps 4. to 6. for all seams to be added to the current sewing
program.

8. Press the P-key to store the settings and leave the submenu.

1-19

5 Required cleanings

To achieve the value and function of the machine, we recommend to keep it
always clean and free of spare materials and waste.

Blow off threats and cloth rests daily from the machine using the air
pistol.Below the air pistol you see a supply bottle for the oil needed in the
sewing head.

Hint

The sewing head must be cleaned regularly. Please see the Operating
Instructions of the sewing head for further information.

1-20

Part 2 Mechanics manual

Hint

This part of the operating instructions contains all information required to put
the machine into operation and to do programming, troubleshooting and
maintenance. It adresses to trained technical personnel, which is able to
overview their tasks and recognize possible danger at an early moment. The
operating instructions given in part 1 of this manual are to be considered as
part of this mechanics manual.

Contents Page

Part 2 Mechanics manual ............................................................................................. 2-1

1 Delivery, transportation, storage ...................................................................... 2-2

1.1 Delivery ................................................................................................................ 2-2

1.2 Transportation...................................................................................................... 2-2

1.3 Storage ................................................................................................................ 2-2

2 Installation ............................................................................................................ 2-2

2.1 Technical data ...................................................................................................... 2-3

2.2 Mechanical installation ......................................................................................... 2-3

2.2.1 Unpack and put up ............................................................................................... 2-3

2.2.2 Connection of air supply....................................................................................... 2-4

2.3 Elektrical installation ............................................................................................ 2-4

2.4 First putting into operation.................................................................................... 2-5

3 Programming instructions ................................................................................ 2-6

3.1 Create new sewing programs .............................................................................. 2-6

3.1.1 Select a M-memory location ................................................................................. 2-6

3.1.2 Add seams ........................................................................................................... 2-6

3.1.3 Copy seams ......................................................................................................... 2-6

3.1.4 Adjust seams ....................................................................................................... 2-6

3.1.5 Name seams........................................................................................................ 2-7

3.1.6 Delete seams ....................................................................................................... 2-7

3.2 Seam functions .................................................................................................... 2-7

3.3 Seam parameters ................................................................................................ 2-9

3.3.1 Seam parameter 30: Flap clamp mode ...............................................................2-11

3.3.2 Working WITHOUT automatic clamp push-back................................................ 2-13

3.3.3 Working WITH automatic clamp push back ....................................................... 2-13

3.3.4 Working with INTERMEDIATE STOP of the main clamp .................................... 2-13

3.3.5 Working with automatic PICK UP PART using the main clamp .......................... 2-13

3.4 Seam images ..................................................................................................... 2-14

3.4.1 Sewing with catch .............................................................................................. 2-14

3.4.2 Sewing with stitch condensation ........................................................................ 2-14

3.4.3 Sewing with stowing ........................................................................................... 2-14

3.5 Basic parameters ............................................................................................... 2-15

4 Troubleshooting hints ..................................................................................... 2-18

5 Maintenance of the machine ........................................................................... 2-22

5.1 Water separator at air connector........................................................................ 2-22

5.2 Grease linear guiding ......................................................................................... 2-22

5.3 Use of the Memory Card .................................................................................... 2-23

5.3.1 Saving seam data on the Memory Card ............................................................. 2-23

5.3.2 Loading seam data from the Memory Card ........................................................ 2-23

5.4 Loading data from the EPROMs ........................................................................ 2-24

5.4.1 Loading the basic parameters ............................................................................ 2-24

5.4.2 Loading seam parameters ................................................................................. 2-24

5.5 Test programs and diagnostics .......................................................................... 2-24

5.5.1 I/O-Test .............................................................................................................. 2-24

5.5.2 Diagnostics ........................................................................................................ 2-27

5.5.3 Service Code ..................................................................................................... 2-30

5.6 Preset sewing programs .................................................................................... 2-30

5.7 Diagram of the menu structure .......................................................................... 2-31

2-1

1 Delivery, transportation, storage

1.1 Delivery

Hint

Check right after receiving the machine, whether all parts according to the
parts list are complete and without damage. Later claims can’t be accepted.

If you see damage to the transportation packing of the machine, which
indicates a possible damage to the delivered parts, don’t hesitate to claim this
to the transportation company.

1.2 Transportation

Generally it is possible to move the machine. Obey the following hints:

1. Cut off the power supply, release the pneumatical pressure.

2. Fix movable and loose parts.

3. Lift the base with a hoisting device and be sure to lift possible additional
devices (e.g. stacker). If the machine is equipped with transportation
casters (option), you will have to release the brakes at every caster.

4. Move the machine carefully to the new location.

Attention

Attention when moving the machine on sloping areas! Enormous pull power
arises from the machine weight.

1.3 Storage

If no other agreement is fixed, the following limitations have to be kept:

1. In closed rooms only.

2. Temperature range -10 ... +45 °C.

3. Humidity max. 80% non-condensing.

Attention

If stored or transported in improper environments, the machine can be
damaged severely. Damages may not be visible from the outside.

2 Installation

Attention

2-2

Installation and putting into operation may only be carried out by mechanically
and electrically qualified staff. These people must read and understand the
complete operating manual before starting.

2.1 Technical data

Dimesions 1.600 x 750 x 1.300mm (LxWxH)

Table height 830 mm

Weight 240 kg

Mains power 220 V AC

Power consumption 0,8 kW

Fuse 10 A

Req. air pressure 6 bar

Req. air quality oil-free

Air consumption 6 NL/WD

2.2 Mechanical installation

Attention

Check before starting the installation, whether the desired location meets the
requirements (see chapter 5.1, technical data). This is very important
regarding the stability of the ground.

2.2.1 Unpack and put up

1. Remove the packing material and possible transportation protections.

2. Position the machine on a solid and horizontal ground.

3. Level the machine to a horizontal stand using the adjustable frame feet.

2-3

2.2.2 Connection of air supply

1. Connect the air pipe (A) to your air system.

2. Open the air supply of your air system.

3. Level the air pressure to 6 bar using the control (B); the air pressure can
be read at the scale (C).

Attention

We recommend to switch off the air supply when the machine is not in duty.
Use the black control (B).

2.3 Elektrical installation

Hint

All work at the electrical components of the machine may only be carried by
qualified staff (qualified electrical employee or instructed person according to
IEC 364 and DIN EN 60204-1).

Danger

Parts under electrical current! Without cutting off the power supply, you might
be injured severely. Please obey the security advice given in chapter 1.

2-4

Attention

The machine will be destroyed by connecting to a wrong mains voltage!
Check, whether the requirements from chapter ‘Technical data’ meet the
local conditions.

1. Use the power cord located at the backside of the machine.

2. Plug it into a socket.

3. Lay the cord in a way, that the danger of stumbling is avoided.

Danger

Danger to life from unsufficient grounding! Do a grounding according to DIN
EN 60204-1.

2.4 First putting into operation

This machine has been configured to the individual requirements of the
customer. The first putting into operation can be done easily:

1. Adjust the machine to a horizontal stand.

2. Connect power and air supply.

3. Switch on the machine using the mains / emergency stop switch at the
front side of the machine.

4. Check all security systems for function and efficiency.

Danger

The machine may only be used for production purposes, after the security
systems have been checked. If a security doesn’t work adequately, it must be
repaired first.

As a factory setting, several production programs are contained in the buffer
of the machine. You may use one of them or create your own programs.

2-5

3 Programming instructions

3.1 Create new sewing programs

The following steps are required to create a new sewing program:

1. Select memory location (Mxx).

2. Add or copy seams.

3. Adjust the seams.

3.1.1 Select a M-memory location

Due to customer-specific configuration, several M-memory locations are
occupied by sewing programs. There are enough memory locations available
for new sewing programs.

Select an available memory locationz:

1. Press the M-key.

2. Enter the number of the desired memory location (e.g. 09).

If the memory location is available, seam No. 50 is assigned six times.

3.1.2 Add seams

If existing seams shall be used in the new program, you can remove the
seams of the memory location and add the desired seams like described in
part 1 of this manual.

If you want to create new seams, you will first have to assign new numbers to
the seams, which are not used in another program.

3.1.3 Copy seams

If existing seams shall be manipulated for the new program, the seams can
be copied to a new seam number. This allows to keep the original seams
unchanged:

1. Move the cursor to the seam number, where you want to copy another
seam to (e.g. No. 45).

2. Press the P-key.

3. Press F1.

4. Press F2.

5. Enter the number of the seam, which you want to copy (e.g. 10).

6. Press the ENT-key.

Now seam No. 10 has been copied to No. 45, a new number has been
assigned. Seam No. 10 and 45 are identic. If you need more new seams, you
can assign further seam number to the program (e.g. 46, 47, 48, a.s.o.) and
copy existing seams to these numbers.

3.1.4 Adjust seams

The seams copied to seam numbers 45 ... can now be edited, without
changing the original seams, which are possibly used in other sewing
programs.

The following seam functions can be edited:

• Mitre knife position, seam lenght, a.s.o.

• Seam functions (see section 3.2)

• Seam parameter (see section 3.3)

• Seam name (see section 3.1.5)

2-6

3.1.5 Name seams

To be able to distinguish seams, it is possible to define seam names. Follow
this procedure:

1. Press the P-key (opens the menu levels).

2. Press the key F5 (INIT-Parameter).

3. Press the key F1 (enter seam name).

4. The keys of the ten-key pad are occupied with letters, too. Each letter is
shown on its key with a color (blue, orange, green). Press one of the keys
F1...F3 together with a number key, to enter the desired letter (F1 blue, F2
orange, F3 green). Examples: A = F1 + 1; N = F2 + 5; U = F3 + 7.

5. Press the arrow keys to switch to the next or prior letter.

6. Press the P-key to terminate the entering and save the seam name.

3.1.6 Delete seams

An existing seam can be deleted.

ATTENTION

If a seam is used in several programs, it will be deleted in all programs. The
deletion of a seam can not be undone.

1. Press the P-key.

2. Press F5.

3. Press F5.

4. Enter the number of the seam to be deleted.

5. Press the P-key to delete the seam.

3.2 Seam functions

Several machine functions can be en- or disabled for a single seam. To do
so, follow this procedure:

1. Select the seam number using the arrow keys.

2. Press the P-key.

3. Press F2.

4. Select the desired function using the arrow keys.

5. Press the ENT-key to enable/disable the function.

6. Repeat steps 4. and 5. for all desired functions.

7. Press the P-key to leave the menu.

An enabled function is displayed inverted (white on black), a disabled
function black on white.

The functions are visualized with icons:

Center knife

cuts the pocket between the seams; if the center knife is disabled,
the mitre knife will be disabled automatically

Mitre knife

cuts the pocket edges; if the center knife is disabled, the mitre knife
will be disabled, too

Stacker

stacks the sewed parts automatically

2-7

Vacuum

keeps the parts in the insertion station, until the main clamp is
closed

Vylene

automatic supply with vylene

Stamp (option)

fixes the parts in the insertion station (3rd hand)

Piping blowing

piping is blown to the folder, to prevent a snapping during insertion;
should be enabled sewing thin parts

Folder up after seam end

increase of the production speed; earlier insertion of new parts is
possible

Flap clamp left

necessary if additional parts to the piping are inserted (e.g. pocket
bag, facing strips)

Flap clamp right

like flap clamp left (see above)

Seam shape trapeze jacket

breast welt production; left seam longer than right one

Seam form parallel

both needles work parallel

Seam shape trapeze troucers

left needle shorter than right one

Seam shape sloping pocket right

left seam with offset to the right one

Seam shape sloping pocket left

2-8

left seam with offset to the right one; mirrored to the right sloping

Piping pulling through (option)

turns the overlap of the piping (only during piping)

Photo cell left

necessary during sewing of left flap

Photo cell right

necessary during sewing of right flap

Positioning point front

calculation point for the seam start during sewing without flap

Positioning point middle

calculation point for the seam start during sewing without flap

Positioning point rear

calculation point for the seam start during sewing without flap

Zipper scissor (option)

during sewing an endless zipper, this function gives a stop­command to the machine to allow the cutting of the zipper

3.3 Seam parameters

Several seam-depending machine processes can be set:

1. Press the P-key.

2. Press F3.

3. Select the desired seam parameter using the arrow keys.

4. Press ENT-key.

5. Enter the desired value.

6. Repeat steps 3. to 5. for all desired seam parameters.

7. Press the P-key to leave the submenu.

During the selection of the parameters, you can scroll line per line using the
vertical arrow keys. You can also select the pages directly:

• Key 0: seam parameters 01 - 14

• Key 1: seam parameters 10 - 24

• Key 2: seam parameters 20 - 34

• Key 3: seam parameters 30 - 44

The seam parameters listed belowcan be changed. The factory-set default
configuration are shown in square brackets [ ], the possible settings in
rounded brackets ( ).

1 Change positioning point 135/225/315 mm

the set value defines the relation point of the seam

2 Insertion speed [60%] (10-90%)

clamp speed from the insertion position to the sew start position; when
photo cell is active, speed will be halved to allow a more exact
scanning; when producing with vylene, reduction to 1/3

3 Revs seam start [1500 rpm] (500 - 2000 rpm)

sewing head revs freely selectable, depending on needle- and center
knife setting

4 Revs during seam [2500 rpm] (500 - 3000 rpm)

freely programmable

5 Revs at seam end [1500 rpm] (500 - 2000 rpm)

freely programmable

6 Distance of seam start revs [5 mm] (0 - 99 mm)

distance with the revs of parameter 3

2-9

7 Distance of seam end revs [5 mm] (0 - 99 mm)

distance with the revs of parameter 5

8 Stitch length seam start [1,5 mm] (0,5 - 3 mm)

stitch length at seam start for tack or stitch condensation

9 Stitch length in the seam [2,4 mm] (0,5 - 3,5 mm)

10 Stitch length seam end [1,5 mm] (0,5 - 3,0 mm)

freely selectable, effects on tack and stitch condensation at seam end

11 Distance stitch length seam start [10 mm] (0,5 - 99 mm)

distance with stitch length of parameter 8

12 Distance stitch length seam end [10 mm] (0,5 - 99 mm)

distance with stitch length of parameter 10

13 Tack length seam start [10 mm] (0 - 20 mm)

if this value is set to 0, stitch condensation will be sewed automatically

14 Tack length seam end [10 mm] (0 - 20 mm)

if this value is set to 0, stitch condensation will be sewed automatically

15 Slope at seam start [3 mm] ( 0 - 10 mm)

seam offset (difference left/right needle) at seam start

16 Slope at seam end [3 mm] (0 - 10 mm)

seam offset at seam end

17 Enable center knife [17 mm] (0 - 30 mm)

depending on seam and knife width, the center knife should cut est. 1
mm further than the mitre knife

18 Disable center knife [0 mm] (0 - 30 mm)

depending on seam and knife width, the center knife should cut est. 1
mm further than the mitre knife

19 Thread monitor on after [30 mm] (0 - 99 mm)

distance after which the thread monitor will be enabled; change this
parameter if seam length < 30 mm

20 Thread monitor filter [07] (00 - 99)

the smaller the digit, the more sensitive the upper thread monitor
reacts; 99: thread monitor disabled

21 Length vylene seam start [60 mm] (0 - 99 mm)

vylene overlay at seam start

22 Length vylene seam end [80 mm] (0 - 99 mm)

vylene overlay at seam end

23 Duration final roller [0,5 Sek.] (0 - 99 Sek.)

exact positioning of the work piece to be stacked

24 Intermediate stop selection + pos. [0 cm] (0 - 48 cm]

enter a position, where the main clamp shall be driven to after
stacking; 01 cm = main clamp is driven to the insertion station

25 Pick up part selection + pos. [0 cm] (0 - 48 mm)

if a value is defined, the main clamp pressure is released after mitre
cutting automatically and the work piece will be driven to the set
position; 01 cm = work piece is driven to the insertion station

26 Revs center knife [40%] (10 - 99%)

definition of the cutting speed

27 Revs final roller [99%] (10 - 99%)

a reduction achieves an optimized positioning for the stacking

30 Flap clamp mode >> see further below

31 Folding slide mode

00: left + right fold slider enabled
01: left fold slider enabled
02: right fold slider enabled

2-10

32 Vacuum mode (option)

00: vacuum disabled
01: vacuum on with foot pedal vacuum (with display ‘enable
vacuum’ if not enabled with foot pedal)
02: vacuum on automatically if main clamp at insertion position
03: vacuum on with foot pedal advance

33 Main clamp mode

00: main clamp left/right down and tight
01: main clamp left down and tigh
02: main clamp right down and tight
03: main clamp both weak, before insertion both tight
04: main clamp laterally

34 Piping cutting / Marking lamp mode

00: switched off
01: front positioning point
02: rear positioning point
03: middle position

35 Stacker mode

01: only final roller
02: only folding stacker
03: folding stacker and final roller

36 Push-back locking off

00: Push-back locking enabled
01: Push-back locking disabled

37 Folder as stamp [00] (00 - 01)

00: normal insertion process enabled
01: with the first step on the foot pedal, the folder is lowered and
fixes the work piece; next step drives main clamp to insertion position;
after clamp is closed, the folder is pushed up to allow the insertion of
the vylene; only required for trouser production with pocket automaton
100/55/56 without stamp

38 Flap clamp mode

00: flap clamp active with foot pedal only
01: flap clamp active automatically

39 Breast welt mode

The breast welt swings in together with the flap station; then is the
01: left main clamp loose
02: both main clamps loose

3.3.1 Seam parameter 30: Flap clamp mode

In the control, you can switch on/off the left or right flap clamp and select one
of eight modes additionally; dependant on the selection, the flap clamp
behave different. In the following table, the mode number is shown in the first
column, the behaviour of the flap clamps is indicated with graphics.

left clamp closed

right clamp closed

left clamp open

right clamp open

2-11

Left and right flap clamp switched on:

00: Insertion position

01: like 00

02: like 00

03: like 00

04: Insertion position

automatic with folding slide

05: like 04

06: like 04

07: like 04

100/55: left flap clamp switched on, right switched off:

00: Insertion position

with foot pedal pressure

01: like 00

02: Insertion position

automatic with folding slide
with foot pedal pressure

03: like 02

04: Insertion position

automatic with folding slide
with foot pedal pressure

05: like 04

06: like 04

07: like 04

100/56: left flap clamp switched off, right switched on:

00: Insertion position

with foot pedal pressure

01: like 00

02: Insertion position

automatic with folding slide
with foot pedal pressure

03: like 02

04: Insertion position

automatic with folding slide
with foot pedal pressure

05: like 04

06: like 04

07: like 04

2-12

Both flap clamps switched on:

00: Insertion position

with foot pedal pressure
with 2nd foot pedal pressure

01: Insertion position

with foot pedal pressure

02: Insertion position

automatic with folding slide
with foot pedal pressure

03: like 02

04: like 00

05: like 01

06: Insertion position

with foot pedal pressure

07: like 06

3.3.2 Working WITHOUT automatic clamp push-back

Seam parameter 24 INTERMEDIATE STOP SELECTION + POS.

This parameter allows to define the positioning of the main clamp after
stacking.

Seam parameter 24 = 0 cm.

This setting causes the main clamp to wait on the mitre knife position, until
the foot pedal seam process is pressed.

3.3.3 Working WITH automatic clamp push back

Seam parameter 24 INTERMEDIATE STOP SELECTION + POS.

Seam parameter 24 = 01 cm

With this setting the main clamp will be driven to the insertion position after
stacking. Pressing the foot pedal seam process closes the main clamp.

3.3.4 Working with INTERMEDIATE STOP of the main clamp

Seam parameter 24 = 20 cm

With this setting the main clamp will be driven until 20 cm before the insertion
position after stacking. Press the foot pedal seam process to drive the main
clamp to the insertion position.

If a different intermediate position of the main clamp is required, it can be
achieved by changing the SP 24. The higher the value the larger is the
distance between intermediate and insertion position.

3.3.5 Working with automatic PICK UP PART using the main clamp

Seam parameter 25 = PICK UP PART + POS.

Seam parameter 25 = 00 cm

Pick up part using the main clamp is disabled.

Seam parameter 25 = 01 cm

Pick up part using the main clamp until the insertion position.

The main clamps will be lifted after mitre cutting and SP 23 (duration final
roller) is carried out. The final roller pulls the work piece a little out of the
open main clamp. Now the main clamp is lowered after the time of basic
parameter 28 and drives with the work piece to the insertion position.

Seam parameter 25 = 01 cm

2-13

When defining SP 23 (duration final roller) = 00 and NSP 23 = 00 sec., the
final roller won’t get active; the main clamp remains closed and drives without
clamp pressure to the insertion position.

Seam parameter 25 = 20 cm

Pic up parts with the main clamp until 20 cm before the insertion position.

3.4 Seam images

3.4.1 Sewing with catch

3.4.2 Sewing with stitch condensation

3.4.3 Sewing with stowing

2-14

3.5 Basic parameters

The basic parameters contain the general settings of the machine. Changes
effect all programmed seams.

Attention

As a factory setting, the basic parameters are optimized. Improper changes
may cause faults in the machine process, which may lead to a reduction of
quality and damages to the machine.

Follow this procedure to changes basic parameters:

1. Press the P-key.

2. Press F4.

3. Select the desired basic parameter using the arrow keys.

4. Press ENT-key.

5. Enter the desired value.

6. Repeat steps 3. to 5. for all desired basic parameters.

7. Press the P-key to leave the submenu.

During the selection of the parameters, you can scroll line per line using the
vertical arrow keys. You can also select the pages directly:

• Key 0: basic parameters 01 - 14

• Key 1: basic parameters 10 - 23

• Key 2: basic parameters 20 - 33

• Key 3: basic parameters 30 - 40

The following basic parameters can be changed [factory-set values in square
brackets]:

01 Front positioning point [135 mm]

distance between insertion position and seam start; if seam length is
changed only the seam end is varied

02 Middle positioning point [225 mm]

with this setting the seam start is calculated that if the seam length is
changed, seam start and end are delayed the same; is used for back
pocket with dart, if dart shall be positioned in the middle of the pocket

03 Rear positioning point [315 mm]

distance between insertion position and seam end; if seam length is
changed, only the seam start is varied
Length of main clamp 165 mm set value 205 mm

245 mm 285 mm
290 mm 330 mm

Attention

This parameter defines the end of the main clamp. If this parameter is set too
large, there may be sewing problems while sewing flaps.

04 Folder up after [335 mm]

time of the folder lifting after the seam; if distance too short, folder gets
caught by the fold pushers

05 Thread length full spool [57 m]

a wrong thread length leads to incorrect values in the display of
remaining thread

06 Time for picking up [0,6 sec.]

delay of the piping taking; independant how fast the operator is able to
insert the piping; if you enter ‘9.9 sec.’, the piping will be picked when
the main clamp reaches insertion position

2-15

07 Pick up duration [0,10 sec.]

time how long the folder presses on the piping

08 Clamp down automatically

if defined, the main clamp closes after reaching the insertion position
and the set time

09 Time after clamp down

time delay between clamp down and next operation

16 Time before insertion

after the set time the main clamp drives from the insertion position to
sewing start (foot pedal machine process pressed)

17 Piping blowing off

piping and flap are blown to the folder, to prevent a tilt movement of
the piping; time may not be too long, since otherwise the thread will be
blown to the needle

18 ‘Thread clamp open’ at seam start (Beisler sewing head)

after the first two stitches the upper threads should be released from
the thread clamp; after the time defined here, the thread clamp opens

19 ‘Thread clamp open’ - duration

duration of ‘thread clamp open’ at seam start

21 Cut til upper thread

time for catching and cutting of the upper thread

22 Upper thread cutting time

length of the threads after upper threads picked up

23 Scissor cutting time

influences the zipper scissor to cut the zipper completely before
moving to the end position

24 Drive to cutting

percentage of the clamp speed used by the main clamp to drive to the
mitre knifes

25 Mitre knife distance

distance between the mitre knifes

26 Mitre knifes cutting time

cutting time of the mitre knifes

27 Main clamp open

open the main clamp after mitre cutting; if time’s too short, the work
piece may slip out of the machine before taken by the stacker

28 Taking parts

when taking parts with weak clamp (inner pocket production) the main
clamp opens after mitre cutting, the final roller moves the part lateral
from the clamp; then the clamp is switched with this parameter, that
the main clamp detects the work piece faster and brings it to the
insertion position

29 Turn til final roller [0.1 sec.]

time for the start of the final roller

30 Time til final roller up [0.5 sec.]

keeping the work piece after rolling, until the stacker has taken the
work piece

31 Clamp speed [90%]

speed of the main clamp to the insertion position

32 Process step-by-step [00]

enter >01 to enable the switching of all machine functions

33 Remaining thread counter on/off [00] (option)

function can be enabled and disabled; 01 = remaining thread
monitoring on; this disables the spool thread counter

2-16

34 Thread cutter revs [250 Rpm]

positioning revs for threat cutting systems:
Beisler sewing head 250 Rpm
Pfaff sewing head 180 Rpm
Singer sewing head 250 Rpm

35 Thread cutter position [45] (01 - 59)

start correction threat cutter impulse; the smaller the number, the
earlier the bobbin threat cutter is started

36 Threat cutter duration [0,1 Sek.]

duration of bobbin threat cutter should be minimized, otherwise the
main clamp is already driving

37 Piping turn delay [00 mm]

37: after the mitre cutting, the main clamp drives the distance set here
in mm.

38 Piping turn duration [0,0 Sek.]

05: impulse duration for the piping turn

39 Smoothing duration (option)

defines the impulse duration of the trouser smoothing device

2-17

4 Troubleshooting hints

The following tables show possible error messages and the recommended
reactions of the operator. Error messages are imaged in the display of the
operating device.

Attention

Please obey the recommended actions in case of errors. Otherwise you
could damage the machine. In this case, producer’s warranty would be
spoiled. We won’t accept any liability for caused damage.

Error message Circumstances Solving

Error 01: No sewing
program

Error 02: Seam not
enabled

Error 05: I/O communi­kation error

Error 06: Step pulses
not valid

Error 07: No step pulses
from motor

current sewing program is empty;
possibly distances are not entered
or the whole program has been
deleted

current sewing program not activa­ted; number is displayed black-on­white

error transmission between control
and I/O module

error position of the clamp carriage check actor connection to clamp motor; check

if the clamp motor made a little
movement, the step pulses cannot
be controlled correctly

if the motor doesn’t move, the
cause is in the control or the power
part for the clamp motor

enter program values manually, copy from other
program or from hard disc buffer (Parameter INIT)

Press <ENT> to activate the program

check connection wires; if not succesful, replace
control and/or I/O module

plug of adaptor module 9020020 > 9020013;
replace adaptor module 9020020

check connections of clamp motor; replace clamp
motor; replace adaptor module 9020020

check status of diodes at the power card (Berger);
search acc. to diagnostics for Berger motor;
check connection to clamp motor (plug); check
connection 9020020 > power insertion (plug);
replace adaptor module 9020020

Error 08: Main clamp at
the stop

Error 09: Clamp does
not move from switch

2-18

termination switch TS01 or TS17
has switched during clamp move­ment, although the clamp must
have been away from the stop

clamp carriage moves to the termi­nation switch during initialization,
but does not move away (no chan­ge of direction)

check step counter with test program (step
pulses); if counter defective, replace clamp motor
or adaptor module 9020020; if counter OK, check
both switches and their connections

enter a low speed in test program ‘Check clamp
motor’ and switch direction using the arrow keys;
if the motor does not change direction, check:
connection 9020020 > power insert (plug); Berger
power part; if the motor changes direction, check
termination switch TS17

Error 10: fabrics inser­ted

push-back protection (photo cell
TS27) is not lighted

check photo cell and foil

Error 11: switch on
vacuum before

Error 12: Vylene end vylene monitor (photo cell TS21)

Error 13: Clamp position
error

Error 14: Insertion/seam
length wrong

Error 15: Stamp not up stamp hasn’t reached home positi-

Error 16: Folder not
straight

Error 17: Folder not up

folder hasn’t reached

vacuum is activated with par32 =
01, but no vacuum has been
switched on before sewing

detects vylene end

difference between must (step
motor setup) and is position (impul­sTS from incremental Gerber) of
the clamp carriage is too large;
clamp carriage possibly blocked

insertion point rear selected; seam
length longer than the distance for
rear insertion point

on after switching off

folder hasn’t reached middle
position within error time

home position within error time check cylindre, valves Y24 Y25, termination

switch on vacuum or select another vacuum
mode

insert new vylene roll or check photo cell

remove blocking part; check clamp carriage for
easy-going; check whether motor pinion is loose
on the shaft; tighten transportation belt

program lengths correctly

check cylindre, valve Y20, termination switch
TS19

check cylindre, valve Y15, termination switch
TS05

switch TS03 TS04

Error 18: Folder not
down

Error 19: Folder not
sloping

Error 20: Knifes not
together

Error 21: Centre knife
not up

Error 22: Front mitre
knifes not down

Error 23: Rear mitre
knifes not down

Error 24: Scissor not up scissor hasn’t reached home

folder hasn’t reached position within
error time

folder hasn’t reached position
‘sloping’ (for picking up) within error
time

the movable mitre knife hasn’t
reached start position before
sewing insertion

centre knife hasn’t reached home
position within error time

front mitre knifes (seam end)
haven’t reached home position
within error time

rear mitre knifes (seam start)
haven’t reached home position
within error time

position within error time

check cylindre, valves Y24 Y25, termination
switch TS03 TS04

check cylindre, valve Y15, termination switch
TS06

check termination switch TS20; check connection
to mitre knife motor (plug); check diodes at the
power card Berger; continue searching acc. to
diagnostics Berger motor

check cylindre, valves Y03 Y48, termination
switch TS13

check cylindre, valve Y04, termination switch
TS19

check cylindre, valve Y04, termination switch
TS18

check cylindre, valves Y21 Y22, termination
switch TS14

Error 25: Scissor not
down

Error 26: Pinole not up the pinole for piping turning hasn’t

scissor hasn’t reached cutting
position within error time

reached upper position within error
time

check cylindre, valves Y21 Y22, termination
switch TS15

check cylindre, valve Y59, termination switch
TS41

2-19

Error 27: Pinole not
down

home position not reached within
error time

check cylindre, valve Y59, termination switch
ES39 ES40

Error 28: no impulses
from sewing motor

Error 29: Sewing motor
too fast

Error 30: No thread
cutting position

Error 33: Sewing motor
doesn’t stop

no impulses from sewing motor
after sewing start (sewing motor
doesn’t move)

during thread cutting, sewing motor
hasn’t reached cutting speed within
error time

sewing motor hasn’t reached
cutting position during thread
cutting

motor doesn’t stop after thread
cutting within error time

check sewing motor and synchronization; check
connection 9020013 > sewing motor; read both
upper diodes at 9020013: left lights shortly when
needle up; right shows synchronization impulses
(512 impulses/rev); if none lights during the hand
wheel is moved: check power supply of sewing
motor, possibly replace sewing motor; if diodes
are functioning and motor makes no move befor
error message, check connection 9020020 >
sewing motor, possibly replace 9020020 or
sewing motor; if motor makes some stitches
before error message, check connection control >
I/O module, possible replace components

replace sewing motor or synchronizator

enter slower cutting speed; enter earlier cutting
position; replace sewing motor or synchronizator

enter slower cutting speed; enter earlier cutting
position; replace sewing motor or synchronizator

Error 34: Needle not up needle is not in upper home positi-

on; together with the error message
the control will try to bring the
needle into upper position again

Error 35: Thread brea­kage

Error 36: Spool empty mode ‘meter counting bobbing

Error 37: Spool only
residual

Error 41: No flap automatic detection of flap length

Error 42: Photo cell not
lighted

thread monitor reports thread
breakage

thread’ enabled; remaining length
reached zero

one of the photo cells at the spool
capsule is lighted, spool empty

with photo cell is enabled; photo cell
hasn’t detected a flap during inserti­on

automatic detection of flap length
with photo cell is enabled; photo cell
hasn’t detected a flap within safety
length

check sewing motor and synchronizator; check
connection 9020013 > sewing motor; read both
upper diodes at 9020013: if none lights during
hand wheel is turned, check power supply of
sewing motor; possibly replace sewing motor; if
diodes are functioning, check connection 9020020
> sewing motor; possibly replace 9020020

if both spools are not empty, one of the photo cells
reflected the thread and must be adjusted less
sensitive

insert flap; check photo cell TS31 and foil

program safety length longer; switch off monito­ring (enter 250 mm as seam length); check photo
cell TS31 and foil

2-20

Error 43: photo cell
lighted too early

automatic flap length detection with
photo cell enabled; photo cell
detected flap end too early

program security length shorter; switch off monito­ring (enter 250 mm as seam length); check photo
cell TS31 and foil; reduce sensitivity of photo cell
(in case of reflections)

Error 45 ... 48: I/O DAC,
ULN, 485, RES

Error 51: Flap station
does not swing

Error 52: Flap station
not in home position

Error 53: Pocket pouch
station not in home
position

Error 54: Station not
locked

internal hardware errors during data
transmission to 9020020

flap station hasn’t reached active
position within error time

flap station hasn’t reached home
position within error time

pocket puch supply hasn’t reached
home position within error time

folder station isn’t locked lock station; check termination switch TS02

replace 9020020

check cylindre, valve Y17, termination switch
TS08

check cylindre, valve Y17, termination switch
TS07

check cylindre, valves Y18 Y19, termination
switch TS11

2-21

5 Maintenance of the machine

This machine works nearly free of maintenance. To achieve the maximum
ability of the machine for a long term, some regular maintenance duties are
required.

Danger

Before starting maintenance and repair duties, the following power down
procedures are to be executed. Otherwise there could be danger to life!

Cut off mains power

• switch the mains / emergency stop switch to '0' and assure that it can't be
switched on

• check whether the machine is without current and that there is no statical
loading

Switch off pneumatic system

• close the main gauge

• ventilate all pipes and gauges

5.1 Water separator at air connector

The air connector is equipped with an automatic water separator. If the air
supply looses pressure, the contained water will be let out automatically.

5.2 Grease linear guiding

At least once a year, the linear guiding must be greased with normal ball­bearing grease:

Schmiernippel

2-22

5.3 Use of the Memory Card

The Memory Card allows to save created seams and/or seam orders on a
removable data cartridge or load them back into the machine.

Hint

We strongly recommend to save own seams or seam orders on the Memory
Card, since otherwise they might get lost in case of an defective EPROM or
possbile other faults.

ATTENTION

The Memory Card contains a battery which is good for est. 2 to 3 years. If the
battery is empty, the saved data will get lost in a short period of time. Don’t
forget to change the battery in time and then save the machine data on the
Memory Card again.

5.3.1 Saving seam data on the Memory Card

1. Insert the Memory Card into the corresponding slot in the front panel of
the operating device (see operating instructions).

2. Press the P-key.

3. Press the F6-key.

4. Press the F2-key.

5. Press one of the keys F1, F3 or F5 (see further below).

6. Confirm by pressing the ENT-key.

You can use one of serveral possibilities to save data on the Memory Card.
Press the key

F1 to save the active seam (which is currently displayed in the

operating device) on the Memory Card;

F3 to save all seam orders;

F5 to save all variables.

If you want to save all your data on the Memory Card, you should press the
F5-key.

5.3.2 Loading seam data from the Memory Card

ATTENTION

Seam data from the Memory Card overwrite the data saved in the operating
device. If you have changed your seams, you will have to save them on the
Memory Card.

1. Insert the Memory Card into the corresponding slot in the front panel of
the operating device (see operating instructions).

2. Press the P-key.

3. Press the F6-key.

4. Press the F2-key.

5. Press one of the keys F2, F4 or F6 (see further below).

6. Confirm by pressing the ENT-key.

2-23

You can use one of serveral possibilities to load data from the Memory Card.
Press the key

F2 to load the active seam (which is currently displayed in the

operating device) from the Memory Card;

F4 to load all seam orders;

F6 to load all variables.

If you want to load all your data from the Memory Card, you should press the
F5-key.

5.4 Loading data from the EPROMs

If desired, you can load the factory-set basic and seam parameters from the
EPROMs (not from the Memory Card). This can be necessary after a
complete loss of data.

5.4.1 Loading the basic parameters

1. Press the P-key.

2. Press the F5-key.

3. Press the F3-key.

4. Enter the number ‘1’ and press the ENT-key.

The basic parameters saved in the EPROM will be loaded and overwrite the
parameters saved in the operating device. This resets the basic parameters
to factory-set conditions.

5.4.2 Loading seam parameters

1. Press the P-key.

2. Press the F5-key.

3. Press the F4-key.

4. Enter the number ‘1’ and press the ENT-key.

The seam parameters saved in the EPROM will be loaded and overwrite the
parameters saved in the operating device. This resets the seam parameters
to factory-set conditions.

5.5 Test programs and diagnostics

This machine contains a huge variety of test programs, with which all
functions can be individually tested.

5.5.1 I/O-Test

1. Press the P-key.

2. Press the F6-key.

3. Press the F1-key.

4. Execute the desired actions (see further below).

5. Press the P-key to end the test.

All inputs with their numbers will be displayed in the upper half of the display.
The inputs displayed inverted are currently active.

All outputs with their numbers are displayed in the lower half of the display.
The outputs displayed inverted are currently active.

You can now select an output using the arrow keys and activate or de­activate it by pressing the ENT-key. If you press the ENT-key longer than two
seconds, the output switches between active and de-active, unitl you press
the ENT-key again (shortly).

The following inputs and outputs are available in this machine.

2-24

5.5.1.1 Available inputs

Basic equipment

Inp. S-No. Description Type Occupation Folder- Mach.type

distrib.

01 01 Clamp front Initiator Opener X24 pin 02 54, 55, 56

02 02 Insertion station safety switch Initiator Closer X27 pin 22 54, 55, 56

03 03 Folder up Initiator Closer X24 pin 04 X49 pin 01 54, 55, 56

04 04 Folder down Initiator Closer X24 pin 05 X49 pin 02 54, 55, 56

05 05 Folder straight Initiator Closer X24 pin 15 X49 pin 03 54, 55, 56

06 06 Folder sloping Initiator Closer X24 pin 16 X49 pin 04 54, 55, 56

07 07 Flap station home position Initiator Closer X27 pin 18 X49 pin 05 54, 55, 56

08 08 Flap station swing-in Initiator Closer X27 pin 19 X49 pin 06 54, 55, 56

11 11 Pocket pouch station home Initiator Closer X27 pin 27 54

12 12 Pocket pouch station in Initiator Closer X27 pin 28 54

13 13 Centre knife up Initiator Closer X24 pin 06 54, 55, 56

17 17 Clamp rear Initiator Opener X24 pin 03 54, 55, 56

18 18 Mitre knife down seam end Initiator Closer X24 pin 07 54, 55, 56

19 19 Mitre knife down seam start Initiator Closer X24 pin 08 54, 55, 56

20 20 Mitre knifes in touch Initiator Closer X24 pin 09 54, 55, 56

22 22 Foot pedal forward Foot pedal Closer X24 pin 01 54, 55, 56

24 24 Foot pedal flap clamp Foot pedal Closer X24 pin 14 54, 55, 56

25 25 Foot pedal pocket pouch clamp Foot pedal Closer X27 pin 26 54

Options

09 09 Stamp up Initiator Closer X27 pin 20 X49 pin 07 56

10 10 Clamp adjustment Magnet sw. Closer X27 pin 21 X49 pin 08 54, 55, 56

21 21 Vylene end Photo cell Photo cell X27 pin 24 54, 55

23 23 Foot pedal vacuum Foot pedal Closer X24 pin 12 54, 55

26 26 Switch reset Foot pedal Closer X24 pin 13 54, 55, 56

27 27 Push-back blocking Photo cell Photo cell X24 pin 11 54, 55, 56

31 31 Photo cell left Photo cell Photo cell X24 pin 10 54, 55, 56

32 Switch jacket/trouser Initiator Closer direct 54, 55, 56

35 35 Thread monitor Detect.head X27 pin 25 54, 55, 56

38 38 Bobbin residual detector Photo cell Photo cell X27 pin 29 54, 55, 56

39 39 Piping pull-through down SE Initiator Closer X27 pin 30 54, 55, 56

40 40 Piping pull-through down SS Initiator Closer X27 pin 31 54, 55, 56

41 41 Piping pull-through up Initiator Closer X27 pin 32 54, 55, 56

28 28 Foot pedal clamp ins. plate Foot pedal Closer X27 pin 23 55

32 33 Right-handed photo cell Photo cell Photo cell X27 pin 17 54, 55, 56

2-25

5.5.1.2 Available outputs

Basic equipment

No. Description Gauge No. Cylindre Occupation

No. Status

01 Bobbin cutter Y01 01 X25 pin 01

03 Center knife impulse Y03 03 X26 pin 26

04 Mitre knifes up Y04 04/04.1 X25 pin 16

11 Threat release Y11 11 X25 pin 02

15 Swing folder Y15 15 X25 pin 11, X49 pin 21

16 Lift flap station Y16 16 X26 pin 23, X49 pin 22

17 Swing flap station Y17 17 X26 pin 22, X49 pin 23

24 Folder up Y24 24 air-free X25 pin 07, X49 Pin 27

25 Folder down Y25 25 air-free X25 pin 08, X49 Pin 28

28 Needles in folder Y28 28 X25 pin 12, X49 pin 29

29 Flap clamp Y29 29 X26 pin 21, X49 pin 30

32 Clamp quick adjustment Y32 32

33 Flap clamp right Y33 33 X26 pin 20

34 Fold pusher left Y34 34 X25 pin 13

35 Fold pusher right Y35 35 X25 pin 14

36 Flap clamp left Y36 36 X26 pin 19

38 Main clamp open Y38 39/40 air-free X25 pin 04

39 Main clamp left Y39 39 air-free X25 pin 05

40 Main clamp right Y40 40 air-free X25 pin 06

41 Upper thread catcher Y41 41 X25 pin 03

48 Center knife pusher Y48 48 X25 pin 15

Options

02 Main clamp laterally Y02 2 X37 pin 14

09 Vylene cutting Y09 9 X26 pin 31

51 Vylene release Y51 51 X26 pin 30

60 Vlylene pushing Y62 60 X26 pin 29

13 Stacker start Y13 X26 pin 18

23 Smoothing device Y23 23 X26 pin 17

20 Stamp Y20 20 X26 pin 25, X49 pin 26 (100-56 only)

10 Vacuum Y10 10 X25 pin 10

42 Piping blowing Y42 X25 pin 09

50 Switch strip jacket/trouser Y50

20 Needle bar large Y08 08/08.1 X26 pin 25 (nur 100-56)

01 Blow bobbin residual thread Y55 X25 pin 01

2-26

No. Description Gauge Cylindre Occupation

No. No. Status

18 Lift pocket pouch supply Y18 18 X37 pin 10 (100-54 only)

19 Drive in pocket pouch supply Y19 19 up X37 pin 09 (100-54 only)

30 Pocket pouch supply clamp Y30 30 X35 pin 08 (100-54 only)

52 Trouser smoothing device Y52 52 X37 pin 16 (100-56 only)

44 Piping cutting knife Y44 44 X25 pin 27, X49 pin 31

45 Piping cutting short/long Y45 45 X37 pin 12, X39 pin 32

46 Piping cutting centre stop Y46 46 X37 pin 13, X49 pin 33

55 Clamp insertion plate Y55 55 X37 pin 11

Machines with sloping

47 Breast welt guiding head Y47 47 X35 pin 07 (100-55 only)

12 Mitre knife centre stop Y12 12 X35 pin 03 (100-55, -56 only)

05 Left mitre knife seam end Y05 05.1 X35 pin 01 (100-55, -56 only)

06 Left mitre knife seam start Y06 06 X35 pin 02 (100-55, -56 only)

53 Needle switch-off right Y53 53 air-free X35 pin 04 (100-55, -56 only)

54 Needle switch-off left Y54 54 air-free X35 pin 05 (100-55, -56 only)

Machines with piping pull-through

56 Piping pull-through push plate Y56 56 X35 pin 04

57 Piping pull-through seam end Y57 57 X35 pin 02

58 Piping pull-through seam start Y58 58 X35 pin 01

59 Piping pull-through pinple up Y59 59 X35 pin 03

5.5.2 Diagnostics

1. Press the P-key.

2. Press the F6-key.

3. Press the F3-key.

Here you can choose from six different sub-menus, with which you are able
to check system components individually.

5.5.2.1 Service Test

ATTENTION

These tests may only be executed by service technicians of the company
Beisler. The complete loss of all data can easily occur due to false
operations.

5.5.2.2 Sewing motor

1. Press the P-key.

2. Press the F6-key.

3. Press the F3-key.

4. Press the F2-key.

Here, four tests for the sewing motor are contained. Select the desired test
by pressing the corresponding F-key:

2-27

F1 Select sewing motor

Here the actual value is compared with the must value of revs of the sewing
motor. After opening the test, you can enter the desired revs using the
number keys.

ATTENTION

The insertion station must be swung out and all threats and bobbins must be
removed from the sewing head before the test can be executed. Beisler
sewing heads may only be run with revs up to 2500 Rpm.

Enter the desired revs of the motor and press the ENT-key. The sewing head
starts and the measured actual value is displayed.

Press the P-key to terminate the test.

F2 Threat cutter

ATTENTION

The insertion station must be swung out and all threats and bobbins must be
removed from the sewing head before the test can be executed.

Press the 0-key (zero) and the sewing head runs for a short time. After the
needle has been positioned, the threat cutter gets active (basic parameter
36: TC duration).

F3 Position actor

ATTENTION

The insertion station must be swung out and all threats and bobbins must be
removed from the sewing head before the test can be executed.

After the selection of this test, the ‘Hand wheel increments’ and ‘Hand wheel
position’ will be displayed. By turning the hand wheel to the left or right, the
increments will be counted. There must be 520 increments per turn.

To check the needle-up-position, press the 0-key (zero) and the needle will
be positioned. There should be 510 increments displayed now. This value
should not deviate for more than 1 increment.

F4 Sewing motor

This function can be used to transfer the parameters required for the sewing
motor from the control. After changing the control or seam motor, the
execution of this function is required.

Select the function and press the ENT-key. The data will be transferred
automatically. Switch off the machine using the main switch. After switching
on the machine again, the data will be loaded automatically.

5.5.2.3 Clamp motor

2-28

1. Press the P-key.

2. Press the F6-key.

3. Press the F3-key.

4. Press the F3-key.

Here three test functions for the clamp motor are contained:

F1 Clamp motor path steps

This function measures the path steps of the clamp path (see Technical
manual, 1.20.2).

F2 Select clamp motor

ATTENTION

This function may only be executed by service technicians of the company
Beisler or authorized and especially trained staff.

F3 Clamp motor long-term test

Hint

The main clamp must be driven into starting position (clamp on initiator 17)
before this function can be executed.

Select the function and press the ENT-key. The main clamp moves back and
forth with high speed and must change direction at the same position.

5.5.2.4 Mitre knife motor

1. Press the P-key.

2. Press the F6-key.

3. Press the F3-key.

4. Press the F4-key.

Here two test functions are contained:

F1 Select mitre knife motor

ATTENTION

This function may only be executed by service technicians of the company
Beisler or authorized and especially trained staff.

F2 Mitre knife motor long-term test

Before execution, the movable mitre knife must be moved into starting
position (on intitiator 20).

Select the function and press the ENT-key. The mitre knife moves back and
forth with constant speed and must change direction always at the same
position.

Turn the mains/emergency stop switch to terminate the function.

5.5.2.5 Center knife motor

1. Press the P-key.

2. Press the F6-key.

3. Press the F3-key.

4. Press the F5-key.

Enter a value between 01 ... 99 to check the speed of the center knife motor.
Press the ENT-key to switch off the motor again.

If the center knife shall be switched on additionally, press the 0-key (zero).
You can also stop the center knife by pressing the ENT-key.

Press the P-key to terminate this function.

2-29

5.5.2.6 Final roller

1. Press the P-key.

2. Press the F6-key.

3. Press the F3-key.

4. Press the F6-key.

Enter a value between 01 ... 99 to check the speed of the final roller. Press
the ENT-key to switch off the motor again.

Press the P-key to terminate this function.

5.5.3 Service Code

Here two codes are contained, whith which all or only a part of the machine
data can be locked.

5.5.3.1 Machine Code

This is required to copy seam parameters, basic parameters or seam
programs and to select a part of the diagnostic programs.

The code number is ‘50190’. If this code is disabled due to safety reasons,
‘00000’ must be entered.

5.5.3.2 Safety Code

This code is required for the execution of most of the diagnostic functions. It
can be ordered in written form giving the machine number from the service
department of the company Beisler.

5.6 Preset sewing programs

The following shows the factory-set structure of the seams in the memory
buffer:

Seam-No. Seam

01 ... 09 Jacket outside pocket; with/without flap

10 ... 19 Jacket outside pocket; slanted pocket / slanted flap

20 ... 29 Inside pocket; lining pocket with pelon

30 ... 39 Pants pocket; pants front/back pocket with/without flap

40 ... 49 Pockets with zipper

The following shows the factory-set occupation of several memory locations
with seams:

Memory loc. Seam

M01 01 Flap pocket; jacket right panel

02 Flap pocket; jacket left panel

03 Welt pocket; jacket right panel

04 Welt pocket; jacket left panel

M02 10 Slanted pocket with flap; right panel

11 Slanted pocket with flap; left panel

12 Slanted welt pocket; right panel

13 Slanted welt pocket; left panel

M03 20 Jacket inside pocket with pelon; pocket length 100 mm

21 Jacket inside pocket with pelon; pocket length 100 mm

22 Jacket inside pocket with pelon; pocket length 150 mm

23 Jacket inside pocket with pelon; pocket length 150 mm

2-30

M04 30 Pants back pocket

31 Pants front pocket

32 Pants back pocket with flap

33 Pants back pocket with button loop

M05 40 Pocket with zipper

41 Pants back pocket with zipper

M07 16 Jacket breast welt pocket

5.7 Diagram of the menu structure

Benötigte Tasten

2-31

2-32

Part 3 Technical manual

Hint

This Technical manual contains information for the further maintenance,
adjustment and troubleshooting. It adresses axclusively to trained
andexperienced technical staff, which is able to assess the tasks and
recognizepossible danger at an early moment. The prior parts of this
documentation ‘1Operating instructions’ and ‘2 Mechanics manual’ are to be
considered as parts of the Technical manual.

Contents Page

Part 3 Technical manual ............................................................................................... 3-1

0.1 Reason for this manua ......................................................................................... 3-3

0.2 Structure of the manual ........................................................................................ 3-3

0.3 Safety instructions ............................................................................................... 3-3

0.4 Preparing measures ............................................................................................ 3-4

0.4.1 Cut off power supply ............................................................................................ 3-4

0.4.2 Release pneumatic pressure ............................................................................... 3-4

1 Clamp adjustment .............................................................................................. 3-5

1.1 Clamp drive belt ................................................................................................... 3-5

1.2 Adjust axial free play of the clamp arms .............................................................. 3-6

1.3 Parallelity of the clamp arms to the sewing head ................................................. 3-6

1.4 Lateral adjustment of the double piping ............................................................... 3-6

1.5 Lateral flap adjustment......................................................................................... 3-6

1.6 Adjust main clamp height ..................................................................................... 3-7

1.7 Adjust main clamp pressure................................................................................. 3-7

1.8 Main clamp pressure distribution ......................................................................... 3-7

1.9 Clamp quick adjustment double/single piping (option) ......................................... 3-8

1.10 Clamp quick adjustment jacket/trouser (option) ................................................... 3-8

1.11 Lateral clamp adjustment without quick adjustments ........................................... 3-9

1.12 Clamp adjustment double piping – flap without quick adjustment ........................ 3-9

1.13 Adjust folding slide path ....................................................................................... 3-9

1.14 Adjust parallelity of folding slide ......................................................................... 3-10

1.15 Adjust folding slide ............................................................................................. 3-10

1.16 Flap clamp position ............................................................................................ 3-10

1.17 Opening path of the flap clamp ...........................................................................3-11

1.18 Photo cell foil ......................................................................................................3-11

1.19 Check/change clamp rubber ...............................................................................3-11

1.20 Adjust clamp path .............................................................................................. 3-12

1.20.1 Adjust front stop ................................................................................................. 3-12

1.20.2 Measure clamp path .......................................................................................... 3-12

1.20.3 Adjust back stop rubber ..................................................................................... 3-12

2 Adjustments at the insertion station .............................................................. 3-13

2.1 Folder height ...................................................................................................... 3-13

2.2 Initiator at the swivel plate .................................................................................. 3-13

2.3 Folder height parallel to sliding plate.................................................................. 3-13

2.4 Folder parallel to main clamp ............................................................................. 3-13

2.5 Setting the piping width ...................................................................................... 3-14

2.5a Guide head height ............................................................................................. 3-14

2.6 Center knife protection ....................................................................................... 3-14

2.7 Lateral distance between guiding plate and needle ........................................... 3-15

2.8 Guding plate vertical stop .................................................................................. 3-15

2.9 Guiding plate pressure ....................................................................................... 3-15

2.10 Mark lamps adjustments .................................................................................... 3-16

2.10.1 Setting the parallelism........................................................................................ 3-16

3-1

2.10.2 Setting the distances.......................................................................................... 3-16

2.10.3 Light cross size .................................................................................................. 3-16

2.10.4 Setting the focus ................................................................................................ 3-16

2.10.5 Installing and removing mark lamps................................................................... 3-16

2.10.6 Replacing the mask ........................................................................................... 3-16

2.11 Stamp ................................................................................................................ 3-17

2.12 Flap clamp adjustment ....................................................................................... 3-17

2.12.1 Flap clamp pressure .......................................................................................... 3-17

2.12.2 Flap clamp height .............................................................................................. 3-17

2.12.3 Parallelism to the folder ..................................................................................... 3-17

2.13 Piping cutter adjustment .................................................................................... 3-18

2.13.1 Replacing knives................................................................................................ 3-18

2.13.2 Setting the pipe length ....................................................................................... 3-18

2.13.3 Piping cutter center position............................................................................... 3-18

3 Adjustments at the sewing head .................................................................... 3-17

3.1 Height adjustment .............................................................................................. 3-17

3.2 Lateral adjustment ............................................................................................. 3-17

3.3 Driving belt tension of the sewing motor ............................................................ 3-17

3.4 Top threat cutter (Beisler sewing head) .............................................................. 3-18

3.5 Height of top threat catcher ................................................................................ 3-18

3.6 Center knife adjustments ................................................................................... 3-18

3.6.1 Switching on ...................................................................................................... 3-18

3.6.2 Switching off ...................................................................................................... 3-18

3.6.3 Safety initiator at the center knife pole ............................................................... 3-18

3.6.4 Depth adjustment of the safety initiator .............................................................. 3-18

3.6.5 Height of center knife ......................................................................................... 3-19

3.6.6 Shear angle of the center knife ......................................................................... 3-19

3.6.7 Lateral adjustment ............................................................................................. 3-19

3.6.8 Needle protection ............................................................................................... 3-19

3.7 Adjustments of the bobbin threat catcher (Beisler sewing head) ....................... 3-20

3.7.1 Catcher adjustment ............................................................................................ 3-20

3.7.2 Time of bobbin threat cutting .............................................................................. 3-20

3.7.3 Duration of bobbin threat cutting ....................................................................... 3-20

3.8 Sensitivity of the bobbin detector (option) ........................................................ . 3-20

3.9 Clean tactual head of the bobbin detector (option) ............................................ 3-21

3.10 Adjust piping detection ....................................................................................... 3-21

3.10.1 Lateral adjustment . ........................................................................................... 3-21

3.10.2 Adjust intensity................................................................................................... 3-21

3.11 Swing up sewing head ...................................................................................... 3-22

3.12 Upper threat monitor ......................................................................................... 3-22

3.12.1 Switch on time ................................................................................................... 3-22

3.12.2 Filter threat monitor ........................................................................................... 3-22

3-2

4 Adjustments at the mitre knifes...................................................................... 3-23

4.1 Basic adjustment locked mitre knife (seam end) ................................................ 3-23

4.2 Basic adjustment movable mitre knife (seam start) ............................................ 3-23

4.3 Mitre knife height ............................................................................................... 3-23

4.4 Mitre knife broadth ............................................................................................. 3-23

4.5 Pre-stabber ........................................................................................................ 3-24

4.6 Lateral adjustment ............................................................................................. 3-24

4.7 Fine adjustment in the length ............................................................................. 3-24

4.8 Tighten cog-belt of the mitre knife drive ............................................................. 3-24

5 Adjustment of machine options ..................................................................... 3-25

5.1 Automatic push-back blocking ........................................................................... 3-25

5.2 Height of the take off roller ................................................................................. 3-25

5.3 Mitre knife slant position .................................................................................... 3-26

5.3.1 Distance between basic bodies ......................................................................... 3-26

5.3.2 Height adjustment ............................................................................................. 3-26

5.3.3 Center adjustment ............................................................................................. 3-26

5.3.4 Adjust mitre knife stops ...................................................................................... 3-26

5.3.5 Knife arrangement ............................................................................................. 3-26

5.3.6 Arrangement of the mitre knife during flap pocket production ............................ 3-27

5.4 Split needle (Beisler sewing head) ..................................................................... 3-27

5.4.1 Distance to cylinder of the top threat catcher ..................................................... 3-27

5.4.2 Center adjustment ............................................................................................. 3-27

5.5 Vylene adjustments............................................................................................ 3-27

5.5.1 Correct vylene adjustment ................................................................................. 3-27

5.5.2 Demount vylene plate ........................................................................................ 3-28

5.5.3 Change cutting pressure .................................................................................... 3-28

5.5.4 Adjust vylene supply .......................................................................................... 3-28

5.5.5 Easy-running of the vylene roll ........................................................................... 3-28

5.5.6 Vylene supply speed .......................................................................................... 3-28

0.1 Reason for this manualsystems.

With this manual, especially qualified and authorized persons shall be
enabled to execute further adjustment and maintenance duties at the
Pocket-Piping machines 100-55/56 manufactured by Beisler. Even these
persons will first have to read and understand the documentation and obtain
all rules and regulationscompleteManometer 3) ein.

0.2 Structure of the manual

This manual is structured in two columns. On the left side you will find
explaining texts, on the right side photos which illustrate the texts and show
certain assemblies or parts of the machine

0.3 Safety instructions

Many of the measures described in this manual can be executed at a
machine powered-off and with released air-pressure. Please obtain the
switch-off procedures described below. Some of the measures described in
this manual can only be executed, if the machine is under electrical power or
air pressure.

DANGER

ever work alone! Assure that a second person is present which can initiate
ife-saving actions and/or calls for paramedical help in the case of an
accident.

DANGER

Danger of mortal electrical shock! While working at a machine where
electrical voltage is present, any contact to hot parts must be avoided.

DANGER

Danger of shearing and crushing! Be very careful working at a machine
which is under pneumatical pressure. Otherwise, unintented moves of
machine components could cause severe injuries.

3-3

0.4 Preparing measures

In this manual, you will find hints at any measure, where the machine must
be powered off or the pneumatic pressure must be released:

<power off> machine must be cut off the power supply

<release pressure> pneumatic pressure must be released from the

machine

To be able to work under maximized safety, the preparing measures should
be obeyed at any time.

0.4.1 Cut off power supply

Use the mains/emergency stop switch to switch off the machine. Cut off the
power supply and assure that it can’t be restored unintentedly.

0.4.2 Release pneumatic pressure

Close the air supply with the black switch at the air supply unit. Cut the
machine from the air supply and assure, that it can’t be restored unintentedly.

3-4

1 Clamp adjustment

The following assemblies must be distinguished in the
clamp area:

1. Clamp motor

2. Clamp carriage

3. Clamp drive belt

4. Clamp arms

5. Main clamp

1.1 Clamp drive belt

The clamp must stand in home position (like shown in
the upper picture).

The drive belt (1) must have enough tension that it gives
about 15 mm when loaded with 1 kg (in the middle bet­ween both belt disks).

If required, loosen both fixing screws (2) and adjust the
set screws (3). Tighten the fixing screws (2) again.

3-5

1.2 Adjust axial free play of the clamp
arms

<power off> <release pressure>

The clamp arms (1) must be adjusted without free play.
Although they have to move easily.

Check the correct adjustment from time to time. If requi­red, you can adjust the axial free play of the clamp arms
with the screws (2).

1.3 Parallelity of the clamp arms to the
sewing head

This is adjusted in the factory and doesn’t have to be
changed.

1.4 Lateral adjustment of the double
piping

<power off> <release pressure>

Insert the folder for the double piping.

The distance between the inner side of the main clamp
and the sole edge at the folder shall be 1.5 mm on the
right and left side (see right).

This distance can be adjusted with the setting rings (1).

1.5 Lateral flap adjustment

<power off> <release pressure>

Insert the folder for single piping.

There should be a distance of 1.5 mm between the in­ner side of the clamp and the sole of the folder.

This can be adjusted with the two outer setting rings (1).

3-6

1.6 Adjust main clamp height

The main clamp height in insertion position must be 30
mm.

To adjust this, loosen the nuts (1) at both clamp pressu­re cylinders and turn the piston pole (2) until the must
height is present.

1.7 Adjust main clamp pressure

The clamp pressure must be 3.5 bar. You can read it at
the pressure gauge (1) on the clamp carriage.

To adjust the pressure, pull out the black knob and turn
it into the required direction. Press the knob down again.

1.8 Main clamp pressure distribution

An even pressure must be over the whole main clamp
area.

Drive the main clamp into insertion position and lay thin
sewing material under the clamp arms. Close the main
clamp (control: check outputs). Pull the sewing material
laterally and check the even clamp pressure.

If required, you can adjust the pressure distribution. Loo­sen the fixing screws (1) of the two allen screws (2).
Turn the two allen screws (2) until the correct pressure
distribution is present. Tighten both fixing screws (1)
again.

3-7

1.9 Clamp quick adjustment double/
single piping (option)

An initiator is mounted at the insertion station, which re­cognizes the folder for double or single piping. The main
clamps will be driven into the correct position dependant
on the inserted folder. These positions are adjustable.

Mount the folder for the double piping and move both
inner setting rings (1) in a way that there is a distance of

1.5 mm between sole edge and main clamp edge (see

lower picture).

Mount the folder for single piping and move the outer
setting ring (1) until there is a distance of 1.5 mm and
the clamp can only move to one side.

Tighten the fixing screws of all setting rings.

1.10 Clamp quick adjustment jacket/
trouser (option)

With the additional initiator at the folder (1) a valve for
the additional clamp move is controlled.

Adjuste the outer position of the clamp with the two ou­ter setting screws (2) in a way that there is a distance of

1.5 mm between the folder sole and the inner side of the

main clamp.

3-8

1.11 Lateral clamp adjustment without

quick adjustments

Mount the folder for the double piping. Adjust the inner
setting rings (2) (3) in a way that there is a distance of

1.5 mm between main clamp and sole.

Mount the folder for single piping. Move clamp and set­ting rings (3) (4) to the outside until there is a distance of

1.5 mm between folder and sole.

Now block the lateral escape of the clamp arms by fi­xing the setting rings.

1.12 Clamp adjustment double piping –

flap without quick adjustment

Here you will have to move one clamp arm with the set­ting rings when changing between folder double or sin­gle piping.

Loosen the setting ring (3) or (4) and move them toge­ther with the clamp arm until there is a distance of 1.5
mm between double piping/flap and main clamp.

1.13 Adjust folding slide path

<power off> <release pressure>

The distance between the folding slide (1) driven in and
out must be 5 mm.

If required you can adjust the setting screw (2) at the
cylinder (3).

3-9

1.14 Adjust parallelity of folding slide

<power off>

In driven in state, the folding slide must be parallel to
and 0.5 mm away from the edge of the main clamp.

This can be adjusted with the fixing screws of the fol­ding slide cylinder (1).

1.15 Adjust folding slide

<power off> <release pressure>

A turn movement of the folding slide must be assured
which allows him to adjust to the strength of the sewing
material.

Adjust the screws (1) to adjust the folding slide with no
free play axially.

1.16 Flap clamp position

<power off> <release pressure>

The flap clamps must stand in a distance of 5 mm paral­lel to the inner side of the main clamp.

To adjust the flap clamp, loosen the fixing screws (1) of
the flap clamp beam. Adjust the flap clamp correctly and
tighten the fixing screws (1) again.

3-10

1.17 Opening path of the flap clamp

The opening path of the flap clamps (4) must be adju­sted in a way that the flap clamp presses with its com­plete length onto the main clamp, when the flap clamp
cylinder is driven out.

Loosen both allen screws (1) at the flap clamp to be
adjusted and adjust the cylinder (2) correctly. Tighten
both allen screws (1) again.

1.18 Photo cell foil

A photo cell foil (5) is fixed to each clamp (3). This al­lows an always good detection of the flap.

Clean the foil with a clean cloth from time to time. If the
foil is damaged, it must be changed.

1.19 Check/change clamp rubber

<power off> <release pressure>

There are moss-rubber strips below each main clamp. If
there are problems of the sewing material and the clamp,
these rubber strips should be checked.

Demount the clamp by loosening the allen screw (1).

The moss rubber strip is fixed with three screws (2).

If the rubber is damaged, loosen them and change the
strip.

Fix the clamp arm again and adjust it.

Hint

When working with thick sewing material it is advan­tageous to use a thicker clamp rubber or mount a
heightening.

3-11

1.20 Adjust clamp path

1.20.1Adjust front stop

<release pressure>

Drive the clamp carriage (1) into insertion position intil
initiator 1 (2) switched dark. The distance (A) between
the beam and the clamp carriage must be 19 mm.

To adjust the distance, loosen the fixing screws of the
initiator 1 (2) and move him in the desired direction. Tigh­ten the fixing screws again.

Loosen the fixing screw of the stopping rubber (3) and
turn this in or out, until there is a distance (B) of 3 mm to
the clamp carriage. Tighten the fixing screw again.

1.20.2Measure clamp path

Switch on the machine with the mains/emergency stop
switch. Wait until the clamp has been initialized.

The machine must be in home position (clamp carriage
in the back position).

Press sequently the keys [P] – [F6] – [F3] – [F3] – [F1] at
the operation device.

Push the clamp forward into insertion position until in­itiator 1 switches dark. Check the value which is display­ed in the lower right corner of the display (in mm):

< 000 mm initiator 17 (see picture in section 1.20.3) is

too far in the back and must be adjusted
towards the sewing head.

= 000 mm initiator 17 is adjusted correctly.

> 000 mm initiator 17 is too far in the front and must

be adjusted away from the sewing head.

1.20.3Adjust back stop rubber

The stop rubber (1) beside initiator 17 (I 17) must show
a gap of 3 mm to the clamp carriage.

Drive the clamp carriage into home position. Loosen the
nut (2) and turn the stop rubber, until there is a distance
of 3 mm to the clamp carriage. Tighten the nut (2) again.

3-12

2 Adjustments at the insertion station

2.1 Folder height

Move the machine to the neutral position and select
outputs 15 and 24 in the control.

The distance (A) between sliding plate and folder sole
must be set in accordance with the sewing material used.
The standard setting is 2 mm.

If the folder is set too low, the material will be blocked. If the
folder is set too high, the folding slides may fail to fold the
sewing material.

To change the setting, loosen the lock nut (1), rotate
the stop screw (2) clockwise or counter-clockwise, then
tighten the lock nut (1).

After the folding height has been changed, the position of
the initiator (4) at the swivel plate should be checked (see
Section 2.2).

2.2 Initiator at the swivel plate

As the folder is lowered completely, this initiator will be
switched to initiate the closing of the folding slides (if this
function is enabled in the program). If the initiator is not set
properly, the folding slides are activated too soon or not
at all.

To set the initiator, loosen the black retaining nut (3),
shift the initiator as required, then tighten the retaining
nut.

2.3 Folder height parallel to sliding plate

Rotate both stop screws (4) so that the folder is oriented parallel
to the sliding plate. While doing this, loosen the clamp
screws, push the folder up and tighten the screws.

2.4 Folder parallel to main clamp

<Power off> <Pressure off>

Loosen the two Allen screws (1) to the right and to the left
of the thumb screw and align the switch parallel to the main
clamp.

In this position, tighten the Allen screws.

3-13

2.5 Setting the Piping width

<Power off> <Pressure off>

To set the piping width, loosen the retaining screw (1) at
the guide head (2). Reposition the guide head (2) until the

desired piping width has been set.

Tighten the retaining screws.

Then check the setting of the folder and correct the
setting, if required (see Section 2.4).

Note

When the double piping width has been set properly,
the single piping width is set properly as well.

Note

The width of the folder sole is crucial for the piping
width;it can also be changed on customer request.

2.5a Guide head height

<Power off> <Pressure off>

Loosen the lock nut (1) of the stop screw (2), then rotate
the stop screw clockwise or counter-clockwise, as
required.

Tighten the lock nut (1).

2.6 Center knife protection

<Power off> <Pressure off>

The center knife protection (2) is attached to the guide
head and should surround the center knife (1) without
touching it.

If required, align the center knife protection (2) carefully to
the center knife.

3-14

2.7 Lateral distance between guiding

plate and needle

<Power off> <Pressure off>

The distance (A) to the needle should be minimal.
However, do not allow the guiding plate (1) to contact
the needle (2) or the needle head as otherwise
excessive noise or thread breakage may occur.

Set the distance using an appropriate bending tool.

2.8 Guiding plate vertical stop

The distance (A) between the upper side of the sole and
the lower side of the guiding plate (1) must not exceed

0.5 mm. This distance must be increased only if parti­cularly thick material is to be used.

To change the height, loosen the retaining nuts of the
two setscrews (2), rotate the screws clockwise or counter­clockwise, then tighten the retaining nuts.

2.9 Guiding plate pressure

Adjust the spring pressure so that both plates are pressed
down safely at all times. In case of insufficient pressure,
the needle may break during the initial bartack. In case
of excessive pressure, the plate will be pushed back at the
beginning of the seam.

Rotate the two adjusting screws (3) until adequate pressure is
applied to the guiding plates.

3-15

2.10 Mark lamp adjustments

2.10.1Setting the parallelism

The centerline of the mark lamp light crosses must
be exactly flush with the center cut.

To adjust the mark lamps, loosen the retaining screw
(6), then loosen the retaining screw in the ring (4) and
rotate the mark lamps as required.

2.10.2Setting the distances

The distance (A) between the first line of the seam begin­ning mark lamp (1) and the needle must be 135 mm (A).
The distance (B) between the first line of the seam begin­ning mark lamp (1) and the last line of the seam end mark

lamp (3) must be 180 mm. The distance (C) between
the first line of the seam bginning mark lamp (1) and the
center line of the seam center mark lamp (2) must
be 90 mm.

Loosen the two retaining screws (5 und 6) and reposition
the mark lamps until the correct distances are set.

2.10.3Light cross size

Loosen the retaining screw (1) and reposition the
mark light in the vertical direction to adjust the size
of the light cross.

2.10.4Setting the focus

To adjust the focus of the light cross, rotate the ring (2).

2.10.5Installing and removing mark lamps

Disconnect the two connectors from the top of the mark
lamp. Remove the retaining screw (1) and remove the
mark lamp.

To install the mark lamp, reverse the above proce-
dure.

2.10.6Replacing the mask

By using different masks, different shapes of light crosses
can be projected.

Remove the mark lamp (see Section 2.10.5) and
remove the Allen retaining screw in the upper lamp
cylinder (1). Be careful when opening the casing as
otherwise the spring pressure may propel lamp com­ponents out of the casing.

Insert the lamp components into the lower lamp cylinder
(6) in the following sequence: Spacer ring (5), mask (4),
lens (3) and spring (2). Make sure that the lens (3) is
inserted into the cylinder with the curved side facing
down. Then, push the upper lamp cylinder (1) in and tighten
the Allen retaining screw.

Install the mark lamp and align it properly.

3-16

2.11 Stamp

2.12 Flap clamp adjustment

2.12.1Flap clamp pressure

Adjust the flap clamp so that he closing pressure is dis­tributed evenly along the entire length.

To ensure this, slightly bend the upper clamp strap (1)
downward (use caution!).

2.12.2Flap clamp height

In the ‘I/O Test’, enable outputs 15, 17,and 24.

The flap clamp (1) must protrude above the sliding
plate (4) by the distance (A = 10 mm).

Loosen the Allen screw (3) and reposition the flap clamp
until the correct distance is set, then tighten the Allen
screw (3).

2.12.3Parallelism to the folder

In the ‘I/O Test’, enable outputs 15, 17, and 24.

The flap clamp (1) must be parallel to the folder (2).
Loosen the Allen Screw (3) and reposition the flap
clamp (1) until it is exactly parallel.

Tighten the Allen screw (3).

3-17

2.13 Piping cutter adjustment

2.13.1Replacing knives

In the ‘I/O Test’, enable outputs 15 and 44.

Remove the four Phillips screws (2) and remove the
insertion plate.

Remove the black retaining screws of the knives (1,
bottom illustration) and remove the knives (3) by lifting
them.

To install the new knives, reverse the above proce­dure.

2.13.2Setting the piping length

Loosen the left self-locking nut (1). Set the piping
length by repositioning the stop (2).

Tighten the nut (1).

2.13.3Piping cutter center position

In the ‘I/O Test’, enable output 45.

Loosen the left self-locking nut (1). Tighten the right
self-locking nut (3).

3-18

3 Adjustments at the sewing head

3.1 Height adjustment

The ground plate of the sewing head must be levelled
with the upper edge of the working table.

To adjust height and horizontal level loosen the nuts (1)
and adjust them by turning in or out. Tighten the counter
nuts again.

3.2 Lateral adjustment

The stitch plate (2) of the sewing head (1) must be exa­ctly in the gap of the sliding plate (3).

Loosen the fixing screws in the mounting frame (see
section 3.1) and level the sewing head exactly. Tighten
the fixing screws again.

3.3 Driving belt tension of the sewing

motor

It must be possible to push down the driving belt (2) of
the sewing motor (1) for 20 mm in its middle.

To adjust the tension loosen the fixing screws (3) of the
motor and move him vertically until the correct tension is
present. Tighten the fixing screws again.

3-17

3.4 Top threat cutter (Beisler sewing
head)

The toip threats will be caught by the top threat catcher
after the sewing during the clamp drives to the mitre
cutting.

The threats will first be clamped on the top side of the
catcher and then cut on the backside. The threat clamp
must hold the threats during the first stitches of the seam
start to assure a clean sewing image at seam start.

3.5 Height of top threat catcher

A distance (A) of 3-4 mm must be present between sli­ding plate (2) and catcher (3) when the threat catcher
cylinder (1) is driven out.

For adjustment loosen the fixing screws (4) of the cylin­der and move him until the correct height is present.
Tighten the screws (4) again.

ATTENTION

The enabled center knife may not get contact with the
top threat catcher!

3.6 Center knife adjustments

3.6.1 Switching on

The center knife is pushed down during the sewing pro­cess with the help of the cylinder Y3 (1). The the pin at
cylinder Y49 (2) takes over the locking of the center kni­fe.

3.6.2 Switching off

As soon as the seam end has been reached the center
knife will be switched off. This can be delayed by an
entering in the control.

The mechanical switching off is done by a withdrawal of
the locking pin at cylinder Y48 (2). This allows the pres­sure pole of the center knife to be pulled upwards by the
pulling spring.

3.6.3 Safety initiator at the center knife pole

During center knife switched off, the diode at the initiator
(3) must be lighted.

3.6.4 Depth adjustment of the safety initiator

The safety initiator (3) must be mounted in a distance of

0.3 - 0.5 mm to the center knife pole.

To adjust it loosen the fixing nut of the initiator (4) and
turn it in until it has contact to the center knife pole. Now
turn it out for half a rev and tighten the fixing nut (4) in
this position.

3-18

3.6.5 Height of center knife

The front edge of the center knife (1) must stand (in
switched on state and deepest position) 1 mm deeper
than the top side of the stitch plate.

To adjust it, loosen both fixing screws (2) and move the
center knife. Tighten both screws again.

3.6.6 Shear angle of the center knife

The center knife should stand slightly folded against the
counter knife in the stitch plate.

Loosen the allen key (3) and turn the holding hook on
the center knife pole until the desired position is met.
Tighten the allen key again.

3.6.7 Lateral adjustment

The center knife (1) must be adjusted laterally that the
pressure is minimized.

Loosen the fixing screws (2) and adjust the center knife
exactly. Tighten both screws again.

ATTENTION

Possible faults in machine sequence! If the center
knife has too strong contact to the counter knife, it
cannot be withdrawn after sewing into home position
by the spring. Additionally the knife gets blunt very fast
which causes bad cutting, different seam lengths,
improper mitre cutting and additional width in the
seam.

3.6.8 Needle protection

The needle protection (2) is mounted at the holder of the
upper threat catcher. It should stand 1 mm deeper than
the top of the center knife (1) and 1 - 1.5 mm away from
the back of the knife.

To adjust it loosen the fixing screws (3) of the needle
protection and move it. Tighten the fixing screws again.

3-19

3.7 Adjustments of the bobbin threat
catcher (Beisler sewing head)

3.7.1 Catcher adjustment

<power off> <release pressure>

Turn the belt disk manually until the spool capsule lever
stands as far as possible back into arrow direction. Fix
the movable knife (4) temporarily with the screw (3) and
press manually onto the top side of the knife (4) to move
it. Tighten screw (3) when the distance between the top
of the movable knife to the holder of the catcher is net­ween 0.05 and 0.2 mm.

Fix the movable knife (4) at the top of the spool clamp
spring now.

3.7.2 Time of bobbin threat cutting

This time can be programmed.

If the time is too early, upper and bobbin threat will be
caught and cut at the same time. Then the upper threats
will be too short for the next sewing process.

3.7.3 Duration of bobbin threat cutting

This time can be programmed.

If the time is too short, the bobbin threats will not get
caught. If the time is too long it is possible that the main
clamp drives to the mitre cutting before the threat cat­cher is in cutting position. This lengthens both threats
remaining at the seam end.

3.8 Sensitivity of the bobbin detector
(option)

Insert full bobbins into the grasper and close the sliding
plate. Activate the bobbin detector.

Open the casing of the switchboard and turn the poten­tiometer (2) to the left until the LED (1) lights up. Now
turn the potentiometer (2) as far to the right until the LED
doesn’t light up during the sewing. Mount the casing of
the switchboard.

Occupation of the LEDs and potentiometers:

(1) (3) right-handed spool

(2) (4) left-handed spool

Hint

During sewing with residual threat on the spool, the
LED (1) (2) must switch several times per rev.

3-20

3.9 Clean tactual head of the bobbin

detector (option)

There is a blowing system at the bobbin detector which
blows the tactual head free of dirt.

Clean the tactual head (1) with a clean and lint-free cloth
from time to time.

3.10 Adjust piping detection

3.10.1Lateral adjustment

The photocell (1) is equipped with a red light point (4 –
illustrated by drawing), which indicates the exact switch
point on the folding slide. The complete light point must
hit the reflecting foil when the folding slide is driven out.

Loosen the fixing screw (2) of the photocell (1) and ad­just it exactly. Tighten the screw again.

3.10.2Adjust intensity

The intensity of the photocell (1) can be adjusted with a
potentiometer (3) which is at the side of the casing.

Drive the clamp into insertion position and close the main
clamp. Insert the flap and press the ‘Program-Stop’ but­ton (remain it pressed). Push the clamp manually under
the photocell.

There is a red and a green LED on the front side of the
photocell (3). Adjust the intensity with the potentiometer
(3) in a way that both LED light up during reflection from
the foil.

Push the clamp until the flap covers the reflecting foil.
Now the green LED must be lighted and the red not.

Hint

After changing the intensity of the photocell you will
have to check and possibly adjust the detection
correction of the flap at flap start and end.

3-21

3.11 Swing up sewing head

The sewing head can be swung up. First you will have to
demount several parts: spooler, position actuator, belt
protector; push sliding plate to the left.

Loosen screw (1) and swing the sewing head upwards.
Use the support (2).

DANGER

During maintenance duties at the swung up sewing
head, the support must be locked completely at the oil
reservoir. Otherwise it can slip away and the sewing
head can cause severe injuries.

3.12 Upper threat monitor

Both upper threats are permanently monitored during
the sewing. The threats must be guided through the threat
guidings with low tension. Both green LED (2) in the con­trol are showing the switching of the tactual heads.

3.12.1Switch on time

The switch on time decides, when the threat monitor is
questioned (key [P] - [F3] - parameter 19). Further infor­mation is contained in the prior parts of this manual.

If the time is set too early, misswitches can arise at se­wing heads with switchable needle in the range of the
tack.

3.12.2Filter threat monitor

The set value defines after how many missing impulses
of the threat monitor the control signalizes threat brea­kage.

Select parameter 20 using the keys [P] and [F3]. For
further details see the prior chapters of this manual.

3-22

4 Adjustments at the mitre knifes

4.1 Basic adjustment locked mitre knife

(seam end)

Between the mitre knife for the seam end and the basic
holder a distance (A) of 21 mm must be adjusted.

Loosen both screws (6 in this and in the picture at sec­tion 4.2) and move the mitre knife axially. Tighten both
screws again.

4.2 Basic adjustment movable mitre

knife (seam start)

When the movable knife for seam start (1) has contact
to the locked mitre knife, the distance between both hol­ders must be 3 mm.

Turn the screw of the magnet (2) in or out to adjust the
distance.

4.3 Mitre knife height

The height of the mitre knife pinoles (3) must be adju­sted that they are in their lower position the distance (B)
of 6-7 mm higher than the holder of the mitre knifes.

Loosen the fixing screws (4) and move the pinoles (3)
axially. Tighten the screws again.

4.4 Mitre knife broadth

Turn the two screws (5 in the picture at section 4.2) until
the mitre knifes can be taken out.

Adjust the broadth (A) of the mitre knifes with the two
screws (1). At a seam distance of 12 mm, you will have
to adjust 10-10.2 mm here.

Now turn the two screws (2) as far until both knifes get
contact at their top.

3-23

4.5 Pre-stabber

The pre-stabber (3) at the mitre knifes is used as a pro­tection. It prevents the piping and the flap to be dama­ges during cutting.

4.6 Lateral adjustment

To achieve an exact mitre knife cutting, the knifes must
be adjusted also laterally.

Bring the mitre knifes into the upper final position (out­put 54). Measure the distance between sliding plate and
mitre knifes exactly.

Loosen both allen screws (1) a little and turn the exenter
adjustment (2). If the exenter for the mitre knife for seam
start is turned to the right, the mitre knife moves to the
left at seam start.

If the exenter for the mitre knife for seam end is turned
to the right, the mitre knife turns to the right.

Tighten the allen screws (1) after the adjustment.

Hint

After changing the exenter adjustment you should
carry out sewing tests before continuing the produc­tion.

4.7 Fine adjustment in the length

This is done in the machine control.

After the first pressing of the key [F2] you can adjust the
mitre knife for seam start, after another pressure you
can adjust the knife for seam end.

4.8 Tighten cog-belt of the mitre knife
drive

It must be possible to press down the middle of the cog­belt of the mitre knife drive (1) 2-3 mm.

To adjust the tension, loosen both fixing screws (2) and
move the motor until the correct tension is present. Tigh­ten both fixing screws.

3-24

5 Adjustment of machine options

5.1 Automatic push-back blocking

The light beam of the photo cell (5) of the automatic
push-back blocking must hit the center of the reflecting
foil (1). This must be 70 mm away from the outer edge
of the table.

The distance between the setting ring (2) of the photo
cell (5) and the bearing shield (3) must be 10 mm. To
adjust it, loosen the fixing screw (4) and push the photo
cell together with the setting ring. Tighten the fixing screw.

To check whether the light beam hits the middle of the
reflecting foil (1) exactly, lay a piece of cloth or paper on
the table and push it from all directions over the reflec­ting foil. As soon as the photo cell switches, the red di­ode (6) turns dark. Move the photo cell by moving and
turning of the setting ring until the light beam is adjusted
exactly.

Hint

In the case of a breakdown of the push-back blocking
it can be disabled in the machine control (seam
parameter 36).

5.2 Height of the take off roller

Lower the take off roller (1) (output 23 in the machine
control).

Check whether the screw (2) has a free play of 1 mm. If
not, loosen the counter nut at the screw and move it
correspondingly.

Tighten the counter nut again.

3-25

5.3 Mitre knife slant position

5.3.1 Distance between basic bodies

<power off> <release pressure>

The distance (A) between the basic bodies of the mitre
knifes must be 3 mm in home position (both knifes com­pletely right).

To set the distance you will have to move the initiator
and adjust the mechanical stop.

Loosen the fixing screws (2) of the initiator (1) and move
it until the required distance is present in the home posi­tion.

Push aside the movable mitre knife, loosen the counter
nut of the mechanical stop (3) and turn this in or out.
Tighten the counter nut.

5.3.2 Height adjustment

This is done similar to the height adjustment of the stan­dard mitre knifes (see section 4.3).

5.3.3 Center adjustment

For the center mitre knife a lateral adjustment must be
executed. This is done similar to the adjustment of the
standard mitre knifes (see section 4.6).

5.3.4 Adjust mitre knife stops

The mitre knife stops must be adjusted at both mitre
knifes. The adjustment procedure is similar and is shown
here for the example of the movable mitre knife:

The right stops (1) are adjusted by loosening the coun­ter nuts (2) und turning the screws (1) in or out. Tighten
the counter nuts again.

The left stops (4) are adjusted by loosening the counter
nuts (3) and turning the allen screws (4) in or out. Tigh­ten the counter nuts again.

ATTENTION

Adjust the stops equally. The basic body of the mitre
knifes must have an equal contact to the upper and
lower stop.

5.3.5 Knife arrangement

Assure to insert the knifes in the correct order when chan­ging the knifes.

At the locked knife for the seam end, the cutting blades
must show an concave bow (left side in the drawing).

At the movable knife for the seam start, the cutting bla­des must show an convex bow (right side in the dra­wing).

3-26

5.3.6 Arrangement of the mitre knife during flap

pocket production

The photo shows the correct Arrangement of the mitre
knife during flap pocket production.

5.4 Split needle (Beisler sewing head)

5.4.1 Distance to cylinder of the top threat catcher

There must be a distance on at least 0.5 mm between
the pushing block of the split needle (1) and the cylinder
of the top threat catcher.

If required, loosen the fixing screws (3) of the top threat
catcher (2) and move it, until the minimum distance is
kept. Tighten the fixing screws again.

5.4.2 Center adjustment

The setting ring of the split needle (1) must be in the
middle of the rectangular metal frame while in home
position.

If required. loosen the fixing screw of the setting ring
and move him. Tighten the fixing screw again.

5.5 Vylene adjustments

5.5.1 Correct vylene adjustment

The vylene strip (3) must be seen with the inserted sli­ding plate but set back from the front edge of the vylene
supply for the distance (A) of 3 mm.

1: Vylene plate

2: Counter knife

3-27

5.5.2 Demount vylene plate

<power off> <release pressure>

Pull out the vylene strip (3) from the supply slot.

Loosen the fixing screw (2) of the roll (3) and take this
out by pulling to the left.

Loosen the three fixing screws (4) of the vylene plate.
Assure that the vylene plate cannot tilt away.

Loosen the fixing screw of the table support (5) and swing
it to the front or back.

Now you can take out the vylene plate.

ATTENTION

Assure that the hoses at the vylene won’t be dama­ged. We recommend to leave the hoses at their
positions.

5.5.3 Change cutting pressure

Loosen both allen keys (1) and move the counter knife
(No. 2 in picture at section 5.5.1) until an adequate cut­ting pressure is present.

Tighten both allen screws.

Hint

By adjusting the fixing screws (4) it is possible to adapt
the height of the vylene plate to the table height.

5.5.4 Adjust vylene supply

The vylene must to be seen when the sliding plate is
inserted. To adjust the supply, loosen the fixing screw
(2) at the cylinder (4) and move this correspondingly.
Tighten the fixing screw again.

5.5.5 Easy-running of the vylene roll

The vylene roll must run easily.

Loosen one of the allen screws (3) and push the roll,
until it runs easily. Tighten the loosened allen screw.

5.5.6 Vylene supply speed

The vylene supply must be adapted and synchronized
to the clamp speed.

Adjust the throttle (1) to change the vylene supply speed:

turn right: slower

turn left: faster

3-28