Fly Piece Unit
Series 1710/2
Operating Instructions
© 1999 Beisler GmbH, Hösbach
Version 2.0, 22.9.1999 – GB
The Operating Instructions on hand contain the following parts:
Part 1: Operators Manual (Pages 1-xx)
this is addressed to the operator of the machine, that is the
person who works with and at the machine.
Part 2: Mechanics Manual (Pages 2-xx)
this is addressed to qualified technical staff and is used for the
putting into operation, set-up, troubleshooting and maintenance.
Please obey all rules and regulations concerning safety and accident
prevention contained in this manual.
The machine described in this manual is subject to a permanent technical
development. Technical changes without prior notice are reserved.
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 .................................................................... 1-3
1.1 Classification .........................................................................................................1-3
1.2 General security advice and warning hints .............................................................1-3
1.3 Introduction ............................................................................................................ 1-4
1.4 Target groups of the manual...................................................................................1-4
1.5 Authorized person ................................................................................................. 1-4
1.6 Contents of this manual .........................................................................................1-5
1.7 Range of validity .................................................................................................... 1-5
1.8 Copyright ...............................................................................................................1-5
1.9 Additional regulations ............................................................................................1-6
2 Preliminary remarks ...........................................................................................1-7
2.1 Limitation of liability ...............................................................................................1-7
2.2 Guarantee regulations ...........................................................................................1-7
2.3 Use as agreed ....................................................................................................... 1-8
2.4 Description of the machine .................................................................................... 1-8
2.5 Main parts of the machine .....................................................................................1-9
2.6 Technical data ....................................................................................................... 1-9
3 Switch on/off, Emergency-Stop, Restart ......................................................... 1-10
3.1 Switch on ............................................................................................................ 1-10
3.2 Switch off............................................................................................................. 1-10
3.3 Emergency-Stop using the main switch ............................................................... 1-10
3.4 Restart after Emergency-Stop ............................................................................. 1-11
3.5 Adjust compressed air pressure .......................................................................... 1-11
4 Operation of the sewing head ......................................................................... 1-11
5 Components of the machine ............................................................................1-12
5.1 Devices for the material supply ............................................................................ 1-12
5.2 Pull-off device ...................................................................................................... 1-13
5.3 Insertion area ....................................................................................................... 1-13
5.4 Operation device ..................................................................................................1-14
5.4.1 Components of the operation device .................................................................... 1-14
5.4.2 Explanation of the display .................................................................................... 1-14
5.5 Sewing head ........................................................................................................ 1-15
5.6 Cutting device ...................................................................................................... 1-15
5.7 Stacking device ................................................................................................... 1-16
1-1
6 Operation of the Machine ................................................................................ 1-17
6.1 Production sequence ........................................................................................... 1-17
6.2 Alignment of the Fly Piece...................................................................................1-17
6.3 Program control ................................................................................................... 1-18
6.3.1 Available sewing programs .................................................................................. 1-18
6.3.2 Select a sewing program ..................................................................................... 1-18
6.4 Additional settings at the operation device ........................................................... 1-18
6.4.1 Select operation language ................................................................................... 1-19
6.4.2 Adjust display contrast ........................................................................................ 1-19
7 Cleaning and Maintenance .............................................................................. 1-20
7.1 Cleaning of the machine ...................................................................................... 1-20
7.2 Maintenance ........................................................................................................1-20
7.2.1 Check oil level in the sewing head ....................................................................... 1-20
7.2.2 Empty water separator ......................................................................................... 1-20
7.3 Troubleshooting hints ...........................................................................................1-20
1-2
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 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 pneumatical 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.
1-3
1.3 Introduction
The manual on hand is divided into two main sections:
• the Operators Manual with all information required for the operation and
daily cleaning and maintenance routines of the machine;
• the Mechanics Manual with all further maintenance and repair duties and a
instruction for the programming of sewing programs.
1.4 Target groups of the manual
The two sections of the manual are adressed to:
Operators Manual to the operator of the machine which is the person
that works at and with the machine;
Mechanics Manual to qualified staff which is trained to estimate the
working duties and recognize possible danger at an
early time.
ATTENTION
All actions at and/or with the machine may only be executed by authorized
persons, who have read and understood the corresponding parts of this
manual.
Especially the following actions are subject to this regulation:
• operation including preparation, troubleshooting during production, cleaning, care
• Servicing (maintenance, inspection, repair)
• Transportation
ATTENTION
A specialist in accordance to IEC 364 and DIN EN 60204-1 is regarded as
qualified staff.
1.5 Authorized person
DANGER
There is danger to human beings, things and environment through inandequate
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.
1-4
Operator of the machine
Persons are regarded as authorized, who were trained in the operation of this
machine and have read and understood the first part of this manual completely.
Staff for installation, preparation, programming and maintenance
Persons are regarded as authorized, who were trained in all aspects of the
machine and have read and understood the complete manual on hand.
1.6 Contents of this manual
The Operating Instructions for the ‘Fly Piece Unit, Series 1710/2’ contains the
following parts:
1. Operators Manual
2. Mechanics Manual
3. Electrical wiring plans
4. Parts list
5. Operating Manual of the sewing head
Please check the documents delivered with the machine for completeness.
1.7 Range of validity
This operating manual is valid for machines manufactured by Beisler named
‘Fly Piece Unit, Series 1710/2’.
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.
1.8 Copyright
© 1999 Beisler GmbH, Hösbach
Fly Piece Unit
The ‘Fly Piece Unit, Series 1710/2’ 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
1-5
1.9 Additional regulations
This manual must be available at the machines location at any time.
The operator has to assure that only authorized persons work at and with the
machine.
The operator is obliged to check the machine for visible damage and faults at
least once per shift. Visible changes must be reported to the corresponding
official immediately after discovery.
The company using this machine has to assure that the machine is always
operated in faultless condition. Security installation may not be dismounted or
put out of function.
If security installation must be dismounted for preparation, repair or maintenance of the machine, they must be mounted immediately after the duties
have been terminated.
Unauthorized changes to the machine exclude liability of the manufacturer for
damages.
1-6
2 Preliminary remarks
2.1 Limitation of liability
We guarantee the faultless functioning of our product in accordance with our
advertising, the product information 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 product-features 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 products 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 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.
2.2 Guarantee regulations
We guarantee the fault-free functioning of the ‘Fly Piece Unit, Series 1710/2’
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.
1-7
2.3 Use as agreed
The ‘Fly Piece Unit, Series 1710/2’ has been developed for the sewing of the
zipper onto the left-handed fly piece.
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.
2.4 Description of the machine
The ‘Fly Piece Unit, Series 1710/2’ allows the rational sewing of the zipper
onto the left-handed fly piece. The machine is equipped with several guiding
facilities for the zipper and a sewing head.
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.
1-8
2.5 Main parts of the machine
1
2
3
4
5
6
7
8
9
1 Spool rack
2 Supply roll back-up tape
3 Sewing head
4 Stacker stamp
5 Sliding table
6 Magacine
7 Main switch
8 Motor
9 Foot pedal
10 Operation device
11 Supply roll zipper
12 Zipper
13 Zipper supply device
14 Insertion area with transportation belt and start button
15 Compressed air supply unit
10
11
12
13
14
15
Further information on the components of the machine are contained in the
coming chapters.
2.6 Technical data
Dimensions (LxWxH) 00 x 00 x 00 mm
Table height 00 mm (adjustable)
Weight 00 kg
Electrical connection 220 V AC
Compressed air connection min. 5 bar
Power consumption 00 kW
Compr. air consumption est. 00 NL/part
1-9
3 Switch on/off, Emergency-Stop, Restart
1
2
3.1 Switch on
Hint
The machine must be connected to the power and compressed air supply
before it can be switched on.
The main switch (2) is located at the machine front beneath the working table.
Turn the main switch (2) clockwise until it engages. The grip of the switch
points on the marking „1 – ON“. The display of the operation device (1) shows
the main screen.
3.2 Switch off
Turn the main switch (2) counter clockwise until it is released. The grip of the
switch points on the marking „0 – OFF“.
3.3 Emergency-Stop using the main switch
The main switch (2) is located at the machine front beneath the working table.
Turn the main switch counter clockwise, until it is released. All movements of
the machine will be stopped immediately, the machine will be free of electrical
power instantly.
1-10
3.4 Restart after Emergency-Stop
ATTENTION
Before you restart the machine you should remove the reason for the
Emergency-Stop. Contact the responsible technician in any doubtful case.
The machine may only be restarted after the reason for the Emergency-Stop
has been removed.
Switch on the machine using the main switch. The current program number
will be imaged in the display of the operation device. The machine is ready to
use.
3.5 Adjust compressed air pressure
The machine needs an air pressure between 5 and 6 bar. This is adjusted at
the air supply unit:
1
2
3
4
5
1 Air connecting hose
2 Control to adjust the air pressure
3 Pressure gauge
4 Collector for condensing water
5 Release valve for condensed water
Check the air pressure at the pressure gauge (3). If the indicated value differs
from 6 bar, adjust the pressure by turning the black control (2).
4 Operation of the sewing head
The operation of the sewing head is explained in the separate manual of the
sewing head, which is part of the machine’s documentation.
Please obtain all rules and regulations.
1-11
5 Components of the machine
The machine contains several components, which are arranged according to
their function:
1. Spool rack, supply roll rack of the back-up tape and supply roll rack for
zippers.
2. Zipper supply device for the tension-free insertion of the zipper into the
machine.
3. Insertion area with stop bar, transportation belt, cover plate and start
button.
4. Operation device with keys and display.
5. Sewing head with photo cell for the sewing of zipper, fly piece and back-up
tape.
6. Cutting device with photo cell for the cutting of the fly piece.
7. Stacking device with stacker stamps, sliding table and magacine.
5.1 Devices for the material supply
1
2
3
This machine is equipped with three devices for the supply of the required
materials:
• the spool rack (1), where the spools with the threads can be fixed;
• the roll rack for the back-up tape (2), located above the sewing head;
• the rack for the zipper rolls (3), where a great variety of different zippers can
be stored for production.
Please assure when inserting rolls onto the racks that the tapes or threads are
inserted into the corresponding guidings.
1-12
5.2 Pull-off device
5
6
1
7
The pull-off device assures a tension-free insertion of the zipper into the
machine.
The zipper (7) comes through the front guiding (1) and then between driving roll
(2) and pressure roll (3). Then it comes around the pull switch (4) before it is
inserted under the cover through the rear guiding (5) and the insertion area (6).
If the zipper is pulled into the machine, the pull switch is pressed upward what
switches the motor on. The zipper will be inserted by the drive roll, until the
pull switch releases the contact.
5.3 Insertion area
In the insertion area, the zipper is located beneath a cover plate (1), on which
2
3
4
a stop (3) is mounted, where the fly piece can be aligned. After pressing the
start button (4), the transportation belt (2) will be lowered and pushes the fly
piece together with zipper and back-up tape under the sewing head.
1
2
3
4
1-13
5.4 Operation device
5.4.1 Components of the operation device
The components of the operation device provide the following functions:
Display (1): all information required for the operation of the
machine are imaged here.
Cursor keys (2): use them to move the cursor and mark all
required commands and options.
Special key (4): press this key if several information is requi-
red for an adjustment.
Minus/Plus keys (3): use them to enable/disable functions, reduce/
increase numeric values and select programs.
1
2
3
4
5.4.2 Explanation of the display
After switching on with the main switch, the program will be displayed which
had been used previously. The machine is ready for sewing instantly:
PRO G .
001
TXT: HAU PTPRO GRAM M
Pcs.
A
0
Fn
1 Number of the current sewing program
2 Current step in the sewing program
3 Sewing speed
4 Photo cell mode
5 Automatic program execution
6 Stitch counting
STEP
03
14
A
STOP
D: 3000
A : 4 5
1-14
5.5 Sewing head
1
2
3
4
1 Sewing head
2 Speed control transportation belt
3 Photo cell seam start/end
4 Sewing foot
With this machine you can sew zippers and back-up tape on large quantities
of left-handed fly pieces. The fly pieces are aligned at the stop bar beneath the
transportation belt. Then the start button must be pressed.
The transportation belt (driven by the sewing motor; speed adjustable at the
sewing head (2)) will be lowered what inserts fly piece, zipper and back-up
tape under the sewing foot.
The beginning of the fly piece is detected by the photo cell (3) which starts the
sewing. The same photo cell detects the end of the fly piece, which is the end
of the seam.
5.6 Cutting device
4
5
6
After the fly piece has been sewed at the sewing foot (1), it will be pushed
forward through the guiding (2). Another fly piece can be aligned and the
sewing can be started.
1
2
3
1-15
When the next fly piece is pushed forward, the photo cell (3) detects the gap
between two fly pieces and triggers the command for the cutting (4) of zipper
and back-up tape. The sewed fly piece will be pulled onto the slide table (6) by
the stacker stamps (5).
5.7 Stacking device
1
2
3
After cutting zipper and back-up tape, the stacker stamps (1) will be lowered
and pull the fly piece onto the slide table (2). This will be opened and the fly
piece falls into the magacine (3).
The slide table is closed and the stacker stamps are driven into home position.
1-16
6 Operation of the Machine
6.1 Production sequence
The ‘Fly Piece Unit, Series 1710/2’ works semi-automatic with high production
speed. The operator of the machine has to:
• select the desired sewing program;
• align the fly pieces correctly;
• start the sewing process by pressing the start button;
• supervise the fault-free functioning of the machine.
The following steps can be distinguished within the production sequence:
1. Align the fly piece at the stop bar beneath the transportation belt.
2. Press the start button to initiate the sewing process.#
3. The transportation belt will be lowered and pushes fly piece, zipper and
back-up tape under the sewing foot. When switching dark, the photo
cell gives the command for the start of the sewing.
4. When the fly piece left the range of the transportation belt, this will be
lifted and the next fly piece can be aligned.
5. After the fly piece has been sewed, zipper and back-up tape will be cut
and the fly piece is stacked in the magacine.
6.2 Alignment of the Fly Piece
1
2
3
Push the fly piece from the front below the transportation belt (1) until it
touches the rear stop (2). The left-handed end of the fly piece must be est. 1
cm away from the sewing foot.
When the fly piece is positioned correctly, press the start button (3) to start
the sewing process.
1-17
6.3 Program control
Hint
This machine is controlled with programs, which are contained in the memory
of the machine and can be opened by the operator. The modification of
existing and the programming of new sewing programs should be reserved to
experienced and qualified personell. The possibilities are explained in the
second part of this manual.
6.3.1 Available sewing programs
In the daily production, the operator will only have to open one of the existing
sewing programs. The following programs are available as a factory setting:
Prog. Description
001 Main Program for sewing zipper and back-up tape
002 Manual Sewing;
after switching the photo cell dark you can sew with the programmed
sewing speed by pressing the foot pedal; the transportation belt
remains lifted, the sewing foot remains lowered, the photo cell is not
active and the sewing will be stopped when the foot pedal is
released
003 Additional Program – lift sewing foot
allows a safe threading up; the sewing foot is lifted and all program
functions will be disabled for safety reasons
The selected sewing program is imaged in the upper left corner of the display.
6.3.2 Select a sewing program
1. Use the arrow keys to move the cursor to the program number.
2. Press the Plus/Minus key repeatedly, until the desired program number is
displayed.
6.4 Additional settings at the operation device
The operator may not open the Setup pages of the machine control. This
should be preserved to especially educated and experienced technicians. You
have to enter the machine code to open the Setup pages.
Attention
Damage to the machine due to inadequate programming possible! The
machine code should be kept secret and accessible to persons only, who are
allowed to program and setup the machine.
Only two settings may be executed by the operator:
• select the operation language;
• adjust display contrast.
1-18
6.4.1 Select operation language
Position the cursor on the program number and press the Minus key once.
This will be displayed:
PROG.
000
DEUTSCH
XXX
Use the arrow keys to move the cursor on the displayed operation language
(here: deutsch = german) and press the Plus key, until the desired operation
language is displayed.
Move the cursor back on „000“.
Hint
The descriptions in the sewing programs will always be displayed in the
language that had been used to enter them.
6.4.2 Adjust display contrast
Open page „Program 000“ (see 6.4.1) and position the cursor on the half-filled
circle symbol. Press the Plus or Minus key to adjust the contrast of the
display.
Position the cursor on „000“ and press the Plus key to select a sewing program.
D : 8000
1-19
7 Cleaning and Maintenance
DANGER
Possible injuries due to improper execution of cleaning and maintenance
duties! The operator of the machine may only carry out the cleaning and
maintenance duties described in this section. Further measures are reserved
to the responsible service technician.
7.1 Cleaning of the machine
Hint
To achieve the value and daily functionality of this machine, it should always
kept clean and free of production waste.
Clean the machine components as described:
Operation device clean it using a dry, clean and lint-free cloth; heavy
dirt can be removed using a slightly saturated cloth.
Complete machine use a vacuum cleaner daily and if required to clean
the machine.
7.2 Maintenance
ATTENTION
Damage to the machine due to inadequate maintenance possible! The
execution of the maintenance duties should be reserved to experienced and
especially qualified staff. The required measures are described in the
mechanics manual in the second part of this documentation.
7.2.1 Check oil level in the sewing head
There is a window in the sewing head, where you can check the level of the oil
contained in the sewing head. Check the oil level daily and fill in required oil
immediately.
ATTENTION
Damage to the sewing head due to low oil! Check the oil level in the sewing
head daily and fill in missing oil immediately. Otherwise, the sewing head can
be damaged.
Information on the oil level check and filling in of missing oil is contained in the
operating instructions of the sewing head which is part of the machine documentation.
7.2.2 Empty water separator
1-20
The machine is equipped with a pressured air supply unit, where an automatic
water separator is mounted.
If there is water in the cup, it will be released automatically if the pressured air
supply is closed.
7.3 Troubleshooting hints
Whenever an error or fault appears or an error message is imaged in the
display, the responsible technician have to be contacted.
Teil 2 Mechanics Manual
Hint
This part of the Operating Instructions contains all information required to put
the machine into operation and for the programming, troubleshooting and
maintenance. It addresses to qualified staff which is able to estimate the given
duties and discover possible danger at an early time. The Operators Manual
contained in part 1 is a part of this Mechanics Manual.
Contents Page
Teil 2 Mechanics Manual ..............................................................................................2-1
1 Delivery, Transportation, Packing......................................................................2-2
1.1 Range of delivery ................................................................................................... 2-2
1.2 Packing .................................................................................................................2-2
1.3 Transportation ........................................................................................................ 2-2
1.4 Storage ................................................................................................................. 2-2
2 Putting up – Connection – Setup .......................................................................2-3
2.1 Technical data ....................................................................................................... 2-3
2.2 Mechanical Installation .......................................................................................... 2-3
2.2.1 Unpacking and Putting up ..................................................................................... 2-3
2.2.2 Connect compressed air ........................................................................................2-4
2.3 Electrical Installation .............................................................................................2-4
2.4 Putting into Operation ............................................................................................2-5
3 Programming and Machine Setup ....................................................................2-6
3.1 General hints .........................................................................................................2-6
3.2 Select Setup pages ...............................................................................................2-6
3.3 Setup page -01 ......................................................................................................2-7
3.4 Setup page -02 ......................................................................................................2-7
3.4.1 Position actor, Turn direction, Needle position .......................................................2-7
3.4.2 Sewing speed (min. and max.) ............................................................................... 2-8
3.4.3 Foot pedal .............................................................................................................2-8
3.4.4 Cover Page ............................................................................................................2-9
3.4.5 Store error messages ............................................................................................ 2-9
3.4.6 Enable access code .............................................................................................. 2-9
3.5 Setup page -03 ......................................................................................................2-9
3.6 Setup page -10 .................................................................................................... 2-11
3.7 Program inputs and outputs................................................................................. 2-12
3.7.1 Setup page of inputs and outputs ........................................................................ 2-12
3.7.2 Settings for this machine ..................................................................................... 2-13
3.8 Meanings of the used symbols ............................................................................ 2-13
4 Use of the storage module ............................................................................... 2-15
4.1 Load data from the storage module...................................................................... 2-15
4.2 Write data on the storage module ........................................................................ 2-16
4.3 Write single programs on the storage module ......................................................2-16
4.4 Read a single sewing program into the machine control....................................... 2-17
5 Troubleshooting hints ....................................................................................... 2-18
5.1 Error – possible solution ...................................................................................... 2-18
5.2 Error messages in the display – possible solution ............................................... 2-18
5.3 Hints for several repair duties ............................................................................... 2-19
2-1
1 Delivery, Transportation, Packing
1.1 Range of delivery
Hint
Check immediately after receiving the machine, whether all parts are delivered
completely and without any obvious damage. Later compensation claims
cannot be accepted.
If you detect damage to the transportation packing of the machine which may
indicate damage of the machine or parts of it, you should claim this immediately at the transporting company. This is the only way to keep all rights
against the transporting company.
1.2 Packing
The company Beisler tries to use recycleable packing materials only. Please
assure that these materials are treated in accordance to the local regulations.
1.3 Transportation
Generally it is possible to move the machine. Please follow these regulations:
1. Cut off the power and compressed air supply and make the pneumatic
system free of pressure.
2. Fix movable and loose parts.
3. Lift the machine frame evenly with a suitable transportation device; assure
that possible additional devices (e.g. stacker) are lifted with the machine.
Loosen the breaks at all transportation rolls, if the machine is equipped
with this option.
4. Move the machine carefully to the desired location.
ATTENTION
Attention during transports on sloping areas! The machine’s weight produces
high pulling power. Be sure to place the machine in environments, which are
suited for the machine.
1.4 Storage
If no other agreements are fixed for the storage of the machine, the following
requirements must be fulfilled:
1. In closed rooms only.
2. Temperature range -10 ... +45° C.
3. Humidity max. 80 %, not condensing.
2-2
ATTENTION
The machine can be damaged due to storage and/or transportation under
inacceptable conditions. Possible damage may be invisible from the outside.
2 Putting up – Connection – Setup
ATTENTION
This machine may only be installed and put into operation by mechanically
and electrically qualified staff. This personell must read and understand the
complete Operating Instructions before.
2.1 Technical data
Dimensions 00 x 00 x 00 mm (LxWxH)
Table height 00 mm (adjustable)
Weight 00 kg
Electrical conn. 220 V AC
Power consumption 00 kW
Fuse 15 A
Compr. air conn. min. 5 bar
Req. compr. air quality free of oil
Compr. air consumptionest. 00 NL/part
2.2 Mechanical Installation
ATTENTION
Check prior to the installation, whether the desired location corresponds with
the environmental requirements for the machine. Please see section ‘Technical
Data’ for further information.
2.2.1 Unpacking and Putting up
1. Remove the packing material and possible transportation lockings.
2. Position the machine on a horizontal grounding.
3. Level the machine with the adjustable feet to a horizontal stand.
2-3
2.2.2 Connect compressed air
1
2
3
4
1. Connect the compressed air hose (2) with a connector of you compressed
air system.
2. Open the compressed air supply.
3. Use the control grip (1) to adjust the machine’s compressed air pressure to
6 bar, readable at scale (3).
4. Water contained in the water separator (4) will be released automatically
when the machine is made free of pneumatical pressure.
2.3 Electrical Installation
Hint
All works at electrical components of this machine may only be carried out by
qualified staff in accordance to IEC 364 and DIN EN 60204-1.
DANGER
Hazardous electrical voltage inside the switchcase! Cut off the power supply to
avoid dangerous injuries. Please obey the safety regulations given at the
beginning of the Operating Instructions and the common rules for accident
prevention.
2-4
ATTENTION
The machine can be destroyed by a connection to a wrong electrical voltage!
Please check, whether the information given in section ‘Technical data’ meet
the local conditions before executing the electrical installation.
1. Use the power cord which is located at the rearside of the machine.
2. Plug it into a socket.
3. Lay the cable in a way that the danger of stumbling is avoided.
DANGER
Danger to life in the case of unsufficient grounding! Ground the machine in
accordance to DIN EN 60204-1.
2.4 Putting into Operation
As a factory setting this machine has been adapted to the requirements of the
customer. The first putting into operation can be done easily:
1. Level the machine to a horizontal stand.
2. Execute electrical and pneumatical connection.
3. Switch the machine on with the main switch on the front side of the machine.
4. Check all safety installations on functionality.
DANGER
The machine may only be used for production after the safety installations had
been checked. If safety installation does not function, they must be repaired
first.
As a factory setting, several sewing programs are contained in the memory of
the machine. You can use one of these programs or program your own.
2-5
3 Programming and Machine Setup
As a factory setting, three sewing programs are contained in the memory of
the machine, which can be selected and used by the operator. These programs are composed based on long-termed experience and should be sufficient for the normal use of the machine. The available sewing programs are
explained in part 1 ‘Operators Manual’ of the Operating Instructions.
The available programs can be modified and adapted to the individual requirements of the customer. You can also program new programs. All modified or
new programs can be copied to a memory module to backup the data.
3.1 General hints
When you want to set or modify certain functions, you will use the arrow keys
to position the cursor on the respective icon and press the Plus/Minus keys to
change the setting or value.
For several functions you can press the Special key to open the setup page
for the selected function.
The machine setup can be modified on the Setup pages:
Setup -01 Machine type
Setup -02 Position actor, turn direction, needle position, sewing speed,
storing error messages, enable access code
Setup -03 Sewing foot, photo cell
Setup -10 Inputs and Outputs
3.2 Select Setup pages
1. Position the cursor on the program number and press the Minus key. This
will be displayed:
PROG.
000
DEUTSCH
XXX
2. Position the cursor on the left-handed „x“ below the key icon.
3. Press the Minus key to display a zero.
4. Position the cursor on the middle „x“ and press the Minus key.
5. Position the cursor on the right-handed „x“ and press the Minus key.
6. Position the cursor on the program number 000 and press the Minus key.
Setup page -01 will be displayed.
: 3000
[ ]
2-6
3.3 Setup page -01
SETUP
-01
Here you can set the machine type. For this machine, „Kettenstich“ (= chain
stitch) must be selected.
3.4 Setup page -02
SETUP
KETTENSTICH
-02
MARKE
P1
P2
TYPE
Six icons are displayed here, representing the machine functions. To select a
function, position the cursor on the corresponding icon and press the Special
key to open the setup page, or the Plus/Minus key to switch the function on or
off.
3.4.1 Position actor, Turn direction, Needle position
SETUP-02
---
280
0
80
Turn direction
After opening the page, the cursor is positioned on the icon of the turn direction. Press the Plus key to alter the turn direction (viewed on the belt disc).
III POS.
II POS.
0
I POS.
Define needle zero position
1. Position the cursor on the icon of the needle zero positon.
2. Turn the hand wheel with impetus in the set turn direction, until the angle
value below the turn direction icon changes.
2-7
3. Continue turning the hand wheel, until the needle stands at the upper edge
of the stitch plate.
4. Press the Plus key to accept the value as zero position.
5. Press the Special key to leave the page or set the needle top and bottom
positions.
Set needle top and bottom positions
These positions are defined as a factory setting but it is possible to change
them:
1. Position the cursor on the label „II Pos.“.
2. Turn the hand wheel in turn direction, until the needle stands in the desired
top position.
3. Read the angle value below the icon of the turn direction (est. 280).
4. Press the Plus or Minus key to enter the displayed angle value into the box
beside the label „II Pos.“.
5. Position the cursor on the label „I Pos.“.
6. Press the Plus or Minus key to enter the angle value „80“ into the box
beside the label „I Pos.“.
7. Press the Special key to leave this page.
3.4.2 Sewing speed (min. and max.)
SETUP-02
Position the cursor on the listed values and press the Plus/Minus key to set
them as follows:
MAX.: 4200
MIN.: 400
ACC. 100 %
DEC. 80 %
Pull: 75
Press the Special key to leave this page.
3.4.3 Foot pedal
Hint
RESET
ON
MIN.: 400
MAX.: 4200
[ ]
5400
Pull: 75
67
100%
ACC.
80%
DEC.
2-8
The settings contained here are optimized as a factory setting and must not
be modified.
3.4.4 Cover Page
Hint
This function is not required at this machine. The respective icon is disabled
(crossed out).
3.4.5 Store error messages
SETUP
-02
Position the cursor on the shown icon and press the Special key to open the
corresponding setup page.
Here, error messages are displayed together with the time of their appearance.
The service personell can use this to evaluate the status of the machine.
3.4.6 Enable access code
If the key icon is not crossed out, the machine code must be entered before
the Setup pages can be entered. If the machine code is disabled, the Setup
pages and all program data are accessible at any time.
ERROR PARTIAL TOTAL
--:-- 12:15
--:--
--:--
04:35
30:00%
38:20
27:15
40:00%
3.5 Setup page -03
SETUP
-03
S
Six icons are displayed here, but only two of them are enabled. To select the
setup page of a function, you have to position the cursor on the icon and press
the Special key.
D
2-9
Hint
If the presser foot cannot be enabled, you will first have to switch off Output F1
on Setup page -10. More information is given further below.
SETUP-02
30V
(max)
15 V
[ms]
100
00
120
1. Position the cursor on the time for maximum power (lower line, left-handed
value) and press the Plus/Minus key, until 100 ms is set. This assures that
the presser foot is lifted safely after the end of the seam.
2. Position the cursor on the value of the holding voltage (upper row, middle
value) and press the Plus/Minus key until 15 V is set. This assures that
the magnetic valve for the foot lifting cannot be overloaded.
3. Position the cursor on the right side on the value of the start delay and
enter 120 ms. This time is needed that the presser foot is safely on the
fabrics before sewing starts.
4. Position the cursor on both presser foot icons and set them to „Presser
foot down“ (like shown in the drawing).
5. Press the Special key to leave this page.
6. Check whether the presser foot is programmed on „up“ on page „PROG
000“, too:
PROG.
: 4200
000
2-10
3.6 Setup page -10
SETUP
-10
F1
M1
All inputs (F1 ... F12) and outputs (M1 ... M8) are displayed on this page. For
diabled inputs/outputs, the respective icon is crossed out.
At this machine, the output F1, F2 and F9 ... F12, and the inputs M4, M6 and
M7 must be disabled. Position the cursor on the icon of an input/output and
press the Plus/Minus key to alter the setting.
The outputs are valves and occupied as follows:
Valve description Output connector
F1 Y1 Lift sewing foot and puller pin 1
F3 Y3 Knife (Push valve) pin 5
F4 Y4 Knife (Push valve) pin 7
F5 Y5 Stacker stamp pin 9
F6 Y6 Stacker transport pin 11
F7 Y7 Slide table pin 13
F8 Y8 Transportation belt down pin 15
F2
F3
M3M2
F4
M4
F5
M5
F6
M6
M7
F8F7
M8
F9
F10
F11
F12
Hint
The output „Lift sewing foot and puller“ (Y1) cannot be programmed on Setup
page -10 and must be programmed on Setup page -03 (see there).
The inputs are occupied as follows:
Description Input connector
M1 ES1 Start button pin 2-4
M2 FZ3 Knife on and stacker start (photo cell) pin 6-4
M3 FZ3 Knife on and stacker start pin 8-10
M5 ES4 Initiator stacker transport in rear position
and slide table open
FZ2 Sewing stop;
pin 19 = -12 V, pin 20 = +12 V, switch output pin 18
2-11
3.7 Program inputs and outputs
The inputs and outputs can be enabled/disabled on setup page -10. Enabled
inputs and outputs can be programmed.
To program an input or output, position the cursor on the respective icon and
press the Special key. The setup page will be opened.
Hint
The programming of inputs and outputs is not executed program-specific. The
setting is the same for all programs. Modifications effect all sewing programs.
3.7.1 Setup page of inputs and outputs
OUT F8
STEP STOP
PRG
STEP
A programming is shown for the example of output F6 (displayed in the upper
left corner of the display).
A function must be selected for each input/output, a start delay and duration
must be programmed. The selected function is displayed on the left side in
front of the background „I/O“. The icons will be explained further below.
The start delay is displayed to the right of the left-handed „hour glass“, the
active duration to the right of the right-handed hour glass. The avilable
functions are displayed above the hour glasses in a horizontal row.
Do the following to program an input or output:
1. Position the cursor on the icon of a function in the upper right part of the
display.
2. Press the horizontal arrow keys until the desired function icon is marked.
3. Press the Plus key to select the marked function icon. It will be displayed
in the area „I/O“.
4. Position the cursor on the time value to the right of the left-handed hour
glass icon if you want to program a start delay (in ms) for the selected
function.
5. Press the Plus/Minus key repeatedly, until the desired value is displayed.
6. Position the cursor on the time value to the right of the right-handed hour
glass, where you can program the active time (in ms) for the selected
funtion.
7. Press the Plus/Minus key repeatedly, until the desired time value is displayed.
8. Press the Special key to leave the setup page and store the changes.
9. Repeat this procedure for all inputs and outputs which you want to modify.
0
10
2-12
3.7.2 Settings for this machine
The inputs and outputs at this machine should be programmed as follows:
Inputs
Start button
M1
STA
RT
Photo cell knife on
M2 Fn
Photo cell stacker stamp down and stacker start
M3 Fn
Stacker transport in rear position and slide table open
M5 Fn F7 ON
Ouputs
Sewing foot
Knife (push valve)
Knife (push valve)
F1
programmed on Setup page -03
F3
M
F4
M
F / F
F5 ON
F6 ON
0 400
90
F3 ON
F4 OFF
Stacker stamp
Stacker transport
Slide table
Transportation belt down
F5
F6
F7
F8
3.8 Meanings of the used symbols
Step type symbols
Pause - passing of a time
if the time symbol is programmed in a step, the program
sequence will be continued after the programmed time has
passed; outputs can be enabled in this step.
M
STEP
7 800
7 800
030
010
2-13
A
Program-specific symbols
Continue with next step
it will be switched to the next step automatically after the
displayed step has been executed.
Manual sewing
if this icon is contained in a step, you can sew manually
pressing the foot pedal forward; switch to the next program
step by pressing the foot pedal backward.
Semi-automatic execution
if this icon is contained in a step, the step will be switched
on by pressing the foot pedal forward; after a programmed
time expired or a stitch counting, it will be switched to the
next step automatically.
Automatic execution
this step will be executed automatically.
Fn
STOP
STOP
Sewing foot up – down
Enabled outputs
one or several outputs are enabled in this step; position
the cursor on this icon and press the Special key, to
display the enabled outputs; crossed out icons represent
disabled outputs.
Stop
the program will be stopped after the execution of this
step; usually this icon is used in the last step of a sewing
program.
No stop
there will be no program stop but a continuation with the
next step.
indicates the position of the sewing foot at program start
and end.
2-14
Needle position after sewing stop
position the cursor on this icon and press the Plus key to
select, whether the needle shall stand in top or bottom
position after the stop.
4 Use of the storage module
KK195
SETUP/PROG
SETUP
PRO G
DATA TRANSFER FRO M KK195 CHIP TO M O TOR
PRESS + TO CONTINU E PRESS TO CANCEL
All sewing programs and the setup data are stored on the storage module
delivered with the machine.
Hint
The delivered module is a backup copy of the machine data. It should be kept
at a safe place.
4.1 Load data from the storage module
1. Switch off the machine using the mains switch.
2. Plug the storage module KK 195 into the slot on the right side of the
operation device.
3. Switch on the machine using the mains switch.
4. The display shows you what you can load from the storage module:
5. Press the Plus key.
6. Confirm the inquiry, whether the data contained in the machine’s memory
shall be overwritten.
7. Use the arrow keys to mark one of the three options (SETUP/PROG =
setup-data and sewing programs will be loaded; SETUP = only setup-data
will be loaded; PROG = only sewing programs will be loaded).
8. Press the Plus key.
9. Now you have to confirm the loading of data into the machine control:
SETUP/PROG
SETUP
PRO G
KK195
CAU TION ! O LD KK195 DATA W ILL BE ERASED
PRESS + TO CONTINU E PRESS TO CANCEL
10.Press the Plus key to start the loading. The selected data will be loaded
into the machine control.
11. Then, setup page -02 will be displayed. Enter all data like described in
section 3.4.
12.Press the Special key. Program 001 will be displayed and the machine is
ready to use.
2-15
4.2 Write data on the storage module
1. Switch off the machine using the mains switch.
2. Plug the storage module KK 195 (Part No. 24.831.08) into the slot on the
right side of the operation device.
3. Switch on the machine using the mains switch. This will be displayed:
SETUP/PROG
SETUP
PRO G
PRO D DATA
DATA TRANSFER FRO M KK195 CHIP TO M OTOR
PRESS + TO CONTINU E PRESS TO CANCEL
4. Press the key „Arrow to the right“ to turn the displayed arrow in the direction like shown in the picture.
5. Select one of four options using the vertical arrow keys: SETUP/PROG =
write setup data and sewing programs; SETUP = write setup data only;
PROG = write sewing programs only; PROG DATA = write program data
only.
6. Press the Plus key and this will be displayed:
KK195
SETUP/PROG
SETUP
PRO G
PRO D DATA
CAU TION ! O LD KK195 DATA W ILL BE ERASED
PRESS + TO CONTINU E PRESS TO CANCEL
7. Press the Plus key to overwrite data which are contained on the storage
module. Then, the selected data will be written.
8. Pull the storage module out of the operation device. The machine is ready
to use.
4.3 Write single programs on the storage module
Hint
For each single program, a separate storage module is required.
1. Select the program to be copied on the storage module.
2. Press the Special key and this will be displayed (example):
KK195
2-16
PRO G .
001
PRG
XXX
COUNTING
M ANUAL
AUTO
PRO G.
OPEN
SELF-TEACH
EDIT.
a/A /B
ALL
PRG
LÖSCHEN
W
R
3. Position the cursor on the „W“ in the upper right corner of the display and
push the storage module into the slot at the operation device.
4. Press the Plus key to write the selected sewing program on the storage
module.
4.4 Read a single sewing program into the machine control
1. Select the program memory location, where the program shall be read to.
2. Press the Special key. The same will be displayed like shown in section
4.3.
3. Position the cursor on the letters „PRG“ and press the Plus key to delete
the data contained on the selected memory location.
4. An inquiry will be displayed, where you have to confirm the deletion by
pressing the Plus key. The deletion cannot be undone.
5. Plug the storage module into the slot at the operation device.
6. Position the cursor on the letter „R“.
7. Press the Plus key to read the program from the storage module into the
machine control.
8. Press the Special key to leave the page. The machine is ready to use.
Hint
You can use this procedure to copy a sewing program from one memory
location to another.
2-17
5 Troubleshooting hints
5.1 Error – possible solution
The machine does not start and the control lamp on the operation
device MT800 is off – replace 10 A melting fuse; if the new fuse melts, too or
the machine does not start: replace control board KK66.
The devices will not be enabled – the motor functions but the devices like
thread cutter, foot lifting or needle cooling will not be enabled – replace 3 A
melting fuses, then cut off all devices electrically from the motor control;
switch on the machine and connect all devices one after another; after every
connection, switch on the machine and check melting fuses; in this way, the
defective device can be detected (possibly magnetic valve); if the electrical
elements of the devices are ok and the replacement of the fuses brought no
success: replace I/O-module, replace control board KK66.
The operation device MT800 is switched on, but the display is not clear
or without function – switch machine off and on; pull out the connecting
cable of the operation device MT800, check and remount it; possibly do the
same with the connecting cable between control board KK66 and I/O-module;
replace operation device MT800, replace I/O-module, replace control board
KK66.
5.2 Error messages in the display – possible solution
Fault in the control board (KG) – replace control board KK66.
External fault (KE) – switch machine off and on; check power supply; check
environment for disturbing devices (spark-generating devices, high-frequency
machines, a.s.o.).
Program defective (KP) – delete defective program and program it again; if
several programs are defective, all programs should be loaded from the
storage module; if the loaded programs are defective: replace control board
KK66.
Position actor defective (SG) – check the connecting cable of the position
actor; check the connecting cable between I/O-module and control board
KK66; replace position actor, replace I/O-module, replace control board KK66.
Driving belt loosened (CA) – make correct belt tension; check, whether the
motor is fixed properly on the base frame.
Motor overloaded (MS) – there can be many reasons: e.g. missing oil in the
sewing head, oil too cold, possibly sewing thread wrapped around the belt
disc, ...
Motor blocked (MB) – possible causes: machine blocked, needle blocked,
...
2-18
5.3 Hints for several repair duties
Replacement of the I/O-module – the replacement of the I/O-module does
not require any adaption duties.
Replacement of the position actor – after replacement, the setting of the
needle zero position is required.
Replacement of control board KK66 – procedure: demount rear cover, pull
off four cable connectors to the control board, loosen both fixing screws, pull
off control board from the motor. Be aware to avoid damage to the electronical
components; put the control board into a bag protecting it from electro-statical
load and avoid any contact to metal things. After replacing the control board,
all setup data and the sewing programs must be loaded into the machine.
Replacement of the front box – this is the statical element of the connec-
tion control box and of the foot pedal; each transmission element of the pedal
is calibrated; since that, the front box should only be replaced as a whole.
Replacement of the motor – this is fixed with four screws in the motor
housing; the control board must be removed before it can be demounted.
Loading of new software – future developments can be loaded into the
control by replacing an EPROM; to replace the EPROM, remove rear cover,
replace EPROM (mounted on a frame in the upper left corner); when inserting
the new EPROM be sure to insert all pins and bend none.
2-19
2-20
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