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DLU-5494N-7/SC-922/M51N/IT-100A
Instruction Manual
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JUKI DLU-5494N-7/SC-922/M51N/IT-100A Instruction Manual

DLU-5494N-7/SC-922/M51N/IT-100A
INSTRUCTION MANUAL

CONTENTS

1. PREFACE......................................................................................................................................1
2. SET-UP
(1) Installing the motor unit ....................................................................................................................... 1
(7) Attaching the connecting rod ............................................................................................................13
3. INSTALLING THE OPERATION PANEL .................................................................................... 15
4. HOW TO USE THE OPERATION PANEL
(1) Names and functions of each components ......................................................................................16
5. SCREEN LIST ............................................................................................................................. 19
(1) Fundamental screen list ..................................................................................................................... 19
6. OPERATING PROCEDURE OF THE SEWING PATTERN ........................................................ 23
(1) Selecting procedure of the sewing pattern ......................................................................................23
7. PATTERN OPERATION .............................................................................................................. 30
(1) Sewing pattern register ...................................................................................................................... 30
8. HOW TO USE THE BOBBIN THREAD COUNTER ................................................................... 34
9. NO. OF PCS. COUNTER
10. PRODUCTION SUPPORT FUNCTION
11. BOTTOM FEED AMOUNT DISPLAY
12. RE-SEWING SWITCH
13. NEEDLE UP/DOWN COMPENSATION SWITCH
14. ON/OFF SWITCH
15. AUTOMATIC THREAD TRIMMING SWITCH
16. ONE-SHOT AUTOMATIC STITCHING SWITCH
17. THREAD TRIMMING PROHIBITION SWITCH
18. KEY-LOCK FUNCTION SETTING
19. INFORMATION
(1) Information operator level ..................................................................................................................39
20. ERROR DISPLAY ..................................................................................................................... 47
(1) Error code list (Error display in panel) .............................................................................................48
.......................................................................................................................................... 1
.................................................................................. 16
............................................................................................................ 35
.................................................................................... 35
........................................................................................ 36
............................................................................................................... 36
.................................................................... 36
OF THE MATERIAL EDGE SENSOR ................................................... 37
..................................................................... 37
................................................................ 37
................................................................... 38
............................................................................................ 38
......................................................................................................................... 39
i

1. PREFACE

For setup or handling of DLU-5494N-7 (1-needle, bottom and variable top feed lockstitch machine with auto-
matic thread trimmer), refer to the Instruction Manual for DLU-5494N-7.
In addition, for the details of handling of SC-922 (sewing machine controller) and IT-100, similarly, refer to the
respective Instruction Manuals.

2. SET-UP

The SC-922 can be used with the direct-motor type machine head as a stand-alone control box.
It can also be used with the belt-driven type machine head by installing on the motor unit.
Install the control box on the motor unit following the instructions given below.

(1) Installing the motor unit

Install the motor unit on the table with the tting bolt
(asm.) supplied with the unit as accessories.
❶
❶
❹
❸
❷
At this time, insert the nuts and washers supplied
with the unit as accessories as shown in the gure
so that the motor unit can be securely xed on the
table.
1) Press three bolts
accessories into the motor hanging bolt hole in
the table and x them.
2) Temporarily tighten convex washer
washer ❸ and nut ❹ on the side where two bolts
are attached.
3) Hang the motor unit to the washer which has
been temporarily tightened, and attach convex
washer ❷, spring washer ❸ and nut ❹ to the
other bolt on the opposite side.
4) After adjusting the installing position of the motor,
securely tighten the respective nuts ❹.
supplied with the unit as
❶
, spring
❷
– 1 –

(2) Installing the control box

❷
❶
1) Attach bracket
four supplied screws (M5 × 10) as shown in the
gure.
2) Loosen four screws
tor unit as accessories, tighten screws ❷ after
hanging control box unit ❸ to the screws, and x
control box unit ❸.
supplied with the unit using
❶
supplied with the mo-
❷
❸

(3) Installing the belt

15 mm (9.8N)
1) The belt distance, between sewing machine pul-
ley and motor pulley, must be parallel.
2) The belt tension should be adjusted by turning
the tension adjust nuts ❶ to change height of the
motor, so that the belt sinks down by about 15
mm (9.8N) when it is depressed by band at the
center of the belt span.
If the belt tension is not tight, speed is unstable
at low-speed or medium-speed operation, and
the needle will not stop exactly in position.
❶
– 2 –

(4) Adjusting the pulley cover

❶
❸
b
❷
a
❶
1) After adjusting the belt tension, adjust the pulley
cover ❶ so that the clearances between the belt
and the pulley cover ❶, a and b should be
❸
the same.
2) After the completion of adjustment, tighten screws
located on the side of pulley cover ❶ and
❷
securely x the pulley cover ❶ so that it does not
slip out of position.
– 3 –
(5) Installation and adjustment for the protecting pin and the belt slip-off
preventing bracket
WARNING :
To protect against possible personal injury due to abrupt start of the machine, be sure to start the following work after turning the power off and ascertaining that the motor is at rest.
1) Attaching hole for the protecting pin
Fit protecting pin ❶ in mounting hole A of motor
❷
❸
❶
pulley cover ❽ with accessory screw ❷ and
washer ❸ supplied with the unit.
A
❽
4 mm or less
❻
❶
4 mm or less
Adjusting position for protecting pin
❽
❻
❼
2) Adjustment for the protecting pin and the belt
slip-off preventing bracket
Adjust the position of protecting pin ❶ and belt
slip-off preventing bracket ❹ in accordance with
the gure on the left.
a) Adjusting the protecting pin
Loosen screw ❷ and adjust so that protecting
pin ❶ is positioned at the location indicated in
the gure on the left.
b) Adjusting belt slip-off preventing bracket
Loosen screw ❺ and adjust so that belt slip-
off preventing bracket ❹ is positioned at the
location indicated in the gure on the left.
If protecting pin ❶ is not properly adjusted, it
is possible that your ngers may be caught in
the clearance provided between the pulley ❼
and the belt ❻ resulting in injury.
If belt slip-off preventing bracket ❹ is not
properly adjusted, it is possible to allow the
belt ❻ to slip off causing safety hazard.
3 mm or less
❺
❹
Adjusting position for belt slip-off preventing bracket
3) After the adjustment, tighten screws ❷ and ❺
so as to secure protecting pin ❶ and belt slip-off
preventing bracket ❹ to prevent these compo-
nents to uctuate because of vibration.
4) Before starting the operation of the sewing
machine, ascertain that protecting pin ❶ and
belt slip-off preventing bracket ❹ do not come in
contact with the pulley ❼ and the belt ❻.
– 4 –

(6) Connecting the cords

WARNING :
• To prevent personal injury caused by abrupt start of the sewing machine, carry out the work after turning OFF the power switch and a lapse of 5 minutes or more.
• To prevent damage of device caused by maloperation and wrong specifications, be sure to
connect all the corresponding connectors to the specied places.
• To prevent personal injury caused by maloperation, be sure to lock the connector with lock.
• As for the details of handling respective devices, read carefully the Instruction Manuals supplied with the devices before handling the devices.
Following connectors are prepared on the SC-922. Connect the connectors coming from the machine head
to the corresponding places so as to t the devices mounted on the machine head.
❷
❶
CN30 Motor signal connector
❶
CN33 Needle bar position detector (+5V type): It
❷
󱢳
❺ ❻
󱢷󱢴
detects the needle bar position.
CN36 Machine head solenoid: Provided with
❸
solenoids for thread trimming, reverse feed stitching, one-touch type reverse feed
switch.
CN37 Presser foot lifting solenoid (Only for the
❹
automatic presser foot lifter type)
CN38 Operation panel: Various kinds of sewing
❺
can be programmed.
CN39 Standing machine pedal : JUKI standard
❻
PK70, etc. Sewing machine can be con­trolled with external signals.
CN41 Stepping motor: It is used only with the
❼
DLU-5494N-7.
CN43 Synchronizer (+12V type) : It detects the
❽
needle bar position.
CN44 Hand switch: Hand switch other than the
❾
touch-back switch.
❽
❸ ❹ ❼
❾
CN48 Safety switch (standard) : When tilting the
󱢳
󱢶
󱢵
sewing machine without turning the power
OFF, the operation of the sewing machine is prohibited so as to protect against dan­ger.
OPTION switch: Input function can be changed by changing over the internal function with this switch.
CN51 Extended input/output connector
󱢴
CN55 LED lamp (+5V type): The LED lamp
󱢵
can be connected optionally. (Refer to
"Instruction Manual for SC-922" for how to adjust the quantity of light.)
CN58 Top-feed amount origin detector (+5V
󱢶
type): This detector detects the origin of the
top feed amount. Extended input connector (for the sensor input, etc.)
CN59 Extended output connector (for the sole-
󱢷
noid valve output)
– 5 –
1) Pass through table hole
of thread trimer solenoid, reverse feed stitch-
❶
under the table cords
A
ing solenoid, etc., synchronizer cord ❷, IT panel
cord ❸, operation display panel cord ❹, top
feed detection cord ❺ and motor control cord ❻.
󱢵
❷
❻
❹
A
B
󱢴󱢶 ❽ 󱢳 󱢼
󱢸 󱢺
❶
󱢷
󱢹
❹
❺
❼
❺
❾
❶
❸
󱢻
❷
2) Loosen screw
open the cover ❼.
❻
in cover ❼ with a screwdriver to
B
3) Connect 14P code
coming from
❶
the machine head to connector
(CN36).
When the optional AK device is
attached, connect 2P connector
coming from the AK device to con-
nector 󱢳 (CN37).
Insert connector
coming from the
❷
detector into connector 󱢴 (CN33).
Connect 9P connector
coming
󱢵
from the motor to connector 󱢶 (CN30)
on the circuit board.
❽
❾
Relay 14P cord
coming from the operation display panel to sub-panel junction cord (asm.) 󱢷
❹
(40148262) and insert the former into connector 󱢸 (CN44).
Relay top-feed detection 4P cord
to origin detector junction cord (asm.) 󱢹 (40148267) and insert the
❺
former into connector 󱢺 (CN58).
Relay 6P cord
coming from the stepping motor to stepping motor junction cord (asm.) 󱢻 (40148268)
❻
and insert the former into connector 󱢼 (CN41).
When using the AK device, set whether to use the AK device after conrming how to select the au-
to-lifter function. (Refer to "Instruction Manual for SC-922".)
– 6 –
[Connecting the connector for the operation panel]
󱢾
󱢽
[Connection of the pedal of standing-work machine]
󱣀
4) The connector for the operation panel is provided.
Paying attention to the orientation of the connec-
tor 󱢽, connect it to connector 󱢾 (CN38) located
on the circuit board. After connecting, securely
lock the connector.
Be sure to turn OFF the power before
connecting the connector.
5) To use the pedal unit with the sewing machine
for standing work, insert PK70 connector 󱢿 into
connector 󱣀 (CN39: 12P) on the PCB.
Be sure to turn OFF the power before
connecting the connector.
󱢿
Be sure to securely insert the respective connectors after checking the inserting directions since all
connectors have the inserting directions. (When using a type with lock, insert the connectors until
they go to the lock.) The sewing machine is not actuated unless the connectors are inserted properly.
In addition, not only the problem of error warning or the like occurs, but also the sewing machine and
the control box are damaged.
[How to bundle all cords]
󱣁
How to x cable clip band
Panel
Pull
󱣁
6) After inserting the connector, put all cords togeth-
er with cable clip band 󱣁 located on the side of
the box.
1. Fix the cord clamp and the cable clip
band 󱣁 following the attaching proce-
dure.
2. When removing the connector, remove it
from the wire saddle and remove it while
pressing the hook of the cable clip band
󱣁
How to remove cable clip band
Panel
Push the hook.
Push
.
󱣁
Pushing the
hook portion,
push the band
to remove it.
– 7 –
B
7) Close cover ❼ and x the cover by tightening
screw B with a screwdriver.
Take care not to allow the cord to be caught
under cover ❼.
❼
󱣅
󱣄
[For CE specications only]
󱣂
󱣃
󱣇
8) Connect 4P connector 󱣂 to connector 󱣃 locat
on the side of the box.
9) Connect motor
outpu
t cord 󱣄 of the power
switch to connector 󱣅.
Connect motor output cord 󱣇 to connector 󱣈 locat-
ed on the side of the box.
ed
CE 1ø 230V
󱣈
Brown
Blue
Green / Yellow (Ground wire)
AC 220V-240V
Installing power switch
Connect power supply cord to the power switch.
[CE specications]
Single phase 230V :
Power supply cords : Brown, Blue, and green/yellow
(ground wire)
– 8 –
[Changing over the voltage between 100 V and 200 V]
WARNING :
To prevent personal injuries caused by electric shock hazards or abrupt start of the sewing machine, carry out the work after turning OFF the power switch and a lapse of 5 minutes or more. To prevent accidents caused by unaccustomed work or electric shock, request the electric expert or engineer of our dealers when adjusting the electrical components.
* The illustration below shows the PWR-T PCB.
The type of PCB differs by destination.
A
Wiring for the single-phase 100 V
(Box side)
Be sure to connect the wire between 1 and 2. If it is connected between 1-3 or 2-3, the sewing machine will be inoperative.
WHITE
BLACK
RED
GREEN/ YELLOW
1
2
3
YELLOW
WHITE BLACK
GREEN/
(Plug side)
B
Wiring for the 3-phase 200 V
(Box side)
WHITE
BLACK
RED
GREEN/ YELLOW
1
2
3
YELLOW
(Plug side)
WHITE BLACK RED
GREEN/
C
Wiring for the single-phase 200 V
(Box side)
Be sure to connect the wire between 1 and 2. If it is connected between 1-3 or 2-3, the sewing machine will be inoperative.
WHITE
BLACK
RED
GREEN/ YELLOW
1
2
3
YELLOW
WHITE BLACK
GREEN/
(Plug side)
󱣉
By making the following two changes, the SC-922 can be used with three different power supplies, i.e., single-phase 100 - 120 V, single-phase 200 to 240 V and 3-phase 200 to 240 V. * Only the control box which uses PWR-T PCB can
be changed.
Replacement of the power cords
①
Changing-round of connector 󱣉 on the PWR PCB
②
1) Turn OFF the power with the power switch after checking that the sewing machine has stopped.
2) Draw out the power cord from the power recep­tacle after checking that the power switch has been turned OFF. Then wait for 5 minutes or more.
3) Loosen the screws which are used to secure the rear lid of the control box cover. Carefully open the rear cover.
4) Changing procedure of the power voltage
If the supply power changing is carried out in a wrong manner, the control box can break. Be extremely careful when taking the supply voltage changing procedure.
A. To change over the supply voltage from 200 -
240 V to 100 - 120 V
Change the power cord with the JUKI genuine cord
・
with the part number (M90355800A0). Change the earth cord with the one with the part number (M90345800A0).
Change over supply voltage changeover connector 󱣉
・
mounted on the PWR PCB with the connector for 100 V.
Connect the crimp style terminal of AC input cord to
・
the power plug as shown in the gure A.
B,C. To change over the supply voltage from 100 -
120 V to 200 - 240 V
Change the power cord with the JUKI genuine cord
・
with the part number (M90175800A0).
Change over supply voltage changeover connector 󱣉
・
mounted on the PWR PCB with the connector for 200 V.
Connect the crimp contact of the AC input cord to the
・
power plug as illustrated in Fig. B for the 3-phase pow­er supply or as illustrated in Fig. C for the single-phase one.
5) Before closing the rear lid of the cover, ascertain again that the relevant parts have been correctly changed without fail.
6) Close the read lid while pressing it, taking care not to allow the wiring to be caught between the read lid of the cover and the main body of the control box. Then, secure the lid with the screws.
Be sure to remove the con­nector while holding its lock-
ing section with your ngers.
Be extremely careful not to
Locking section
pull the connector forcibly.
– 9 –
[In case of using the power switch for LA]
󱣇
󱣈
JA 3ø 220V
JA 1ø 120V
Black
Red
White
Green / Yellow (Ground wire)
Black
White
Green / Yellow (Ground wire)
AC 200V-240V
AC 100V-120V
Connect motor output cord 󱣇 to connector 󱣈 locat-
ed on the side of the box.
Installing power switch
Connect power supply cord to the power switch.
[JA specications]
3-phase 220 V :
Power supply cords : black, white, red and green/
yellow (ground wire)
Single phase 120V :
Power supply cords : black, white, and green/yellow
(ground wire)
When the metallic conduit is used, be sure to change over the power cord section following the steps of pro­cedure described below.
Be sure to carry out this procedure before installing the control box on the machine table.
Place the control box with its frame side down on
❼
①
the machine table as illustrated in the sketch.
Loosen screw
②
in underside cover ❼ to open
B
the cover.
B
Change over the cord shown in the red-line
③
circle following the steps of procedure described
below.
– 10 –
F
C
D
E
Remove two screws C to remove clamping plate
④
from the main body of the control box.
D
Remove connector E while holding its locking
⑤
section F with your ngers.
F
D
G
Turn connector G to remove the cord locking
⑥
section.
Loosen nut H to remove the connector from
⑦
clamping plate D.
H
– 11 –
I
J
D
Put locknut I on the power cord and draw out
⑧
the cord J from inside clamping plate D.
J
I
J
I
D
Install clamping plate D back to the control box.
⑨
Pass power cord J through conduit K.
⑩
Fix conduit K with locknuts I with clamping
⑪
plate D placed between the locknuts.
K
B
❼
– 12 –
Close underside cover ❼ and secure the cover
⑫
with screw B.
10) Make sure that the power switch is turned OFF
and insert power supply cord coming from the
power switch into the power plug socket.
󱣆

(7) Attaching the connecting rod

WARNING :
To protect against possible personal injury due to abrupt start of the machine, be sure to start the following work after turning the power off and a lapse of 5 minutes or more.
󱣆
1. Top end of power supply cord varies in
accordance with destination or supply
voltage. Check again the supply voltage
and the voltage designated on the con-
trol box when installing the switch.
2. Be sure to prepare power plug 󱣆 con-
formed to the safety standard.
3. Be sure to connect the ground wire (green
/ yellow).
1) Fix connecting rod ❶ to installing hole B of ped-
al lever ❷ with nut ❸.
2) Installing connecting rod ❶ to installing hole A
will lengthen the pedal depressing stroke, and
the pedal operation at a medium speed will be
easier.
❸
❷
B
❶
A
– 13 –

(8) Installing the operation display panel

❸
❷
A
❶
❶
1) Fix operation display panel ❶ in tapped hole
in the rear section of the machine arm using
A
screw ❷ and washer ❸.
2) Attach operation display panel ❶ to the afore-
mentioned place so that it is in parallel to the bed
surface and does not come in contact with the
lower section of the machine arm.
Parallel to the bed surface
No contact

(9) How to use the operation display panel

• Operation
Partial shirring switch
❶
・ This is the switch used to change over the partial shirring process.
Indicator lamp (LED) of the partial shirring process step
❷
・ Indicates the current state of partial shirring process step.
indication panel
❶
❷
❸
❹
Partial shirring
process step
1
2
3
4
5
6
7
8
Partial shirring pattern indicator lamps (LEDs) under the alternate stitching mode
❸,❹
If partial shirring pattern or is selected under the alternate stitching mode, LED ❸ will light up.
・
Indicator lamp (LED)
A B C D
○ ● ● ● ○ ○ ● ● ○ ○ ○ ● ○ ○ ○ ○
● ○ ○ ○
● ● ○ ○
● ● ● ○
● ● ● ●
(Note)
……
○
……
●
Lights up
Goes out
If partial shirring pattern or is selected under the aforementioned mode, LED ❹ will light up.
If the machine is not operated under the alternate stitching mode, both LEDs ❸ and ❹ will go out.
・
– 14 –
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