SUN STAR AC Servo Motor series III Parts List

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USER’S MANUAL

PARTS BOOK

Version 03

1) For at most use with easiness, please certainly read this manual before starting use.

2) Keep this manual in safe place for reference when the machine breaks down.

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AC Servo Motor series

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Thank you for purchasing our product. Based on the rich expertise and experience accumulated in industrial sewing machine production, SUNSTAR will manufacture industrial sewing machines, which deliver more diverse functions, high performance, powerful operation, enhanced durability, and more sophisticated design to meet a number of user’s needs.

2. Please read this user’s manual thoroughly before using the machine. Make sure to properly use the machine to enjoy its full performance.

3. The specifications of the machine are subject to change, aimed to enhance product performance, without prior notice.

This product is designed, manufactured, and sold as an industrial sewing machine. It should not be used for other than industrial purpose.

USER’S

MANUAL

1. Safety instruction 6

2. Precautions before use

3. Locating and using parts of the controller box

4. Installation

5. Wiring and grounding

6. Connection the earth wire of the sewing machine and motor

7. Things to be checked after installation

8. Program unit part names and method of use

9. Simple operation unit part names and method of use

10. Fortuna series 3 full function software method of use

11. Breakdown and troubleshooting

12. How to place for controller

13. Block diagram

※Parts Book

CCOONNTTEENNTTSS

Be sure to read and keep in mind the following instructions before you install and use thr FORTUNA SERVO MOTOR.

1) Use and Purpose

This product is designed, manufactured, and sold as an industrial sewing machine. It should not be used for other than industrial purpose.

2) Working Environment

Power Source

It is desirable that voltage of the power source be kept within the range of 10% of the rated voltage. It is desirable that frequency of the power source be kept within the rage of 10% of the rated frequency. (50/60

)

The SERVO MOTOR can be expected to work normaly only in case the foregoing things are kept.

Electromagnetic Noise

It is desirable that those equipments causing strong electromagnetic field or high frequency not use the same electrical outlet as this on and stay away from it.

Temperature and Humidity

Keep the ambient temperature above 5 degrees and below 40 degrees Centigrade. Never use it outdoors and avoid direct ray of light. Keep it away from an hot object like a stove.

30% 95%. Never use it near gases and explosives. Do not use it at a spot located 1,000m or higer above sea-level. Keep the storage temperature higher than 25 degrees below zero and lower than 55 degrees Centigrade when not in use.

3) Installation

Follow the instruction carefully when installing it.

Be sure to start installing it after pulling the power plug off the outlet. Fix the cable so that it may not move, and do not allow the moving parts like belts to be interfered with.(keep distance of at least 25mm from them.) Be sure to have the Controller, the Motor and the sewing Machine grounded. Be sure that the voltage of power source fits the specification of the Controller before the power is on Be sure to use Safety Extra Low Voltage when an extra item or an accessory is fitted into the Controller.

4) Disassembly

Indisassembling it, be sure to wait at least 360 seconds before taking any action after pulling the plug off the power source after turning it off. When pulling off the plug from the power source, be sure to hole the plug itself instead of the wire connected to the plug.

5) Service and Maintenance

Make sure that service and maintenance are carried out by a skilled technician.

Never try to operate with the Motor and the Controller open. When inserting a thread into or touching the machine, be sure to turn the power off and step down from the platform. Be sure to use standard products specified for replacement of parts.

6) Other Safety Instructions

Tack care not to let your fingers touch any moving parts including belts. In case of remodelling or fitting of additional device, be sure to follow safety standards and do not ever try to go ahead based on your own judgments. Do not try to operate with the safety device removed. Take care not to let water or coffee or something like those admitted into the Controller or the Motor. Never drop the Controller or the Motor to the ground.

The instructions presented above are for the safer and more proper operation of the Fortuna Servo Motor. Ignoring such instructions could cause damage to the machine or physical injury of the user. Please follow all the instructions when operating the machine.

1. Do not turn on the power while stepping on the pedal. 2. Turn off the power when leaving the servomotor overnight.

3. Turn off the power when servicing the servomotor or changing the needle.

4. Be sure to keep the servomotor securely grouned.

5. Do not connect multiple servomotor power plugs to the same power strip.

6. Install the servomotor away from noise sources, such as highfrequency equipments and welding machines.

7. Avoid electrical shock when servicing the controller box. (Wait for 6 minutes before opening the cover after turning off the power.)

8. When an error message “Er”sppears on the digital display,

take a note of the “Er” code, and then turn on and off before resuming operation(Contact the local dealer if “Er” message persists on the display)

9. Adjust the belt tension to the optimum level.

Belt-tension adjustment should be performed after the motor is mounted on the table : First, loosen both the upper and lower anchoring bolts(①, ② ). The belt tension will then be adjusted by the weight of servo motor itself. Fasten both anchoring bolts.

10. Clean it every two or three weeks so that no dirt or a dirty substance may be piled up.

11. When replacing the fuse, use a standard item, opening the cover as shown in the diagram.

12. Make the length of the cable connected with an outside parts like stand-up pedal as short as possible.

F4 250V/1A

250V/6.3A

Control box right sideControl box left side

1) Left and right side of control box

2) Rear panel

Caution

Motor AC INPUT

Motor Power Cable

AC Power switch

Standard Solenoid

Connector

Switch and Lamp

Foot-lift Solenoid(Green)

Right lift Solenoid(Blue)

Tension-release and

Auxiliary solenoid(White)

Hazardous voltage will cause injury. Be sure to wait at least 360 seconds before opening this cover after turn off main switch and unplug power cord.

고압 전류에 의해 감전될 수 있으므로 커버를 열 때 는 전원을 내리고 전원 플러그를 뽑고 나서 360초간 기다린 후 여십시오.

WARNING

경고

Encoder Connector

(Green)

OPTION

Connector for Position

Sensor(Black)

Program Unit

Connector(White)

1) Mounting your Servo Motor on the table

Insert three motor-fixing bolts through the three holes on the table. Attach the motor base padded with vibration-proof rubber, and slide flat and spring washers over the bolt stems, and then fasten the bolts with nuts.

Motor-Fixing Bolts

Vibration-Proof rubber

Flat Waser

Spring Waser

Motor-Fixing Bolts(3ea)

Table

Make sure that the center of motor pulley is matched to that of the sewing machine before tightening the motor-fixing bolts and nuts.

Make sure that the holes are bored on the table as shown in the figure.

Nut

Base

Controller Box

Motor-Fixing Bolts(3ea)

Table

Belt Hole

ф41 Cable-Hole

2) Assembling the belt cover and adjusting the belt tension

(1) Belt cover assembling procedure

Upon the completion of the motor mounting, bring the two

pulleys of motor and sewing machine closer to each other, by

pulling back the sewing machine. You can then mount the belt

easily as shown in the figure.

Place the belt cover B , making sure that the belt cover does

not contact the belt, and then fasten the cover with the fixing

screw.

(2) Adjusting the belt tension

Optimum Tension Level The optimum tention level is

achieved when the belt is pushed by 5-10mm when the top

surface portion of the belt at about 30-50mm above the tabletip

is pressed by a finger with a force of~1 m/sec2or 1 Newton.

Adjusting the Tension Level If the tension level is out of the

optimum range, adjust the tension as follows. First, loosen both

the upper and lower nuts for the anchor bolt, letting the belt be

stretched by the motor weight itself. Second, tighten the upper

nut only to the extent that the motor does not move. Third,

fasten the bottom nut tightly so that the motor is securely fixed.

Controller Box

Upper Nut for the Anchor Bolt

5~10mm

30~50mm

Lower Nut for the Anchor Bolt

Belt Cover A

Belt Cover B

Belt

Belt Guide Fixing Screw

Belt Cover Fixing Screw

Belt Guide

Pulley

Belt Guide Fixing Screw

3) Mounting and adjusting the foot-lift solenoid

(1) SunStar KM-235 Model

Attach the main power switch first since the power switch is

located normally in between the solenoid brackets.

By referring to the figure on the right and the mounting

instructions enclosed in the packaging box, locate the insertion

surface of the oil pan, and then attach the foot-lift solenoid.

(2) SunStar KM-250 Model

First, assemble a panel for the attachment of presser foot

solenoid on the back of KM-250.

Attach the presser foot solenoid to a bracket A .

Attach the bracket A with the presser foot solenoid to the

panel above.

Attch a crank to a solenoid shaft and then connect it to a

sewing machine.

Place a cover on the solenoid.

(3) SunStar Special-specification models

The same mounting procedure for KM-235 model is applicable

for other models listed below.

(4) Adjusting the stroke(Gap) of the automatic foot-lift

solenoid

Check point

Check to make sure that the stroke-adjusting screw is located at the center of the solenoid axis, i.e., the solenoid should be assembled in parallel with the bottom surface of the table. If the solenoid is not in paralle, make an adjustment so that the screw is in parallel with the center of the solenoid axis using the connection link-fixing screw.

Adjusting Procedure

The verical travel distance of the presser foot can be adjusted by

the stroke-adjusting screw. First, Loosen the two fixing screws,

and adjsut the vertical stroke using the stroke-adjusting screw.

loosening and tightening the stroke-adjusting screw will decrease

and increase the verical stroke of the presser foot respectively.

After the adjustment, fasten the fixing screw tightly.

No.

Solenoid No.

SPF-2

Applicable Models

KM-235A, B

Oil Pan Insertion Surface

Mounting Position for Legs(4)

Mounting Position(4)

for Automatic

Foot-Lift Solenoid

Oil Pan Insertion Surface

Mounting Position(4)

for Automatic

Foot-Lift Solenoid

Belt Holes

Oil Pan

Fixing Nuts

Solenoid Axis

Stroke-Adjusting Screw

Connection Link-

Fixing Screw

※Specification viewed from the table bottom

※KM-250 Rear Panel

Solenoid Bracket A

Cover for Foot-Lift Solenoid

No.

1 2 3 4 5 6 7

Solenoid No.

SPF-3

SPF-4 SPF-6 SPF-8 SPF-9

Applicable Models

KM-750-7, KM-750BL-7 KM-790-7, KM-790BL-7

KM-857-7, KM-867-7

KM-560-7

KM-957-7, KM-967-7

KM-757-7

KM-640BL-7

4) Mounting the position sensor (Synchronizer) and setting the film

(1) Mounting the position sensor(Synchronizer)

SunStar thread-cutting sewing machine.

All SunStar thread-cutting sewing machines are equipped with a position sensor. Users, therefore, are required to the adjust the film position, if necessary, as shown in the figure.

All other sewing machines(including other manufacturers’ brands)

First, attach the position sensor-mounting adapter to the upper shaft of the sewing machine. Second, attach the position sensor-fixing plate to the body of the sewing machine as shown below in the figure. Third, secure the position sensor to the adapter with the fixing screws.

L Wrency

Pulley

Synchro shaft-fixing screw(2)

Synchro shaft

Photo film (Adjusted left and right)

Photo INTERRUPT

COVER

Upper Shaft

P.C.B Holder

Adapter

Position Sensor-Fixing Bolts

Position Sensor

Cable

Position Sensor-Fixing Plate(Type B)

Nylon Cable Tie

Fiixing Bolt for Position Sensor-Fixing Plate

Position SensorFixing Plate(Type A)

Pulley

(2) Adjusting the film of the position sensor

Assemble the films and position sensor in the order as shown

in the figure.

Upon the completion of the assembling, position the needle shaft tight at the rising point from the lowest needle position by manually

rotating the pulley. Loosen the film-fixing screw, and adjust the DOWN film so that the film-adjsting line and the sensor housing

calibration line are matched. Tighten the film-fixing screw just to the extent that the film can not be rotated. Likewise, position the thread

take-up at the highest position. Loosen the film-fixing screw, and adjust the UP film as shown in the figure, while using caution not to

move the DOWN film which is already adjusted earlier. Tighten the adjusted film with the fixing screw.

(3) Adjustion the films of reverse rotation sewing machines

For reverse-rotation sewing machines, the film-adjusting lines located at right edge of the “UP”and “DOWN”film should be matched to

the center line of the sensor.

[ Caution ] After adjustment the film of the position detector, be sure to rotate the motor for 3~5 seconds by pedalling so that the Controller may remember location of the film.

Fixing Washer

Fixing Bushing

Film-Fixing Screw

Position Sensor Shaft

Fixing Nut Fixing Nut

Fixing NutFixing Nut

Setting Position

Sensor Calibration Line

Film-Adjusting Line

Film-Adjusting Line(Reverse Rotation)

Sensor Housing

The highest position of take-up lever

Up Film Adjustment

Down Film Adjustment

2mm turning around from the lowest position of needle bar

2m turning around from the lowest position of needle bar

5) How to equip and adjust a built-in location detector(synchronizer)

(1) How to equip the built-in location detector

(synchronizer)

In case of a SunStar thread trimmer

When a built-in location detector(synchronizer) for the sewing machine with the SunStar thread trimmer is equipped, all that the users need to do is to simply adjust the location of magnetic for detection according to their needs.

Locate detector (synchronizer)

Position magnetic up

Upper Shaft

Position magnetic down

Position magnetic up

Sewing machine pulley

Locate detector (synchronizer)

Position magnetic down

Sewing machine

(2) How to adjust the magnet of the location detector

Assemble the detector in order following the pictures.

Once assembling is completed, power the controller on and step on the pedal. At this time, make sure that the needle moves up and down.

Stop the needle at a desired location by moving the magnet back and forth along the location where the needle stops.

(3) How to adjust a location detector in case of a reverse rotation sewing machine

It is the same as that used for the normal rotation direction

[ Note ] After adjusting a location detector, rotate the motor by stepping on the pedal for 3~5 seconds so that a controller can remember the location.

Locate detector(synchronizer)

Normal rotation direction

Reverse rotation direction

Normal rotation direction

The highest position of take-up lever

Locate detector (synchronizer)

2mm turning around from the lowest position of needle bar

[ Caution ] Fix the cable using the cable tie so that cable is not in the way of the belt.

6) Mounting the Program Unit(P/U)

(1) SunStar KM-235 Sewing Machine

First, attach the P/U bracket to the P/U using three fixing screws

and a supporting bolt with nut attached on it as shown in the

figure. Second, securely attach the P/U to the head of the sewing

machine using two fixing screws and washers, keeping a 3~4mm

distance between the bottom surface of the nut and the base of the

supporting bolt.

(2) Other SunStar thread-machine

First, attach the P/U bracket to the P/U using the four fixing screws. Second, attach the P/U to the main body of the sewing machine using the

three bracket-fixing screws as shown in the figure.

Program Unit

P/U Bracket

P/U Bracket-Fixing Screw(3)

7) An example of installing the SunStar sewing machine

1) Specification of the power plug

(1) Single phase 100V~120V

(2) Single phase 200V~240V

(3) Three phase 200V~240V

Be sure to connect Protective Earth

2) Specification of electric current in wiring of power plug

Be sure to use wiring materials which can stand electric current of higher than 15A.

110V

220V

EARTHV

Switch Box

Control Box

Switch Box

3) Name and description on the outside connector of control box

Standard solenoid connector Tension-release and auxiliary solenoid

Foot-lift solenoid Switch and lamp(Used in twin-needle sewing machine)

Right/Left solenoid(Used in twin-needle sewing machine)

4) How to change the electric voltage supplied for solenoid (The factory installed setting is J2)

This is to make the movement of solenoid smooth in times of fluctuation in the incoming electric voltage.

Set Value for electric voltage supplied (for 220V series) for Solenoid against the incoming voltage.

For 30V-regular Solenoid For 24V-regular Solenoid

Incoming Voltage Set Value

Below 210V J5

210V~230V J6

Above 230V J7

Incoming Voltage Set Value

Below 180V J5

180V~190V J6

Above 190V J7

[ Shape of pin ]

Connector Color：Green

Connector Color：Blue

[ No. of pin ]

Connector Color：White

4, 8：GND, VDC

(DC 46V or DC 32V)

9, 10：Button 󳟇 to insert/delete the

back-tack operation

11, 12：Button 󳟆 for manual back-

tack operation

1, 5：Back Tack Solenoid 2, 6：Thread-Cutting Solenoid 3, 7：Wiper Solenoid

Foot-Lift Solenoid Switch

Auxiliary Solenoid

Tension-Release Solenoid

①＋5V ②＋5V ③ L LED ④ R LED ⑤ L S/W ⑥ R S/W

⑦ GND ⑧ 4/4 (N.C) ⑨ 3/4 (N.C) ⑩ 2/4 (N.C) ⑪1/4 (N.C) ⑫ (N.C)

Right-Needle Control Solenoid

Left-Needle Control Solenoid

Foot-Lift Solenoid

[ Shape of pin ] [ No. of pin ]

Set Value for electric voltage suplied (for 110V series) for Solenoid against the incoming voltage.

Setting of pin

For 30V-regular Solenoid For 24V-regular Solenoid

Incoming Voltage Set Value

Below 100V J5

100V~120V J6

Above 120V J7

Incoming Voltage Set Value

Below 90V J5

90V~100V J6

Above 100V J7

Method

Connect the motor and sewing machine using the ground wire (green, green/yellow) as shown in the figure. Make sure that the factory-connected ground wire between the controller box and motor is securely in place.

Caution

Failure to ground the motor can cause abnormal operations, such as overspeed rotation or unwanted stitching.

1) Before the power is on...

Make sure that the incoming voltage is in accordance with that shown in the name plate of the Control box. Check whether the following connectors are connected.

Connector for incoming AC power source Connector for motor power Connector for motor encoder Connector for pedal Connector for position detector

Connector for others (option, knee-lift, program unit etc.) Check to see whether the belts are in touch with the wiring. Check the tensile strength of the belts. Check to see the fixing nuts for pulley are tightly fastened. Check whether the sewing machines are right kinds (Chain Stitch S/M, Lock Stitch S/M) Check the rated voltage for Solenoid (Refer to How to change the electric voltage supplied for Solenoid ))

2) After the power is on...

Check whether the lamp for the position detector is on. (Except in the case of built-in position detector) Check whether the program unit is working. Check the direction of rotation of the Sewing Machine.

In case the direction of rotation is not right, action shall be taken to change set it right, referring to the methods of changing the program and the list of changing functions

(N. 65 in Group A )

Check to see whether there are abnormal heat, smell or noise nearby.

In case there are, turn the power off and call our regional office.

1) Program unit part names

2) Program Unit Method of Use

(1) 4-Digit Displayer and 2-Digit Displayer Functions and Method of Use

A. 4-Digit Displayer and 2-Digit Displayer Functions

When you turn the power on, you will see a screen as shown in the figure. The 4-digit displayer shows the start and end B/T sewing and the 2-digit displayer shows the current abbreviation for the letters or numbers shown in the 4-digit displayer (bt: the abbreviation for back tack),

The 4-digit displayer shows the error number for each type of error discovered and also shows the programmed value after it has been programmed. The 2-digit displayer shows the number of the parameter specific item's content or name which is shown in the 4-digit displayer.

[ Caution ] The 4-digit displayer and 2-digit displayer show the current condition. Therefore the user should always check it before using the machine.

2--Digit Displayer

Sunstar Logo

4-Digit Displayer

1/2 Stitch Button

Button for Program Change

Button for Counter Use after Counter Programming

Button to use Edge Sensor Selection after Edge Sensor Programming

Button to Save Program Changes

Pattern Work Selection Button

Start B/T Selection Button

End B/T Selection Button

Button to Select Needle Plate Location When Machine Stops

Button to Select Presser Foot-lift Location When Machine Stops

Thread-trimmer and Wiper Selection

Button to Change the Sewing Speed Installation

Pattern Work Connecting Button

Constant Sewing Speed Selection Button

B. Method of Use: 4-Digit Displayer and 2-Digit Displayer

a. Method to change the start and end B/T stitch numbers

In order to change the start B/T stitch numbers which is programmed when you first purchase this machine, you must use the , buttons. If you want to

change the end B/T stitch numbers, you must use the , buttons. 󳢯The program range is from 0 to 9.

(Ex: How the screen looks when changing both start and end B/T stitch numbers to 4).

b. Method to check or change the specifics of the parameter

(2) Method of Use： Stitch Button Function

Press the button and as you press it, also press the button. Then you can either check or change the programming items for the parameter of group A. (A group： , B group： , C group： , D group： )

Users should turn the machine off to select B, C, or D group. While pressing the button, turn the power switch on. The screen will be changed to the initial screen after showing the "PrEn" message. Then, the users can select B, C, or D group by pressing B, C, or D button while holding program button.

You can move to the parameter item you want with the and buttons. The parameter item number will appear in the 2-digit displayer and the wanted value will appear in the 4-digit displayer.

(Ex) Screen showing the maximum speed limit preset in the item 2 of A group)

After using the (increase) button and (decrease) button to choose

the value you want, press the (Enter) button and save the value you

chose. (Ex: Reducing the maximum sewing speed limit from 4000RPM to

3000RPM).

After saving, press the button and go back to the initial screen.

[ Caution ]

󳢯Be aware that if you don't press after changing the programmed value for the parameter item, the value will not be saved. 󳢯When the B, C, or D group selection is completed, users should turn off the machine first and restart to secure the selected group. 󳢯If the user changes the programmed value from the parameter specifics carelessly, the user may cause break down or physical damage to

the machine. The user must therefore be well-trained before changing the parameter group.

When necessary, make stitches by pressing the stitch ( ) button.

When the needle plate makes a down stop, shortly press the stitch ( ) button once and the needle plate will make an up stop.

And when the needle plate makes an up stop, shortly press the

stitch ( ) button once and the needle plate will make a down stop.

[ Caution ] Be aware that if you are continuously pressing the ( ) button, the machine will keep on moving at the stitch ( ) speed.

+ 58 hidden pages

SUN STAR AC Servo Motor series III Parts List

Specifications and Main Features

Frequently Asked Questions

User Manual