CLINTON SERVICE GUIDE

Transcription

1 ML890TKR-75-A CLINTON SERVICE GUIDE MODEL 890TKR FOR JUKI LK-980 MACHINE PREPARATION REMOVE ALL STOP MOTION CONTROL PARTS ON THE CAM SIDE. ONLY THE PARTS SHOWN REMAIN. REMOVE THE REMAINING STOP MOTION PARTS OFF THE MACHINE DRIVE SIDE AS SHOWN. QUITE TODAS LAS PIEZAS DE CONTROL PARA DETENER EL MOVIMIENTO EN EL LADO DE LA VOLANTA. SÓLO DEBEN PERMANECER LAS PARTES MOSTRADAS. QUITE TODAS LAS PIEZAS RESTANTES DE DETENER EL MOVIMIENTO DE LA PARTE DE ACCIONAMIENTO DE LA MÁQUINA COMO SE MUESTRA. DEJE EL PIVOTE DEL RODILLO. LEAVE ROLLER ON PIVOT PIN.

2 ML890TKR-75-A STEP GUIDE BUSHING GUIDE BUSHING & SLIDE ARM STEP 5 SYNCHRONIZER COLLAR SLIDE ARM DISC - MAGNET ASS'Y MOUNTING PLATE ASS'Y L' WASHER NOTE: INSERT SLIDE ARM INTO FOOT CLAMP AND WIPER SLOTS L' WASHER PC BOARD STEP END PLATE STEP 6 PULLEY & HANDWHEEL END PLATE FLAT WASHER PULLEY HANDWHEEL NOTE: LUBRICATE ALL MOVING PARTS BEFORE MOUNTING THE END PLATE SET STEP BRACKET SET PIN HEX NUT BLOCK NOTE: EXISTING & NUT STEP BRACKET FLAT WASHER CLAMP AIR CYLINDER TRIM CYLINDER CLAMP LIFT CYLINDER FLAT WASHER ELBOW AIR CYLINDER ELBOW COTTER PIN CLEVIS PIN CLEVIS HEX NUT FLAT WASHER ELBOW {* STEP PROXIMITY SWITCH MAGNET 0--0 MAGNET HOLDER SET PART OF 0--0 * CABLE ASSEMBLY PROXIMTIY SWITCH HEAVY DUTY FOOT SWITCH ASSEMBLY FOOT SWITCH PLASTIC TUBING BRACKET GROMMET COVER CONNECTOR TO SYNCHRONIZER BOARD INS-44

3 ML890TKR-75- MACHINE ASSEMBLY PROXIMTIY SWITCH TRIM CYLINDER END PLATE ASS'Y SYNCHRONIZER PULLEY & HANDWHEEL RED TUBING YELLOW TUBING GUIDE BUSHING SLIDE ARM CLAMP LIFT CYLINDER RED TUBING NOTE: MOUNT THE VARIOUS COMPONENTS ON THE END PLATE ASSEMBLY IN THE STEPS SHOWN. CLEAR TUBING BRACKET CABLE STRAIN RELIEF SOLENOID VALVE COVER LOCK WASHER AIR CONTROL ASSEMBLY ML890TKR BRACKET TERMINAL BLOCK HEX NUT L' WASHER CABLE ASS'Y STRAIN RELIEF FITTING FITTING TEE GAUGE FILTER, REG., LUB. FILTER, OILER, REGULATOR, GAUGE ASSEMBLY BRACKET LOCK NUT QUICK DISCONNECT - MALE QUICK DISCONNECT - FEMALE TUBE FITTING GAUGE AIR SCHEMATIC /4" CLEAR " AIR INPUT /4" CLEAR 4" P CLAMP LIFT SOLENOID P CLAMP LIFT CYLINDER REGULATOR LUBRICATOR TRIMMER SOLENOID A B /6" RED " /6" YEL. " A B /4" CLEAR " /4" RED " TRIMMER CYLINDER

4 ML890TKR-75-4A TIMING INSTRUCTIONS W X Y P V Z A. SYNCHRONIZER TIMING. TURN MACHINE HANDWHEEL (V) IN THE DIRECTION OF NORMAL ROTATION UNTIL THE TAKE-UP (W) REACHES IT'S UPPER MOST POSITION.. AT THIS TIME, WITH POWER ON, LOOSEN THE TWO SET S (X) AND TURN THE SYNCHRONIZER DISC COUNTERCLOCKWISE UNTIL THE MAGNET ON THE DISC IS ALIGNED WITH THE HALL SENSOR AND THE SYNCHRONIZER BOARD'S GREEN LIGHT GOES ON. B. END OF CYCLE TIMING A PROXIMITY SENSOR AND MAGNET IS USED TO DETECT THE END OF CYCLE ROUTINE. THE ADJUSTMENT DEPENDS ON THE SETTING OF THE END OF CYCLE (EOC) SENSOR.. ADJUST THE GAP BETWEEN THE PROXIMITY SENSOR (Y) AND MAGNET (P) TO APPROXIMATELY /8".. ROTATE, BY HAND, THE SEWING MACHINE HANDWHEEL SO THAT THE STITCH CAM IS IN THE START POSITION WITH THE NEEDLE IN THE UP POSITION.. TURN THE POWER ON AND NOTE THAT THE YELLOW LIGHT ON THE SYNCHRONIZER BOARD IS OFF. 4. POSITION THE MAGNET HOLDER (Z) ON THE STITCH CAM PLATE AWAY FROM THE PROXIMITY SENSOR BUT ON THE SIDE THAT IS OPPOSITE TO THE DIRECTION THAT THE STITCH CAM NORMALLY ROTATES. MAKE SURE THE YELLOW LIGHT IS STILL OFF. 5. SLOWLY MOVE THE MAGNET HOLDER TOWARDS THE PROXIMITY SENSOR UNTIL THE YELLOW LIGHT ON THE SYNCHRONIZER BOARD TURNS ON. LOCK THE MAGNET HOLDER IN PLACE AND SECURE WITH. 6. OPERATE THE MACHINE. CHECK THE MACHINE DECELERATION, TRIMMING AND STOPPING POSITION. IF NOT CORRECT THEN IT MAY BE NECESSARY TO MAKE PARAMETER CHANGES USING THE LCD DISPLAY. A. CRONOMETRAJE DEL SINCRONIZADOR. GIRE LA RUEDA MANUAL (V) EN DIRECCIÓN DE LA ROTACIÓN NORMAL HASTA QUE LA TOMA (W) LLEGUE A SU POSICIÓN MÁS ALTA.. EN ESE MOMENTO, CON LA MÁQUINA ENCENDIDA, AFLOJE LOS DOS TORNILLOS COLOCADORES (X) Y GIRE EL DISCO SINCRONIZADOR EN SENTIDO CONTRARIO A LAS MANECILLAS DEL RELOJ HASTA QUE EL MAGNÉTICO DEL DISCO QUEDE ALINEADO CON EL SENSOR DEL HALL Y SE ENCIENDA LA LUZ VERDE DEL TABLERO DEL SINCRONIZADOR. B. CRONOMETRAJE DEL FINAL DEL CICLO UN SENSOR DE PROXIMIDAD Y UN MAGNÉTICO SE USA PARA DETECTAR EL FINAL DEL CICLO HABITUAL. EL AJUSTE DEPENDE DE LA COLOCACIÓN DEL SENSOR DEL FINAL DEL CICLO (EOC).. DEJE UN ESPACIO DE /8 DE PULGADA ENTRE EL SENSOR DE PROXIMI- DAD (Y) Y EL MAGNÉTICO (P).. ROTE A MANO LA RUEDA MANUAL DE LA MÁQUINA DE COSER PARA QUE LA VOLANTA DE LA PUNTADA SE COLOQUE EN LA POSICIÓN DE ARRANQUE CON LA AGUJA EN LA POSICIÓN ARRIBA.. ENCIENDA LA MÁQUINA Y ASEGÚRESE QUE LA LUZ AMARILLA DEL TABLE- RO DEL SINCRONIZADOR SE ENCUENTRE APAGADA. 4. POSICIONE EL RETENEDOR DEL MAGNÉTICO (Z) EN EL PLATO DE LA VOLANTA DE LAS PUNTADAS LEJOS DEL SENSOR Y EN EL LADO OPUESTO A LA DIRECCIÓN QUE ROTA NORMALMENTE DICHA VOLANTA. ASEGÚRESE QUE LA LUZ AMARILLA TODAVÍA ESTÉ APAGADA. 5. MUEVA LENTAMENTE EL RETENEDOR DEL MAGNÉTICO ACERCÁNDOLO AL SENSOR HASTA QUE LA LUZ AMARILLA DEL TABLERO DEL SINCRONIZA- DOR SE ENCIENDA. ASEGURE EN SU LUGAR EL RETENEDOR DEL MAGNÉTICO CON EL TORNILLO. 6. OPERE LA MÁQUINA. COMPRUEBE LAS POSICIONES DE DESACELERA- CIÓN, CORTE Y DETENIMIENTO DE LA MÁQUINA. SI NO SON CORRECTAS, PUEDE SER NECESARIO CAMBIAR EL PARÁMETRO MEDIANTE EL USO DE LA PANTALLA LCD.

5 ML890TKR-4A CLINTON MODEL 890TKR A890 SERIES SERVO MOTOR POSITIONER/TRIMMER FOR TACKER SEWING MACHINES SERVICE MANUAL

6 ML890TKR-44 TABLE OF CONTENTS SECTION I - INTRODUCTION SECTION II - INSTALLATION A. B. C. D. E. MOTOR LCD DISPLAY SWITCH BOX POWER AND CABLE CONNECTIONS MOTOR ROTATION SECTION III - ADJUSTMENTS A. B. SYNCHRONIZER TIMING PROXIMITY SENSOR SECTION IV - PROGRAMMABLE LCD DISPLAY A. B. C. D. PARAMETER ADJUSTMENTS MASTER RESET PULLEY RATIO TEST PROGRAM SECTION V - CONNECTOR DIAGRAMS SECTION VI - DRAWINGS AND PARTS LIST A. B. C. D. E. F. G. MAJOR ASSEMBLIES MOTOR ASSEMBLY, DC SERVO CONTROL BOX ASSEMBLY SYNCHRONIZER ASSEMBLY SYNCHRONIZER ASSEMBLY END OF CYCLE SENSOR PROGRAMMABLE DISPLAY

7 SECTION I ML890TKR-45 A. SYSTEM DESCRIPTION INTRODUCTION Clinton's Model 890TKR is an electronically controlled variable speed drive for industrial sewing machine tackers. The system consists of a brushless DC Servo motor, a hall effect synchronizer, end of cycle sensor, foot or hand switch and programmable LCD display. The drive is used to replace the mechanical stop motion mechanism used in tackers. Air cylinders are used to operate the clamp lift and on some machines, the trimmer. No clutches or brakes are used. The result is a smooth, reliable and accurate stop motion system. The components of the system are shown below. B. OPERATION A foot or hand switch is used to start the sew cycle. It is also used to drop the clamp without sewing. When the switch is fully depressed, the sew cycle begins. Initially the machine sews at a speed of about 900 RPM for a few stitches to prevent skipped stitches. The speed and number of stitches can be adjusted. The machine then accelerates to maximum speed until the end of cycle sensor is sensed. At this time the machine decelerates to about 800 RPM. After sewing a few stitches, the synchronizer hall sensor detects needle up. The machine speed then ramps down during the final stitch and stops at needle up. During this time the trimmer is operated. The work clamp is lifted after the machine stops. -

8 SECTION II ML890TKR-46 A. MOTOR INSTALLATION INSTALLATION Refer to instructions for specific machine being installed. B. LCD DISPLAY Mount the LCD display console at a convenient location on the table top. C. SWITCH BOX Install switch box at a convenient location under the table. D. POWER AND CABLE CONNECTIONS Refer to figure below and connect all cables as shown. The system can be operated from 0V, phase or 0V, phase power. Caution: It is important that the ground wire be connected between the motor and sewing machine to prevent a static charge buildup. -

9 ML890TKR-47 E. MOTOR ROTATION Temporarily remove the "V" belt. Turn power on then move the pedal forward and note the direction of motor pulley rotation. If incorrect, do the following:. Turn power off.. Refer to section V-B, Hidden Parameters, and follow the instructions to change motor rotation. The parameter is in the "**** Toggle Switches" group.. Install the "V" belt. -

10 SECTION III ML890TKR-48 A. SYNCHRONIZER TIMING ADJUSTMENTS A hall effect sensor/magnet is used to sense when the machine is in the Needle Up position. Refer to figure - below and adjust the disc as follows: FIG. -. Turn power on.. Loosen the disc locking screws.. Rotate the machine handwheel until the takeup is in the proper position for trimming. 4. Rotate the disc in the direction that the machine normally turns until the green Led on the synchronizer PC board turns on. While turning, push the disc against the spacer. 5. Lock disc in place. B. PROXIMITY SENSOR A proximity sensor/magnet is used to sense the end of cycle. The sensor is activated a fixed number of stitches before the machine stops. The number of stitches is set by the "END COUNT" parameter. See section IV. The default count is three (). Adjust the proximity sensor and magnet as follows:. Adjust the gap between the proximity sensor and magnet to between /6" and /8". See figure -.. Start with the machine in the home position and the takeup "UP".. Rotate the handwheel in the reverse direction, by hand, -/ stitches. If the "END COUNT" parameter has been changed, use this number plus / stitch. 4. Turn power on. 5. Move the magnet in the direction the cam normally rotates, until the amber light on the synchro nizer board turns on. Lock the magnet holder in place. -

11 ML890TKR-49 FIG. - Operate the machine and check for positioning accuracy and speed. If the machine does not stop in the proper position, readjust the synchronizer disc. The speed of the machine, during the last stitch,can be changed with the "POSITION" parameter in the ****SPEEDS group. See section IV. -

12 SECTION IV ML890TKR-50 PROGRAMMABLE LCD DISPLAY The LCD display, shown in figure below is used to program and set the various parameters of the 890TKR; SPEEDS, TIMERS, COUNTERS and TOGGLE SWITCHES. Two () different modes of operation are available. They are:. Operating Mode. Programming Mode When power is turn on, the display is in the operating mode. The parameters are separated into main groups, as shown in the following tables. They can be changed or reset to their default values, as described below. In addition, the LCD module can be used to display the pulley ratio and test the synchronizer, speed control and motor encoder. A. PARAMETER ADJUSTMENTS Table is divided into four (4) subgroups, SPEEDS, TIMERS, COUNTERS and TOGGLE SWITCHES. Table is divided into three () subgroups, SPEED, MISCELLANEOUS and TOGGLE SWITCHES. To change a parameter, follow the sequence described below.. Press the key to enter the programming mode. Continue pressing this key until the parameter group that is to be changed is displayed. As an alternative; press the key to enter the programming mode and display the last changed parameter.. Press the key to step to the next parameter in the selected group.. Press the key to increase or the key to decrease the contents of the display parameter. Both keys are used to toggle parameters between states in the Toggle Switches group. Hold the key closed to make the display step automatically. 4. Press the key to return to the operating mode. 4-

13 ML890TKR-5A TABLE PARAMETER DESCRIPTION FACTORY SETTINGS RANGE JUKI 980 SINGER 69 BROTHER SPEED GROUP RPM RPM SLOW STRT END SPEED Initial start speed. Sews at this speed for number of stitches set by soft strt count parameter. Speed for last stitch TIMER GROUP MISCELLANEOUS STRT DEL WAIT TIME Delays machine start to allow clamp to drop. When parameter "Pdl Start" is set to "Continuous", this is the time from the end of one cycle to the start of the next COUNTER GROUP STITCHES SLOW STRT END COUNT Number of stitches sewn at slow strt speed at start of cycle. Number of stitches sewn after end of cycle sensor is detected TOGGLE SWITCHES NOT N/U CLP PDL START SLOW ST If set to "UP", clamp remains up if machine is not in up position. If set to "CONTINUE", machine will restart after "wait time" seconds when foot switch is held closed. If set to "ON", soft start feature is enabled. See soft start in speed group. UP CONTINUE OFF UP CONTINUE OFF UP CONTINUE OFF UP/DOWN CONTINUE/ NEUTRAL ON/OFF TABLE PARAMETER DESCRIPTION RANGE POSITION MAXIMUM JUKI 980 SINGER 69 BROTHER ****SPEEDS RPM RPM Machine speed during the position cycle. If *** Tgl switch "position" is set to "w/ramp", position speed affects the slope of the ramp. If "no ramp" is selected, position speed is constant and can be changed by this parameter. Maximum sewing machine speed ****MISC MISCELLANEOUS PF DUTY TRIM ON Average voltage applied to Pr. Ft. solenoid. The voltage should be high enough to keep the solenoid energized without overheating. Percentage of last (position) stitch that trimmer is on TURNBAK At end of cycle motor reverses to raise needle. Encoder increments are counted. 80 increments equals revolution ****TOGGLE SWITCHES DIRECTION POSITION TURNBAK SAFETY SW Direction of motor rotation viewed from pulley. Select position with ramp or position at constant speed. Turns turnbak on or off. See turnbak parameter in ****MISC GROUP. Enables or disables safety switch. CCW W/RAMP OFF DISABLED CW OFF DISABLED CCW W/RAMP OFF DISABLED CW/CCW W/RAMP NO RAMP ON/OFF ENABLED/DISABLED SAFETY SW SEW MOTOR Determined by configuration of safety switch. If normally open type set to OPN; if normally closed set to CLS. Determines type of motor. Type is new design. OPN TYPE OPN TYPE OPN TYPE OPN/CLS TYPE / TYPE 4-

14 ML890TKR-5 B. MASTER RESET In some cases it may be necessary to reset all parameters to their default values. This is done as follows:. Turn power off, if it is on, then wait until the display goes blank.. Press the key, key and key simultaneously. Keep pressed then,. Turn power on. The LCD displays "PUSH SET TO RESET". 4. Push the key within 0 cycles. 5. The word "Programming" is displayed. The parameters will be reset to their default values after a few seconds. C. PULLEY RATIO (RATIO BETWEEN MOTOR AND MACHINE PULLEYS) During the initial setup and after power is first turned on, the pulley ratio must be calculated. The pedal must be moved to the maximum forward position to do this. While the ratio is being taken, the machine speed is limited for several stitches. After the ratio is taken, the machine will then accelerate to maximum speed. Each time power is turned off then back on, the ratio is checked when the pedal is moved forward the first time. If the ratio has changed, because of a pulley change, then the ratio will be recalculated. The ratio can be displayed by pressing the and keys simultaneously. If the ratio is correct, a star (*) will be displayed after the ratio number. D. TEST PROGRAM A test program is available to test the speed control, synchronizer and encoder for proper operation. To select the program, press the and keys simultaneously. The word "Test Program" is displayed. Press the key to toggle between each test, i.e. Treadle, Synchronizer or Encoder. Press the key to activate whichever test is selected.. Treadle Test a. Move the pedal from neutral to heel to heel. The display indicated each position. b. Move the pedal forward, slowly. As the pedal is moved a number (0 to 55) proportional to the position of the pedal is displayed. The lowest number should not be more than 8 and the highest number not less than 50 with the "Maximum Speed" pot set to its maximum clockwise position. c. With the pedal full forward, rotate the maximum speed pot ccw. The displayed count should de crease as the pot is turned. Return the pot to its maximum cw position.. Synchronizer Rotate the handwheel. As the synchronizer passes through the UP, DOWN and TRIM position, the display will indicate each of these positions.. Encoder Push the pedal forward as indicated. The speed will vary with pedal position but will not go to maximum speed. The pulley ratio will be displayed at all positions of the pedal and should agree, + or counts, with the actual pulley ratio (see section D). 4-

15 SECTION V ML890TKR-5 CONNECTOR DIAGRAMS Listed below are the pinouts for the Model AS 890 control box connectors. NO. TOTAL PINS CONNECTOR PIN NO. FUNCTION 6 SYNCHRONIZER AUX INPUTS AUX OUTPUTS 4 4 FOOTLIFT 5 9 TRIM SOLENOIDS DOWN SENSOR UP SENSOR TRIM SENSOR GND LED +5 GND CHASSIS GND I I I +48 V R +48 V R FOOTLIFT SOL. +48V NOT USED NOT USED TRIMMER SOL. - TRIMMER SOL. +(48V) NOT USED NOT USED NOT USED NOT USED NOT USED

16 ML890TKR-54 NO. TOTAL PINS CONNECTOR PIN NO. FUNCTION 8 8 COMMUTATOR LCD DISPLAY AC POWER 0V, PHASE 4 MOTOR VOLTAGE ENCODER (S) ENCODER (S) SIG. GND PHASE C PHASE B PHASE A -5V EXIT CHASSIS GND +5V GND D0 D D D D4 D5 D6 D7 CA E ERD CA0 PHASE A PHASE B PHASE C CHASSIS GND PHASE A PHASE B PHASE C CHASSIS GND 5-

17 SECTION VI ML890TKR-55 DRAWINGS AND PARTS LIST MODEL 890TKR (WITH LCD) (NO LCD) A. MAJOR ASSEMBLIES 6-

18 ML890TKR-5-A

19 ML890TKR-5-A MOTOR ASSEMBLY PARTS LIST, DC SERVO ITEM DESCRIPTION PART NO. QUANTITY COVER, S.S.S. FAN PC BOARD, ENCODER SPACER ENCODER DISC ENCODER SENSOR MOTOR, DC, S.S.S. MOTOR/ENCODER ASSEMBLY BELT GUARD, FIXED PULLEY - 50MM PULLEY - 60MM PULLEY - 65MM PULLEY - 70MM PULLEY - 75MM PULLEY - 80MM PULLEY - 85MM PULLEY - 90MM PULLEY - 95MM PULLEY - 00MM PULLEY - 05MM PULLEY - 0MM PULLEY - 5MM PULLEY - 0MM PULLEY - 5MM PULLEY - 0MM PULLEY - 40MM PULLEY - 50MM BELT GUARD, ADJUSTABLE KEY, PULLEY M5 X 0 HEX HD. BOLT, CARRAIGE SPACER WASHER, FLAT WASHER, SPLIT LOCK NUT, HEX HARDWARE KIT, MOTOR MOUNT PIN BRACKET, MOTOR MOUNT SNAP RING BOLT, ADJUSTING NUT, HEX WASHER, SPLIT LOCK GROMMET

20

21

22

23 ML890TKR-59 F. END OF CYCLE SENSOR MODEL 890TKR "A" LENGTH " BROTHER LK-840, SINGER " JUKI " SANLI LK-999, JUKI LK-850 PART NO. " A " LENGTH MACHINE G. PROGRAMMABLE DISPLAY ITEM DESCRIPTION PART NO. QUANTITY 4 PROGRAMMABLE DISPLAY BRACKET, MOUNTING M4 X