Beisler 1220/5 Operating instructions

1220/5

Single-head se wing unit for serging and overlocking for trou sers wit hout knee li ning

Operating Instructions

Installation Instructions

Service Instructions

1

2

3

Frohn rad stra ße 10, D-63768 Hös bach

Telefon Ser vice +49 (0) 60 21/ 50 19 40 Telefax +49 (0) 60 21/ 54 00 61 E-mail: [email protected]

Aus ga be / Edi ti on: 06/2005 Prin ted in Fe de ral Re pub lic of Ger ma ny Tei le-Nr.:/Part-No.:

Foreword

This instruction manual is intended to help the user to become familiar with the machine and take advantage of its application possibilities in accordance with the recommendations.

The instruction manual contains important information on how to operate the machine securely, properly and economically. Observation of the instructions eliminates danger, reduces costs for repair and down-times, and increases the reliability and life of the machine.

The instruction manual is intended to complement existing national accident prevention and environment protection regulations.

The instruction manual must always be available at the machine/sewing unit.

The instruction manual must be read and applied by any person that is authorized to work on the machine/sewing unit. This means:

– Operation, including equipping, troubleshooting during the work cycle, removing of fabric waste,

– Service (maintenance, inspection, repair and/or

– Transport.

The user also has to assure that only authorized personnel work on the machine.

The user is obliged to check the machine at least once per shift for apparent damages and to immediatly report any changes (including the performance in service), which impair the safety.

The user company must ensure that the machine is only operated in perfect working order.

Never remove or disable any safety devices.

If safety devices need to be removed for equipping, repairing or maintaining, the safety devices must be remounted directly after completion of the maintenance and repair work.

Unauthorized modification of the machine rules out liability of the manufacturer for damage resulting from this.

Observe all safety and danger recommendations on the machine/unit!

The yellow-and-black striped surfaces designate permanend danger areas, eg danger of squashing, cutting, shearing or collision.

Besides the recommendations in this instruction manual also observe the general safety and accident prevention regulations!

General safety instructions

The non-observance of the following safety instructions can cause bodily injuries or damages to the machine.

1. The machine must only be commissioned in full knowledge of the instruction book and operated by persons with appropriate training.

2. Before putting into service also read the safety rules and instructions of the motor supplier.

3. The machine must be used only for the purpose intended. Use of the machine without the safety devices is not permitted. Observe all the relevant safety regulations.

4.

When gauge parts are exchanged (e.g. needle, presser foot, needle plate, feed dog and bobbin) when threading, when the workplace is left, and during service work, the machine must be disconnected from the mains by switching off the master switch or disconnecting the mains plug.

5. Daily servicing work must be carried out only by appropriately trained persons.

6. Repairs, conversion and special maintenance work must only be carried out by technicians or persons with appropriate training.

7. For service or repair work on pneumatic systems, disconnect the machine from the compressed air supply system (max. 7-10 bar).

Before disconnecting, reduce the pressure of the maintenance unit.

Exceptions to this are only adjustments and functions checks made by appropriately trained technicians.

8. Work on the electrical equipment must be carried out only by electricians or appropriately trained persons.

9. Work on parts and systems under electric current is not permitted, except as specified in regulations DIN VDE 0105.

10. Conversion or changes to the machine must be authorized by us and made only in adherence to all safety regulations.

11. For repairs, only replacement parts approved by us must be used.

12. Commissioning of the sewing head is prohibited until such time as the entire sewing unit is found to comply with EC directives.

It is absolutely necessary to respect the safety instructions marked by these signs.

Danger of bodily injuries !

Please note also the general safety instructions.

Index

Preface and general safety instructions

Page:

5.

5.1

5.2

5.3

5.4

2.

3.

3.1

3.2

3.3

3.4

4.

4.1

4.2

4.3

Part 1: Operating instructions Cl. 1220/5

1.

1.1

1.2

1.3

Description of product

Description of proper use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Brief description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Optional equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Switching on - Switching off - Program stop

Switching on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Switching off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Program stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Restart after program stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operation of the sewing machine head

General notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Recommended threads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removing /Putting on the fabric sliding sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operation of the sewing unit

Feeding the trousers parts and starting the sewing process . . . . . . . . . . . . . . . . . . . .

10

Adjusting the edge guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11

Adjusting the blowing air for the nozzles in the table top . . . . . . . . . . . . . . . . . . . . . .

12

Adjusting the guide blade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12

7

8

9

3

3

4

5

5

5

6

6

1

6.

6.1

6.2

Operation of the control

Operator terminal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13

User interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14

6.2.1

Menu structure of the sewing and setting programs . . . . . . . . . . . . . . . . . . . . . . . . .

14

6.3

Seam programs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

6.4

Adjusting the control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

17

6.4.1

Altering seam-specific parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

17

6.4.2

Altering global parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

19

6.4.3

Input - Output test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

20

6.4.4

Creation of seam programs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

21

6.4.5

Deleting a seam program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

22

6.4.6

Altering seam programs (Changing /Completing the sequence) . . . . . . . . . . . . . . . . . .

22

7.

Error messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

23

Index: Page:

8.

8.1

8.2

USB stick

General notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

24

Formatting the USB stick . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

24

8.3

8.4

Plugging the USB stick in the control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

24

USB functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

25

8.4.1

Storing data on the USB stick . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

27

8.4.2

Loading data from the USB stick . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

27

8.4.3

Data comparison . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

28

8.4.4

Deleting data from the USB stick . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

28

8.4.5

Loading software version from the USB stick . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

29

8.5

Removing the USB stick . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

30

9.

9.1

9.2

Maintenance

Cleaning and checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

31

Oil lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

33

1.

Description of product

1.1

Description of proper use

The 1220/5 is a sewing unit which can properly be used for sewing light to medium-weight material. Such material is, as a rule, made of textile fibres. These materials are used in the garment industry.

In general only dry material must be sewn on this machine. The material must not contain any hard objects.

The seam is generally made with core thread, polyester fibre or cotton threads.

The dimensions for needle and hook threads can be taken from the table in chapter 4.2.

Before using any other threads it is necessary to estimate the consequential dangers and to take the respective safety measures, if required.

This sewing unit must only be installed and operated in dry and well-kept rooms. If the sewing unit is used in other rooms, which are not dry and well-kept, further measures to be agreed upon may become necessary (see EN 60204-31 : 1999).

We, as a manufacturer of industrial sewing machines, assume that at least semi-skilled operating personnel will be working on our products so that all usual operations and, where applicable, their risks are presumed to be known.

1

1.2

Brief description

The Beisler 1220/5 is a single-head sewing unit for serging and overlocking of long skirt and trousers parts. The overlocking of the seat and fly bow as well as of the trousers hem can be integrated.

All sewing unit components are mounted on a stand welded of square steel tubes and controlled by a microprocessor system.

The sewing unit is operated via a control panel. Here it is possible to call up various control programs, to define new programs and to check all inlets and outlets for maintenance and repair purposes.

Machine head

– Pegasus two- or three-thread overlock machine

EX 5205-22/233-6KS

– Direct drive Efka Type DC 1500 /AB 221

– Microprocessor control, freely programmable

– Light barrier for recognizing the seam beginning and seam end for the automatic sewing start and stop

– Height-adjustable edge guide for different material thicknesses

– External control panel Efka V850 with:

Menu navigation

Freely programmable parameters for “machine parameters”, “Global parameters”, “Program sequences”

Input and output tests

20 program storage locations

up to 7 seam programs per program storage location

3

– Vertical cutter with suction for overlocking and serging in one operation

– Chain separator with suction, programmable

– Adjustable blowing nozzles in the table top for supporting the material feed

– Height-adjustable stand, infinitely variable from 850 mm to

1200 mm

– Integrated stacking device

1.3

Technical data:

Machine head:

Stitch type:

Number of needles:

Needle system:

Needle size:

Threads:

Speed:

Speed upon delivery: 7500 r/ min

Stitch length

Pegasus EX 5205-22/233-6KS

504/ 505

1

B27

Nm 80 to Nm 110 see table chapter 4.2

7500 r/ min

Seam width

Standard EX-head:

Optional EX-head:

Standard S52-head:

Optional S52-head:

Material:

Operating pressure:

Air consumption:

Rated voltage:

Rated load: 0.9 kVA

Dimensions:

Working height:

Weight: min.

max.

1.0 mm

5.0 mm

6 mm

4 mm/ 5 mm

6 mm

4 mm/ 5 mm

Light to medium-weight material

6 bar

20 NL per working cycle

1 x 230 V 50/60 Hz

1500 x 900 x 1400 mm (L x W x H)

850...1200 mm

(upper table top edge)

120 kg

Noise level: LC = 81dB (A)

Workstation-specific emission value according to DIN 45635-48-B-1

Stitch length: 3 mm

Seam length:

Speed:

1160 mm

7000 r/min

Material: G1 DIN 23328 1 layer

Measuring point according to DIN 4895 Part 1 X = 600 mm Y = 350 mm Z = 600 mm x - axis = at right angles to the feeding direction y - axis = main feeding direction z - axis = height

4

2.

Optional equipment

See annex

3.

Switching on - Switching off - Program stop

3.1

Switching on

3.2

Switching off

1

– Switch on main switch 1 (turn in clockwise direction).

The control loads the machine program.

The basic display appears in the display of the control panel.

– Switch off main switch 1 (turn counter-clockwise).

1

5

3.3

Program stop

2 2 1

For an immediate stop in case of operating errors, needle breakage etc. the safety system of the 1220/5 provides the following measures:

– Press program stop switch 2 at the control panel.

The running operations are stopped immediately.

– Turn main switch 1 counter-clockwise.

The sewing unit drops out immediately; all movements of the sewing unit stop immediately.

3.4

Restart after program stop

Caution: Risk of injury!

Switch the main switch off.

Clear the fault only with the sewing unit switched off.

Only restart the sewing unit after the fault has been cleared.

– Switch on main switch 1 (turn in clockwise direction).

– Unlock the program stop switch.

The control loads the machine program.

The basic display appears in the display of the control panel.

The sewing unit is ready for operation again.

6

4.

Operation of the sewing machine head

4.1

General notes

The operation of the sewing machine head (needle insertion, threading of needle thread and hook thread etc.) is described in the attached separate Pegasus operating instructions.

The instruction manual is included in the accessories of the sewing unit.

Attention: Risk of injury!

Please read the operating instructions of the sewing machine head carefully and observe all notes on safety.

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7

4.2

Recommended threads

Needle system:

Recommended needle size:

B27

Nm 80 for very thin material

Nm 90 for thin material

Nm 100 for medium-weight material

Nm 110 for heavy-weight material

High sewing security and good sewability are achieved with the following core threads:

– Two-ply polyester endless polyester core-spun

(e.g. Epic Poly-Poly, Rasant x, Saba C, ...)

– Two-ply polyester endless cotton core-spun

(e.g. Frikka, Koban, Rasant, ...)

If these threads are not available, the polyester fibre or cotton threads listed in the table can also be sewn.

Often two-ply core threads are offered by the thread manufacturers with the same designation as three-ply polyester fibre threads

(3cyl.-spun).This causes uncertainty with regard to twisting and thread thickness.

When in doubt, unravel the thread and check whether it is twisted 2- or

3-ply.

The label no. 120 on the thread reel of a core thread corresponds e.g.

to the thread size Nm 80/2 (see table values in brackets).

In case of monofilament threads you can use needle threads and hook threads of the same thickness. The best results are achieved with soft and elastic threads (software) of the thread thickness 130 Denier.

Needle size

Nm

Recommended thread thicknesses:

Needle thread

Polyester endless

Label No.

Core thread

Hook thread

Polyester core-spun

Label No.

Core thread

Needle thread

Polyester endless

Label No.

Hook thread

Cotton core-spun

Label No.

80

90

100 - 110

Needle size

Nm

80

90

100 - 110

120 (Nm 80/2)

100 (Nm 65/2)

120 (Nm 80/2)

100 (Nm 65/2)

Needle thread

Nm 120/3

Nm 80/3-120/3

Nm 70/3-100/3

Polyester fibre thread

(3cyl.-spun)

Hook thread

Nm 120/3

Nm 80/3-120/3

Nm 70/3-100/3

120 (Nm 80/2)

100 (Nm 65/2)

120 (Nm 80/2)

100 (Nm 65/2)

Cotton thread

Needle thread

Ne

B

60/3-80/3

Ne

B

50/3-70/3

Ne

B

40/3-60/3

Hook thread

Ne

B

60/3-80/3

Ne

B

50/3-70/3

Ne

B

40/3-60/3

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4.3

Removing / Putting on the fabric sliding sheet

2 3 2 1

The fabric sliding sheet 2 is held in the gap of the table top by the magnets 1.

The edge guide 3 is fastened on the fabric sliding sheet.

Removing the fabric sliding sheet

– Carefully remove the edge guide 3 from the magnets in upward direction.

– Swivel the fabric sliding sheet aside.

The lower section of the sewing machine head is accessible now.

Putting on the fabric sliding sheet

– Push the fabric sliding sheet into the gap of the table top and insert in downward direction.

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9

5.

Operation of the sewing unit

5.1

Feeding the trousers parts and starting the sewing process

The overlock unit 1220/5 works semi-automatically.

The operator of the sewing unit has to do the following: l call up the desired seam program; l feed the material precisely; l supervise the sewing process of the unit; l remove the finished parts from the stacker.

10

5 3 4 3 2 1

Feeding the trousers part and starting the sewing process

1) Select the seam program at the control panel (see chapter 6.3).

2) Position the trousers part 1 from the right on the table top 2 and

under the contour guide 3.

ATTENTION!

As soon as the trousers part is pushed under the light barrier 5, the sewing process starts automatically and the contour guide 3 lowers.

3) The trousers part is sewn.

4) As soon as the workpiece has left the light barrier 5, the seam is finished and the stamp 4 lowers.

5) The contour guide 3 moves upward.

6) The stacker clamp moves to the front.

7) The stamp 4 moves upward again.

8) The trousers part is stacked with an air blast.

5.2

Adjusting the edge guide

4 3 2 1

The height-adjustable edge guide ensures a precise positioning of the trousers part in front of the sewing head. The height of the edge guide can be adjusted according to the thickness of the material to be sewn.

The draw roll 3 guarantees that the workpiece is precisely guided under the sewing foot.

1

Adjusting the height of the edge guide

– Draw dial 1 in the direction of arrow.

– Set dial 1 on one of the four lock-in positions.

Position 1 = minimum height

Position 4 = maximum height

Fine adjustment of the height of the edge guide

– Turn dial 2 correspondingly.

Setting the contact pressure of roller 4

– Turn dial 3 in clockwise direction

The contact pressure of the roller is increased

– Turn dial 3 counter-clockwise

The contact pressure of the roller is reduced

11

5.3

Adjusting the blowing air for the nozzles in the table top

1

5.4

Setting the guide blade

2

The blowing nozzles 1 in the table top support the precise stacking of the workpieces.

– Set the intensity of the air blast by dial 2 at the control panel.

Turn the dial to the right = increased intensity of air blast

Turn the dial to the left = reduced intensity of air blast

2

1

By means of the guide blade 1 the run of the workpiece can be influenced.

– Release lever 2.

– Pull the guide blade 1 out or push it in.

– Tighten lever 2.

12

6.

Operation of the control

6.1

Operator terminal

For the input and output of data an operator terminal with an LCD display and function keys is used.

Display Enter keys

Keys 1 - 0

Function keys

Programstop

1

Key

—

Function

Seam program 1 to program 20

Manual stacking

Menu selection/ Data storage

Set function auxiliary roller

Set function holding stamp

Set machine parameters

Key sewing stop in the seam

Input/ Output test

Sequence programming (S)

Program creation (Prg)

Set global parameters

Enter key

Select parameters / scroll

Alter parameter values

13

6.2

User interface

6.2.1

Menu structure of the sewing and setting programs

Switch on main switch

Main screen

to

Call up sewing programs Menu selection

Key 3 Adjust auxiliary roller

Key 4 Adjust holding stamp

Key 5 Set machine parameters

Key 7 Sewing stop in the seam

Key 8 Input-Output test

Key 9 Set global parameters

Key 0 Program creation / Sequence creation

Key F2

Manual stacking

14

Calling up sewing programs

– Switch the main switch on.

The control initializes.

The seam program previously used is loaded.

– Press one of the keys “1, 2, 3, 4, 5, 6, 7, 8, 9, 0”.

The selected seam program is loaded.

Calling up the parameter menu


The control initializes.

The previously used program appears in the display.

– Press key “P”.

The selection menu is called up.

– Press one of the keys “1, 2, 3, 4, 5, 6, 7, 8, 9, 0”.

The display changes over to the corresponding function.

Manual stacking

When the seam program is selected:

– Press key “F2”.

The stacker makes a stacking movement.

1

15

6.3

Seam programs

16

Designation of the individual seams:

1 = hem

2 = waistband

3 = fly seam or seat seam

4 = crotch seam

5 = side seam

The sewing unit 1220/5 is delivered with 5 standard seam programs:

Program Description

001

002

Sew crotch seam (4)

Sew side seam (5)

003 Sew hem (1) with joining crotch seam (4)

004

005

Sew hem (1) with joining side seam (5)

Sew hem (1) and seat seam (3) with joining crotch seam (4)

A seam program in the display of the control panel

Program No.

Seam No.

6.4

Adjusting the control

The parameter values are altered in the individual parameter menus.


– Select the menu item.

– Select the parameter to be altered with the keys “F1” or “F2”.

– Press key “E”.

– Alter the parameter value with the keys “Plus” or “Minus”.


The new parameter value is stored.


You return to the selection menu


You return to the sewing program

6.4.1

Altering seam-specific parameters

Auxiliary roller

Via this parameter the auxiliary roller is adjusted.

Parameter 13: Number of stitches when the auxiliary roller lowers.

Setting range: 0 …400 stitches

Parameter 14: Number of stitches how long the auxiliary roller remains lowered.


1

Adjusting the holding stamp

Via this parameter the holding stamp is adjusted.

Parameter 15: Number of stitches when the stamp lowers.


Parameter 16: Number of stitches how long the warp separator remains switched on.


Parameter 17: Switch the stacker on or off

Setting range: 0 … 2000

Parameter 57: Time how long the holding stamp is down.

Setting range: 0 / 1

17

18

Altering the machine parameters

Parameter 30: Set the main speed

Setting range: 0 …7000

Parameter 31: Switch manual sewing on or off


Parameter 32: Time how long the table blowing remains switched on


Parameter 44: Number of stitches until the contour guide lowers

Input: 0 …200

Parameter 60: Softstart speed

Setting range: 500 ...5000

Parameter 61: Switch the softstart on or off


Parameter 62: Softstart speed

Setting range: 1 ...5000

Parameter 76: Switch the start via light barrier on or off


Parameter 77: Switch the autostart on or off


Parameter 78: Number of stitches when the autostart starts

Setting range: 0 ...400 stitches

Altering the seam lines

Via this parameter the parameters for the individual seam lines are set.

Parameter 81: Length of seam line 1


Parameter 82: Switch the speed reduction in seam line 1 on or off


Parameter 83: Reduce the speed in seam line 1


Parameter 84: Switch the stop within the seam on or off


Parameter 85: Switch the sewing foot lift within the seam on or off


Parameter 86: Seam line 2 to

Parameter 90 Values see seam line 1

Parameter 91: Seam line 3 to

Parameter 95 Values see seam line 1

6.4.2

Altering the global parameters

Parameter 45: Number of stitches until the table blowing is switched on

Input: 0 …200

Parameter 46: Duration of the stacker impulse

Input: 0 ..2000

Parameter 47: Time of stacker movement

Input: 0 …2000

Parameter 48: Speed limitation

Input: max. 7000

Parameter 49: Speed at warp separation

Input: 0 …5000

Parameter 50: Number of stitches until the thread tension is opened (seam end)

Input: 0....50

Parameter 56: Seam programming on/ off

On = Determine the seam sequences in the current

Input: program

Off = Create the next free program with seams

0 and 1

Parameter 58: Display of the software version

Parameter 59: Number of stitches how long the seam chain is sucked (seam beginning)

Input: 0 ...150

1

19

6.4.3

Input - Output test

Via the input - output test the different input and output elements can be checked.

Input test


– Press key “8”.

– Actuate the corresponding input.

Example:

Cover the light barrier.

– Press key “Program stop”.

The program is quitted.

Input elements

Switch Designation

01

05

Light barrier 01

Switch “Program stop”

Output test



– Press key “Plus”.

– Select the output element to be tested with the keys “Plus” or

“Minus”.

– Switch the output on or off with the key “F2”.

– Press key “Program stop”.

The program is quitted.

Output elements

Switch Designation

Y01

Y02

Y03

Y04

Y05

Y06

Y12

Y13

Y14

Sewing foot up / down

Thread tension lift open / closed

Contour guide up / down

Stacker off / on

Holding stamp up / down

Auxiliary roller up / down

Warp separator off / on

Table blowing off / on

Dirt suction off / on

20

6.4.4

Creation of seam programs

Note

Before a new seam program can be created or an existing one can be deleted, the global parameter “56” has to be set to the value “0”.

This avoids that the existing programs are changed inadvertently.


– Press key “0” (global parameters).

– Change over to parameter 56 with key “F1”.


The parameter 56 is selected.

– Set the parameter value to “0" with key “Minus.


The new parameter value is stored.


You return to the selection menu.

1

Creating a seam program


– Press key “9” (Prg = programs).

– Press key “F1” twice.

– Select a seam with one of the keys “1” to “9”.


The selected seam is taken over.

– Select a further seam with one of the keys “1” to “9”.

or


The new setting is stored and you return to the selection menu.

Note

After the creation of a new seam program the parameter “56" has to be reset to the value “1” for safety reasons.

21

6.4.5

Deleting a seam program




The display indicates:

DELETE?

– Press key “F2” anew.

The program is deleted.


You return to the selection menu.

6.4.6

Altering seam programs (Changing / Completing the sequence)

Note

Before a seam program can be altered,the parameter “56” has to be set to the value “1".

This avoids that the existing programs are deleted inadvertently. (see chapter 6.4.3, paragraph 1)

– Select the program to be altered.


– Press key “9” (S = sequence).

– Select a free location with the keys “Plus” or “Minus”.

– Select a seam number with the keys “1” to “9”.

You can select further seam numbers or quit the menu.

– Select another free location with the keys “Plus” or “Minus”.

Or


The seam program is stored and you return to the selection menu.

22

7.

Error messages

In case of an error in the control system or in the machine program corresponding error messages are indicated in the display.

Display Meaning

Error 1

Error 2

Error 3

One of the parameters “18” or “19” is switched on

(value = 1)

Both parameters “18” and “19” are switched on

(value = 1)

In the current program the last existing seam was to be deleted.

Errors of free programming

Info U1 FP custom code wrong, e.g. describing a parameter which does not exist.

Info U2 Wrong system function

Info U3

Info U4

Info U5

Info U6

Wrong in / out number

Too many user variables

Too many system variables

Not enough storage location for the user program

Info U7

Info U8

Info U9

Wrong or undefined key in the Vario

Unknown device address

Fatal exception error

Errors and informations bootload

Info B1 Switch on control in the boot mode and press key “F2”

Info B2

Info B3

Programming of segment number

Flash programming failed

Info B4 Flash programming okay

1

23

8.

USB stick

8.1

General notes

1

The USB stick 1 serves for storing and transferring of the sewing unit software.

By means of the USB stick program and parameter data can also be transferred to other sewing units.

Commercially available USB 1 sticks can be used, too.

8.2

Formatting the USB stick

Before using a new USB stick this has to be formatted correspondingly.

The file format is the “FAT 16” system.

– Format the USB stick with the FAT 16 system via a PC.

8.3

Plugging the USB stick in the control

– Switch the main switch off.

– Plug the USB stick 1 in the lower slot of the Efka control.

– Press key “P” and keep it pressed.


The message appears for a moment.

USB. DEV. DETECT:

– Keep key “P” pressed until the following message appears in the display:

SERVICE - CODE

– Enter CODE 3112.


24

8.4

USB functions

The following functions can be carried out with a USB stick:

1) Storing and loading of global parameters

File extension = *. PAR

Parameter

F-510

F-511

F-512

F-513

Function

Securing from the control on the USB stick

Loading from the USB stick in the control

Comparing USB stick and control data

Deleting data from the USB stick

2) Storing and loading of programs and seam parameters

File extension = *.PAY

Parameter

F-514

F-515

F-516

F-517

Function

Securing from the control on the USB stick

Loading from the USB stick in the control

Comparing USB stick and control data

Deleting data from the USB stick

1

3) Loading a new software version

File extension = *.PRG

Parameter

F-523

Function

Load a new software version from the

USB stick in the control

By means of the FAT 16 file system the control allocates file names with max. 8 characters.

Max. 8 characters 1 2 3 4 5 6 7 8

1 2 2 0 _ 5 D _ 1 A .PRG

Software version

Machine type

Language

Equipment

1 = Parameter file

2 = Program file

Version

25

26

If different program or parameter files are stored, the control allocates a new name each.

Example:

Storing of different parameter data

1st file 0100DATA.PAR

2nd file etc.

0101DATA.PAR

The files can individually be renamed by the file manager or explorer on a PC.

Note

On principle, the Efka control can read data from the main level of the

USB stick only. Data from subdirectories cannot be processed.

8.4.1

Storing data on the USB stick

– Enter parameter.

Example: 510

– Press key “E”

The cursor flashes.


The file name chosen by the control appears.

Example

0100DATA.PAR


The data are written on the USB stick.

Note

The file name is allocated automatically.

8.4.2

Loading data from the USB stick


Example: 511

– Press key “E”

The cursor flashes.


The name of the first file stored on the stick appears.

Example

0100DATA.PAR

– Select the desired file with the keys “+” or “-”.


The message appears.

READ DATA YES = E

– Press key “E” within 2 seconds.

The data are read from the USB stick.

1

27

8.4.3

Data comparison


Example: 512


The file name chosen by the control appears.

Example

0100DATA.PAR



READ DATA YES = E


The data of the USB stick and the control are compared.


READ DATA

Possible displays

DATA OK

DATA DIFFERENT

The data on the stick are identical with the data of the control

The data of the stick and the control are not identical.

8.4.4

Deleting data from the USB stick


Example: 513


The cursor flashes.


The name of the first file appears on the stick.

Example

0100DATA.PAR

– Select the desired file with the keys “+” or “-”.

Example

0105DATA.PAR


The data from the USB stick are deleted.


READY

28

8.4.5

Loading software version from the USB stick

– Enter parameter 523.


The cursor flashes.



Example

20_5D_1A.PRG

– Select the desired parameter file with the keys “+” or “-”.



READ DATA YES = E



– Press key “P” and wait approx. 3 seconds until “Save Data” fades out.

1

– Press key “E” twice.

The cursor flashes.



Example

20_5D_2A.PRG

– Select the desired program file with the keys “+” or “-”.



READ DATA YES = E



– Switch the main switch off and on again.

The new software version is loaded now.

29

8.5

Removing the USB stick

1

– Switch the main switch off.

– Pull the USB stick 1 out of the slot of the Efka control.

30

9.

Maintenance

9.1

Cleaning and checking

Caution: Risk of injury !


The maintenance of the sewing unit must only be carried out with the machine switched off.

Maintenance work has to be done after the intervals indicated in the tables at the latest (see column “Operating hours”).

The processing of fluffy material may require shorter maintenance intervals.

A clean sewing unit protects from disturbances.

1

1

2

6 5 4 3

31

Maintenance work to be done

Machine head

- Remove sewing dust and thread

remainders.

(e.g. with compressed air pistol)

Explanation

Clean the entire area 1 of the thread guides under the fabric sliding sheet

Suction device Empty container 2 of the suction device

- Turn the bottom part of the container to the left and remove it

- Empty the container

- Screw the bottom part on again in clockwise direction

Pneumatic system

- Check the water level in the

pressure regulator 3

- Clean the filter insert 4

The water level must not rise up to the filter insert 4.

- Let the water run out of the water separator under pressure after pressing the drain plug 5.

The filter insert 4 separates dirt and condensed water.

- Separate the sewing unit from the compressed air net.

- Push in drain plug 5.

The pneumatic system of the sewing unit has to be pressureless.

- Screw the water separator 6 off

- Remove filter insert 4.

Wash the dirty filter tray and the filter insert with benzine (no solvent!) and blow them clean.

- Reassemble the water separator and connect the maintenance unit.

- Make leak test of the system

Operating hours

8

8

40

500

500

32

9.2

Oil lubrication

Maintenance work to be done

Lubrication

2 1


Oil may cause skin eruption.

Avoid a longer contact with the skin.

Wash yourself thoroughly after a contact.

ATTENTION !

The handling and disposal of mineral oils is subject to legal regulations.

Deliver used oil to an authorized collecting station.

Conserve your environment.

Be careful not to spill any oil.

Oil the head of the sewing unit exclusively with lubricating oil DA-10 or an equivalent oil with the following specification:

– Viscosity at 40° C:

– Ignition point:

10 mm²/s

150° C

DA-10 can be bought at the sales points of DÜRKOPP ADLER AG under the following parts numbers:

Container 250 ml:

Container 1 litre:

Container 2 litres:

Container 5 litres:

9047 000011

9047 000012

9047 000013

9047 000014

Explanation

Check the oil level at the sewing machine head regularly (inspection glass 1 and 2).

Operating hours

8

Please take further details from the enclosed operating instructions of the sewing machine head.

1

33

Note:

34

In dex Page:

Part 2: Assembly in structions cl. 1220/5

1.

2.

3.

3.1

3.2

3.3

3.4

4.

4.1

4.2

5.

6.

6.1

Sco pe of de li very. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3

Ge ne ral no tes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3

In stal ling the se wing unit

Trans port pro tec tions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4

Setting the wor king height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4

Mounting the thread reel hol der. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5

Aligning the con trol panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5

Elec tri cal con nec ti on

Che cking the no mi nal vol ta ge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6

Ma king the mains con nec ti on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6

Pneu ma tic con nec ti on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7

2

Put ting into ope ra ti on

Se wing test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8

7

6

1

2

3

4

5

1.

Sco pe of de li very

The scope of delivery depends on your order.

The sewing unit consists of:

– 1 Sewing machine head (as per order)

– 2 Thread reel holder

– 3 Control with control panel

– 4 Material tray

– 5 Stand and table top

– 6 Suction unit with suction container

– 7 Stacker

– Compressed air maintenance unit

2.

Ge ne ral no tes

ATTENTION !

The sewing unit must only be installed by trained specialist staff.

Any work on the electrical equipment of the sewing unit must only be carried out by electricians or correspondingly instructed persons.

The mains plug must be pulled out.

The enclosed operating instructions of the drive motor manufacturer have to be observed.

2

3

3.

In stal ling the se wing unit

3.1

Trans port pro tec tions

1

Before the installation of the sewing unit all transport protections have to be removed.

– Remove the security tapes at the thread reel holder, machine table etc.

– Remove the protective foils 1.

3.2

Setting the working height

1

2

The working height is adjustable between 850 and 1200 mm

(measured up to the top edge of the table top).

– Loosen screws 1 and 2 at the spars.

– Set the desired working height with the help of suitable auxiliary means.

In order to avoid jamming lift the table top equally on both sides.

– Retighten screws 1 and 2 at the spars.

4

3.3

Mounting the thre ad reel hol der

2 1 3 2

– Insert thread reel holder 1 in retainer 2.

– Tighten the thread reel holder with the two screws 3.

3.4

Aligning the con trol panel

2

3 2 1

The control panel 1 has been lowered for transportation.

– Loosen screws 3.

– Pull tube 2 holding the control panel right to the top.

– Retighten screws 3.

5

4.

Elec tri cal con nec ti on

ATTENTION !

Any work on the electrical equipment of the sewing unit must only be carried out by electricians or correspondingly instructed persons.

The mains plug must be pulled out.

4.1

Che cking the no mi nal vol ta ge

ATTENTION !

The nominal voltage indicated on the type plate of the sewing machine control and the mains voltage must correspond.

Nominal voltage = 190 - 240 V, 50/60 Hz

4.2

Ma king the mains con nec ti on

– Connect the mains plug.

6

5.

Pneu ma tic con nec ti on

For the operation of the pneumatic components the sewing unit has to be provided with anhydrous compressed air.

ATTENTION!

For a trouble-free function of the pneumatic control processes the compressed air net has to be rated as follows:

Even in the moment of maximum air consumption the minimum operating pressure must not drop below 6 bar.

In case of a too high air pressure decrease:

– Increase the compressor output.

– Increase the diameter of the compressed air supply line.

3 2 1

Connecting the compressed air maintenance unit

– Connect the connecting hose 3 to the compressed air net.

Setting the operating pressure

– The operating pressure amounts to 6 bar.

It can be read off at the manometer 1.

– For setting the operating pressure pull up and turn the rotary handle 2.

Turn in clockwise direction = increase the pressure

Turn counter-clockwise = reduce the pressure

ATTENTION !

No oil-bearing compressed air must be fed from the compressed air net.

Behind the filter cleaned compressed air is withdrawn as blowing air for cleaning machine parts and for blowing workpieces out.

Oil particles contained in the blowing air lead to malfunction and stains on the workpieces.

7

2

6.

Put ting into ope ra ti on

6.1

Se wing test

After completion of the installation work a sewing test should be made.

– Plug in the mains plug.



Thread in needle and hook thread only with the sewing unit switched off.

– Thread in needle and hook thread

(see operating instructions of the sewing machine head).


The control is initialized.

– Select the sewing program.

– For feeding and operating see part 1:

Operating instructions 1220/5

8

Index Page:

Part 3: Service instructions class 1220/5

1.

General notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.

Brief instructions for the sewing head

2.1

Adjusting the height of the needle bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.2

Adjusting the hook . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.2.1

Distance between left hook and needle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.2.2

Distance between right hook and needle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.3

Adjusting the needle protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.3.1

Hind needle protection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.3.2

Front needle protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.4

Adjusting the feed-dog. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.4.1

Feed-dog position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.4.2

Feed-dog height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.5

Presser foot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.5.2

Presser foot lift of head EX5204 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.5.2

Presser foot lift of head S52 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.5.2

Presser foot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.6

Upper and lower knife . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.6.1

Changing and adjusting the upper knife . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.6.2

Changing and adjusting the lower knife . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.7

Thread regulation of overlock hook . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.

Adjusting the sewing unit

3.1

Adjusting the light barrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.2

Direct sewing drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.2.1

Setting the reference. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.

Oil lubrication

4.1

Oil change and oil filter change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3

19

20

20

21

22

13

13

14

15

10

11

11

12

16

16

17

18

9

9

5

7

4

5

3

1.

General notes

The service instructions on hand describe the adjustment of the single-head overlock unit 1220/5.

The manual consists of:

·

Brief instructions for the sewing head

·

Service instructions for the sewing unit

ATTENTION !

The brief instructions are a summary of the detailed operating instructions of the sewing head. In any case these operating instructions have to be carefully read and all regulations have to be observed. The Beisler company does not guarantee the accuracy of the following specifications.

ATTENTION !

The operations described in the service instructions must only be executed by qualified staff or correspondingly instructed persons respectively!


In case of repair, alteration or maintenance work switch the main switch off.

Carry out adjusting operations and functional tests of the running machine only under observation of all safety measures and with utmost caution.

3

The instruction manual on hand describes the adjustment of the sewing unit in an appropriate sequence.

Please observe in this connection that various setting positions are interdependent.

Therefore it is absolutely necessary to do the adjustment following the described order.

For all setting operations of parts involved in the stitch formation a new needle without damage has to be inserted.

3

2.

Brief instructions for the sewing head

2.1

Adjusting the height of the needle bar

1 2

5

3

4



Check and adjust the height of the needle bar only with the sewing unit switched off.

Standard checking

In the top dead centre of the needle bar the distance between the needlepoint 4 and the throat plate should amount to 9.7 - 9.9 mm.

– Move the needle bar in its top dead centre.

– Check whether the distance between needlepoint 4 and throat plate 5 amounts to 9.7 - 9.9 mm.

Correction

– Unscrew screws 1 and remove cover 2.

– Move the needle bar in its top dead centre.

– Swivel the sewing foot out.

– Loosen screw 3 until the needle bar can just be pushed.

– Shift the needle bar in such a way that the distance between needlepoint 4 and throat plate amounts to 9.7 - 9.9 mm.

– Tighten screw 3.

– Screw cover 2 on again.

4

2.2

Adjusting the hook

2.2.1

Distance between left hook and needle

5

2,3 - 2,5 mm

1

2

3

4

5



Check and adjust the hook only with the sewing unit switched off.

Cross-line adjustment


In the left reverse point of hook 5 the distance between the middle of the needle and the hook tip should amount to 2.3 - 2.5 mm.

– Move the left hook in its left reverse point by handwheel.

– Check whether the distance between the middle of the needle and the hook tip amounts to 2.3 - 2.5 mm.

Correction

– Unscrew the throat plate, the front feed-dog as well as the front and hind needle protection.

– Move the hook in its left reverse point by handwheel.

– Loosen screw 1 and take care that the hook abuts on stop 2.

– Tighten screw 1 again.

– Loosen screw 4 until the hook support 3 can just be turned.

– Turn the hook support in such a way that the distance between the middle of the needle and the hook tip amounts to 2.3 - 2.5 mm.

Note

Do not yet tighten screw 4.

3

5

6

4

2,3 - 2,5 mm

3

0 - 0,05 mm

6

7

Adjustment in sewing direction


The distance between hook tip 6 and needle 7 should amount to

0.0 - 0.05 mm.

– Turn handwheel in direction of rotation until the hook tip is exactly at the level of the middle of the needle.

– Shift the hook support 3 in such a way that the distance between hook support and needle amounts to 0.0 - 0.05 mm.

– Check the cross-line adjustment once again and readjust, if necessary.


2.2.2

Distance between right hook and needle

1

9

10

4,3 - 4,5 mm

3

4

8

7 5

6

2



Check and adjust the hook only with the sewing unit switched off.

Cross-line adjustment


When the right hook is in its top reverse point, the distance between hook tip 9 and the middle of the needle should amount to 4.3 - 4.5 mm.

– Screw off thread guides 1 and 3 as well as cover 2.

– Move the hook in its top dead centre by handwheel.

– Loosen screw 4 until the hook can just be pushed.

– Shift the hook in such a way that the hook shank (1) is flush with the right side of the hook holder.

– Loosen screw 6 a little.

– Turn lever 5 in such a way that there is a distance of 4.3 - 4.5 mm between hook tip and the middle of the needle.

Take care that the bar 8 in the bearing 7 does not move too heavy.


Note

Do not yet tighten screw 4.

3

7

8

4

Adjustment in sewing direction


When the right hook crosses the left hook, the distance “A” should amount to 0.5 mm and the distance “B” to 0.2 mm.

Correction

– Turn handwheel in direction of rotation until the right hook crosses the left hook.

– Turn and shift the right hook in such a way that the distance “A” amounts to 0.5 mm and the distance “B” to 0.2 mm.

– Tighten screw 4 in this position.

– Check all adjustments once again and readjust, if necessary.

– Remount thread guides 1 and 3 as well as cover 2.

– Adjust thread guides according to chapter “thread regulation of the overlock hooks”.

Note

The right overlock hook is dependent on the needle size.

Use hook No. 28 for needles Nm 60 - 80 and hook No. 22 for needles

Nm 80 - 100.

2.3

Adjusting the needle protection

2.3.1

Hind needle protection

3

1

2 3

4

3

4



Check and adjust the needle protection only with the sewing unit switched off.


When the tip of the left hook 3 is at the level of the middle of the needle, the needle protection 1 should abut on the needle. There should be a distance of 0.0 - 0.05 mm between hook tip and needle.

– Turn handwheel in direction of rotation until the hook tip points in the needle direction.

– Check the distance between hook tip and needle.

Correction of the mobile version


– Loosen screw 2.

– Shift the needle protection 1 in such a way that it abuts on the needle and there is a distance of 0.0 - 0.05 mm between hook tip and the middle of the needle.


Correction of the stationary version


– Loosen screws 4.

– Shift the needle protection 3 in such a way that it abuts on the needle and there is a distance of 0.0 - 0.05 mm between hook tip and the middle of the needle.

– Tighten screws 4.

3

9

2.3.2

Front needle protection

1

4

1

2



Check and adjust the needle protection only with the sewing unit switched off.


In the lower dead centre of the needle the distance between needle protection 1 and needle should amount to 0.03 - 0.05 mm.

– Turn handwheel in direction of rotation until the needle is in its lower dead centre.

– Check the position of the front needle protection.

Correction

– Turn handwheel in direction of rotation until the needle is in its lower dead centre.

– Loosen screw 2.

– Shift the needle protection 1 in such a way that there is a distance of 0.03 - 0.05 mm between needle protection and needle.


10

2.4

Adjusting the feed-dog

2.4.1

Feed-dog position

1

2

2 1



Check and adjust the feed-dog position only with the sewing unit switched off.


In their highest position the feed-dogs should be horizontal.

– Turn handwheel in direction of rotation until the feed-dogs are in their highest position.

– Check the position of the feed-dogs.

Correction

– Turn handwheel in direction of rotation until the feed-dogs are in their highest position.

– Loosen screw 1.

– Turn screw 2.

Feed-dogs are horizontal

Feed-dogs are inclined backwards

Feed-dogs are inclined forwards


3

11

2.4.2

Feed-dog height

6

3

4

5

1

2



Check and adjust the feed-dog height only with the sewing unit switched off.


When the feed-dogs are in their highest position, the teeth of the main feed-dog 4 should be 0.8 mm above the top edge of the throat plate, the teeth of the differential feed-dog 5 0.9 to 1.0 mm and the teeth of the auxiliary feed-dog 6 0.6 to 0.7 mm.

– Turn the handwheel in direction of rotation until the feed-dogs are in their highest position.

– Check the position of the feed-dogs to the throat plate.

Correction

– Unscrew throat plate.

– Loosen screws 1, 2 and 3 a little.

– Put throat plate on again.

– Set the height of the feed-dogs.

– Remove the throat plate.

– Tighten screws 1, 2 and 3.

– Put throat plate on again and tighten.

12

2.5

Presser foot

2.5.2

Presser foot lift head EX5204

7 6 5 4 3 2 1



Check and adjust the presser foot lift only with the sewing unit switched off.

8

7

Standard

When the piston rod 7 is extended, the lever 6 should abut on screw 5 and the clearance under the sewing feet should amount to 4 mm.

Correction

– Loosen counternut 4 and screw the screw 5 down completely.

– Swivel the sewing foot in.

– Turn handwheel in direction of rotation until the teeth of the feed-dog are underneath the top edge of the throat plate.

– Loosen screw 2 and press ring 1 backwards as far as it will go.


Take care that ring 1 and lever 3 have no axial backlash.

– Press lever 6 down until there is a distance of approx. 4 mm between sewing foot and throat plate.

– Let screw 5 abut on lever 6 in this position and fix it by a locknut.

Note

If lever 6 does not abut on screw 5 when the piston rod 7 of the cylinder is extended, please proceed as follows:

– Loosen nut 8.

– Shift cylinder 1 correspondingly.

– Tighten nut 8.

3

13

2.5.2

Presser foot lift head S52

2 3

4

1

8

1

7

9

10

6

11

5



Check and adjust the presser foot lift only with the sewing unit switched off.

Standard

When the piston rod 1 is extended, the lever 4 should abut on screw 6 and the clearance under the sewing feet should amount to 5 mm.

Furthermore there should be a distance of 0.3 mm between stop 11 and screw 10 in this position.

Correction

– Loosen counternut 5 and screw the screw 6 down completely.

– Swivel the sewing foot in.

– Turn handwheel in direction of rotation until the teeth of the feed-dog are underneath the top edge of the throat plate.

– Loosen screw 2 and press ring 3 backwards as far as it will go.


Take care that ring 3 and lever 4 have no axial backlash.

– Press lever 7 down until there is a distance of approx. 5 mm between sewing foot and throat plate.

– Let screw 6 abut on lever 4 in this position and fix it by a locknut.

Note

If lever 4 does not abut on screw 6 when the piston rod 1 of the cylinder is extended, please proceed as follows:

– Loosen nut 8.

– Shift cylinder 1 correspondingly.

– Tighten nut 8.

– Loosen screw 9.

– Turn screw 10 in such a way that there is a distance of approx.

0.3 mm between screw 10 and stop 11.

Take care that lever 7 is pressed down as far as it will go.


14

2.5.2

Presser foot

1

3

2



Check and adjust the presser foot only with the sewing unit switched off.


When the feed-dogs are in their lowest position, the sole of the presser foot should be 0.1 to 0.2 mm up at the front.

Furthermore, the needle hole of the sewing foot and that of the throat plate should be in line.

– Move the feed-dogs in low position.

– Check the presser foot position.

3

Correction

– Loosen screws 2 and 3.

– Shift the presser foot in such a way that the needle hole of the presser foot and that of the throat plate are in line.

– Tighten screws 2 and 3.

Take care that the sole of the presser foot is above the throat plate in parallel position.

– Turn screw 1 in such a way that the sole of the presser foot is 0.1

to 0.2 mm up at the front.

15

2.6

Upper and lower knife

2.6.1

Changing and adjusting the upper knife

Head EX 5205-22/233-6KS Head S52 134B

1 2 3

16

4

6

7

5

3 2 1



Change and adjust the upper knife only with the sewing unit switched off.

Standard

In the lowest position of the upper knife the front edge of the blade should be 0.5 to 1.0 mm underneath the top edge of the throat plate.

Correction

– Turn the handwheel until the needles are in their top reverse point and swivel the sewing foot out.

– Screw off screw 1.

– Remove the knife holder 2 with the knife.

– Loosen screw 3 and remove the knife.

– Insert a new,sharp knife and tighten with screw 3.

– Insert knife holder 2 and tighten slightly with screw 1.

– Turn the handwheel until the knife is in its lowest position.

– Shift the knife in such a way that it slightly abuts on the lower knife and the front edge of the blade is approx. 0.5 to 1.0 mm underneath the top edge of the throat plate.

Head S52 134B only

– Let the stops 4 and 5 abut on the knife in this position and tighten screws 1 and 3.

– Turn the handwheel until the knife is in its highest position.

– Loosen screw 6.

– Shift the lower knife to the left and let it spring against the upper knife.


2.6.2

Changing and adjusting the lower knife

Head EX 5205-22/233-6KS Head S52 134B

1

2

4

3

4 3 2 1



Change and adjust the lower knife only with the sewing unit switched off.

3

Standard

The blade of the lower knife has to be flush with the top edge of the throat plate.

Correction

– Remove the fabric sliding sheet.

– Swivel the sewing foot out.

– Loosen screw 4.

– Draw the holder of the lower knife 3 to the left as far as it will go and tighten screw 4 slightly.

– Loosen screw 2 and remove the old knife.

– Insert a new, sharp knife in guide 1 in such a way that the blade is flush with the top edge of the throat plate.


– Turn the handwheel until the upper knife is in its highest position.

– Loosen screw 4 and let the holder of the lower knife 3 spring against the upper knife.


17

2.7

Thread regulation of overlock hook

1 2 3

5

4

10

9

8 7 6



Check and adjust the thread regulation only with the sewing unit switched off.

Standard

The position of the individual thread guides or thread pullers is dependent on the material, the sewing thread and the stitch type.

Therefore the following setting values have to be regarded as standard values only.

Correction

– Turn the handwheel until the right hook is in its top reverse point.

– Loosen screw 10 and shift the thread puller 9 in such a way that there is a distance of approx. 32 mm between the middle of the screw and the middle of the eyelet.


Take care that the thread puller 9 is in vertical position.

– Loosen screws 6 and 8 a little.

– Position the thread pullers 3 and 7 as shown in the illustration.

– Tighten screws 6 and 8.


– Position the thread guide 5 as shown in the illustration.



– Shift the thread guide 1 in such a way that the screw 2 is in the centre of the longitudinal hole.


Note

If the seam requires more or less thread, shift the thread pullers 3 and

7 in the direction “+” or “-” respectively.

18

3.

Adjusting the sewing unit

3.1

Adjusting the light barrier

2 1

6 5

4 3


The adjustment of the light barrier is done with the sewing unit switched on.

Carry out adjustment and function test with utmost caution.

Aligning the light barrier

The light barrier 2 has to be aligned to the area 1 of the machine head.

– Loosen screw 3.

– Align the light barrier support 4 correspondingly.


Adjusting the light barrier intensity

– Turn the sensitivity potentiometer 5 at the front above the light-emitting diode 6 to the left stop (minimum sensitivity).

– Turn the potentiometer in clockwise direction until the light-emitting diode 6 switches on.

– For a safe light barrier function turn the potentiometer once again in clockwise direction.

If the light-emitting diode does not shine, the light barrier should be cleaned, reset or exchanged.

3

19

3.2

Direct sewing drive

3.2.1

Setting the reference

1



Check and adjust the hook setting only with the sewing unit switched off.

Standard

When the needle is in the position “7 mm after the bottom dead

centre”, the drive belt has to be put on in such a way that the feather key 2 in the motor shaft points to the marking 1 in the motor casing.

Correction

– Remove the toothed belt.

– Move the needle bar in the position “7 mm after the bottom dead

centre” by handwheel.

– Turn the motor shaft in such a way that the feather key 2 in the motor shaft points to the marking 1 in the motor casing.

– Put the toothed belt on again.

7 mm bottom dead centre

20

4.

Oil lubrication


Oil can cause skin eruption.

Avoid a longer contact with the skin.

Wash yourself thoroughly after a contact.

ATTENTION !

The handling and disposal of mineral oils is subject to legal regulations.

Deliver used oil to an authorized collecting station.

Conserve your environment.

Be careful not to spill any oil.

4.1

Oil change and oil filter change

2

5

6

1

4

7

8

4 weeks after the initial start-up and subsequently every two years an oil change has to be carried out with the machine head disassembled.

The oil filter should be cleaned or exchanged every two years.

Note

If the oil pressure gauge 5 does not move downwards when the machine head is running or if the oil is dirty, the oil filter has to be cleaned or exchanged.

– Unscrew the drain screw 1 and collect the used oil in a collecting basin.

– Screw drain screw 1 in again.

– Unscrew screws 6 of the cover.

– Screw one of the screws 6 in filter 8 and unscrew the filter.

– Clean or exchange filter 8.

– Insert a new gasket 7, put the cover on again and tighten.

– Unscrew screw 2 and fill in oil until the point of the oil level indicator 3 has reached the upper marking of the oil inspection glass 4.

We recommend to use oil with a density of 0.865 g/cm³ at 15 ° C.

– Insert screw 2 again.

3

21

5.

Maintenance



The maintenance of the sewing unit must only be done with the machine switched off.

The daily or weekly maintenance work (cleaning and oiling) to be carried out by the operators of the sewing unit is described in the operating instructions (chapter 8). This is listed in the following table for the sake of completeness only.

Maintenance work to be carried out

Machine head

- Remove sewing dust and thread remainders

- Check the oil level

- First oil change

- Subsequent oil change

Control box

- Remove sewing dust and thread remainders

- Keep the fan grill clean

Suction device

- Empty the container

- Clean the zone under the fabric sliding sheet from sewing dust and thread remainders

Pneumatic system

- Check the water level in the pressure regulator

- Clean the filter insert in the maintenance unit

- Make leak test of the system

X

X

X

X

Operating hours

8 40 160 500

X

X

X every 2 years

X

X

22

warp separator

Kett up dirt suction

Schmutz saugen table blowing

Tischblasen contour guide

Konturenführung

Z03 sewing foot

Nähfuß

Z01 auxyliary roller up

Konturenrolle lüften

Z06 stacker

Stapler

Z04 holding stamp

Haltestempel

Z05 thread tension

Spannungslüftung

P

A

R

Y12

2

1

Y14

2

1

Y13

2

1

Y03

4 2

5

1

3

Y01

2

1 3

Y06

2

1 3

Y04

4 2

5

1

3

Y05

4 2

5

1

3

Y02

2

1 3 a b c d

Aenderung Datum Name gez.

Datum Name

30.11.05

Roth gepr.

Benennung:

Pneumatikplan 1220-5

Zeichnungs-Nr.

P 1220-5

Anlage

Ort

Blatt

Nr.

von

Blatt

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