Benutzerhandbuch Sprint-Sprint XL-JAFA-JNFA-RACER

USER MANUAL
SPRINT • SPRINT XL
JAFA • JNFA
RACER
MADE
IN
GERMANY
ZSK STICKMASCHINEN MADE IN GERMANY
User Manual
for Machine Type
sprint • sprint xl
jafa • jnfa
RACER
Made
in
Germany
ZSK Stickmaschinen Made in Germany
ZSK Stickmaschinen GmbH • Magdeburger Str. 38-40 • 47800 Krefeld • Germany
Contents
Inhaltsverzeichnis
Machine base Sprint-Series
Safety guidelines���������������������������������������������������������������������������������������������������������������������������11
Safety instructions in operator’s guide��������������������������������������������������������������������������������������11
Prescribed use ������������������������������������������������������������������������������������������������������������������������ 13
Electromagnetic compatibility �������������������������������������������������������������������������������������������� 13
Operational safety ������������������������������������������������������������������������������������������������������������������� 14
Regulations concerning safety at work ����������������������������������������������������������������������������������� 14
All work at and with the machine ��������������������������������������������������������������������������������������������� 14
Operation �������������������������������������������������������������������������������������������������������������������������������� 15
Essential operations before any manual work ������������������������������������������������������������������� 15
Embroidering ��������������������������������������������������������������������������������������������������������������������������� 16
Cleaning and maintenance������������������������������������������������������������������������������������������������������ 18
Repairs and modifications�������������������������������������������������������������������������������������������������������� 18
Unloading, unpacking and handling������������������������������������������������������������������������������������������� 19
For your safety ������������������������������������������������������������������������������������������������������������������������ 19
Unloading��������������������������������������������������������������������������������������������������������������������������������� 19
Consignments delivered in a transport crate���������������������������������������������������������������������� 19
Unpacking�������������������������������������������������������������������������������������������������������������������������������� 20
Moving to the installation location�������������������������������������������������������������������������������������������� 21
Attaching carrying handles (4x)������������������������������������������������������������������������������������������������ 21
Casters (optional)��������������������������������������������������������������������������������������������������������������������� 22
After moving the machine��������������������������������������������������������������������������������������������������� 22
Disposing of packaging materials ������������������������������������������������������������������������������������������� 23
Setting up and aligning���������������������������������������������������������������������������������������������������������������� 24
Setting up machine������������������������������������������������������������������������������������������������������������������ 24
Stand (optional) ����������������������������������������������������������������������������������������������������������������������� 24
Assembling stand���������������������������������������������������������������������������������������������������������������� 25
Installing machine �������������������������������������������������������������������������������������������������������������� 26
Applying caster brakes�������������������������������������������������������������������������������������������������������� 27
Detaching carrying handles������������������������������������������������������������������������������������������������������ 28
Aligning machine feet��������������������������������������������������������������������������������������������������������������� 28
Adjusting yarn rack (e.g. FA head)������������������������������������������������������������������������������������������� 28
Installing control unit���������������������������������������������������������������������������������������������������������������� 29
Connecting cables�������������������������������������������������������������������������������������������������������������� 30
Control unit�������������������������������������������������������������������������������������������������������������������������� 30
Adjusting control unit holder������������������������������������������������������������������������������������������������ 30
3
Contents
Installing���������������������������������������������������������������������������������������������������������������������������������������� 32
Mains connection��������������������������������������������������������������������������������������������������������������������� 32
Fuses/automatic circuit breakers��������������������������������������������������������������������������������������������� 33
Machine overview ������������������������������������������������������������������������������������������������������������������������ 34
General view���������������������������������������������������������������������������������������������������������������������������� 34
Operation��������������������������������������������������������������������������������������������������������������������������������� 35
Main switch������������������������������������������������������������������������������������������������������������������������� 35
EMERGENCY STOP���������������������������������������������������������������������������������������������������������� 35
Control Unit ������������������������������������������������������������������������������������������������������������������������ 36
Start/Stop keys�������������������������������������������������������������������������������������������������������������������� 36
Switching on key cluster����������������������������������������������������������������������������������������������������� 38
Appliqué key����������������������������������������������������������������������������������������������������������������������� 38
Aligning pantograph ����������������������������������������������������������������������������������������������������������� 39
Risk of crushing������������������������������������������������������������������������������������������������������������������ 39
Aligning with arrow keys����������������������������������������������������������������������������������������������������� 40
Aligning by way of control unit�������������������������������������������������������������������������������������������� 41
Changing modes�������������������������������������������������������������������������������������������������������������������������� 42
Tabletop embroidery - tubular system�������������������������������������������������������������������������������������� 42
Dismantling frame locator��������������������������������������������������������������������������������������������������� 42
Dismantling work table�������������������������������������������������������������������������������������������������������� 43
Installing cylinder arm frame holder������������������������������������������������������������������������������������ 43
Inserting frame�������������������������������������������������������������������������������������������������������������������� 43
Tubular system - tabletop embroidery�������������������������������������������������������������������������������������� 44
Changing from tubular system to cap embroidery������������������������������������������������������������������� 44
Work to be performed after each mode change����������������������������������������������������������������������� 44
Preparing to embroider���������������������������������������������������������������������������������������������������������������� 45
Clamping embroidery material������������������������������������������������������������������������������������������������� 45
Tubular system embroidery������������������������������������������������������������������������������������������������� 45
Adjusting frame tension������������������������������������������������������������������������������������������������������ 45
Clamping embroidery material in the frame������������������������������������������������������������������������ 46
Tabletop embroidery����������������������������������������������������������������������������������������������������������� 47
Single frame technology, (optional)������������������������������������������������������������������������������������� 47
Cap embroidery������������������������������������������������������������������������������������������������������������������ 47
Cap device (optional)���������������������������������������������������������������������������������������������������������� 47
4
Contents
Machine Base J- and RACER-Series
Safety guidelines ������������������������������������������������������������������������������������������������������������������������� 51
Safety instructions in operator’s guide ������������������������������������������������������������������������������������ 51
Prescribed use ������������������������������������������������������������������������������������������������������������������������ 53
Electromagnetic compatibility �������������������������������������������������������������������������������������������� 53
Operational safety ������������������������������������������������������������������������������������������������������������������� 54
Regulations concerning safety at work ����������������������������������������������������������������������������������� 54
All work at and with the machine ��������������������������������������������������������������������������������������������� 54
Operation �������������������������������������������������������������������������������������������������������������������������������� 55
Essential operations before any manual work ������������������������������������������������������������������� 55
Embroidering���������������������������������������������������������������������������������������������������������������������������� 56
Cleaning and maintenance������������������������������������������������������������������������������������������������������ 58
Repairs and modifications�������������������������������������������������������������������������������������������������������� 58
Unloading, unpacking, handling ������������������������������������������������������������������������������������������������ 59
For your safety������������������������������������������������������������������������������������������������������������������������� 59
Unloading from a truck with box body�������������������������������������������������������������������������������������� 59
Using a crane and fork-lift truck������������������������������������������������������������������������������������������ 59
Using a fork-lift truck����������������������������������������������������������������������������������������������������������� 60
Unpacking�������������������������������������������������������������������������������������������������������������������������������� 61
Consignments delivered in a transport crate���������������������������������������������������������������������� 61
If delivered on a pallet��������������������������������������������������������������������������������������������������������� 62
Machines without casters�������������������������������������������������������������������������������������������������� 62
Moving to the installation location�������������������������������������������������������������������������������������������� 63
Moving by crane������������������������������������������������������������������������������������������������������������������ 63
Moving by fork-lift truck ������������������������������������������������������������������������������������������������������ 65
Disposing of packaging materials ������������������������������������������������������������������������������������������ 66
Setting up and aligning���������������������������������������������������������������������������������������������������������������� 67
Setting up machine������������������������������������������������������������������������������������������������������������������ 67
Removing transit blocks������������������������������������������������������������������������������������������������������ 67
Machine variants��������������������������������������������������������������������������������������������������������������������� 68
Casters�������������������������������������������������������������������������������������������������������������������������������� 68
Applying caster brakes�������������������������������������������������������������������������������������������������������� 68
Machine shoes�������������������������������������������������������������������������������������������������������������������� 69
Installing machine shoes����������������������������������������������������������������������������������������������������� 69
Installing���������������������������������������������������������������������������������������������������������������������������������������� 70
Comparing mains voltage�������������������������������������������������������������������������������������������������������� 70
Mains connection��������������������������������������������������������������������������������������������������������������������� 70
Fuses/automatic circuit breakers���������������������������������������������������������������������������������������� 71
5
Contents
Operating elements���������������������������������������������������������������������������������������������������������������������� 72
General view���������������������������������������������������������������������������������������������������������������������������� 72
Main switch������������������������������������������������������������������������������������������������������������������������������ 73
1 and 2-head machines������������������������������������������������������������������������������������������������������ 73
4 to 8-head machines��������������������������������������������������������������������������������������������������������� 73
EMERGENCY STOP��������������������������������������������������������������������������������������������������������������� 74
Control unit������������������������������������������������������������������������������������������������������������������������������� 75
Start/Stop keys�������������������������������������������������������������������������������������������������������������������� 75
Pantograph positioning key cluster������������������������������������������������������������������������������������� 76
Switching on key cluster����������������������������������������������������������������������������������������������������� 77
Applikations-Taste �������������������������������������������������������������������������������������������������������������� 77
Risk of crushing������������������������������������������������������������������������������������������������������������������ 78
Aligning pantograph������������������������������������������������������������������������������������������������������������ 79
Aligning with arrow keys����������������������������������������������������������������������������������������������������� 79
Aligning by way of control unit�������������������������������������������������������������������������������������������� 80
Changing modes�������������������������������������������������������������������������������������������������������������������������� 81
Changing from border frame to tubular system embroidery����������������������������������������������������� 81
Removing pantograph frame���������������������������������������������������������������������������������������������������� 82
Installing cylinder arm frame holder����������������������������������������������������������������������������������������� 82
Moving work tables������������������������������������������������������������������������������������������������������������������ 83
Machines without a work table support������������������������������������������������������������������������������� 83
Machines with a work table support������������������������������������������������������������������������������������ 84
Manually adjustable work table support������������������������������������������������������������������������������ 84
Manually adjusting work table support�������������������������������������������������������������������������������� 84
Hydraulic work table support����������������������������������������������������������������������������������������������� 85
Removing middle pantograph guide rail����������������������������������������������������������������������������� 85
Adjusting work table support hydraulically ������������������������������������������������������������������������� 86
Changing from tubular system to border frame embroidery����������������������������������������������������� 87
Changing from tubular system to cap embroidery������������������������������������������������������������������� 87
Preparing to embroider���������������������������������������������������������������������������������������������������������������� 88
Clamping embroidery material������������������������������������������������������������������������������������������������� 88
Tubular system embroidery ������������������������������������������������������������������������������������������������ 88
Adjusting frame tension������������������������������������������������������������������������������������������������������ 88
Clamping embroidery material in the frame������������������������������������������������������������������������ 89
Border embroidery�������������������������������������������������������������������������������������������������������������� 90
Clamping element, fitting���������������������������������������������������������������������������������������������������� 90
Clamping elements with locking mechanism���������������������������������������������������������������������� 91
Position and sequence of clamping elements��������������������������������������������������������������������� 91
Bronze-colored clamping element (without locking mechanism)���������������������������������������� 92
Single frame embroidery����������������������������������������������������������������������������������������������������� 92
Single frame technology, (optional)������������������������������������������������������������������������������������� 92
Cap embroidery������������������������������������������������������������������������������������������������������������������ 92
Cap attachment (optional) �������������������������������������������������������������������������������������������������� 92
6
Contents
Maintenance and Troubleshooting (All Types)
Maintenance and troubleshooting���������������������������������������������������������������������������������������������� 93
For your safety ������������������������������������������������������������������������������������������������������������������������ 93
Lubricants��������������������������������������������������������������������������������������������������������������������������������� 93
Overview���������������������������������������������������������������������������������������������������������������������������������� 94
Troubleshooting����������������������������������������������������������������������������������������������������������������������� 96
7
Contents
8
machine Type
sprint • SPRINT Xl
Made
in
Germany
ZSK Stickmaschinen Made in Germany
Safety guidelines
1.
safety guidelines
This chapter contains a summary of the principal rules of behavior that must
be observed in order to exclude the risk of injury to yourself and others. It is
therefore essential that you read this chapter carefully and thoroughly.
The safety guidelines, together with the relevant regulations governing safety at
work, must be observed by all personnel working with the embroidery machine.
1.1
safety instructions in operator’s guide
The operator’s guide contains various remarks under the following headings:
‘DANGER’, ‘WARNING’, ‘CAUTION’ und ‘NOTICE’.
These are differentiated as follows:
safety instructions must be observed in order to avoid the risk of
personal injury.
risk of injury from electric shock.
Danger from suspended loads.
this symbol marks instructions in the operator’s guide whose
infringement can give rise to personal in juryor damage top roperty.
risk of crushing by moving machine parts.
risk of piercing by moving mechanical parts (needles, borers).
risk of burning by hot components (magnets, motors).
11
Safety guidelines
Instructions labeled “notice” must be observed to avoid malfunctions/operating errors.
Indicates waste disposal regulations and procedures.
12
Safety guidelines
1.2
Prescribed use
Theembroiderymachineisdesignedforindustrialuse.Itisintendedforfinishing
textilesandsimilarmaterialsbyembroidering.Ifthemachineisfittedwiththe
requisite auxiliaries, it can also embroider sequins and cord, and execute boring
patterns.
The machine can be used with textile fabrics and threads that are customary in
embroidery. Our customer service organization will be pleased to advise you, and
is also available for testing unfamiliar material combinations on your behalf.
On principle, do not use the machine for purposes other than described in the
operator’s guide. It must not be used, for example, as a support surface or in place
of a step ladder. Utilization for other than the intended purpose can give rise to
risks of personal injury and material damage.
The following conditions must be met for a safe operation of the machine:
Ambient temperature from 15 ° C to 35 ° C.
Relative humidity of 30% to 85% non-condensing.
Direct sunlight on the machine should be avoided.
electromagnetic compatibility
this machine is a class-a device. It can cause radio interference
in residential areas; in such cases the operator may be required
to take appropriate measures.
13
Safety guidelines
1.3
Operational safety
The embroidery machine is designed according to modern principles. Its electricalequipment complies with the stringent German VDE regulations. Numerous
design provisions have been made to improve safety.
Design provisions cannot, however, exclude all risks. The embroidery machine
must therefore be operated only by thoroughly instructed personnel familiar with
the operatorsguide,safetyguidelinesandrelevantaccidentpreventionregulations.’
1.4
regulations concerning safety at work
In addition to the present safety guidelines, observe all the mandatory accident
prevention regulations that apply in the country of use and at the operating
location as well as the recognized technical rules for safe working practices.
The valid regulations must be known and accessible to all those entrusted
with working at the machine.
1.5
all work at and with the machine
Wearclose-fittingclothesand,ifyouhavelonghair,ahairnetorsuitable
headgear when working at the machine. Do not wear jewelry. Wide sleeves, loose
hair, rings or chains can become caught or entangled in moving machine parts.
Wear shoes with non-slip soles in order to avoid the risk of falls.
14
Safety guidelines
1.6
Operation
the machine is to be operated only by thoroughly instructed personnel. For instruction purposes we recommend attending an operator
training course run by zsK stickmaschinen Gmbh. In any case,
before commencing work with the machine, make yourself familiar
with the proper operating practices with reference to the operator’s
guide.
1.6.1 essential operations before any manual work
equipping and setting-up work, conversions (between tabletop,
cylinder arm and cap embroidery on tubular system machines, for
instance), eliminating needle and thread breaks:
As a matter of principle, carry out such tasks only when the machine is at
a standstill. Certain tasks involve switching off the machine and removing
themainsplugfirst.Ensurecompliancewiththerelevantinstructionsinthe
operator’s guide.
Before working on the stationary machine with the main switch on, switch on the
pantograph positioning keys be pressing the ZSK key (1) (LED (2) next to the
keys lights up).
In this setting, you can operate the pantograph manually, but cannot start the
machine inadvertently.
1
2
15
Safety guidelines
1.7
embroidering
Do not remove any machine covers – they are provided for your
safety. see Machine overview.
As a general principle, operate the machine from the front long side. Each time
before starting the machine, make certain that nobody is in the vicinity of its
moving parts.
1
2
Fig. 1: Work areas
Users are allowed to enter this area (1) only when the machine is switched off.
This area (2) can be entered for monitoring purposes while the machine isrunning.
Keep hands away from moving parts during embroidering. There is a risk of
serious injury especially in the vicinity of the needles, borers, take-up levers and
rotary hooks.
Stop the embroidery machine before all manual operating procedures at
the machine,evenwhensimplyremovingflufforloosethreadsfromthestartof
embroidery. Consider your own safety at all times.
Never thread the threads while the machine is running.
16
Safety guidelines
Fig. 2: Working range of pantograph
Keep your hands well away from pantograph guide slot (1) because of the risk of
injury. See (Fig. 3).
Do not support yourself by the work table.
1
Fig. 3: Risk of crushing, pantograph guide slot
Do not place any objects on the embroidery machine or work table. They could be
pushed off the work table by movements of the pantograph. Objects that enter the
pantograph guide slot can cause operating malfunctions or damage the machine.
To prevent unauthorized intervention, never leave the embroidery machine
running unsupervised.
17
Safety guidelines
1.8
cleaning and maintenance
Insofar as they are described in the operator’s guide, cleaning and maintenance
tasks must be carried out only by appropriately instructed personnel.
More extensive maintenance and repair tasks must always be carried out by
service personnel that has been trained and accordingly equipped by ZSK
Stickmaschinen GmbH because this work requires the application of special
knowledge and resources.
Always disconnect the power supply before carrying out cleaning and
maintenance work.
The machine is at zero current only when the mains plug is pulled out and after a
delay of at least 30 seconds.
Observe the regular servicing periods laid down in the operator’s guide.
1.9
Repairs and modifications
Repairandmodificationworkmustbecarriedoutonlybyservicepersonnel
that has been instructed and trained by ZSK Stickmaschinen GmbH. Note the
following:
Use only genuine spare parts and accessories or parts that have been approved by
ZSK Stickmaschinen GmbH.
The machine must not be started up until it is fully assembled with all safet covers
and devices installed.
Independentchangesandmodificationstothemachinearenotpermittedfor
safety reasons. Such alterations can invalidate the CE Conformity Declaration.
Modificationworkdoesnot include the conversion tasks described in the
operator’s guide (e.g. changing between tabletop, cylinder arm and cap
embroidery).
18
Unloading, unpacking and handling
2.
Unloading, unpacking and handling
2.1
For your safety
the machine is to be lifted only by 4 persons, each of whom can
lift at least 25 kg.
Make certain that the table is capable of carrying the load (at
least 300 kg). In case of doubt, please consult the manufacturer
or supplier of the table.
2.2
Unloading
2.2.1 consignments delivered in a transport crate
In view of its weight, lift the crate off the truck with a fork-lift
truck or ropes and a crane only.
Fig. 4: Unloading by fork-lift truck
19
Unloading, unpacking and handling
2.3
Unpacking
1
2
3
4
5
6
(1)
(2)
(3)
(4)
(5)
Lid
Lashing straps
Arrows pointing upward
Unloading instructions
Symbol indicating approximate
position of center of gravity
(6) Insert locations for lifting forks
Fig. 5: Transport crate
•
Remove lashing straps (2).
•
Lift off lid (1).
•
Remove all individual parts.
•
Remove the packing material and desiccant sachets.
(1) Stand (optional)
1
Fig. 6: Transport crate, opened
20
Unloading, unpacking and handling
2.4
Moving to the installation location
For safety reasons, if the machine is delivered in a transpor
crate, move the machine to the installation location with a forklift
or stacker truck before detaching it from the floor of the crate if
possible.
Cut through and remove the lashing
straps (1), that secure the control
cabinet and machine to the pallet.
1
Fig. 7: Removing lashing straps
2.5
attaching carrying handles (4x)
If the machine is being delivered in a transport crate, the machine
carrying handles are detached for space reasons. the handles form
part of the delivery scope.
Slacken off nut (3) on machine foot
(4) and create a gap between the nut
and the frame.
1
2
4
3
Insert carrying handle (2) between
frame (1) and nut (3) into contact with
the frame.
Make nut (3) tight against the carrying
handle.
Fig. 8: Installing carrying handles
(view from below)
Attach a carrying handle to each corner of the frame.
21
Unloading, unpacking and handling
2.6 Casters (optional)
1
3
2
4
Slacken off and remove bolt (1)
Attach caster (2) and loosely fasten
screw (4).
Insert and tighten screw (3).
Fig. 9: Installing casters, illustration: back of machine, left
3
1
4
5
2
Push bar (1) through the opening in
the side of caster (2) so that it rests
underneath the head of top screw (3).
Apply downward pressure to bar (1)
until machine foot (5) is raised.
Tighten screw (4).
Repeat this procedure on the other
side.
Fig. 10: Aligning caster (section view)
After moving the machine
Slowly slacken off screws (4).
ÖÖ The mahine feet are lowered to the floor.
Detach screws (4), (5) and casters (2).
Insert bolt, see (Fig. 9) item (1).
22
Unloading, unpacking and handling
2.7
Disposing of packaging materials
Dispose of the materials in compliance with national and local law.
Keep the parts that make up the crate in case required for service
purposes.
The wooden packaging is made almost entirely from natural, non-toxic materials
and can be disposed of accordingly. Other treatment guidelines apply in a small
numberofspecificcountries.Adviceaboutthesecanbeobtainedlocallyfromthe
relevant authorities.
Packaging paper and foil can be reused and should be recycled.
The desiccant bags contain a natural salt that can be disposed of together with
domestic refuse.
23
Setting up and aligning
3.
setting up and aligning
3.1
setting up machine
all the fastening elements (bolts, washers, cable ties etc.) are located
together with the accessories.
Note the following:
Placetheembroiderymachineonlyonasolidsurfaceofsufficientloadcarrying
capacity (e.g. desk, workbench etc.). Make sure that the machine is standing
securely.
Each time it is installed, distribute the load between all the machine feet and align
the machine. The machine may not wobble!
3.2
stand (optional)
The stand for the machine can be
adjusted to three different heights.
Fig. 11: Stand
24
Setting up and aligning
3.2.1 assembling stand
Attach two casters (one with and one
without a brake) to each end of the
stand.
Fig. 12: Attaching casters
Fasten two of the side struts, with the
broaderflangeatthebottom,toone
end of the stand with the screws and
associated washers, making them hand
tight.
Fig. 13: Assembling stand
Loosely attach the other end of the
stand to the pre-assembled side struts.
Fig. 14: Assembling stand
Insert the shelf between the two
bottom side struts of the stand.
Loosely attach the other two side
struts in the envisaged positions on
the opposite side of the stand with the
screws and associated washers.
Fig. 15: Assembling stand
25
Setting up and aligning
Insert the variable-height machine rests
into the ends of the stand from above.
With the rests located at the desired
height, fasten the screws with washers
so that they are hand tight.
Fig. 16: Assembling stand
Placethestandonafirm,flatsurface.
Tighten all the screws.
3.2.2 Installing machine
the machine is to be lifted only by 4 persons, each of whom can
lift at least 25 kg.
Lift the machine by the 4 carrying
handles.
Fig. 17: Installing machine
26
Setting up and aligning
Place the machine on the stand by
locating the machine feet in the
provided seat (1).
1
Fig. 18: Machine on stand
3.2.3 applying caster brakes
It is essential that you apply the caster brakes before starting up
the machine otherwise it could roll away.
Fig. 19: Typical casters
Left: released, braking
Right: brake engaged, releasing brake
27
Setting up and aligning
3.3
Detaching carrying handles
Slacken off nut (3) on machine foot
(4)and create a gap between the nut
and the frame.
1
2
3
4
Take out carrying handle (2)
Tighten nut (3)against frame (1)so
that it is hand tight.
Detach the carrying handle from each
corner of the frame.
Fig. 20: Detaching carrying handles (view from below)
3.4
aligning machine feet
Slacken off nut (1)
1
Rotate machine foot (2) to the desired
position (see sketch)
2
Each time it is installed, distribute the
load between all the machine feet and
align the machine.
Tighten nut (1).
Fig. 21: Machine foot, adjusting
3.5
adjusting yarn rack (e.g. Fa head)
1
Slacken off screws (2).
Adjust yarn rack (1).
Tighten screws (2).
2
Fig. 22: Yarn rack, adjusting height
If the yarn rack is not moved to the top position, an obstruction can
occur during a color change and the machine can be damaged .
28
Setting up and aligning
3.6
Installing control unit
Slacken off and remove screw (2).
1
Rotate top holder bracket (1) through
180º.
2
Insert screw (2) and make hand tight.
Fig. 23: Holder in transit position
Attach the control unit by inserting the
threaded pins on the rear panel into the
appropriate holes in the holder.
Fig. 24: Rear of control unit
Place serrated lock washers (3) on
threaded pins (2).
1
Tighten nuts (1).
2
3
Fig. 25: Rear of control unit
29
Setting up and aligning
3.6.1 connecting cables
control unit
1
Connect cable (2) to rear of control
unit and fasten with screws (1).
2
Fig. 26: Rear of control unit
3.6.2 adjusting control unit holder
the control unit holder can be individually adjusted.
Do not align the control unit as described below until the
machine has been connected and started up.
Before the control unit is adjusted horizontally or vertically to a
new position, the traversing and fully equipped yarn rack has to
approach the final needle (right) position by executing a color
change (change of needle position).
Die ausrichtung der Bedieneinheit kann jetzt durchgeführt Once
this position has been adopted, the control unit can be adjusted.
Make certain that adequate clearance is maintained between the
control unit and yarn rack in order to avoid damage and malfunctions when a color change takes place. the machine can be
damaged!
30
Setting up and aligning
Slacken off screw raube (1).
1
Adjust the control unit to the desired
angle.
Tighten screw (1).
Fig. 27: Control unit, holder, adjusting vertically
Slacken off screws (1).
1
Rotate the control unit to the desired
position.
Tighten screws (1).
Fig. 28: Control unit, holder, adjusting horizontally
31
Installing
4.
Installing
4.1
comparing mains voltage
all installation and service work is to be carried out exclusively
by trained experts.
the machine is at zero current only when the mains plug is
pulled out and after a delay of at least 30 seconds.
The supply voltage of the machine is 230V AC (+-15%) 50/60Hz.
compare the mains voltage stated on the rating plate with the
system voltage available at the machine location. If the values
are not the same, do not start the machine, but contact our
customer service department.
4.2
Mains connection
On completion of the installation work, run the connecting
cable between the embroidery machine and mains socket-outlet
in such a way that it is not an obstacle to foot traffic (risk of
tripping).
Do not connect the machine to the power supply until it is fully
assembled and the control cabinet is closed.
32
Installing
4.3
Fuses/automatic circuit breakers
The machine is supplied with power cable and plug and may only be operated at
a plug connector with a correctly connected grounding conductor, which has been
setup according to the valid regulations. Compliance with applicable regulations
and, in particular protective measures against electric shocks according to IEC
364/VDE 0100 or corresponding national and local safety regulations must be
observed.
Fuses and circuit-breakers are safety devices. Before starting up
the machine again, the reason for the power loss has to be investigated in order to avoid the risk of damage or further production
down-times.
33
Machine overview
5.
Machine overview
5.1
General view
3
1
2
8
5
4
2
2
6
7
Fig. 29: General view, SPRINT series
(1)T8 Control Unit
(2)Machine cover
(3)Type plate
(4)Frame
(5)Pantograph guide
(6)Light barrier
(7)Work table
(8)Main switch/EMERGENCY STOP switch
34
Machine overview
5.2
Operation
This chapter provides an overview of the embroidery machine’s operating
elements. These controls are used, for example, to position the pantograph, for
starting and stopping the embroidering routine, for reverse embroidering, and
when working with appliqués.
the position of the individual operating elements on the machine is
illustrated under Machine overview and control unit.
5.2.1 Main switch
The machine and control cabinet are switched on and off with the main switch.
5.2.2 eMerGencY stOP
the main switch also serves as the eMerGencY stOP switch.
Before switching the machine back on, make sure that the cause of
the EMERGENCY STOP has been rectified.
all the operating elements described below operate only if the main
switch is switched on.
35
Machine overview
5.2.3 control Unit
In line with more recent zsK control units, this control unit has a
start/stop control panel and a control panel for manual pantograph
positioning.
4
1
2
3
4
6
5
Fig. 30: T8 control unit
(1)Start key
(2)ZSK-key
(3)Stop key
(4)Light-emitting diode (LED)
(5)Appliqué key
(6)Pantograph positioning keys
start/stop keys
You can use the start/stop key cluster when the leD (light-emitting
diode) in the cluster is illuminated. the pantograph positioning keys
must be switched off.
The start/stop cluster of keys is situated on the control unit. It consists of the keys
for starting and stopping the machine, selecting and deselecting the pantograph
positioning keys (ZSK key), reverse embroidery and executing single stitches.
36
Machine overview
Operation
Function
Press
Stops the machine
Press
Starts the machine
Press
Switches pantograph positioning keys
on/off
Pressbriefly
Executes a single stitch
Hold down
Executes a sequence of single stitches
(embroidering at low speed)
Pressbriefly
Moves the pantograph back one stitch
at a time (reverse embroidery)
Hold down
Executes a sequence of reverse
stitches
You can stop the machine at any time with the stop key. the
interrupted embroidering routine is resumed as soon as the machine
is restarted with the start key.
Pantograph positioning key cluster
Do not select manual pantograph positioning while the machine is
running. this would stop the machine and interrupt the embroidering
routine.
The key cluster for positioning the pantograph manually is situated on the control
unit. It consists of the arrow keys for positioning the pantograph and the Appliqué
key.
37
Machine overview
switching on key cluster
Press ZSK key (1).
1
Fig. 31: ZSK key
2
Pantograph positioning keys switched
on.
LED (2) illuminated.
Fig. 32: LED
appliqué key
The appliqué key is located in the Pantograph positioning key cluster; it is
required when you wish to embroider with appliqués. The key cannot be used
unless the key cluster is switched on.
Press the appliqué key for 1 sec at least.
38
Machine overview
5.2.4 aligning pantograph
risk of crushing
1
Fig. 33: Risk of crushing by pantograph
the pantograph responds straight away.
Keep your hands well away from the pantograph guide slot (1)
and frame.
risk of injury!
You cannot align the pantograph unless the machine is stationary.
39
Machine overview
aligning with arrow keys
1
Fig. 34: Directions of pantograph movement (example)
Keys for positioning pantograph (e.g. to the left)
Align the pantograph with the arrow keys (1).
Taste
Bewegungsrichtung des Pantographen
Backwards
(away from the front edge of the work table)
Forwards
(towards the front edge of the work table)
To the left
To the right
Press the ZSK key again.
Ö The pantograph positioning keys are deselected (LED goes out).
Once you have aligned the pantograph, switch off the positioning
key cluster because the machine cannot be started while manual
positioning is switched on.
40
Machine overview
aligning by way of control unit
aligning the pantograph by way of the control unit is possible only in
the Machine module.
By way of the control unit the pantograph position can also be controlled with
reference to the screen display. This allows paths to be traveled quickly or slowly
or in 1 mm or 1/10 mm steps (increments).
Press the taste [U5] button below the screen display to activate manual
pantograph positioning.
Ö
The following symbols are displayed at the bottom of the screen.
the control unit operator’s guide contains more detailed information
on using the menu keys.
Press button [U1] and hold down arrow button to move pantograph continuously
and fast.
Press button [U2] and hold down arrow button to move pantograph continuously
and slowly.
Press button [U3]andbrieflypressarrowbuttontomovepantographin1mm
steps with each press.
Press button [U4]andbrieflypressarrowbuttontomovepantographin1/10mm
steps with each press.
Once you have aligned the pantograph, switch off the manual
pantograph positioning function. With manual pantograph positioning selected, the machine cannot be started.
41
Changing modes
6.
changing modes
This part of the operator’s guide refers exclusively to machines with tubular
system functionality.
6.1
tabletop embroidery - tubular system
the conversion is not to be carried out when the machine is
running.
2
1
Fig. 35: Examples for SPRINT
(1)
Tabletop embroidery
(2)
Tubular system embroidery
6.1.1 Dismantling frame locator
Take out single frame (1).
2
3
Slacken off screws (2).
Remove Z rail (3).
1
Fig. 36: Dismantling frame locator
42
Changing modes
6.1.2 Dismantling work table
Slacken off and remove screws (1)
(left/right).
2
Pull out work table (2) to the front and
set it down safely.
1
Insert and tighten screws (1).
Fig. 37: Removing work table
6.1.3 Installing cylinder arm frame holder
Tighten screws (1) in cylinder arm
frame holder (2) about 2 turns.
Slide cylinder arm frame holder (2)
underneath carriage support (3).
Tighten screws (1).
Fig. 38: Installing cylinder arm frame holder
6.1.4 Inserting frame
1
3
2
Place frame holder (1) on stop pins (2).
Slide frame holder (1) underneath
springs (3) and engage stop pins (2).
Fig. 39: Inserting frame
each time you convert the machine for a different mode, change
the pantograph configuration to suit the application (e.g. border
frame embroidery) by way of the control unit.
43
Changing modes
6.2
tubular system - tabletop embroidery
the conversion is not to be carried out when the machine is running.
to convert from tubular system to tabletop embroidery, follow the
same steps as for converting from tabletop embroidery to tubular
system operation, but in the reverse sequence.
6.3
changing from tubular system to cap embroidery
the conversion is not to be carried out when the machine is running.
the conversion for optional cap embroidery is described in the
operating instructions for the cap attachment.
6.4
Work to be performed after each mode change
each time you convert the machine for a different mode, change
the pantograph configuration to suit the application (e.g. border
frame embroidery) by way of the control unit.
44
Preparing to embroider
7.
Preparing to embroider
as a general rule, carry out the work described here only when
the machine is stationary. Make sure that no-one is able to start
the machine while you are fitting the embroidery material and
setting it up.
this chapter describes additional work that has to be executed
before embroidering. Further information, including on the choice of
needles, filling the yarn rack, thread tension etc., is contained in the
relevant operator’s guide – head –.
7.1
clamping embroidery material
7.1.1 tubular system embroidery
adjusting frame tension
Adjust the frame tension to match the
thickness of the embroidery material
with the adjusting screw (1) on the
outer frame.
Fig. 40: Tubular system embroidery, screw for adjusting frame tension
45
Preparing to embroider
clamping embroidery material in the frame
1
2
Fig. 41: Tubular system embroidery, clamping tubular fabric in cylinder arm frame
Place outer frame (1) underneath
the area that you wish to embroider
(between the two layers of tubular
fabric).
Apply pressure with the ball of the
thumb to press inner frame (2) into
the outer frame from above so that
the embroidery material is stretched
smoothly over the frame.
Fig. 42: Tubular system embroidery, screw for
adjusting frame tension
Optional clamping aids are available to facilitate clamping the
embroidery material in the cylinder arm frame.
46
Preparing to embroider
7.1.2 tabletop embroidery
single frame technology, (optional)
a separate frame technology operating manual is provided with the
single frame embroidery option.
Fig. 43: Single frame
7.1.3 cap embroidery
cap device (optional)
a separate manual is provided with the cap device.
Fig. 44: Cap frame
47
Machine Type
JAFA • JNFA
RACER
Made
in
Germany
ZSK Stickmaschinen Made in Germany
Safety guidelines
8.
safety guidelines
This chapter contains a summary of the principal rules of behavior that must
be observed in order to exclude the risk of injury to yourself and others. It is
therefore essential that you read this chapter carefully and thoroughly.
The safety guidelines, together with the relevant regulations governing safety at
work, must be observed by all personnel working with the embroidery machine.
8.1
safety instructions in operator’s guide
The operator’s guide contains various remarks under the following headings:
‘DANGER’, ‘WARNING’, ‘CAUTION’ und ‘NOTICE’.
These are differentiated as follows:
safety instructions must be observed in order to avoid the risk of
personal injury.
risk of injury from electric shock.
Danger from suspended loads.
this symbol marks instructions in the operator’s guide whose
infringement can give rise to personal in juryor damage top roperty.
risk of crushing by moving machine parts.
risk of piercing by moving mechanical parts (needles, borers).
risk of burning by hot components (magnets, motors).
51
Safety guidelines
Instructions labeled “notice” must be observed to avoid malfunctions/operating errors.
Indicates waste disposal regulations and procedures.
52
Safety guidelines
8.2
Prescribed use
Theembroiderymachineisdesignedforindustrialuse.Itisintendedforfinishing
textilesandsimilarmaterialsbyembroidering.Ifthemachineisfittedwiththe
requisite auxiliaries, it can also embroider sequins and cord, and execute boring
patterns.
The machine can be used with textile fabrics and threads that are customary in
embroidery. Our customer service organization will be pleased to advise you, and
is also available for testing unfamiliar material combinations on your behalf.
On principle, do not use the machine for purposes other than described in the
operator’s guide. It must not be used, for example, as a support surface or in place
of a step ladder. Utilization for other than the intended purpose can give rise to
risks of personal injury and material damage.
The following conditions must be met for a safe operation of the machine:
Ambient temperature from 15 ° C to 35 ° C.
Relative humidity of 30% to 85% non-condensing.
Direct sunlight on the machine should be avoided.
electromagnetic compatibility
this machine is a class-a device. It can cause radio interference
in residential areas; in such cases the operator may be required
to take appropriate measures.
53
Safety guidelines
8.3
Operational safety
The embroidery machine is designed according to modern principles. Its electricalequipment complies with the stringent German VDE regulations. Numerous
design provisions have been made to improve safety.
Design provisions cannot, however, exclude all risks. The embroidery machine
must therefore be operated only by thoroughly instructed personnel familiar with
the operatorsguide,safetyguidelinesandrelevantaccidentpreventionregulations.’
8.4
regulations concerning safety at work
In addition to the present safety guidelines, observe all the mandatory accident
prevention regulations that apply in the country of use and at the operating
location as well as the recognized technical rules for safe working practices.
The valid regulations must be known and accessible to all those entrusted
with working at the machine.
8.5
all work at and with the machine
Wearclose-fittingclothesand,ifyouhavelonghair,ahairnetorsuitable
headgear when working at the machine. Do not wear jewelry. Wide sleeves, loose
hair, rings or chains can become caught or entangled in moving machine parts.
Wear shoes with non-slip soles in order to avoid the risk of falls.
54
Safety guidelines
8.6
Operation
The machine is to be operated only by thoroughly instructed personnel. For
instruction purposes we recommend attending an operator training course run by
ZSK Stickmaschinen GmbH. In any case, before commencing work with the
machine, make yourself familiar with the proper operating practices with
reference to the operator’s guide.
Do not climb on the work table.
8.6.1 essential operations before any manual work
equipping and setting-up work, conversions (between tabletop,
cylinder arm and cap embroidery on tubular system machines, for
instance), eliminating needle and thread breaks:
As a matter of principle, carry out such tasks only when the machine is at
a standstill. Certain tasks involve switching off the machine and removing
themainsplugfirst.Ensurecompliancewiththerelevantinstructionsinthe
operator’s guide.
Before working on the stationary machine with the main switch on, switch on the
pantograph positioning keys be pressing the ZSK key (1) (LED (2) next to the
keys lights up).
In this setting, you can operate the pantograph manually, but cannot start the
machine inadvertently.
1
2
- caUtIOn! - the pantograph travels at a very high speed. Do not
rest on the work table or lean against the table recesses within
the working range of the pantograph (Fig. 46) a collision with the
high-speed pantograph can cause bruising and injuries resulting
from crushing or shear forces. (Fig. 47).
55
Safety guidelines
8.7
embroidering
As a general principle, operate the machine from the front long side. Each
time before starting the machine, make certain that nobody is underneath the
embroidery machine or in the vicinity of its moving parts.
1
2
Fig. 45: Work areas
Users are allowed to enter this area (1) only when the machine is switched off.
This area (2) can be entered for monitoring purposes while the machine is
running.
Keep hands away from moving parts during embroidering. There is a risk of
serious injury especially in the vicinity of the needles, borers, take-up levers and
rotary hooks.
Stop the embroidery machine before all manual operating procedures at
the machine,evenwhensimplyremovingflufforloosethreadsfromthestartof
embroidery. Consider your own safety at all times.
Never thread the upper threads while the machine is running.
Do not carry out any work at an embroidery unit even when it is switched off
because the take-up lever, rotary hook and thread trimmer continue to operate.
56
Safety guidelines
- caution! - the pantograph travels at a very high speed.
Do not rest on the work table or lean against the table recesses
within the working range of the pantograph (Fig. 46) a collision
with the high-speed pantograph can cause bruising and injuries
resulting from crushing or shear forces. (Fig. 47).
1
2
Fig. 46: Working range of pantograph
Keep your hands well away from the insides of supports (1), the table recesses (2)
and pantograph guide slot (3) because of the risk of injury. Also see (Fig. 47).
Do not support yourself by the work table.
Fig. 47: Risk of crushing against pantograph frame
(Work table recess)
Do not place any objects on the embroidery machine or work table. They could be
pushed off the work table by movements of the pantograph. Objects that enter the
pantograph guide slot can cause operating malfunctions or damage the machine.
To prevent unauthorized intervention, never leave the embroidery machine
running unsupervised.
57
Safety guidelines
8.8
cleaning and maintenance
Insofar as they are described in the operator’s guide, cleaning and maintenance
tasks must be carried out only by appropriately instructed personnel.
More extensive maintenance and repair tasks must always be carried out by
service personnel that has been trained and accordingly equipped by ZSK
Stickmaschinen GmbH because this work requires the application of special
knowledge and resources.
Always disconnect the power supply before carrying out cleaning and
maintenance work.
The machine is at zero current only when the mains plug is pulled out and after a
delay of at least 30 seconds.
Observe the regular servicing periods laid down in the operator’s guide.
8.9
Repairs and modifications
Repairandmodificationworkmustbecarriedoutonlybyservicepersonnel
that has been instructed and trained by ZSK Stickmaschinen GmbH. Note the
following:
Use only genuine spare parts and accessories or parts that have been approved by
ZSK Stickmaschinen GmbH.
The machine must not be started up until it is fully assembled with all safety
covers and devices installed.
Independentchangesandmodificationstothemachinearenotpermittedfor
safetyreasonsandmayconflictwithCEregulations.
Modificationworkdoes not include the conversion tasks described in the
operator’s guide (e.g. deinstallation/reinstallation of the sequin device).
58
Unloading, unpacking, handling
9.
Unloading, unpacking, handling
9.1
For your safety
Only appropriately trained personnel are to be entrusted with
handling the machine. ensure compliance with the relevant
safety regulations for operating handling equipment.
In particular, make sure that no-one is standing in the danger
area near the machine before each lifting operation.
Do not allow anyone to walk under the suspended load while it is
being moved.
9.2
Unloading from a truck with box body
9.2.1 Using a crane and fork-lift truck
Fig. 48: Unloading using a crane and fork-lift truck
59
Unloading, unpacking, handling
9.2.2 Using a fork-lift truck
Make sure that the stand used to support the crate has an
adequate load carrying capacity.
Fig. 49: Correct way of unloading by fork-lift truck
Fig. 50: Incorrect way of unloading by fork-lift truck
60
Unloading, unpacking, handling
9.3
Unpacking
9.3.1 consignments delivered in a transport crate
Unloading and handling instructions are attached to the crate at
the illustrated places (Fig. 51)
Begin by opening and removing the crate lid.
1
2
4
3
5
7
6
Fig. 51: Transport crate Unloading instructions
(1)
Lid
(2)
Arrows indicating where lid is divided
(3)
Front of crate
(4)
Arrows indicating top of crate
(5)
gravity
Symbol indicating approximate position of center of
(6)
Securing points for handling chains and cables
(7)
Insert locations for lifting forks
Remove the front panel and then (if necessary) the sides.
Remove the packing material and the desiccant sachets attached to the machine.
Remove all individually packed components situated on and underneath the work
table.
61
Unloading, unpacking, handling
Slacken off the bolts securing the wooden transit blocks to the bottom of the crate.
See (Fig. 52).
(1) Fixing bolts
(2) Floor of pallet/crate
(3) Transit block
1
2
3
Fig. 52: Machine mounted on wooden transit blocks, illustration
9.3.2 If delivered on a pallet
Unloading and handling instructions are attached to the foil packaging.
Proceed as follows to unpack a machine delivered on a pallet:
Remove the foil packaging
Remove the desiccant sachets.
Remove all individually packed components situated on and underneath the work
table.
Slackenoffthefixingboltssecuringthewoodentransitblockstothepallet.See
(Fig. 52).
Machines without casters
Do not detach the machine from the transit blocks until you
install it in the working position. they are not replaced by the
machine shoes until the machine is finally installed.
62
Unloading, unpacking, handling
9.4
Moving to the installation location
Prevent the machine from tipping to one side. the machine is
liable to tip because the center of gravity is not always in the
middle. Personal injury or damage to property can result from the
machine tipping over.
The machine is to be moved only by appropriately trained personnel familiar with
the relevant safety regulations. Also observe the following points before moving
the machine:
Prevent the machine from tipping to one side.
Commence lifting movements with care.
9.4.1 Moving by crane
(not 1-head machines)
attach the handling chains or cables only at the eye bolts. the
eyes of the eye bolts must be positioned parallel to the long side
of the machine. see .
For instructions on handling 1-head machines, see Moving by forklift
truck (only if the use of a crane is ruled out).
The 2 to 8-head machines are equipped with two eye bolts for handling the
machine by crane.
Fig. 53: Eye bolts, illustration
63
Unloading, unpacking, handling
The handling chains or cables should be as close to vertical as possible and must
not exceed an angle from the vertical of 26° when the load is being lifted. For this
reason, a cross-bar is generally necessary for handling purposes.
The dimensions refer to (Fig. 54):
Fig. 54: Moving by crane with cross-bar
the permitted value of 26° will not be exceeded if the dimensions
shown in the tables in are observed.
64
a
[cM]
B
[cM]
c
[cM]
a
[cM]
B
[cM]
c
[cM]
50
24
56
21
10
23
75
37
83
41
20
46
100
49
111
62
30
68
125
61
139
82
40
91
150
73
167
103
50
114
175
85
195
123
60
137
200
98
223
144
70
160
225
110
250
164
80
182
250
122
278
185
90
205
205
100
228
226
110
251
Unloading, unpacking, handling
9.4.2 Moving by fork-lift truck
(only if the use of a crane is ruled out)
Before raising the forks, make certain that the two bottom cross
beams of the embroidery machine are in full contact with and
resting securely on the forks, otherwise the machine is likely to
tip over and cause personal injury or damage to property.
In order to avoid personal injury and property damage, at
least two people must always be present when the embroidery
machine is being moved (the fork-lift operator and a marshal).
In ideal circumstances the embroidery machine is to be moved by a crane. Use
a fork-lift truck only in the absence of a crane. The fork-lift truck must have
sufficientliftingcapacitytoaccommodatetheweightofthemachine,andafork
length that allows the bottom cross beam(s) of the embroidery machine to make
full contact with the fork when the machine is raised. See (Fig. 55).
When introducing and raising the forks, make certain that they
do not contact any part of the machine (cables, stepping motor
etc.) except for the bottom cross beams.
Introduce the forks underneath the machine cross beams at the center from the
back.
Raise the forks carefully until they make contact with the bottom cross beams of
the machine. See (Fig. 55).
Fig. 55: Fork-lift truck with machine
65
Unloading, unpacking, handling
9.5
Disposing of packaging materials
Dispose of the materials in compliance with national and local law.
Keep the parts that make up the crate in case required for service
purposes.
The wooden packaging is made almost entirely from natural, non-toxic materials
and can be disposed of accordingly. Other treatment guidelines apply in a small
numberofspecificcountries.Adviceaboutthesecanbeobtainedlocallyfromthe
relevant authorities.
Packaging paper and foil can be reused and should be recycled.
The desiccant bags contain a natural salt that can be disposed of together with
domestic refuse.
66
Setting up and aligning
10. setting up and aligning
10.1 setting up machine
the machine is to be set up and installed by trained service
personnel of zsK or its agents only.
all the fastening elements (bolts, washers, cable ties etc.) are located
together with the accessories.
Only trained assembly personnel are allowed to set up the machine at its operating
site.
Placetheembroiderymachineonlyonasolidsurfaceofsufficientloadcarrying
capacity. Make sure that the machine is standing securely.
10.1.1 removing transit blocks
You are recommended to lift the machine with a fork-lift/stacker
truck.
1
Detach transit block (2) from the
machine by removing the bolts,
washers and nuts (1).
2
Fig. 56: Removing transit blocks, illustration
67
Setting up and aligning
10.2 Machine variants
There are two variants of the machines:
- Mounted on casters
- Mounted on machine shoes
10.2.1 casters
applying caster brakes
It is essential that you apply the caster brakes before starting
up the machine, otherwise there is a risk of the machine rolling
away.
Fig. 57: Brake Left: released, braking
Fig. 58: Right: applied, releasing
68
Setting up and aligning
10.2.2 Machine shoes
Installing machine shoes
You are recommended to lift the machine with a fork-lift truck.
Take off cover (4).
1
Insert adjusting screw (1) in hole (2)
from above.
Tighten the adjusting screw in tapped
hole (3).
2
3
4
Fig. 59: Installing machine shoe
Fasten nut (2) tightly on adjusting
screw (1) from underneath.
1
2
3
Locate machine shoe (4) centrally
underneath adjusting screw (1), so that
the adjusting screw mates with the
recess (3) in the machine shoe.
Continuously monitor the exact
position of the machine shoes while
slowly lowering the machine.
Replace cover (4).
4
Fig. 60: Installing machine shoe, cross-section
Make sure that all 4 nuts (2) are tight and that the machine is
standing securely before starting up the machine.
69
Installing
11. Installing
11.1 comparing mains voltage
all installation and service work is to be carried out exclusively
by trained experts.
the machine is at zero current only when the mains plug is
pulled out and after a delay of at least 30 seconds.
The supply voltage of the machine is 230V AC (+-15%) 50/60Hz.
compare the mains voltage stated on the rating plate with the
system voltage available at the machine location. If the values
are not the same, do not start the machine, but contact our
customer service department.
11.2 Mains connection
On completion of the installation work, run the connecting
cable between the embroidery machine and mains socket-outlet
in such a way that it is not an obstacle to foot traffic (risk of
tripping).
Do not connect the machine to the power supply until it is fully
assembled and the control cabinet is closed.
70
Installing
11.3 Fuses/automatic circuit breakers
The machine is supplied with power cable and plug and may only be operated at
a plug connector with a correctly connected grounding conductor, which has been
setup according to the valid regulations. Compliance with applicable regulations
and, in particular protective measures against electric shocks according to IEC
364/VDE 0100 or corresponding national and local safety regulations must be
observed.
Fuses and circuit-breakers are safety devices. Before starting up
the machine again, the reason for the power loss has to be investigated in order to avoid the risk of damage or further production
down-times.
control cabinets in the series Mscl and MscF do not have fuses of
their own. the machines are covered by the protective provisions of
the operator’s power supply.
71
Operating elements
12. Operating elements
12.1 General view
1
2
3
4
5
8
9
7
6
Fig. 61: General view, examples: 6-head frame
(1)
Control unit
(2)
Start/Stop keys
(3)
Eye bolt
(4)
Socket wrench entry for main shaft
EMERGENCY STOP button (on machines with 4 and
(5)
more heads)
(6)
Type plate
(7)
Pantograph frame
(8)
Work table
(9)
Main switch, also EMERGENCY STOP switch
on 1- and 2- head machines
72
Operating elements
This chapter provides an overview of the embroidery machine’s operating
elements. These controls are used, for example, to switch the machine on and off,
to position the pantograph, for starting and stopping the embroidering routine, for
reverse embroidering, and when working with appliqués.
the position of the individual operating elements on the machine is
illustrated under General view and control unit.
12.2 Main switch
The machine and control unit are switched on and off with the main switch.
12.2.1 1 and 2-head machines
The main switch of the 1 and 2-head machines also functions as the
EMERGENCY STOP switch.
12.2.2 4 to 8-head machines
4 to 8-head machines are equipped with additional, separate EMERGENCY
STOP buttons.
12.3 eMerGencY stOP
The main switch also functions as an EMERGENCY STOP switch on 1 and
2-head machines; machines with a larger number of heads have EMERGENCY
STOP buttons.
73
Operating elements
the main switch functions as the eMerGencY stOP switch as
well on 1 and 2-head machines.
If the eMerGencY stOP button has been operated (illustration on
right in (Fig. 62)), it has to be reset by turning it clockwise. Before
switching the machine back on, make sure that the cause of the
EMERGENCY STOP has been rectified.
not operated
Operated
Fig. 62: EMERGENCY STOP button
all the operating elements described below operate only if the main
switch is switched on.
74
Operating elements
12.4 control unit
In line with more recent zsK control units, this control unit has a
start/stop control panel and a control panel for manual pantograph
positioning.
4
1
2
3
4
6
5
Fig. 63: T8 control unit
(1)Start key
(2) ZSK-key
(3)Stop key
(4)Light-emitting diode (LED)
(5)Appliqué key
(6)Start/Stop keys
(7)Pantograph positioning keys
12.4.1 start/stop keys
You can use the start/stop key cluster when the leD (light-emitting
diode) in the cluster is illuminated. the pantograph positioning keys
must be switched off.
The Start/Stop key cluster is situated on the control unit and, in some cases,
between the heads (without the ZSK key). It consists of the keys for starting and
stopping the machine, selecting and deselecting the pantograph positioning keys
(ZSK key), reverse embroidery and executing single stitches.
75
Operating elements
Operation
Function
Press
Stops the machine
Press
Starts the machine
Press
Switches pantograph positioning
keys on/off
Pressbriefly
Executes a single stitch
Hold down
Executes a sequence of single
stitches (embroidering at low speed)
Pressbriefly
Moves the pantograph back one
stitch at a time (reverse embroidery)
Hold down
Executes a sequence of reverse
stitches
You can stop the machine at any time with the stop key. the
interrupted embroidering routine is resumed as soon as the machine
is restarted with the start key.
12.4.2 Pantograph positioning key cluster
Do not select manual pantograph positioning while the machine is
running. this would stop the machine and interrupt the embroidering
routine.
The key cluster for positioning the pantograph manually is situated on the control
unit. It consists of the arrow keys for positioning the pantograph and the Appliqué
key.
76
Operating elements
switching on key cluster
1
Press ZSK key (1)
Fig. 64: ZSK key
2
Pantograph positioning switched on:
(LED (2)illuminated).
Fig. 65: LED
applikations-taste
The appliqué key is located in the Pantograph positioning key cluster; it is
required when you wish to embroider with appliqués. The key cannot be used
unless the key cluster is switched on.
Press the appliqué key for 1 sec at least.
- caution! - the pantograph travels at a very high speed.
Do not rest on the work table or lean against the table recesses
within the working range of the pantograph (Fig. 46) a collision
with the high-speed pantograph can cause bruising and injuries
resulting from crushing or shear forces. (Fig. 47).
77
Operating elements
risk of crushing
Fig. 66: Risk of crushing against pantograph frame
(Work table recess)
- caution! - the pantograph travels at a very high speed.
Do not rest on the work table or lean against the table recesses
within the working range of the pantograph (Fig. 46) a collision
with the high-speed pantograph can cause bruising and injuries
resulting from crushing or shear forces. (Fig. 47).
You cannot align the pantograph unless the machine is stationary.
78
Operating elements
12.4.3 aligning pantograph
aligning with arrow keys
Fig. 67: Directions of pantograph movement (example)
Directions of pantograph movement
Align the pantograph with the arrow keys.See (Fig. 67).
Key




Direction of pantograph movement
Backwards
(away from the front edge of the work table)
Forwards
(towards the front edge of the work table)
To the right
To the left
Press the ZSK key again.
Ö The pantograph positioning keys are deselected (LED goes out).
Once you have aligned the pantograph, switch off the positioning
key cluster because the machine cannot be started while manual
positioning is switched on.
79
Operating elements
aligning by way of control unit
aligning the pantograph by way of the control unit is possible only in
the Machine module.
By way of the control unit the pantograph position can also be controlled with
reference to the screen display. This allows paths to be traveled quickly or slowly
or in 1 mm or 1/10 mm steps(increments).
Press the [U5] button below the screen display to activate manual pantograph
positioning.
Ö The following symbols are displayed at the bottom of the screen.
the control unit operator’s guide contains more detailed information
on using the menu keys.
Press button [U1] and hold down arrow button to move pantograph continuously
and fast.
Press button [U2] and hold down arrow button to move pantograph continuously
and slowly.
Press button [U3]andbrieflypressarrowbuttontomovepantographin1mm
steps with each press.
Press button [U4]andbrieflypressarrowbuttontomovepantographin1/10mm
steps with each press.
the pantograph responds straight away.
- caution! - the pantograph travels at a very high speed.
Do not rest on the work table or lean against the table recesses
within the working range of the pantograph (Fig. 46) a collision
with the high-speed pantograph can cause bruising and injuries
resulting from crushing or shear forces. (Fig. 47).
Once you have aligned the pantograph, switch off the manual
pantograph positioning function. With manual pantograph positioning selected, the machine cannot be started.
80
Changing modes
13. changing modes
this part of the operator’s guide refers exclusively to machines with
tubular system functionality.
- caution! - the pantograph travels at a very high speed.
Do not rest on the work table or lean against the table recesses
within the working range of the pantograph (Fig. 46) a collision
with the high-speed pantograph can cause bruising and injuries
resulting from crushing or shear forces. (Fig. 47).
13.1 changing from border frame to tubular system embroidery
the conversion is not to be carried out when the machine is running.
Fig. 68: Operating mode, examples
Left: border frame mode with optional sequin device
Right: Tubular system embroidery
81
Changing modes
13.2 removing pantograph frame
Slacken off screws (2) that fasten
pantograph frame (1) to carriage (3) of
the pantograph drive.
1
2
Remove pantograph frame (1).
3
Fig. 69: Dismantling pantograph frame, illustrated: 1 head machine
13.3 Installing cylinder arm frame holder
Insert cylinder arm frame holder (3).
1
Fasten cylinder arm frame holder (3)
with screws (1) to carriage (2) of the
pantograph drive.
2
3
Fig. 70: Installing cylinder arm frame holder, illustrated on a 1 head machine
each time you convert the machine for a different mode, change the
pantograph configuration to suit the application (e.g. border frame
embroidery) by way of the control unit.
82
Changing modes
13.4 Moving work tables
the work tables are heavy. at least two people are required to
move them.
to allow tubular system embroidery, the work table has to be lowered
to its travel limit.
The Jxx series consists of three machine variants:
- Machines without a work table support
- Machines with manually adjustable work table support
- Machines with hydraulic work table support
13.4.1 Machines without a work table support
2
Slacken off star-shaped screws (1) with
which work table (2) is secured.
Pull out work table.
Insert work table in bottom
1
mounting bracket (3).
Fig. 71: Upper mounting bracket
Insert star-shaped screws in rear
position.
Secure work table by tightening
star-shaped screws (1).
3
1
Fig. 72: Lower mounting bracket
83
Changing modes
13.4.2 Machines with a work table support
Manually adjustable work table support
On machines with work table support with manual adjustment, the work table
position is changed in the same way as on machines without work table support.
In addition, however, the work table support must also be adjusted as follows:
Manually adjusting work table support
1
2
Slacken off star-shaped screws (1) or
center support (2).
Fig. 73: Star-shaped screws for center support
Remove work tables (3).
Unscrew and remove starshaped screw
(7).
3
4
Pull keeper (5) off pin (6).
Hold work table support (4)firmlyand
fully extract pin (6).
Lower work table support (4) and
rotate through 180° to the rear.
5
Insert pin (6) in the envisaged hole.
6
7
Secure the pin with keeper (5).
Tighten star-shaped screw (7).
Fig. 74: Work table support in top position
Slide the work tables from the front onto the bottom mounting bracket (right and
left sides) and the work table support.
Secure the work tables with the star-shaped screws.
84
Changing modes
It is essential that you rotate the work table support through 180°
to the rear, otherwise you risk injuring yourself on projecting part (8).
8
Fig. 75: Attachment of work table to center support
hydraulic work table support
Make sure that nobody is busy at or underneath the work table
while it is being moved.
removing middle pantograph guide rail
Detach the middle pantograph guide rail before lowering the
work table.
Fig. 76: Pantograph, middle guide
85
Changing modes
Slackenofffixingscrew(2).
Remove work table extensions (1).
1
2
Fig. 77: Dismantling work, table extension
Move the “front-to-back” pantograph guide as far forward as
possible (front edge of work table).
3
Remove screws (3).
Remove middle pantograph guide rail (4).
4
Fig. 78: Dismantling middle pantograph guide rail
adjusting work table support hydraulically
Turn crank (1) counterclockwise.
1
Ö Work tables are lowered to the
bottom position.
Turn crank (1) clockwise.
Ö Work tables are raised to the top
position.
Fig. 79: Hydraulic drive for adjusting work table support
86
Changing modes
13.5 changing from tubular system to border frame
embroidery
the conversion is not to be carried out when the machine is running.
When you wish to embroider in the border frame mode, it is
essential that you return the work table support to the top
position, otherwise the work tables can break.
to convert from tubular system to border frame embroidery, follow
the same steps as for converting from border frame to tubular
system operation, but in the reverse sequence.
each time you convert the machine for a different mode, change the
pantograph configuration to suit the application (e.g. border frame
embroidery) by way of the control unit.
13.6 changing from tubular system to cap embroidery
the conversion for optional cap embroidery is described in the
operating instructions for the cap attachment.
each time you convert the machine for a different mode, change the
pantograph configuration to suit the application (e.g. border frame
embroidery) by way of the control unit.
87
Preparing to embroider
14. Preparing to embroider
as a general rule, carry out the work described here only when
the machine is stationary. Make sure that no-one is able to start
the machine while you are fitting the embroidery material and
setting it up.
This chapter describes all the work that has to be executed before embroidering.
It covers fundamental manual intervention by the operator as required after faults
(e.g. changing needles and threading) or when optimizing the embroidered work
(e.g. adjusting thread tension) as well.
14.1 clamping embroidery material
14.1.1 tubular system embroidery
(machines with tubular system functionality only)
- caution! - the pantograph travels at a very high speed.
Do not rest on the work table or lean against the table recesses
within the working range of the pantograph (Fig. 46) a collision
with the high-speed pantograph can cause bruising and injuries
resulting from crushing or shear forces. (Fig. 47).
adjusting frame tension
Adjust the frame tension to match the
thickness of the embroidery material
with the adjusting screw (1) on the
outer frame.
1
Fig. 80: Tubular system embroidery, screw for adjusting frame tension
88
Preparing to embroider
clamping embroidery material in the frame
1
2
Fig. 81: Tubular system embroidery, clamping tubular fabric in cylinder arm frame
Place outer frame (1) underneath
the area that you wish to embroider
(between the two layers of tubular
fabric).
Apply pressure with the ball of the
thumb to press inner frame (2)into
the outer frame from above so that
the embroidery material is stretched
smoothly over the frame.
Fig. 82: Tubular system embroidery, screw for adjusting frame tension
Optional clamping aids are available to facilitate clamping the
embroidery material in the cylinder arm frame.
89
Preparing to embroider
14.1.2 Border embroidery
- caution! - the pantograph travels at a very high speed.
Do not rest on the work table or lean against the table recesses
within the working range of the pantograph (Fig. 46) a collision
with the high-speed pantograph can cause bruising and injuries
resulting from crushing or shear forces. (Fig. 47).
Clamping element, fitting
Make sure that the clamping elements lie absolutely flat otherwise the presser feet will be damaged as they pass over.
Pullclampingprofile(2) of clamping
element (1) over the cloth from the
inside towards border frame (4) until
contact is made.
1
2
3
4
Fig. 83: Clampingelement,fitting
90
Pull the border clamp over angle rail
(3) overcoming the spring resistance,
until it engages.
Preparing to embroider
clamping elements with locking mechanism
Make sure that the locking mechanism on the clamping element
is securely engaged before starting up the machine. Otherwise
damage may be caused to the embroidery material, embroidery
head or any auxiliaries (e.g. sequin attachment).
Depending on the version, the lateral (bronze-colored) clamping
elements are equipped with a locking mechanism. Make sure that the
locking lever is released when fitting the clamping element. See (Fig. 84).
To lock or release the clamping
element, move locking lever to its
travel limit.
1
(1)Released
2
(2)Locked
Fig. 84: Clamping element with locking mechanism
Position and sequence of clamping elements
Attachtheclampingelementsontheshortsidesfirst,thenontherearpantograph
rail,andfinallythoseonthefront.Compliancewiththissequenceprevents
unnecessary distortion of the embroidery material.
1
2
Fig. 85: Position of clamping elements
(1)Bronze color
(2)Aluminium color
91
Preparing to embroider
Bronze-colored clamping element (without locking mechanism)
You can opt to equip the entire pantograph with bronze colored
border clamps,which have a stronger spring action than the aluminium ones. The exclusive use of bronze clamps is beneficial when
embroidering designs that contain an exceptionally large number of
stitches.
14.1.3 single frame embroidery
single frame technology, (optional)
a separate frame technology operating manual is provided with the
single frame embroidery option.
Fig. 86: Single frame
14.1.4 cap embroidery
cap attachment (optional)
a separate manual is provided with the optional cap attachment.
Fig. 87: Cap frame
92
Maintenance and troubleshooting
15. Maintenance and troubleshooting
15.1 For your safety
Before undertaking any cleaning or maintenance work:
Make certain that the machine cannot be switched on unintentionally by unauthorized persons.
covers have to be removed to perform some maintenance work.
On no account is the machine to be restarted before you have
reinstalled all covers properly.
15.2 lubricants
The standard machine accessories include:
Ö A spray can containing sewing machine oil
(JCW35SuperLubrifiant,ZSKorderNo.750081)
Ö A grease cartridge
(Gleitmo 585M, ZSK order No. 667 055).
As far as possible, use only the original lubricants supplied with the machine
when carrying out maintenance work. These lubricants are available from ZSK.
Waste grease and oil are to be treated in compliance with the
disposal regulations applicable in the country concerned or surrendered to a hazardous waste facility.
93
Maintenance and troubleshooting
15.3 Overview
the stated maintenance intervals are guidelines for conventional
single shifts. In case of 2 or 3-shift duty cycles, the intervals are to
be reduced accordingly.
Before applying grease or oil, remove dirt and old residual lubricant.
all installed lifting magnets are maintenance-free and must not be
oiled.
More detailed maintenance instructions are contained in the Maintenance guide.
Do not apply an excessive amount of grease or oil, otherwise
moving parts can hurl off lubricant or give rise to dripping. this
could cause the work to be soiled.
Key to maintenance table
~
94
1x
(No� of shots)
every three months
every day
every six months
every month
every twelve months
as necessary
Maintenance and troubleshooting
Type
Maintenance
machine in general
SPRINT
Grease linear guide
J-Series
(pantograph control , grease
side-to-side drive)
RACER
L-Z
Lubricant
Frequency
Gleitmo
585M
Fett
Grease linear guide
(pantograph control , grease
side-to-side drive)
Type
Maintenance
control components
SPRINT
Clean control components
J-Series
Clean ventilation filter
Frequency
~
RACER
L-Z
95
Maintenance and troubleshooting
15.4 Troubleshooting
The following tables are designed to help you rectify faults caused by incorrect
operation or minor damage.
Fault
Pantograph
offset
Design offset
Machine runs
irregularly
96
Cause
Remedy
Pantograph adheres to work
table as a result of using
adhesive spray
• Clean work table
Parts of design lie outside
embroidery field
• Position in such
a way that entire
design lies within
embroidery field
(framing)
Design is defective
• Prepare new copy
from original
Clamped connections of
toothed-belt pulleys are slack
• Check clamped
connections,
take up slack if
necessary
Embroidery material is
clamped too slackly
• Clamp material
taut
Material distortion, especially
with very fine material
• Reinforce
embroidery
material, e.g. with
nonwoven fabric
Embroidery frames not sufficiently secured
• Secure individual
frames, mounting
rails etc. well
Upper and bobbin thread
tension too high
• Set correct thread
tension
Punch faults
(processing sequence not
operating smoothly, especially
with stitchintensive designs)
• Obtain information
from card
manufacturer
Belt tension too slack
• Tighten belts
Components not running
freely
• Notify ZSK
customer service
• If possible avoid
use of adhesive
spray - use
nonwoven fabric
instead
• Notify ZSK
customer service
Maintenance and troubleshooting
Fault
Inaccurate
stopping
position
Machine does
not start
Cause
Remedy
Belt tension too slack
• Tighten belts
Drive belts coated with oil and
slipping
• Degrease pulley
Components not running
freely
• Notify ZSK
customer service
Power supply interrupted
• Press ZSK-button
on control panel
(LED in start/
stop switch group
comes on)
• Renew drive belts
• Check fuse/
automatic circuit
breaker
97
Subject to change!
© ZSK Stickmaschinen GmbH
2018
Printed in Germany
[ GB ] 02391T15
Version 1.5 • 02.2018