HVP-70 Servo Motor (Energy-saving) for Heavy Duty Industrial Sewing Machines
Operating Instruction
Taizhou Mingyuan Hightex Special Sewing Machine Co., Ltd
Catalogue Safety Instruction ................................................................................................................................................ 1 Scope of Application ............................................................................................................................................ 1 Product Features ................................................................................................................................................. 2 Major Technical Indexes and Model Specification .............................................................................................. 2 Installation ........................................................................................................................................................... 3 Operating instruction of pedal: ........................................................................................................................... 9 Operating instruction of operation panel: .......................................................................................................... 8 Fault Code and Repair ....................................................................................................................................... 10 Warranty Service: .............................................................................................................................................. 12 Packing List ........................................................................................................................................................ 13
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Safety Instruction z z z
z z z z
Please carefully read this Instruction before installation and debugging; This product must be installed and debugged by specially trained technicians only; Please be sure to cut off the system power supply before the following operation: 1) When pulling out or inserting any connecting plug on the control box; 2) When replacing the needle, threading and replacing the bobbin thread; 3) In repairing and adjusting; 4) When turning up the sewing machine head. It is strictly forbidden to open the control box when it is powered on. Please lift your feet off the pedal of sewing machine when the power is turned on. 8A fuse is recommended for 220V motor, and 15A fuse is recommended for 110V motor. The sewing machine, motor and controller must be reliably grounded, to prevent accidents and guarantee stable operation of the system.
Scope of Application This product has two type,one is external mounting,the other is direct drive,with 400W,550W and 750W,external mounting can replace all the industrial sewing machine clutch motors.Can be widely applied in garment, footwear, leather, luggage and toy industries. Among them,400W is suitable for lignt load sewing equipment,such as lockstitch sewing machine〠overlock sewing machine etc;550W apply to be double-needle sewing machine,interlock sewing machine and mid heavy material sewing machine;750W apply to be all kinds of special heavy sewing equipment.direct drive motor with sewing machine manufacturers supporting,used for all kinds of direct drive sewing machines.
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Product Features z
z z z z z z
Efficient, energy-saving, and start-and-stop, with no idling energy consumption. The product can save 60%-75% power compared with the mechanical clutch motor of same power, and it is predicted that the motor cost can be recovered within 8~10 months after use. The motor speed is continuously adjustable and, with a big output torque, supportive to various sewing equipment. With needle automatic positioning function, the product can be set into automatic needle position: upper or lower needle position, thus increasing the sewing efficiency. With simple structure, small volume and light weight, this motor weighs only one third of mechanical clutch motor of same power. With brushless design, the product can be used for a long time without replacing the components; maintenance-free, safe and reliable, with a long lifetime and stable performance. With low noise, low calorific value, and small interference to other electronic equipment during the operation. Adopt split design, which makes it convenient for users to install and operate.
Major Technical Indexes and Model Specification Output Power Rated voltage Rated speed Max torque Needle position Safety switch/LED light(5V)
400W 110V/220V 50/60Hz 5000rpm 4.0 N路m Optional Optional
550W 110V/220V 50/60Hz 5000rpm 5.0 N路m Optional Optional
750W 110V/220V 50/60Hz 4000rpm 6.5 N路m Optional Optional 3
Installation 1. External mounting motor installation
Sewing machine table Mounting bracket of motor Mounting screw and nut package
Fixing bolt of pulley cover
Locknut of motor
Pulley cover Speed regulating handle
Pulley Inner pulley cover
Fig. 1
1.1 Install the motor below the sewing machine table with the attached mounting screw and nut package, adjust the motor position to align the belt pulley of motor with the belt pulley of sewing machine, and then tighten the mounting nut of motor. 1.2 Loosen the locknut of motor, mount the belt and adjust it into an appropriate condition, and then tighten the locknut of motor. 1.3 Adjust the inner protective cover of belt pulley to an appropriate position to prevent it from friction with the belt; tighten the fixing screw of inner protective cover of belt pulley, put the outer protective cover of belt pulley on the inner protective cover of belt pulley, and tighten it with the 4
mounting bolt of outer protective cover of belt pulley. 1.4 Connect the attached pedal connecting link to the speed regulating handle and sewing machine pedal, with the direction of link vertical to the ground. Adjust the length of pedal link to form an angle of 30째 between the sewing machine pedal and the ground. 2. Direct drive motor installation(skip,it has been inside of sewing machine head).driect drive motor adjustable speed box installation:install the adjustable speed box of motor in the position behind the table of sewing machine stand with 3pcs self-tapping screw,then,connect the attached pedal connecting link to the speed regulating handle and sewing machine pedal, with the direction of link vertical to the ground. Adjust the length of pedal link to form an angle of 30째 between the sewing machine pedal and the ground. 3.
Install the control box of motor in the position below the table on the right of sewing machine stand with the attached self-tapping screw (as shown in Fig. 2), to make it convenient to operate keys. Then connect the connecting wire plug between the motor and controller, ensure that the connection is reliable. Sewing machine table
Mounting bracket of control Control box of motor Self-tapping
Sewing machine stand
Fig. 2 5
4.
Control box outlet diagram：
4.1 Safety switch、LED light socket instruction： LED light power anode
5V 200mA
Outlet Motor outlet
Needle positioner outlet
Safety switch、 LED light socket (Optional)
Foot controller outlet
AC power (Optional)
Fig.3 6
LED light power
Connnect safety
cathode
switch
Fig.4
5.
Installation of synchronizer (optional part) for external mounting motor Installation of inside synchronizer: Green synchronizer magnet
Sewing machine head
Pulley of sewing machine
Synchronizer Mounting screw
Mounting screw of pulley Red sychronizer magnet
Red synchronizer magnet
(1) (2) Fig. 5 a. Dismount the belt pulley of sewing machine, and install the needle positioner on the sewing machine head with its indicator lamp upward (as shown in Fig. 5-1); b. Install the red and green sychronizer magnets in corresponding position of belt pulley of sewing machine (as shown in Fig. 5-2); Fig. 5-2 shows two installation methods of different belt pulleys, respectively. c. Mount the belt pulley of sewing machine back to the sewing machine, adjust the axial position of the belt pulley to guarantee about 0.5~1mm spacing between the needle positioner magnet and needle positioner, and then tighten the fastening screw on belt pulley. d. Insert the sychronizer plug into corresponding socket of motor control box. e. Adjust the needle position Adjustment of upper needle position: Power on the system. Start the motor and stop the sewing machine in the upper needle position, and then observe whether the sewing machine stops in the required needle position; if the sewing machine does not reach the upper needle position, adjust the green sychronizer magnet clockwise within its mounting groove; if the sewing machine exceeds the upper needle position, adjust the green sychronizer magnet counterclockwise within its mounting 7
groove. Then start the motor and check whether it is in the upper needle position; if not, repeat the above adjustment until it is correctly in the upper needle position. Adjustment of down needle position: The adjustment method of down needle position is same with that of upper needle position, and the only difference is it is adjusted with a red needle sychronizer magnet. Installation of outside synchronizer: a Installation of synchronizer: Set the sychronizer onto the sewing machine head belt pulley spindle or butting connector (adapter), and tighten the fixing screw on the aluminum shaft of sychronizer. Fix the relative position of synchronizer and machine head with a fixed baffle (as shown in Fig. 6). bAdjustment of synchronizer: Before adjustment, make sure that the power switch is turned off, loosen the fixing screw of upper cover of synchronizer, and take down the upper cover of synchronizer. Adjustment of upper needle position: Rotate the hand wheel of sewing machine head manually and stop the sewing machine in the upper needle position, press the hand wheel, rotate the sensor of upper needle position of positioner to aim the notch center of such sensor at the center of corresponding photoelectric sensor on the circuit board. Then the adjustment of upper needle position is finished. Adjustment of down needle position: Rotate the hand wheel of sewing machine head manually and stop the sewing machine in the lower needle position, press the hand wheel, rotate the sensor of lower needle position of positioner to aim the notch center of such sensor at the center of corresponding photoelectric sensor on the circuit board. Then the adjustment of lower needle position is finished. Synchronizer aluminum shaft Fixing screw
Sensor of needle position above needle threader eyelet
Fig.
6
Sensor of needle position below needle threader eyelet
6. 8
Then fix all the cables below the sewing machine table with the attached thread-pressing fastener and nylon cable ties.
Operating instruction of pedal: Step on the pedal slowly from the initial position “0”, and when it is in position “1”, the sewing machine starts to sew at a low speed; when it is in position “2”, the sewing machine sews at a high speed. In the position between “1” and “2” is step-less speed regulation.
-1-Position switch 0-Initial position 1-Low-speed sewing 2-High-speed sewing
Fig. 7 When the pedal is stepped on backward from the initial position “0” to position “-1”, the system shall conduct conversion of needle positions; if it is originally set that the sewing machine stops in lower needle position, step on the pedal, and it will stop in upper needle position; if it is originally set that the sewing machine stops in upper needle position, step on the pedal, and it will stop in lower needle position.
Operating instruction of operation panel: z
Selection key of needle position above or below/positive and negative rotation switch key Needle position setting: Short-press the key, and the sewing machine needle position can be changed; in setting, LED will display F1, F2 or F3, with 3s display time. In F1 status, when the pedal stops in the initial position, the sewing machine stops in lower needle position; then step on the pedal backward, and the needle position will turn to the upper needle position. In F2 status, when the pedal stops in the initial position, the sewing machine stops in upper needle positio; then step on the pedal backward, and the needle position will turn to the lower needle position. In F3 status, when the pedal stops in the initial position, the sewing machine stops in upper needle position; then step on the pedal backward, the upper needle position remains the same. Note: This function is invalid when the synchronizer is not mounted or the synchronizer plug is not inserted into the motor control box. 9
Operation panel diagram: Setting of motor rotation direction: Long-press this key (at least for 3s), and the rotation direction of motor can be changed. When the setting changes, LED will display d1 or Power switch d2; d1 means the motor rotates counterclockwise, d2 means the motor rotates clockwise, and the display time is 3s. Selection key of needle position above or z Speed mode switch key below/positive and negative rotation switch Short-press this key once, and the speed mode of the Speed mode switch key motor may be changed, and two speed modes (P1 and P2)are Speed setting key adopted for this machine; P1 mode means low-speed range LED display panel mode and in this mode, in the process of stepping on the pedal, there is one section of low-speed range, within which, the motor shall keep running at the lowest speed, and it will be accelerated when reaching the end position of low-speed range. P2 mode means non-low-speed range mode and in this mode, in the process of stepping on the pedal, the machine will be accelerated immediately after starting. In the setting, LED will display P1 or P2, and the display time is 3s. 10
Long-press this key once (at least for 3s), and the soft start mode of motor can be opened or closed; in the setting, LED will display S0 or S1; when the machine is set in S1, the soft start mode is opened, and when the system is electrified for the first time or the pedal is stepped on reversely and the needle position is switched, when starting the motor, the motor will run at a speed of 200rpm for the first two circles, and then the motor will run at the normal operating speed. When the machine is set in S0, the soft start mode is closed. z Speed setting key The key is used to display and set the maximum working speed of motor. When the motor is in standby mode, press this key, and it will display the current speed of motor, and then press this key again, and the speed will increase by 100rpm; the speed of motor can be adjusted between the minimum speed and maximum speed and when it reaches the maximum value, press this key, and the speed will return to the minimum value; hold down this key, and fast circular adding setting can be made, LED will display the thousand and hundred of motor speed; for example, for 3,800rpm, LED will display: 3 8, and the display time is 3s. (The maximum speed limit of motor is set in the factory according to user’s requirement) Fault Code and Repair If a fault occurs to motor system, the system LED panel will display corresponding fault code; when several abnormal faults occur at the same time, the display window will display all fault codes by turns, the retention time of each fault code is about 4s, and users can repair them according to the fault codes. If the fault cannot be removed, please contact the dealer or the manufacturer. Fault code PF
Fault description System power failure
Fault analysis and troubleshooting guide The system power failure is indicated and the system stops working, if such case occurs during the working, check whether the power is poor contact. 11
E1
Motor overcurrent fault
E2
Hall signal fault
E3
Governor box fault
E4
Motor overload
E5 E6 E7
Belt drive fault
E8
Driver protection fault
E9
System hardware fault
Eb
Safety switch
EA
Overvoltage Repeated indication
EF
12
Motor rotor is locked Over-temperature fault
fault
System overcurrent protection; please check whether the sewing machine is jammed and whether the plug from motor to control box is loose. Fault alarm of motor position sensor; check whether the plug of wire from motor to control box is loose. Fault alarm of pedal speed regulator; check whether the pedal is in initia position, and whether the plug from governor box to control box is loose. Motor overload protection; check whether the sewing machine is overloaded and is jammed. Motor is jammed; check whether the sewing machine and motor are jammed and whether the plug from motor to control box is loose. Currently, the hardware does not support this fault, and the fault code will be reserved. Needle positioner error; check whether the installation of needle positioner and needle positioner magnet is correct and whether the belt drive is invalid. Hardware overcurrent protection; check whether the motor is jammed or in short circuit and whether the plug from motor to control box is loose. This fault type is controller internal fault; when it occurs, please return the machine to the manufacturer for maintenance. With double lift safety switch sewing machine head,or the safety switch failure. Voltage is too high or too low,check voltage whether the voltage is normal. If the similar fault occurs for three times continuously, lock the system, and remove the fault before re-electrifying.
Warranty Service: 1． The free warranty period of the product is one year from the date of purchasing. Any product quality problem occurring within the warranty period shall be solved by the Company free of charge, but the user shall show the proof of purchase and assume the freight. 2． If the problem cannot be solved by the user, please contact the dealer, or contact the Company directly. 3． The maintenance service in the warranty period shall be paid in the following circumstances: ① The machine is damaged or in fault arising from rule-breaking operation of the user; ② The machine fault results from dismantling, repairing and assembling of the product without the authorization of the Company.
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Packing List
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No. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17.
Name Brushless motor Motor control box Pedal connecting link L=310mm Mounting bolt M8*75mm Hexagon nut M8 Plain washer φ8 Thread-pressing fastener Self tapping screw ST4*14 Nylon cable tie Operating instruction Conformity certificate Protective cover of belt pulley Bolt of outer protective cover of belt pulley Internal needle positioner External needle positioner
Unit Unit Unit Set Bolt Nut Washer Washer Fastener Screw Piece Book Piece Set Bolt Set Set
Quantity 1 1 1 3 3 3 3 5 4 1 1 1 1 1 1 1
Direct drive needle positioner
Set
2
Spring washer φ8
Remarks
Direct drive type don’t deserve Direct drive type don’t deserve Direct drive type don’t deserve Direct drive type don’t deserve Direct drive type 7PCS
Direct drive type don’t deserve Direct drive type don’t deserve Optional Optional According to the model configuration