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JUKI PS-800SB-2850 Instruction Manual

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PS-800SB-2850
INSTRUCTION MANUAL

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  • Page 1 PS-800SB-2850 INSTRUCTION MANUAL...

  • Page 2: Table Of Contents

    CONTENTS PREFACE ......................1 1. SPECIFICATIONS ....................3 2. CONFIGURATION ....................4 3. INSTALLATION ....................5 3-1. Installing the panel ....................5 3-2. Installing the air hose ..................6 3-3. Installing the thread stand ................7 3-4. Cautions for the compressed air supply (source of supply air) facility ..8 3-5.
  • Page 3 4-15. Adjusting the intermediate presser stroke ..........30 4-16. Making a template..................31 4-17. Preparation for sewing ..................33 4-18. RFID (How to use the IC tag) ................35 4-19. Configuration of the operation panel ............37 4-20. Maintenance mode ..................39 4-21. List of parameters..................40 4-22.

  • Page 4: Preface

    PREFACE 1) Lift clamp ❶ as shown in the pic- ❶ ❶ ture. If the clamp is not lifted up sufficiently, unpack- ing will not be smoothly carried out. ❷ ❷ 2) Detach top cover ❷ first. Then, detach the remaining covers from the four surfaces. 3) Remove clamping plates of front and rear caster seats ❸...
  • Page 5 4) Remove the plastic cover. 5) Lift the sewing machine with a forklift to bring it to the specified location. (Weight of the sewing machine: 305 kg) Insert the forks of the forklift into this portion. 6) Turning casters ❹ , check to make sure that the sewing machine is put horizontally on the forks of the forklift.

  • Page 6: Specifications

    10821- C.6.2 -ISO 11204 GR2 at 2,800 sti/min. Lubricating oil #10 (Equivalent to JUKI NEW DEFRIX OIL No. 1) #32 (Equivalent to JUKI NEW DEFRIX OIL No. 2), Lithium based grease No. 2 Grease information Manufacturer: WERATCHE Type and number: Lithium base 2# grease...

  • Page 7: Configuration

    2. CONFIGURATION ❽ ❽ ❻ ❻ ❹ ❹ ❶ ❶ ❺ ❺ ❷ ❷ ❸ ❸ ❾ ❾ ❼ ❼ ❶ Machine head ❷ Table ❸ X-axis feed mechanism ❹ Y-axis feed mechanism ❺ Cassette clamp device ❻ Operation panel ❼...

  • Page 8: Installation

    3. INSTALLATION 3-1. Installing the panel 1) This figure shows the operation panel in the shipped state. 2) Remove fixing screws ❶ and ❷ . ❷ ❷ ❶ ❶ 3) Install the operation panel to the arm with screws ❶ and ❷ . 4) Connect the cable to the operation panel.

  • Page 9: Installing The Air Hose

    3-2. Installing the air hose WARNING : Check to be sure that the air hose is fully inserted into the air cock before supplying the air to the machine so as to prevent the air from being blown directly to the human body. Then, carefully open the air cock.

  • Page 10: Installing The Thread Stand

    3-3. Installing the thread stand 1) This figure shows the thread stand in the shipped state. ❷ ❷ ❶ ❶ 2) Install thread stand bar (lower) ❶ to the table as shown in the figure . ❸ ❸ 3) Assemble spool support (asm.) ❷ and thread stand bar (lower) ❶...

  • Page 11: Cautions For The Compressed Air Supply (Source Of Supply Air) Facility

    When the supply air contains a considerable amount of carbon Mist separator and dust (Most troubles in the air solenoid valves are caused by carbon.) Be sure to install a mist separator. Standard equipment supplied by JUKI Filter regulator Air solenoid valve Air cylinder Cautions for main piping •...

  • Page 12: Installing The Bobbin Winder Device

    3-5. Installing the bobbin winder device 1) Insert the bobbin deep into the bobbin winder ❽ spindle ❶ until it will go no further. 2) Pass the bobbin thread pulled out from the spool rested on the right side of the thread stand following the order as shown in the figure on the left.
  • Page 13 8) Before you wind a bobbin, remove the needle thread from the thread take-up lever and detach the bobbin case. 9) Press the "Next page" button on the main screen to call up the test mode screen. 10) Adjust the bobbin winding speed. Then, press the start button of the sewing machine to start winding the bobbin.

  • Page 14: Precautions For Installation Of The Machine

    3-6. Precautions for installation of the machine 1. Depending on the size of template, the sewing machine may extend beyond the sewing machine table in X direction. Take care not to allow the machine to hit against someone standing near the table to cause injury.

  • Page 15: Preparation Of The Sewing Machine

    2,000 sti/min or less. 2. For the oil for hook lubrication, purchase JUKI NEW DEFRIX OIL No. 1 (part number : MDFRX1600C0) or JUKI CORPORATION GENUINE OIL 7 (part number : 40102087).

  • Page 16: Attaching The Needle

    4-2. Attaching the needle WARNING : Turn OFF the power before starting the work so as to prevent accidents caused by abrupt start of the sewing machine. Use the specified needle for the machine. Use the proper needle in accordance with the thickness of thread used and the kinds of the materials.

  • Page 17: Threading The Machine Head

    4-3. Threading the machine head WARNING : Turn OFF the power before starting the work so as to prevent accidents caused by abrupt start of the sewing machine. 1) Put sewing machine thread ❶ on thread stand ❷ . ❶ ❷...

  • Page 18: Bobbin Replacement Procedure

    4-4. Bobbin replacement procedure WARNING : Turn OFF the power before starting the work so as to prevent accidents caused by abrupt start of the sewing machine. (1) Removing the bobbin case 1) Open cover ❶ . Then, the bobbin can be changed.

  • Page 19: Adjusting The Thread Tension

    4-5. Adjusting the thread tension ❶ ❸ ❷ 4-5-1. Adjusting the needle thread tension 4-5-2. Adjusting the bobbin thread tension 1) Turn thread tension No. 1 nut ❶ clockwise (in di- 1) Turn tension adjusting screw ❸ clockwise (in rection A), to shorten the thread length remaining direction E) to increase or counterclockwise (in direction F) to reduce the bobbin thread tension.

  • Page 20: Adjusting The Thread Take-Up Spring And The Thread Take-Up Stroke

    4-6. Adjusting the thread take-up spring and the thread take-up stroke [DDL-8000A-*MS] ❾ ❽ ❻ ❶ ❶ ❸ ❷ (1) Adjusting the stroke of thread take-up spring ❶ 1) Loosen setscrew ❷ . 2) Turn tension post ❸ clockwise (in direction A), the stroke of the thread take-up spring will be increased, and turn the post ❸...

  • Page 21: Needle-To-Hook Relationship

    4-7. Needle-to-hook relationship WARNING : Turn OFF the power before starting the work so as to prevent accidents caused by abrupt start of the sewing machine. Adjust the timing between the needle and the hook as follows : 1) Adjusting the needle bar height. Turn the handwheel to bright the needle bar down to the lowest point of its stroke, and loosen setscrew ❶...

  • Page 22: Adjusting The Needle Thread Presser Device

    (2) Position of the needle and the inner hook holder 1) An axial clearance of 0.3 to 0.8 mm should be provided between the projecting part of the inner hook holder and the groove portion of the inner hook. 0.3 ～ 0.8mm 2) The difference in height between the upper end of the projecting part of the inner hook holder and the upper end of the groove portion of the inner...

  • Page 23: Adjusting The Thread Trimmer

    4-9. Adjusting the thread trimmer WARNING : When you turn ON the power to the sewing machine to carry out adjustment, pay attention to abrupt startup of the sewing machine. 4-9-1. For checking of the thread trimming cam timing 1) Remove the waste oil tube of the oil pan located ❻...

  • Page 24: Adjustment Of The Thread Trimming Cam Timing

    5) Turn handwheel ❻ by hand in the normal direc- ❸ ❶ ❹ tion of rotation and press cam follower ❶ to the left (in the direction of arrow E) with your finger from under the table to allow roller ❷ to fit and engage in the groove C of thread trimming cam ❼...

  • Page 25: Checking Of The Knife Unit

    4-9-3. Checking of the knife unit WARNING : Turn OFF the power before starting the work so as to prevent accidents caused by abrupt start of the sewing machine. 1) Check to make sure that the power switch is in ❶...

  • Page 26: Adjustment Of The Knife Unit

    4-9-4. Adjustment of the knife unit WARNING : Turn OFF the power before starting the work so as to prevent accidents caused by abrupt start of the sewing machine. 1) Check to make sure that the power switch is in the OFF state.

  • Page 27: Led Hand Light

    4-10. LED hand light WARNING : In order to protect against personal injury due to unexpected start of the sewing machine, never bring hands near the needle entry area or place foot on the pedal during the adjustment of intensity of the LED.

  • Page 28: Adjusting The Amount Of Oil (Oil Splashes) In The Hook

    4-11. Adjusting the amount of oil (oil splashes) in the hook WARNING : Be extremely careful about the operation of the machine since the amount of oil has to be checked by turning the hook at a high speed. 4-11-1. Adjusting the amount of oil in the hook ❹...

  • Page 29: How To Confirm The Amount Of Oil (Oil Splashes)

    4-11-2. How to confirm the amount of oil (oil splashes) WARNING : Be extremely careful about the operation of the machine since the amount of oil has to be checked by turning the hook at a high speed. Amount of oil (oil splashes) confirmation paper Position to confirm the amount of oil (oil splashes) Hook driving shaft front bushing Hook...

  • Page 30: Setting The Mechanical Origin

    4-12. Setting the mechanical origin 1) Loosen screw ❶ of the coupling on the main shaft ❶ ❶ side. 2) Turn the main shaft until the needle bar is brought to its upper dead point. 3) Adjust the QEP value to 0 ± 5 when the needle bar is brought to its upper dead point by turning the pulley.

  • Page 31: Adjusting The Disk Presser Pressure

    4-13. Adjusting the disk presser pressure 1) Adjust the disk presser air cylinder pressure regu- ❶ ❶ lation valve ❶ . Pull up nut ❷ . Then, turn the nut clockwise to increase the disk presser pressure or turn it counterclockwise to decrease it. The air pressure has been factory-set to 0.15 MPa at ❷...

  • Page 32: Adjusting The Thread End Position At The Beginning Of Sewing

    4-14. Adjusting the thread end position at the beginning of sewing It is possible to set the needle thread end posi- tion at the beginning of sewing to top side ❶ or underside ❷ of material. Change over the setting of the wiper function be- ❶...

  • Page 33: Adjusting The Intermediate Presser Stroke

    4-15. Adjusting the intermediate presser stroke It is necessary to adjust the intermediate presser stroke (A) appropriately since there would be the need for preventing stitch skipping depending on thickness or type of the material. ❶ on the main screen of electrical 1) Press box.

  • Page 34: Making A Template

    4-16. Making a template (1) Machining a template 2850 type template of dimensions of the maximum sewing range ・ Material of template: PVC plate ・ The template is a PVC plate thickness of which is 2 mm or less. ・ The whole thickness of the template should be 5 mm or less including the thickness of the fabric to be set. Be aware that the template may interfere with the intermediate presser and the disk presser if its whole thickness exceeds the aforementioned value.
  • Page 35 (2) Attaching the templates Machine the upper and lower templates based on the design. ❶ ❶ 1) Place the upper template on the lower template in such a way that the sewing slits A of the upper and lower templates are aligned and overlap with each other as shown in the figure.

  • Page 36: Preparation For Sewing

    4-17. Preparation for sewing 1) Turning ON the main power switch. Press button ❶ to turn ON the main power switch. 2) Turning ON the main air source switch Move main air valve ❷ to the right to open the main air source.
  • Page 37 7) Selecting the reference ❺ In order to align the locus of sewing pattern with the sewing slits of the pattern, it is necessary to set a reference. Specifically, set the reference re- ferring to the Instruction Manual for the electrical system scanner.

  • Page 38: Rfid (How To Use The Ic Tag)

    4-18. RFID (How to use the IC tag) 1. Attaching the IC tag Attach IC tag ❶ onto the pattern with double-sid- ed adhesive tape or the like. ❶ ❶ 2. Writing sewing pattern data 1) Place IC tag ❶ on black dot ❷ on the sewing ma- chine table.
  • Page 39 3) Press the "File Management" ❹ on the menu screen. ❹ 4) Select sewing pattern data ❺ you want to write on the IC tag on the memory file screen. After you have made a selection, press "RFID" ❻ to write the sewing pattern data on the IC tag. ❺...

  • Page 40: Configuration Of The Operation Panel

    4-19. Configuration of the operation panel ※ 1 LCD portion of the touch panel PAUSE key Used to temporarily stop sewing OPEN key Move the cylinder lifting plate up and down. PRESS key Used to move up/down the cassette holder START key Used to start sewing USB port...
  • Page 41 Explanation of the operation panel screen ❶ ❷ ❸ ❹ ❺ ❻ ❼ ❽ ❾ Buttons / display Description ❶ Lock key Used to lock the sewing pattern ❷ Threading key Used to thread the machine head ❸ Main shaft speed change key Used to change the sewing machine main shaft speed ❹...

  • Page 42: Maintenance Mode

    4-20. Maintenance mode The maintenance mode is the mode under which the notice telling that the duration of use of the sewing machine has reached the time requiring maintenance is provided in order to extend the product life of the sewing machine.

  • Page 43: List Of Parameters

    4-21. List of parameters Classifi- Standard cation of Parameter name Range Meaning of parameter and comment value parameters Automatic Clamp is opened after the Yes/No Cassette clamp is lifted every time the completion of automatic machining continuous sewing cycle is completed machining Number of stitches to be 0 to 8...
  • Page 44 Classifi- Standard cation of Parameter name Range Meaning of parameter and comment value parameters Automatic P172 Intermediate presser is Yes/No Intermediate presser motor is reset at machining reset after the completion the end of sewing of operation P248 Whether or not the shaft Yes/No travel is required before setting a reference...
  • Page 45 Classifi- Standard cation of Parameter name Range Meaning of parameter and comment value parameters Speed Button sewing speed 2 100 to 20000 1500 Eight direction keys are supported parameter after the button is pressed Operation speed using icon (mm/min) Button sewing speed 3 100 to 20000 8000 Eight direction keys are supported...
  • Page 46 Classifi- Standard cation of Parameter name Range Meaning of parameter and comment value parameters Reset Return-to-origin speed 100 to 60000 15000 X, Y axes speed during resetting to the setting (mm/min) origin P756- Output I/O setting before OUT1 to OUT6 Not set Setting of IO before resetting P761...
  • Page 47 Classifi- Standard cation of Parameter name Range Meaning of parameter and comment value parameters Thread Thread clamp position at 0 to 200 Thread clamp position at the beginning clamp the beginning of sewing of sewing setting P236 Laser output IO Out 1 to OUT12 Laser output Detection...
  • Page 48 Classifi- Standard cation of Parameter name Range Meaning of parameter and comment value parameters Other Repetitive machining time 1 to 65535 1440 Cyclic machining total time: When the settings (min) set time has elapsed, cyclic machining is stopped Repetitive machining inter- 0 to 20 Interval from the completion of machin- val (s)

  • Page 49: List Of Error Codes

    4-22. List of error codes Error Error description Fault Cause Solution Code E001 There is no reset The machine is not reset or reset Click the "Reset" button to reset abnormally after power on E002 Couldn't find X zero signal 1.
  • Page 50 Error Error description Fault Cause Solution Code E023 X axis driver software 1. The parameters are incorrect 1. Reset or redirect parameters overcurrent 2. The motor is stuck 2. Check the machinery 3. The motor is broken or the motor 3.
  • Page 51 Error Error description Fault Cause Solution Code E044 Z axis encoder failure Cause of failure When retrieving the origin of the inter- mediate presser, the sewing machine al- ways runs to lift the intermediate presser and read its origin. If you intentionally lift the intermediate presser by hand, an error may be caused since the interme- diate presser interferes with the bushing.
  • Page 52 Error Error description Fault Cause Solution Code E060 Main axis overvoltage 1. The mains voltage is too high 1. Check the internal drive to preview whether the spindle voltage is higher than 400V, check whether the AC power supply voltage fluctuates abnormally, and see if there are high power equipment around the equip- ment that frequently start and stop;...
  • Page 53 Error Error description Fault Cause Solution Code E074 Y servo encoder AB inter- 1. The Y servo board program is the 1. Look at the screen "Internal Drive" - ference old version "Y "Version Number", 1 means the old version needs to be returned to the factory to update the program 2.
  • Page 54 Error Error description Fault Cause Solution Code E094 Y servo origin regression 1. There is a problem with the en- 1. Overhaul the encoder failure coder 2. There is a problem with the direc- 2. Overhaul the drive direction tion of the drive 3.
  • Page 55 Error Error description Fault Cause Solution Code E113 Broken spindle encoder 1. Poor contact or broken wire of 1. Check the spindle encoder line the spindle encoder 2. The spindle motor is damaged 2. Replace the spindle motor E114 Spindle encoder AB inter- 1.
  • Page 56 Error Error description Fault Cause Solution Code E134 Spindle overspeed 1. Wiring error 1. Check the line 2. The acceleration is too high 2. Reduce acceleration 3. The grid voltage is too low 3. Check the input power 4. Low spindle power 4.
  • Page 57 Error Error description Fault Cause Solution Code E207 Input IO timeout error 1. The corresponding input IO wir- 1. Test wiring or sensor ing or sensor is broken 2. The corresponding input IO 2. Check the mechanical structure mechanism cannot be triggered 3.
  • Page 58 Error Error description Fault Cause Solution Code E214 The quantity of work is full Prompt when "Current Piece Count" 1. The current value of redesigned parts reaches "Total Piece Count" in pro- or the total number of piece counts cessing statistics 2.
  • Page 59 Error Error description Fault Cause Solution Code E225 Connecting the main con- 1. The screen cable interface is 1. Check the screen cable for bad con- trol board... loose or damaged tact or damage 2. Screen or motherboard hardware 2. Replace the screen or motherboard failure E226 Current file is invalid...
  • Page 60 Error Error description Fault Cause Solution Code E240 Communication fault 2 1. Bad communication or damage 1. Check the screen line to the screen leads to CAN com- munication failure 2. The screen or motherboard pro- 2. Upgrade the latest screen or mother- gram is too old board program 3.
  • Page 61 Error Error description Fault Cause Solution Code E252 Rotating motor failure 1. Rotary motor alarm due to me- 1. Check if the machine is stuck chanical overload, etc. 2. The motor wire of the rotating mo- 2.Chec k the corresponding wiring tor is disconnected, the interface is loose, and the connection line between the motor and the driver...
  • Page 62 Error Error description Fault Cause Solution Code E414 (0x) Drive board drive 1. Excessive friction increases the 1. Lubrication overload operating load 2. Insufficient power or improper ad- 2. Adjust the gain or adjust the parame- justment of internal parameters ters E415 (0x) Driver board motor...
  • Page 63 Error Error description Fault Cause Solution Code E431 (0x) The driver board is Refer to E097 Error Handling Method powered off and restarted E432 (0x) Driver board initializa- Spare alarm tion LAN9252 error E433 (0x) Communication be- Spare alarm tween driver board DSP and ESC is interrupted E434 (0x) The communication...
  • Page 64 Error Error description Fault Cause Solution Code E453 (0x) Drive board reverse Exceeded the set target itinerary Press the reset button to reset overtravel warning E470 (0x) driver board overpres- Regulator failure Overhaul voltage regulator sure E471 (0x) Driver board under- 1.

  • Page 65: Maintenance Of Sawing Machine

    5. MAINTENANCE OF SAWING MACHINE WARNING : Turn OFF the power before starting the work so as to prevent accidents caused by abrupt start of the sewing machine. In addition, attach the covers which have been removed before operation back in place.
  • Page 66 New Defrix oil No. 1 (part number: Not enough sewing is displayed machine oil 40214221) or MDFRX1600C0 or on the operation panel. JUKI CORPORATION GENUINE OIL 7 (part number: 40102087). ❶ ❶ – 63 –...

  • Page 67: Troubles And Corrective Measures (Sewing Conditions)

    5-1. Troubles and corrective measures (Sewing conditions) Trouble Cause Corrective measures ① Stitches are slipped at the start. ◦ Adjust the clearance provided between the nee- 1. The needle thread slips off at the start dle and the hook. ◦ Set soft-start sewing at the beginning of sewing. of bar-tacking.
  • Page 68 Trouble Cause Corrective measures ① Clearance provided between the nee- ◦ Adjust the clearance between the needle and the 5. Stitch skipping often occurs. dle and the hook is not correct. hook. ② Position of the inner hook holder ◦ Adjust the position of the inner hook holder against the needle is not correct.

  • Page 69: Disposal Of Batteries

    5-2. Disposal of batteries The operation panel has a built-in battery in order to operate the clock even when the power is turned OFF. Be sure to dispose of the battery following the local laws and regulations. ■ How to remove the battery 1) Remove screws ❶...
  • Page 70 3) Remove setscrews ❹ of the electrical control box cover located inside. Remove cover ❺ from the top of the electrical control box. ❹ ❹ ❺ ❺ ❹ ❹ ❹ ❹ 4) Slide the stopper A A of battery ❻ in the direction of the arrow to remove battery ❻...

  • Page 71: Draining Waste Oil

    5-3. Draining waste oil When you turn ON switch ❼ , you can put the oil in ❼ ❼ the head into polyethylene oiler ❽ . If polyethylene oiler ❽ is filled with oil, turn OFF switch ❼ and discard the oil in polyethylene oiler ❽ . ❽...

  • Page 72: Barcode Reader

    6. Barcode reader 1) Take one seal from the bar code seals. One hundred barcode seals (with serial numbers from 001 to 100) are provided. ❻ ❻ 2) Stick the barcode seal to the cassette at the posi- tion that is 119 mm left from the center of cassette 119mm (setup guide) and 30 mm below the upper side of 30mm...
  • Page 73 2. Setting the barcode functions ● Setting the barcode functions on the opera- tion panel 1) Press button A. 2) Press button B. In the default state, the factory-set password is provided. The password is "11111111". 3) Press button C. 4) To allow the barcode reader to recognize the template, change D from "Electronic identification label"...
  • Page 74 ● Setting the barcode number 1) Press button A. 2) Press button B. 3) Select the sewing pattern file you want to read and press button C. 4) Press button D. Save the data. – 71 –...
  • Page 75 ● Cancelling the barcode number When you want to cancel the barcode reader number, it is necessary to set the current number to the largest value (the largest one of unassigned numbers, such as 100) first. Then, change that number to "0". Example) When the number "3"...

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