ZOJE WR580 Product Manual
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ZOJE WR580 Product Manual

ZOJE WR580 Product Manual

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WR580 PRODUCT MANUAL
V1.0

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Jihad
May 27, 2025

Zoje board e501

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1 comments:
Mr. Anderson
May 27, 2025

The ZOJE WR580 board E501 is an encoder board, as indicated by the code "E" in the motor model serial number and PCB category. Its function is to detect position or movement and send signals to the main control unit for precise control of the motor or spindle.

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Abdul hameed
February 25, 2025

I need this hardware in Pakistan plss help me

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Summary of Contents for ZOJE WR580

  • Page 1 WR580 PRODUCT MANUAL V1.0...
  • Page 2 Catalogue Application Model Code Hardware Structure Error Solution...
  • Page 3 Specification Model WR580 WR580（110V） AC 220V±20% AC 110V±20% Voltage 50/60HZ 50/60HZ MAX. speed (rpm ) 5000RPM MAX. torque (N*m 1.1Nm@5000rpm Rated power (W) 550W Human-computer interface integrated control box 4pin connector (DC5V/200mA) Needle bar led connector Turn up switch、Overvoltage and undervoltage protection、Overload protection、Blocking protection、Short...
  • Page 4 Matching models corresponding motor model Serial Corresponding Control model Matching the head motor model Full automatic WR580 integrated ZJ9503 All in one Automatic medium 80SF90-B5000-S02 Full automatic materials Lockstitch WR580(110V) integrated(110V) Full automatic integrated heavy WR580H ZJ9503ZJ9703All in material machine...
  • Page 5 Composition of the product...
  • Page 6 Interface definition Motor outlet Power outlet Motor coder outlet Outlet for pedal Outlet for LED fill needle outlet...
  • Page 7 H 110V ① ② ③ ④ ⑤ ⑥ ①According to the corresponding head brand：WR---On behalf of sewing products series，the corresponding customer Zoje series products(The brand: ZOJE, JOYEE, SINGER, NEUTRAL) ②Product platform No.: 1---Embroidery machine； 5 ----Single-axis platform； 6 ----1 Spindle+1 stepper；...
  • Page 8 Machine code - pedal Pedal PL - 3 02 ① ② ③ ①:PL----pedal； ②:1 ---- At present using the common pedal ，With analog and digital signal； 2 ---- Vertical pedal； 3 ---- Pure analog signal pedal； ③:Serial NO.
  • Page 9 Model description - motor Motor model serial number...
  • Page 10 Circuit board coding instructions S C 12 03 A6 ① ② ③ ④ ⑤ ①:Product category； S----behalf of sewing products PCB;； ②:PCB category； For sewing products： C ---- control panel; E ---- encoder board; H ---- HMI board; D ---- driver board P ---- Power Board S ---- synchronizer board F ---- pedal PCB...

  • Page 11: Safety Precautions

    Safety Precautions •  1, control box working voltage range :180V-260V. •  2, Keep away from the high-frequency electric machinery to avoid signals interference •  3 Make sure the ground line is well conneted. •  4 Machine is forbidden to work in high humidity environment. • ...
  • Page 12 Structure and composition of the hardware. Hardware structure is divided into three parts 1、the main control box (control and operation) 2、pedal 3、motor...
  • Page 13 PCBA Hardware structure assembly instructions •  Control box assembly(control and operation) Plastic Control pedal control box Press plate cover Control PCB positioning colum Plastic Finish Control PCB mounting plate cover Note: Current control box PCB version number: SC1203A5 WR     Currently operating Box PCB version number: SH1203A4 WR     Do not forget to plug the socket when installing control box, to avoid no power or display error code.
  • Page 14 PCBA Hardware structure assembly instructions •  Pedal PCB board Pedal Case Pedal magnet Pedal lifting iron Pedal magnet Location column •  Note： Do not forget to plug the socket when installing pedal, to avoid no power or display error code. Position of magnet will affect the sewing speed and thread cut size to adjust the pedal strength.
  • Page 15 PCBA Hardware structure assembly instructions •  Pedal assembly •  Pedal zero adjustment steps： 1、Install pedal PCBA。Make sure the spacing between magnetic and PCBA hall sensor in 1.5mm~1.8mm，then fixed PCBA。 2、Connect pedal and control box, with 80V isolation transformer supply power, turn the magnet, make the sensor output voltage(both side of C2) from 2.77V to 2.83V.[Note: When adjust the pedal, must use 80V power supply] 3、Test each button on the pedal。...
  • Page 16 PCBA Hardware structure assembly instructions •  Motor assembly Motor Raster Encoder Pressure line boards and dust cover, positioning retainer Location column Note： 1）Turn over the motor after installed the encoder to make sure the Raster not touch the sensor, not touch the connect line, and the height for raster is just in the center of the sensor. 2）Installed the raster will affect the motor angle [motor angle is 252±5] 3）Installed the pressure line boards, put it into the line box, otherwise the line skin will easy to broken.
  • Page 17 PCBA Hardware structure assembly instructions •  Motor assembly Installed the pressure line boards, put it into the line box, otherwise the line skin will easy to broken. Turn over the motor after installed the encoder to make sure not touch the connect line Install the motor direction consistent with the picture due to the motor started wheel fixed Turn over the motor after installed...
  • Page 18 Function -----Control box Operator interface Standby mode, press “S” for 2 seconds to enter to the monitoring state, press keys to change the monitor serial number, monitor the value read. Specific display contents are: press “S” to enter into specific values​ ​ , press “P” to exit and return to standby mode.
  • Page 19 Function-----Motor Angel Test Model Press “S” key, into the motor Angle test mode, the system display： Press “P” + key star to test, after the finish, it show the motor angel： ▼ 252±5...
  • Page 20 Function----- Pedal calibration mode •  Press to starting up，it will display Pdl on the operation box •  Press “P” + to start check，after finish will show the data .(Normal ▼ value between +15~ -15) •  It will show error when the value is out of normal.
  • Page 21 Function-----Aging mode •  Press to enter the aging mode •  Then press ▼ to start, press again to stop.
  • Page 22 External interface definition Motor outlet Power outlet Outlet for pedal Motor coder outlet Outlet for LED fill needle outlet...
  • Page 23 Internal interface definition –operation panel 5V-2 5V-2 PGND PGND DATA...
  • Page 24 External interface definition – power Ground wire...
  • Page 25 External interface definition - pedal PEDAL PGND Factory 5V-2...
  • Page 26 External interface definition – Light, Needle Needle 5V-1...
  • Page 27 External interface definition – motor\encoder HALL_A AC servo motor HALL_B HALL_A HALL_C HALLB HALL_C ENCA ENC_B ENCB PGND ENC_A 5V_2(F PGND 5V_2(F2) Ground...
  • Page 28 Main board PCBA appearance...
  • Page 29 Control box theory diagram...
  • Page 30 code Error Error Contents Reason & Solution Code Check whether Earth-connection well; whether Drive Hardware over-current device broken or not. Check whether Earth-connection well; whether Current Software over-current sampling circuit works or not. Over-voltage when shutdown Check whether system line voltage over high Under-voltage when shutdown Check whether system line voltage too low Over-voltage when runtime Check whether system line voltage over high...
  • Page 31 Error code Error Contents Reason & Solution Code Check whether Earth-connection well; whether Current Under-voltage when runtime sampling circuit works or not. motor HALL_A signal lost error Check whether motor plug loosen or not. Check whether the machine stuck; the frequent operation motor overload of acceleration and deceleration EEPROM error...
  • Page 32 Error solution E1---Hardware over-current (Motor over-current, PB_FLT protection signal effective) Steps: 1.  check the motor well or not: check whether it’s short-circuit between the pin4 and the Pin 1,2,3 by Using Ω channel of multimeter, check whether the impedance of U3 ,V2,W1 of three phase motor is the same 2. ...
  • Page 33 Error solution E1--- Hardware over-current (Motor over-current, PB_FLT protection signal effective) interface U20[OPA2377] Raster manually rotate the motor to Installation see whether the grating height U8[IR2136S] touch the sensor chip, and height is right in the Q3~Q8 center position of the sensor [IGBT] R169 C101...
  • Page 34 Error solution E2----Software over-current (soft test motor current over Alert value [16A]) Steps: 1.  A ccess supervisory interface of operation panel, check at CUR interface, the current value when motor accelerate and scram. (Normally the value is 0.3) 2.  c heck the motor well or not : check whether it’s short-circuit between the pin4 and the Pin 1,2,3 of motor’s plug by Using Ω channel of multimeter, check whether the impedance of U3 ,V2,W1 of three phase motor is the same 3. ...
  • Page 35 Error solution E3--- Overvoltage when shutdown (the bus voltage is greater than 450v for 3 second when shutdown) Steps: 1.  Check whether the inlet voltage of control box is stable, if it’s within the specified range of 200V-250V 2.  when standby, enter monitoring interface of operation control box and see what’s the voltage appear in UDC interface, then run the motor to see how much voltage rise while scram(usually around 410V)[the inlet voltage multiplied by 1.41 = interface voltage] 3. ...
  • Page 36 Error solution E4---Overvoltage when shutdown (the bus voltage is less than 180v for 3s when shutdown Steps: 1.  Check whether the inlet voltage of control box is stable, if it’s within the specified range of 200V-250V 2.  when standby, enter monitoring interface of operation control box and see what’s the voltage appear in UDC interface, then run the motor to see how much voltage rise while scram(usually around 410V)[the inlet voltage multiplied by 1.41 = interface voltage] 3. ...
  • Page 37 Error solution E5---Overvoltage when running (the bus voltage is greater than 460v for 10ms when running) Steps: 1.  Check whether the inlet voltage of control box is stable, if it’s within the specified range of 200V-250V 2.  when standby, enter monitoring interface of operation control box and see what’s the voltage appear in UDC interface, then run the motor to see how much voltage rise while scram(usually around 410V )[the inlet voltage multiplied by 1.41 = interface voltage] 3. ...
  • Page 38 Error solution E6---needle position signal error(when the motor speed over 50rpm, “UP” signal keeps continuous 1s low frequency or high frequency, that means the frequency without change for continuous 1s) Steps: 1.  c heck the encoder socket and the main control encoder connect well or not 2. ...
  • Page 39 Error solution 5. Check the C30 two side impedance which on the main board: around 11K，the standby voltage:5.2V 6. Check the U2 (49pin) or U6 (16pin ) impedance to C4 negative terminal: around 3M, use 80Visolating transformer to supply power , the standby voltage:3.2V U6【chip model：74LVC244】...
  • Page 40 Error solution E7--- motor HALL signal error ( when the power on HALL_A HALL_B HALL_C signal is low or high level) Steps: 1.  Check whether the encoder socket connect well with main control encoder socket or not(whether there is dust inside encoder or not) 2. ...
  • Page 41 Error solution 4) Check the two-terminal impedance of C29 on main control board: about 11K .(Standby voltage:5.1V); impedance of U2(38 pin) or U6(14 pin) to C4 negative terminal: around 3M (Standby voltage:3.2V) 5) Check the two-terminal impedance of C39 on main control board: : about 11K.(Standby voltage: 5.1V);impedance of U2(52 pin) or U6(18 pin) to C4 negative terminal: around 3M(Standby voltage:3.2V)·...
  • Page 42 Error solution E8--- Motor stuck running (motor running speed continuous 2s less than 25rpm or the current more than 10A) Step of Solution： 1.  This error happened when work in thick materials, please enter Ⅱ parameter adjust no. 22(Different thickness materials with different parameters,it depands on the actual material) 2. ...
  • Page 43 Error solution Encoder U6 & CN4 pin & definition U8[IR2136S]pin The motor power supply interface...
  • Page 44 Error solution E9---Motor overspeed error(exceed the designed max speed) Step of solution 1.  If the motor angle correct；Check the operating box monitoring interface DJ [Observe if the motor angle is in the range of 252 ± 5] (if the deviation of motor angle is too big, then motor acceleration or will cause large current or ​...
  • Page 45 Error solution E10---Overvoltage when running (the bus voltage is less than 80v for 10ms when running) •  Troubleshooting steps •  1）Check whether the inlet voltage of control box is stable, if it’s within the specified range of 200V-250V •  2）when standby, see what’s the voltage appear in UDC interface, then run the motor to see how much voltage rise while scram(usually around 410V), 【the inlet voltage multiplied by 1.41 = interface voltage】...
  • Page 46 Error Solution E11—HALL initialization signal fault ( when the power on HALL_A HALL_B HALL_C signal in low level) •  Troubleshooting steps 1）Check the encoder socket with main control encoder socket interface（Whether inside the encoder dusty ） 2） Check the U3—pin 2 impedance to pin 3(ground) which on the encoder board: about 1.2M ; ( the standby voltage : with the grating angle is different switch between 0V with 5.1V);...
  • Page 47 Error Solution E11—HALL initialization signal fault ( when the power on HALL_A HALL_B HALL_C signal in low level) J1 pin and definition U3/4/5 position and foot...
  • Page 48 Error solution 4）check the C29 two-terminal impedance on main control board: about 11K .(Standby voltage:5.1V); U2(38 pin) or U6-14 pin to impedance on C4 negative terminal: around 3M (Standby voltage:3.2V 5）check the C39 two-terminal impedance on main control board: about 11K.(Standby voltage:5.1V); U2(52 pins) or U6-18 pins to impedance on C4 negative terminal: 3M detection(Standby voltage:3.2V) 6）check the C41 two-terminal impedance on main control board: about 11K.(Standby voltage:5.1V);...
  • Page 49 Error solution E12--- motor (motor overload long 2me high current opera2on) •  Solu&on step •  1) motor angle is correct; check the opera&ng box monitoring interface in DJ [observe the motor angle is in the range of ± 5 [252] the motor angle devia&on is too large, large current or speed phenomenon will accelerate and quick stop] •  2) encoder inside is an ash •  3) the operator is very frequent pedal, this fault is a frequency too frequently lead to, can put [2] parameter set to 5 relief work frequency...
  • Page 50 Error solution E13---EEPROM error (DSP reads the wrong data.) •  Solu&on step •  1) restore factory seIngs •  2) the main control re-entry into a program •  3)replace the U2 chip 【TMS320F28031 /64PIN】...
  • Page 51 Error solution Fault detec2on circuit of E14---- current (/CUR_A or /CUR_B signal zero offset value is too large) •  Solu&on step •  1) detec&on on the main control board impedance between two C55/C67: 13.5K; 80V transformer electric, measuring voltage is U20 1.46V [1, 7 feet of 4 foot [to] between impedance: 13.5K standby voltage: 1.46V] •  2) detec&on on the main control board impedance between the ends of 100 C54/C62:?; 80V transformer electric, measuring voltage 0V •  3) the main control end of the D8/D11 plate &lts, with a mul&meter measuring (block) two diode resistance: Infinity [nega&ve] does not make a mistake when measuring Negative pole-Multimeter black pen 【OPA2377 C55/C67 pin】...
  • Page 52 Error solution E15（Pedal zero point adjust error：zero point adjust over size（-1.5degree~1.5） •  Trouble shooting procedure •  1）Adjust the number of parameter 25 •  2）Only in the pedal zero point adjustion testing function.it will cause this error.Adjust pedal positioning screw a bit. • ...
  • Page 53 Error solutin E16--- OZ loop trouble（can’t be enter for 1s and oz interrupted）mainboard •  Trouble shooting precedure •  1）to check the relay which running in 220V whether it sounds like tick-tock. •  2）to check the voltage of UDC in panel’s monitor interface. • ...
  • Page 54 Error solution E17----Motor reversion（The speed of reversion 100ms >750rpm higher than alarm value） •  Trouble shooting procedure 1) Check the angle of motor whether in right position; Check the supervisory interface of operation panel DJ【check the angle whether the angle is in the range 252±5】【Too big angle will cause over current and over speed when motor accelerate and sudden stop】...
  • Page 55 ERROR SOLUTION E18----Error of motor angle testing (Motor angle error when running) •  Error solution steps •  Whether the motor in correct angle; Check the monitoring interface of operation panel dj [check whether the motor angle within 252 ±5] [Big deviation of motor angle will cause overcurrent or over speed when motor is accelerating or sudden stop] • ...
  • Page 56 ERROR SOLUTION E19---（Turn over warn: turn over switch is effective） •  Error solution steps •  Check the impedance between two legs of mercury switch U5 when the main board is in upright position: around 11.7K; If the main board is in horizontal position the mercury switch will be short circuit and the impedance: 0Ω...
  • Page 57 ERROR SOLUTION OFF-Power cut warn(200ms do not detect cut of OZ) •  Solu&on step •  1）Error solution steps •  To hear whether it is sound of relay when the power is cut. •  Check impedance of R15:220K, check D3 by channel on multimeter, check the resistance of diode: 0.48V • ...
  • Page 58 ERROR SOLUTION No power/No display •  Check the fuse. •  Check impedance of rectifier bridge: 2.1M; supply power of 80V by isolation transformer, voltage of rectifier bridge +、 − :around 120V: impedance of Q3~Q8(IGBT): 10K •  Check impedance of T2’s output voltage: impedance of D20: around 5.7K;...
  • Page 59 ERROR SOLUTION TNY398 Rectifier bridge IGBT gative-Black of muitimeter...
  • Page 60 谢 谢！...

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