Sankosha DF-050E-V4 Instruction Manual

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DF-050E-V4

Instruction Manual

For your safety, read this Instruction Manual carefully and understand

all instructions before starting operating of the machine.

If at any time you have any questions, please do not hesitate to contact us.

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Summary of Contents for Sankosha DF-050E-V4

Page 1: Instruction Manual
DF-050E-V4 Instruction Manual Instruction Manual For your safety, read this Instruction Manual carefully and understand all instructions before starting operating of the machine. If at any time you have any questions, please do not hesitate to contact us.
Page 3 Welcome Thank you for choosing our DF-050E-V4 (Form Finisher). This machine was delivered to you after thorough inspection at our plant. Read this manual carefully for proper usage of this machine. Product Specifications Model DF-050E-V4 Power Single phase 230V 50Hz 6A...
Page 4: Table Of Contents
Table of Contents INSTRUCTION MANUAL ............. 1 INSTRUCTION MANUAL ............1 Safety Guidelines ..................5 Hazardous Area ................... 8 Safety Labels on the Machine ..............11 Parts Name ....................12 Main device ..................12 Control box switch position ..............13 Control Panel ..................
Page 5: Safety Guidelines
Sankosha cannot be held legally responsible for any injuries to operators or damages to the machine caused by alterations to the machine or operations not described in the machine manual.
Page 6 Do not put a finger or metal into the machine should be performed only by an authorized or Control Box. Sankosha distributor or by qualified personnel who has read this manual. It may cause electric shock or explosion. Improper installation or rigging of this machine may result in shock, injury or burn.
Page 7 It may cause electric shock without power-off. ■ Check and cleaning Electric plugs and electric sockets need to be checked and cleaned periodically. If you find any damage, call us or your Sankosha distributor. Breakage can cause electric shock and fire. ■ Adequate space Adequate space around the machine should be secured for service and maintenance.
Page 8: Hazardous Area
Hazardous Area Electrically Live Area DANGER Control box has terminals with lethal voltage. -Only maintenance personnel can open the box. -Turn off the power before opening the box. Ignoring this warning will result in serious injury or death due to electrical shock.
Page 9 Range of the Machine in Motion WARNING The machine has a certain range of motion. Keep your hands away from the moving area during operation. Before starting up or checking for maintenance, turn off the air and power first. Ignoring this warning could result in serious injuries.
Page 10 High Temperature Area CAUTION The machine has high temperature area. Never touch these area during operation. Do not also touch these areas for 30 minutes after the steam has been turned off. Ignoring this warning may result in burns.
Page 11: Safety Labels On The Machine
Safety Labels on the Machine ① ② ⑥ ⑥ ⑦ ④ ⑧ ⑤ ③ ③ (Inside Box) ⑧ ① ② It may cause electric shock. ③ Before opening Control Box or maintenance, always turn the power off. High pressure air! ④...
Page 12: Parts Name
Parts Name Main device Body Side Expander Front Clamp Control Box Blower Filter Inverter Display Multi function Foot Pedal Body up Foot Pedal Solenoid Valve Box Body down Foot Pedal Shoulder Expander Foot Pedal Center Vents Clamp Sleever Holder Steam Pressure Gauge Power Switch Steam Inlet Sleever...
Page 13: Control Box Switch Position
Control box switch position ③ ⑤ ② ⑨ ⑩ ① ⑥ ⑦ ⑧ ④ ① Power Switch The switch is for the main power. Black Button is for turning the Power ON. Red Button is for turning the Power OFF. ②...
Page 14 ⑦ Blower Power Dial By turning this dial, you can change the blower power. Turn the dial clockwise and the power will go up. Turn the dial counterclockwise and the power will go down. ⑧ Auto Start Button If you push this button, this machine makes operation automatically whatever process you are in. However shoulder expander, body up and down operations are not made automatically.
Page 15: Control Panel
Control Panel ⑨ ① ② ③ ④ ⑤ ⑥ ⑧ ⑦ ① Steam Timer Button (The light turns green when the button is ON.) When this button is turned ON, you can change the steam injection time with Set/Select Dial ⑧. ②...
Page 16: Foot Pedal
Foot pedal ① Shoulder Expander Foot Pedal When you step this pedal, Shoulder area will expand and you can adjust clothes. Shoulder size returns when you step again. ② Body Down Foot Pedal When you keep on stepping this pedal, body will move down. ③...
Page 17: Operation Procedures
Operation Procedures Follow the procedure for proper operation. CAUTION Improper operation can cause mechanical failure or injury to operators. Provide Air  Check whether air pressure is set at the ① required level for main regulator and other ③ regulators as below. ②...
Page 18: Provide Steam
Provide Steam  Check whether steam with the pressure at 0.5MPa or more can be supplied to the machine. If the steam pressure does not reach the required level, it may adversely affect the garment finishing quality. Always check whether the steam pressure meets its requirement. ...
Page 19: Set The Clothes On The Body
・Make sure there is no one working near the machine before beginning operation. CAUTION ・Beware of pinching hands or garment by moving part during the operation. Set the clothes on the body ≪In case of finishing center vents/side vents≫ Mode Selection Switch （1）...
Page 20 （6） Straighten front placket and step the multi function pedal. →Front side of the garments will be clamped. (“―2―” is displayed.) Front Clamp ＊If the setting is not correct, push the reset button. The machine will return to its previous position. Attention! The processes are different between “Side Vents Mode”...
Page 21 ≪In case of the jumper finishing≫ Mode Selection Switch （1） Change the Mode Selection Switch to the “Jumper Mode”. （2） Set garment on the body and straighten its shoulder position. （3） Step the shoulder expander foot pedal. →Shoulder area of the body will expand according to the shoulder line.
Page 22: After The Work Of The Day
After the work of the day. To use for a long time, do the following procedure. ● ①Close the steam valve of steam inlet part to the machine. ②Do some idle operation until remove humidity from the covers and machine. ③Open the steam trap valve of steam outlet part and eject drain from the machine.
Page 23: Cover/Pad Replace Instruction
Turn the power off before doing this operation. For optimal performance use a factory original cover made only by Sankosha. Using another company’s cover may give a bad finish. Sankosha takes no responsibility if you do not use factory original covers & padding.
Page 24 2. Upper Body Cover setting （1） Put Left shoulder cover on left shoulder Upper body cover part. Left shoulder cover Pull strings so that there is no wrinkle on the cover and tie strings. Right shoulder cover Circle of string （2）...
Page 25: Test Operation
Test Operation Before using the test operation, make sure there is no one working WARNING near the machine. The Test mode operation enables the machine to run each process while the machine runs all the functions continuously on the normal operation. Operation Procedures Step 1: Push the "Test"...
Page 26: Test Number List
Test Number List Test No. Test Item Remarks Steam Injection Solenoid o 0 1 ・It will work 0.3 seconds when steam button is ON. (No.2) ・ Buzzer sounds 1.0 second later when Center Vents Clamp Center Vents Clamp Solenoid closes. Buzzer sounds 0.7 seconds later when it opens. o 0 2 (No.3) Adjust the speed to the beep.
Page 27: Service Menu
Service Menu It is extremely dangerous in Control Box. WARNING Do not touch anywhere unless otherwise specified. Push the Service Button (BP1) on the main circuit board in the control box; you can check the “Input Test”, “Output Test”, “Volume Setting”, “Dip Setting” and “Timer Setting”. Furthermore, you can reset all the settings to factory initial setting and check the software version.
Page 28 Service Menu List (See “Service Menu Explanation”for further details.) ■ Display Displayed word Function Input test 1 is operated. Input test 2 is operated. Output test is operated. Each volume setting. Dip function setting. Time setting displayed in display window. Initialization of volume setting is operated.
Page 29 Chart-1 “Input Test 1” List (continue from the previous page) Input Button／Sensor Name Input Button／Sensor Name Shoulder Expander Foot Pedal Short Time Select Switch Ｓ１Ｓ９ Body Down Foot Pedal Ｓ２ Long Time Select Switch Ｓ１０ Body Up Foot Pedal Ｓ...
Page 30 4. VoL (Volume Setting) by Operation Procedure 1 and 2. Push ④ the “Enter Button” to select. ・Display ・ Turn ⑤ “Set/Select Dial”. Select the number (Chart-3) you want to change, then push ④ the “Enter Button”. The timer of the selected Volume Setting shows up. ・...
Page 31 6. tou (Timer Setting) by Operation Procedure 1 and 2. Push ④ the “Enter Button” to select. ・Display ・ Turn ⑤ the “Set/Select Dial”. Select the number (Chart-5) you want to change, then push ④ the “Enter Button”. The selected timer shows up. ・...
Page 32: Trouble Shooting
◎ During the operation, an error number shows up at the Display Window on the Operation Panel if something is wrong. Check below List, and take the necessary action. Call your dealer or Sankosha if the normal operation does not resume. It is extremely dangerous in Control Box.
Page 33 1. Error Item Error No. 2. Error Description 3. Check Point 1. Reset Button Error 2. Reset Button remains ON more than 15 seconds if the button is staying pushed by something when the main power is ON, or the machine is at the original position. 3.
Page 34 Check whether the switch is broken or a wire connection is loose or disconnected. 1. 24V Error 2. The abnormalities of the emergency stop circuit of a substrate. 3. The error will be released when you push the reset button. When occurring many times, call your dealer or Sankosha...
Page 35: Daily Maintenance
Use “Item Check List” for checking the correct service procedures. If at any time you have any questions, please do not hesitate to contact your Sankosha dealer or us. Check Item List...
Page 36: Check Item（Daily
Check Item（Daily） (1-2) (1-3) (1-1) 1. Air Pressure（Daily）： Figure-1 Check whether air pressure is set at the required level for main regulator and other regulators. (1-1) Main Regulatorꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏ 0.5MPa (1-2) Side Expander Cylinder ꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏ 0.3MPa (1-3) Shoulder Expander Cylinder ꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏ 0.2MPa (Pressure decreases) (Pressure increases) Adjustment ②...
Page 37 Steam Pressure Gauge 3. Steam Pressure ： Figure-3 (0.5MPa) Check the steam pressure gauges(0.5MPa) ※If the steam pressure does not reach the required level, it may adversely affect the garment Cock finishing quality. 4. Steam trap check ： Figure-3 Check to see if the Steam Trap works properly. If not, it may malfunction.
Page 38: Start Operation
7. Blower Filter Check ： Figure-5 Check to make sure the Blower Filter is not clogged by any dirt and dust. If so, clean immediately. If you keep using the filter without cleaning, this can cause poor finishing quality as well as a decrease in the blower power.
Page 39: Item Check List
Item Check List Check Item (Daily) Item Air Pressure Regulator Steam Pressure Steam Trap Cover Emergency Stop Blower Filter Item Air Pressure Regulator Steam Pressure Steam Trap Cover Emergency Stop Blower Filter Check Item (Annual) Item 11 12 13 Regulator Filter Photocopy this checklist for ongoing maintenance.
Page 41: Spare Parts List
Spare Parts List Index 1 : Front Diagram 2 : Rear Diagram 3 : Steam Piping Diagram 4 : Cover Diagram...
Page 42: Front Diagram
1 : Front Diagram REV:1 Front Diagram...
Page 43 Front Diagram REV：2 Part Name Part Number Q'ty Remark 101 Body FRP Q0D214 102 Shoulder (Right) FRP Q0D215 103 Shoulder (Left) FRP Q0D216 Cylinder B1C003 Front Clamp Cylinder Packing Set B6H020 105 Knuckle Joint B6B001 106 Speed Controller C1A076 Cylinder B1C012 Side Expander Cylinder Packing Set...
Page 44: Rear Diagram
2 : Rear Diagram REV:3 Rear Diagram...
Page 45 Rear Diagram REV：3 Part Name Part Number Q'ty Remark 201 Cylinder B1L004 Shoulder Expander 202 Knuckle Joint B6A007 203 Joint C0C161 204 Cable Bear K1B039 Cylinder B1C004 Rear Clamp Cylinder Packing Set B6H012 206 Speed Controller C1A076 207 Knuckle Joint B6B001 208 Filter Regulator D0C003...
Page 46: Steam Piping Diagram
Steam Piping Diagram REV:3 Steam Piping Diagram...
Page 47 Steam Piping REV：3 Part Name Part Number Q'ty Remark Piston valve with air joint and 301 Piston Valve Unit DF-UNT-007-0 air tube. 302 Steam Trap J2N001 303 Y Type Strainer J2M007 304 Radiator RD140-000-1 305 Steam Gauge J0A003 306 Air Muffler J0A001...
Page 48: Cover Diagram
4 : Cover Diagram REV:1 Cover Diagram...
Page 49 Cover Diagram REV：1 Part Name Part Number Q'ty Remark 401 Upper Body Cover S1D160 402 Shoulder Cover (Right) S1D161 403 Shoulder Cover (Left) S1D162 404 Lower Body Cover S1D163 S1D048 Wire Filet Front and Back Clamp Cover 406 Front and Back Clamp Mat S1D051 407 Wooden Sleever Q0A013...
Page 50: Attached Diagram
Attached Diagram Sensor Diagram Electric Connection Diagram 1/4~4/4 Steam Piping Diagram Air Connection Diagram...
Page 51 Sensor（Push Button）Diagram SB05:Steam Button SB01:Emergency Button VR01:Blower Power Dial SB04:Blower Button SW03:Timer Select Switch SB03:Auto Start Button SW01:Mode Select Switch SB02:Reset Button FP01：Shoulder Pedal FP02：Body Down Pedal FP03：Body Up Pedal FP04：Multi Function Pedal...
Page 52 Green/緑 Green/緑 U/T1 V/T2 W/T3 Blower Motor TOSHIBA (0.4kW) Yellow /Green Yellow /Green Shield Type Page Model DF-050E DF050E-V4 2014.06.05 Date （YYYY/MM/DD) Software Approved Checked Designed Ver 1.00 ～ Serial No. ～ Drawing No. 01-1 Koiso Koiso Maki Revision SANKOSHA　三幸社...
Page 53 XE03 XE03 XE04 XE04 XE05 XE05 XE06 XE06 KM01 XE07 XE07 1-E6/XP02-2 +24-OUTPUT 4-B2/+24V-OUTPUT Type Page Model DF-050E DF050E-V4 2014.06.05 Date （YYYY/MM/DD) Software Approved Checked Designed Ver 1.00 ～ Serial No. ～ Koiso Koiso Maki Drawing No. 01-1 Revision SANKOSHA　三幸社...
Page 54 Red/赤ロング時間選択 SW03-2 XS11 XS12 XS13 Green/緑 Green/緑 1-G1/FLC Orange/橙 Orange/橙インバータアラーム 1-G1/FLB Type Page Model DF-050E DF050E-V4 2014.06.05 Date （YYYY/MM/DD) Software Approved Checked Designed Ver 1.00 ～ Serial No. ～ Drawing No. 01-1 Koiso Koiso Maki Revision SANKOSHA　三幸社...
Page 55 XO06 XO07 XO08 XO09 +24V XO10 XO10 BZ01 Red/赤 Red/赤 Buzzer ブザー Black/黒 Black/黒 Type Page Model DF-050E DF050E-V4 2014.06.05 Date （YYYY/MM/DD) Software Approved Checked Designed Ver 1.00 ～ Serial No. ～ Koiso Koiso Maki Drawing No. 01-1 Revision SANKOSHA　三幸社...
Page 56 Steam Piping Diagram ①　Y Strainer　　：FC KY-4G4-15A 100Mesh ②　Pressure Guage：AMT7/16 60φ 1.6MPa ③　Piston Valve　：VND104D-10A ④　Steel Muffler ：SBN-38 ⑤　Steam Trap　　：YH-15A ⑥　Radiator　　　：RD140-000...
Page 58 Sankosha Manufacturing Co.,Ltd. 988 Kanoya Cho, Hachioji, Tokyo 193-0815 JAPAN T e l： 81-42-621-1181 F a x： 81-42-620-0751 URL： http://overseas.sankosha-mfg.com/ Distributor DF-050E-V4 Rev. 7 2020. 7...