Atlanta Attachment Company 1315A User manual

Atlanta Attachment Company
362 Industrial Park Drive
Lawrenceville, GA 30046
770-963-7369 • www.atlatt.com
Technical Manual & Parts Lists
Model
1315A
Revision 3.1 Updated Aug 29, 2012
From the library of: Diamond Needle Corp

From the library of: Diamond Needle Corp

Technical Manual & Parts Lists
ATLANTA ATTACHMENT COMPANY,INC.
Confidential and Proprietary Information
The materials contained herein are confidential and proprietary information of Atlanta
Attachment Company. In addition to any confidentiality and non-disclosure obligations that currently
exist between you and Atlanta Attachment Company, your use of these materials serves as an
acknowledgment of the confidential and proprietary nature of these materials and your duty not to make
any unauthorized use or disclosure of these materials.
All materials contained herein are additionally protected by United States Copyright law and
may not be used, disclosed, reproduced, distributed, published or sold without the express written
consent of Atlanta Attachment Company, which consent may be withheld in Atlanta Attachment
Company’s sole discretion. You may not alter or remove any copyright, trademark or other notice from
copies of these materials.
Patents & Patents Pending
The sale of this product does not sell or otherwise transfer any license or other rights under any
U.S. Patent or other corresponding foreign patent.
This equipment is manufactured under one or more of the following patents:
4,280,421 ● 4,432,294 ● 4,466,367 ● 4,644,883 ● 5,134,947 ● 5,159,889 ● 5,203,270 ● 5,373,798 ●
5,437,238 ● 5,522,332 ● 5,524,563 ● 5,562,060 ● 5,634,418 ● 5,647,293 ●5,657,711 ● 5,743,202 ●
5,865,135 ● 5,899,159 ● 5,915,319 ● 5,918,560 ● 5,924,376 ●5,979,345 ● 6,035,794 ● 6,055,921 ●
6,202,579 ● 6,279,869 ● 6,295,481 ● 6,494,225 ●6,523,488 ● 6,574,815 ● 6,802,271 ● 6,834,603 ●
6,968,794 ● 6,994,043 ● 7,543,364 ●7,574,788 ● 7,647,876 ● 7,735,439
Foreign Patents: 9-520,472 ● 0,537,323 ● 92,905,522.6 ● 96,936,922.2 ● 2,076,379 ● 2,084,055
Other U.S. and Foreign Patents Pending.
IMPORTANT
It is important to readandunderstand the information contained withinthis
manual before attempting to operate the machine. Atlanta Attachment Co., Inc.
shall not be heldliable fordamage resulting frommisuse of the information
presented within, and reserves the right to change the informationcontained
within, without prior notification.
From the library of: Diamond Needle Corp

Technical Manual & Parts Lists
Contents
Important Safety Instruction ....................................................................................................................... 1
Liability ...................................................................................................................................................... 2
Safety Equipment on the Machines ............................................................................................................ 3
Protective Eyewear ..................................................................................................................................... 4
Important Notices........................................................................................................................................ 5
Maintenance................................................................................................................................................ 7
Repair.......................................................................................................................................................... 8
A Word to the End User.............................................................................................................................. 9
Safety Precautions....................................................................................................................................... 9
Component Identification ......................................................................................................................... 10
General Machine Data .............................................................................................................................. 11
Electrical & Pneumatic Specifications...................................................................................................... 11
Basic Machine Operation.......................................................................................................................... 11
Efka Control Box...................................................................................................................................... 14
General Machine Maintenance................................................................................................................. 14
Daily.......................................................................................................................................................... 14
Weekly...................................................................................................................................................... 14
Monthly..................................................................................................................................................... 14
Electric Eye Sensor Adjustment ............................................................................................................... 15
Reflective Tape Maintenance ................................................................................................................... 15
Efka Parameter Settings (Sewing Head Motor)........................................................................................ 16
Programming Instructions......................................................................................................................... 16
To Perform Master Reset of Parameters................................................................................................... 16
Programming ACTech SCL/SCM Drive.................................................................................................. 17
Conveyor Motor Parameter Menu............................................................................................................ 18
Rotate Arm Motor Parameter Menu......................................................................................................... 20
Speed Setting Controls.............................................................................................................................. 22
Side Sewing Speed Controls..................................................................................................................... 22
Corner Sewing Speed Controls................................................................................................................. 22
Auxiliary Sewing Speed Controls............................................................................................................. 22
Conveyor Belt Tracking Instructions........................................................................................................ 23
Servicing the Sew Head............................................................................................................................ 24
Installation................................................................................................................................................. 24
Lubrication................................................................................................................................................ 25
Caution:..................................................................................................................................................... 25
To Oil the Arm Shaft ................................................................................................................................ 25
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Technical Manual & Parts Lists
To Oil the Bed Shaft................................................................................................................................. 25
Other Oiling Points ................................................................................................................................... 25
Caution:..................................................................................................................................................... 25
Setting the Needle..................................................................................................................................... 26
Threading the Machine ............................................................................................................................. 27
Tension...................................................................................................................................................... 28
Needle Thread Tension............................................................................................................................. 28
Looper Thread Tension............................................................................................................................. 28
Pressure..................................................................................................................................................... 28
Presser Foot Pressure................................................................................................................................ 28
Alternating Pressers .................................................................................................................................. 28
Alternating Presser with Pneumatic Pressure Control.............................................................................. 29
Upper Feed Roll Pressure ......................................................................................................................... 29
Stitch Length............................................................................................................................................. 29
Machine with Puller Feed......................................................................................................................... 30
Presser Bar Lift ......................................................................................................................................... 30
Machines with Alternating Pressers.......................................................................................................... 31
Setting the Height of Feed Bar.................................................................................................................. 32
Centralizing the Feed Dog........................................................................................................................ 32
Setting the Height of the Feed Dog........................................................................................................... 32
Timing the Feed Lift Eccentric................................................................................................................. 33
Needle Bar Positioning............................................................................................................................. 33
Positioning the Loop Deflectors ............................................................................................................... 33
Setting the Distance from the Looper to the Needle................................................................................. 34
Sidewise Setting........................................................................................................................................ 34
Lengthwise Setting & Setting the Height of the Needle Bar.................................................................... 34
Timing Looper Driving Crank.................................................................................................................. 35
Setting the Needle Guards ........................................................................................................................ 35
Positioning Spreader................................................................................................................................. 36
Sidewise and Height Setting..................................................................................................................... 36
Changing Movement of Spreader............................................................................................................. 36
Adjusting Needle Thread Tension Releaser ............................................................................................. 37
Adjusting Looper Thread Take-Up........................................................................................................... 37
Singer® 300UX6 Assembly Drawings & Parts Lists............................................................................... 39
Upper Shaft Assembly.............................................................................................................................. 41
Front Assembly Sewing Arm.................................................................................................................... 43
External Parts Sewing Arm #1.................................................................................................................. 45
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Technical Manual & Parts Lists
Lower Shaft Assembly.............................................................................................................................. 47
Front Assembly Sewing Bed .................................................................................................................... 49
Cross Shaft in Sewing Bed ....................................................................................................................... 51
External Parts Sewing Arm #2.................................................................................................................. 53
External Parts Sewing Arm #3.................................................................................................................. 55
External Parts Sewing Arm #4.................................................................................................................. 57
External Parts Sewing Arm #5.................................................................................................................. 59
Assembly Drawings & Parts Lists............................................................................................................ 61
11315A Auto Tape Edge Machine ........................................................................................................... 63
1315030 Backstop Assembly.................................................................................................................... 65
1315050 Rotate Arm Assembly................................................................................................................ 67
1315060 Foot Pedal Assembly ................................................................................................................ 68
1315620 Guide Roller Assembly.............................................................................................................. 69
1315100 Sew Head Assembly.................................................................................................................. 71
1315115 Arm Gearbox Assembly ............................................................................................................ 73
1315200 Column Assembly...................................................................................................................... 75
1315300 Console Assembly ..................................................................................................................... 77
1315327 Lift Platform Assembly.............................................................................................................. 79
1315400 Flipper Assembly....................................................................................................................... 81
1315430 Pneumatic Panel......................................................................................................................... 82
1315595 Head Pusher Assembly.............................................................................................................. 83
1315575 Tape Roll Holder........................................................................................................................ 84
1315450 Tape Guide Assembly................................................................................................................ 85
1315479 Air Jet Assembly; (Right Side).................................................................................................. 86
1315483 Air Jet Assembly; (Left Side) .................................................................................................... 87
1315498 Push Plate Assembly.................................................................................................................. 89
1315502 Table Assembly ......................................................................................................................... 91
1315560 Control Box Assembly............................................................................................................... 93
1315603 Sensor Bracket Assembly........................................................................................................ 94
1315610 Touch Screen Assembly ............................................................................................................ 95
1315A-PD Pneumatic Diagram ................................................................................................................ 96
1315A-WD Wiring Diagram .................................................................................................................... 97
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Technical Manual & Parts Lists
1
Important Safety Instruction
This part of the Instruction Material is provided for the safe use of your equipment.
It contains important information to help work safely with the unit and describes the
dangers inherent in machinery. Some of these dangers are obvious, while others are
less evident.
Mandatory Information
All persons operating and/or working on the 1959 Automatic Handle Workstation should read and
understand all parts of the Safety Instructions. This applies, in particular, for persons who only operate
and/or work on the unit occasionally (e.g. for maintenance and repair). Persons who have difficulty
reading must receive particularly thorough instruction.
Scope of the Instruction Material
The Instruction Material comprises:
Safety information
Operator Instructions
Electrical and Pneumatic diagrams
And may also include;
A list of recommended spare parts
Instruction Manual(s) for components made by other manufacturers
The layout and installation diagram containing information for installation
Intended Use
Our machines are designed and built in line with the state of the art and the accepted safety rules.
However, all machines may endanger the life and limb of their users and/or third parties and be damaged
or cause damage to other property, particularly if they are operated incorrectly or used for purposes
other than those specified in the Instruction Manual.
Exclusion of Misuse
Non-conforming uses include, for example, using the equipment for something
other than it was designed for, as well as operation without duly installed safety
equipment. The risk rests exclusively with the end user.
Conforming use of the machine includes compliance with the technical data,
information and regulations in all parts of the complete Instruction Material, as
well as compliance with the maintenance regulations. All local safety and
accident prevention regulations must also be observed.
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2
Liability
The machine should only be operated when in perfect working order, with due regard for safety and the
potential dangers, as well as in accordance with the Instruction Material. Faults and malfunctions
capable of impairing safety should be remedied immediately. We cannot accept any liability for personal
injury or property damage due to operator errors or non-compliance with the safety instructions
contained in this booklet. The risk rests exclusively with the end user.
The Instruction Material should always be kept near the machine so that it is accessible to all concerned.
The local, general, statutory and other binding regulations on accident prevention and environmental
protection must also be observed in addition to the Instruction Material. The operating staff must be
instructed accordingly. This obligation also includes the handling of dangerous substances and
provision/use of personal protective equipment.
The Instruction Material should be supplemented by instructions, including supervisory and notification
duties with due regard for special operational features, such as the organization of work, work
sequences, the personnel deployed, etc.
The personnel's awareness of the dangers and compliance with the safety regulations should be checked
at irregular intervals.
Choice and Qualification of Personnel
Ensure that work on the machine is only carried out by reliable persons who have been appropriately
trained for such work - either within the company, by our field staff or at our office - and who have not
only been duly appointed and authorized, but are also fully familiar with the local regulations. Work on
the machine should only be carried out by skilled personnel, under the management and supervision of a
duly qualified engineer.
This not only applies when the machine is used for production, but also for special work associated with
its operation (start-up and maintenance), especially when it concerns work on the hydraulic or electrical
systems, as well as on the software/serial bus system.
Training
Everyone working on or with the machine should be duly trained and informed with regard to correct
use of the safety equipment, the foreseeable dangers which may arise during operation of the machine
and the safety precautions to be taken. In addition, the personnel should be instructed to check all safety
mechanisms at regular intervals.
Responsibilities
Clearly define exactly who is responsible for operating, setting-up, servicing and repairing the machine.
Define the responsibilities of the machine operator and authorize him to refuse any instructions by third
parties if they run contrary to the machine's safety. This applies in particular for the operators of
machines linked to other equipment. Persons receiving training of any kind may only work on or with
the machine under the constant supervision of an experienced operator. Note the minimum age limits
permitted by law.
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A Word to the Operator
The greatest danger inherent in our machines:
is that of fingers, hands or loose clothing being drawn into a machine by live, coasting or rotating tools
or assemblies or of being cut by sharp tools or burned by hot elements.
ALWAYS BE CONSCIOUS OF THESE DANGERS!
Safety Equipment on the Machines
All machines are delivered with safety equipment, which shall not be removed or
bypassed during operation.
The correct functioning of safety equipment on machines and systems should be
checked every day and before every new shift starts, after maintenance and repair
work, when starting up for the first time and when restarting (e.g. after prolonged
shutdowns).
If safety equipment has to be dismantled for setting-up, maintenance or repair work, such safety
equipment shall be replaced and checked immediately upon completing the maintenance or repair work.
All protective mechanisms shall be fitted and fully operational whenever the machine is at a standstill or
if it has been shut down for a longer period of time.
Damage
If any changes capable of impairing safety are observed in the machine or its mode of operation, such as
malfunctions, faults or changes in the machine or tools, appropriate steps must be taken immediately, the
machine switched off and a proper lockout tagout procedure followed. The machine should be examined
for obvious damage and defects at least once per shift. Damage found shall be immediately remedied by
a duly authorized person before resuming operation of machine.
The machine should only be operated when in perfect working order and when all protective
mechanisms and safety equipment, such as detachable protective mechanisms, emergency STOP
systems, etc. are in place and operational.
Faults or Errors
The machine must be switched off and all moving or rotating parts allowed to come to a standstill and
secured against accidental restart before starting to remedy any faults or errors.
Signs on the Machine
Safety and danger signs on the machine should be observed and checked at regular intervals to ensure
that they are complete and undamaged. They should be clearly visible and legible at all times.
Clothing, Jewelry, Protective Equipment
Long loose hair, loose-fitting clothes, gloves and jewelry, including rings, should be avoided in order to
avoid injuries due to being caught, drawn in and wound up inside the machine.
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Protective Eyewear
Protective eyewear that has been tested by the local authorities should be worn
whenever there is a possibility of loose or flying objects or particles such as when
cleaning the machine with compressed air.
Tools
Always count the number of tools in your possession before starting work on the machine. This will
allow you to check that no tools have been left behind inside the machine. Never leave a tool in the
machine while working.
Oils, Lubricants, Chemicals
Note the applicable safety regulations for the product used.
No Smoking, Fire, Explosion Hazard
Smoking and open flame (e.g. welding work) should be prohibited in the production area due to the risk
of fire and explosions.
Workplace
A clear working area without any obstructions whatsoever is essential for safe operation of the machine.
The floor should be level and clean, without any waste.
The workplace should be well lit, either by the general lighting or by local lights.
Emergency STOP
The emergency STOP buttons bring all machine movements to a standstill. Make sure you know exactly
where they are located and how they work. Try them out. Always ensure easy access to the nearest
emergency STOP button while working on the machine.
First Aid
1. Keep calm even when injured.
2. Clear the operator from the danger zone. The decision of what to do and whether to seek
additional assistance rests entirely with you, particularly if someone has been trapped.
3. Give First Aid. Special courses are offered by such organizations as the employers' liability
insurance association. Your colleagues should be able to rely on you and vice versa.
4. Call an ambulance. Do you know the telephone numbers for the ambulance service, police and
fire service?
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Important Notices
Reporting and Fighting Fires
Read the instructions posted in the factory with regard to reporting fires and the emergency exits. Make
sure you know exactly where the fire extinguishers and sprinkler systems are located and how they are
operated. Pass on the corresponding information to the firemen when they arrive. Ensure there are
enough signs to avoid fire hazards.
The following fire extinguishers may be used:
- Dry powder extinguishers, ABC fire-extinguishing powder.
- Carbon dioxide fire extinguishers to DIN 14461 for electronic components. Great care must be
exercised when using carbon dioxide fire extinguishers in confined, badly ventilated rooms (see DIN
14406 and 14270).
Isolate the machine from the power supply if a fire breaks out. Do not use water on burning electrical
parts until it is absolutely certain that they have been completely disconnected from the power supply.
Burning oils, lubricants, plastics and coatings on the machine can give off gases and vapors that may be
harmful to your health.
A qualified person should be consulted to repair the damage after a fire.
Electrical Power Supply
Before undertaking any maintenance or repair work on the machine, switch off the
electrical power to the machine at the main source and secure it with a padlock so
that it cannot be switched on again without authorization.
In practice, this may mean that the technician, electrician and operator all attach
their own padlock to the master switch simultaneously so that they can carry out
their work safely. Locking extension plates should be available for multiple locks if
required. The primary purpose for a lockout/tagout procedure is to protect workers
from injury caused by unexpected energizing or start-up of equipment.
Energy sources (electrical/pneumatic/hydraulic, etc.) for the equipment shall be turned off or
disconnected and the switches locked or labeled with a warning tag. It is the responsibility of the
employer to establish control procedures. Follow lockout/tagout procedures before, setup and/or any
service or maintenance work is performed, including lubrication, cleaning or clearance of jams.
Caution: The machine is still not completely de-energized even when the master
switch is off.
- Electricity - The machine is always isolated from the electrical power supply whenever the master
switch has been switched off. However, this does not apply for the power supply in the control cabinet,
nor for equipment that does not draw its power via the master switch.
- Pneumatic / hydraulic energy - Almost all our machines carry compressed air. In addition to switching
off the master switch, the air supply must also be disconnected and the machine checked to ensure it is
depressurized before starting any work on the machine; otherwise the machine may execute
uncontrolled movements.
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- Kinetic energy - Note that some motors or spindles, for example, may continue to run or coast run on
after being switched off.
- Potential energy - Individual assemblies may need to be secured if necessary for repair work.
Delivery of the Machine/Packaging
Note any markings on the packaging, such as weights, lifting points and special information. Avoid
temperature fluctuations. Condensation may damage the machine.
Transport Damage
The packaging and machine must immediately be examined for signs of damage in transit. Such damage
must be reported to the shipper/transporter within the applicable time limits. Contact Atlanta Attachment
Company and/or your transport insurer immediately, if signs of damage are visible. Never operate a
damaged machine.
Interim Storage
If the machine has to be stored temporarily, it must be oiled or greased and stored in a dry place where it
is protected from the weather in order to avoid damage. A corrosion-inhibiting coating should be applied
if the machine has to be stored for a longer period of time and additional precautions taken to avoid
corrosion.
Transporting the Machine
Disconnect the machine from all external connections and secure any loose assemblies or parts. Never
step under a suspended load. When transporting the machine or assemblies in a crate, ensure that the
ropes or arms of a forklift truck are positioned as close to the edge of the crate as possible. The center of
gravity is not necessarily in the middle of the crate. Note the accident prevention regulations, safety
instructions and local regulations governing transport of the machine and its assemblies.
Only use suitable transport vehicles, hoisting gear and load suspension devices that are in perfect
working order and of adequate carrying capacity. Transport should only be entrusted to duly qualified
personnel.
Never allow the straps to rest against the machine enclosure and never push or pull sensitive parts of the
machine. Ensure that the load is always properly secured. Before or immediately after loading the
machine, secure it properly and affix corresponding warnings.
All transport guards and lifting devices must be removed before the machine is started up again. Any
parts that are to be removed for transport must be carefully refitted and secured before the machine is
started up again.
Workplace Environment
Our machines are designed for use in enclosed rooms: Permissible ambient temperature approx. 5 - 40
°C (40 - 104 °F). Malfunctions of the control systems and uncontrolled machine movements may occur
at temperatures outside this range.
Protect against climatic influences, such as electrostatic charges, lightning strikes, hail, storm damage,
high humidity, salinity of the air in coastal regions.
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Protect against influences from the surroundings: no structure-borne vibrations, no grinding dust, or
chemical vapors.
Protect against unauthorized access.
Ensure that the machine and accessories are set up in a stable position.
Ensure easy access for operation and maintenance (Instruction Manual and layout diagram); also verify
that the floor is strong enough to carry the weight of the machine.
Local Regulations
Particular attention must be paid to local and statutory regulations, etc. when installing machines and the
plant (e.g. with regard to the specified escape routes). Note the safety zones in relation to adjacent
machines.
Maintenance
General Safety Instructions
The machine shall be switched off, come to a standstill and be secured so that it cannot be switched on
again inadvertently before starting any maintenance work whatsoever. Use proper lockout/tagout
procedures to secure the machine against inadvertent startup.
Remove any oil, grease, dirt and waste from the machine, particularly from the connections and screws,
when starting the maintenance and/or repair work. Do not use any corrosive-cleaning agents. Use lint-
free rags.
Retighten all screw connections that have to be loosened for the maintenance and repair work. Any
safety mechanisms that have to be dismantled for setting-up, maintenance or repair purposes must be
refitted and checked immediately after completing the work.
Maintenance, Care, Adjustment
The activities and intervals specified in the Instruction Manual for carrying out adjustments,
maintenance and inspections must be observed and parts replaced as specified.
All hydraulic and pneumatic lines should be examined for leaks, loose connections, rubbing and damage
whenever the machine is serviced. Any defects found must be remedied immediately.
Waste, Disassembly, Disposal
Waste products should be cleared from the machine as soon as possible as not to create a fire hazard.
Ensure that fuels and operating lubricants, as well as replacement parts are disposed of in a safe and
ecologically acceptable manner. Note the local regulations on pollution control.
When scrapping (disassembling) the machine and its assemblies, ensure that these materials are disposed
of safely. Either commission a specialist company familiar with the local regulations or note the local
regulations when disposing of these materials yourself. Materials should be sorted properly.
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Repair
Replacement Parts
We cannot accept any liability whatsoever for damage due to the use of parts made by other
manufacturers or due to unqualified repair or modification of the machine.
Repair, Electrical
The power supply must be switched off (master switch off) and secured so that it cannot be switched on
again inadvertently before starting any work on live parts.
Those parts of the machine and plant on which inspection, maintenance or repair work is to be carried
out must be isolated from the power supply, if specified. The isolated parts must first be checked to
determine that they are truly de-energized before being grounded and short-circuited. Adjacent live parts
must also be isolated.
The protective measures implemented (e.g. grounding resistance) must be tested before restarting the
machine after all assembly or repair work on electric parts.
Signal generators (limit switches) and other electrical parts on the safety mechanisms must not be
removed or bypassed. Only use original fuses or circuit overloads with the specified current rating. The
machine must be switched off immediately if a fault develops in the electrical power supply.
The electrical equipment of our machines must be checked at regular intervals and any defects found
must be remedied immediately.
If it is necessary to carry out work on live parts, a second person should be on hand to operate the
emergency OFF switch or master switch with voltage release in the event of an emergency. The working
area should be cordoned off and marked by a warning sign. Only use electrically insulated tools.
Ventilation/Hazardous Gases
It is the end users responsibility to ensure adequate ventilation is provided to exhaust any and all
noxious or hazardous gases that may be present in the working environment.
Hydraulic and Pneumatic Systems
Work on hydraulic or pneumatic equipment shall only be carried out by persons with training,
knowledge and experience of hydraulic systems. Pressure lines shall be depressurized before starting
any repair work.
General Liability
Liability for machine damage and personal injury is extinguished completely if any unauthorized
conversions or modifications are undertaken. The machine must not be modified, enlarged or converted
in any way capable of affecting safety without the manufacturer's prior approval.
Starting Machine Movements
Read the Instruction Manual carefully to establish which keys and functions start machine movements.
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A Word to the End User
The end user has sole responsibility to enforce the use of safety procedures and guards on the machine.
Any other safety devices or procedures due to local regulations should be should be retrofitted in
accordance to these regulations and/or the EC Directive on the safety of machines.
Operator’s position must always be readily accessible. Escape routes must always be kept clear and
safety areas should be identified.
Safety Precautions
Safety should be a constant concern for everyone. Always be careful when working with this equipment.
While normal safety precautions were taken in the design and manufacture of this equipment, there are
some potential safety hazards.
Everyone involved with the operation and maintenance of this equipment should read and follow
the instructions in this manual.
Operate the equipment only as stated in this manual. Incorrect use could cause damage to the
equipment or personal injury.
It is the owner’s responsibility to make certain that the operator reads and understands this
manual before operating this equipment. It is also the owner’s responsibility to make certain that
the operator is a qualified and physically able individual, properly trained in the operation of this
equipment.
Specific safety warning decals are located on the equipment near the immediate areas of potential
hazards. These decals should not be removed or obliterated. Replace them if they become non-readable.
•ALWAYS keep safety shields and covers in place, except for servicing.
•ALWAYS maintain a safe distance from people when operating.
•ALWAYS operate equipment in daylight or with adequate working lights.
•Follow daily and weekly checklists, making sure hoses are tightly secured and bolts are
tightened.
•ALWAYS watch and avoid holes or deep depressions.
•ALWAYS wear adequate eye protection when servicing the hydraulic system and battery.
•NEVER operate a poorly maintained machine.
•NEVER allow persons to operate this machine without proper instruction.
•NEVER put hands or feet under any part of the machine while it is running.
•NEVER attempt to make any adjustments or repairs to the machine while running. Repairs or
maintenance should be performed by trained personnel only.
•NEVER work under the machine unless it is safely supported with stands, blocks or a hoist and
blocks.
•NEVER touch hot parts of machine.
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Component Identification
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General Machine Data
Electrical & Pneumatic Specifications
Electrical: 220 VAC, 5amp, 50/60 Hz Single Phase
Pneumatic: Main Air - 80 PSI, 5 SCFM avg. (3/8” supply line)
Belt Tension - 40-50 PSI
Sewing Head: Singer 300UX5
Sewing Speed: 3000 RPM
Needle (Standard): SN62X8524
Stitch Density: 5-6 SPI
Basic Machine Operation
The operator loads a mattress and covers the Mattress Edge Detect Eye. The machine will not sew
unless the eye is covered.
The Footlift Touch Switch is used to raise the foot for loading a mattress. The machine will not sew if
the footlift output is on. If the sew pedals are pressed while the foot is up, the conveyor will run at
forward Aux speed or forward High speed.
There are four pedals that can be used: Aux Speed Sew, High Speed Sew, Head & Platform Down and
Head & Platform Up.
•The Aux Speed Sew pedal runs the sew head at a preset speed set in the Efka motor and the
conveyor will run at a preset speed set in the conveyor inverter. This pedal can be used to finish
sewing off a mattress when the binding is overlapped or for sewing difficult mattresses at a slower
speed.
•The High Speed Sew pedal runs the sewing head at high speed and the conveyor moves forward
at medium (sew) speed.
•The Head & Platform Up and Down pedals are used to adjust the height of the sewing head and
operator to the thickness of mattress being sewn.
There are three speed pots located on the side of the sewing head console: Side Speed, Corner Speed and
Conveyor Speed.
•The Side Speed pot is used to adjust only the speed of the sew head while sewing at high speed
down the side of a mattress.
•The Corner Speed pot is used to adjust only the speed of the sewing head while sewing at low
speed during the corner rotation.
•The Conveyor Speed pot is used to adjust only the speed
of the conveyor while sewing down the side of a mattress.
The operator starts sewing in the middle of the foot end of the
mattress. As the mattress approaches a corner, the Mattress
Edge Detect Eye detects the edge of the mattress which starts
the Edge to Corner Stitch Count setting. This setting decides
how many stitches are sewn after the eye is uncovered before
the mattress is rotated for corner sewing. The Backstop Lock
Stitch Count setting is also used during this time to lock the
Backstop in place a few stitches before the mattress is rotated
for
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corner sewing. This setting ensures that the mattress is tight
against the Backstop before the mattress is rotated.
After the Edge To Corner Stitch Count is reached, the head
switches to a corner sew speed (low), the conveyor moves
forward at low speed and the Rotate arm turns on in a forward
medium speed. Everything stops if the operator releases the sew
pedal.
Once the Rotate Arm Low Speed Sensor is reached, the Rotate
Arm switches into a forward low speed until the Rotate Arm
Out Sensor is reached which automatically sends the Rotate
Arm home.
The Rotate Arm then goes toward home in a reverse high speed for the length of the Rotate Arm
Reverse High On Time setting. As the Rotate Arm starts home, the Backstop Return Delay is also
turned on which delays the timing of when the Backstop transfer cylinder is sent home. This setting
delays the Backstop from going home until it is clear of the mattress.
Once the Rotate Arm Reverse High On Time setting is reached. The arm is then switched into reverse
low speed. The arm continues to move in reverse low speed until the Rotate Arm Home Sensor is
reached. The Rotate Arm Home Stop Delay then starts which allows for adjusting the arm to stop
parallel to the conveyor. Sewing resumes at high speed once the Rotate Arm Home Sensor is reached.
After all 4 corners are sewn and the binding is overlapped and finished off, the operator sews off the
mattress and trims the thread with scissors.
The operator then pushes the Mattress Flip Cycle button to start the flipping cycle.
The first thing that happens during the flip cycle is the head push plate cylinder extends which pushes
the mattress away from the head for flipping. Once the head push plate out sensor is reached, the
conveyor turns on to move the mattress toward the mattress flipper.
If the Mattress Flip Location setting is set to "0" (infeed) the conveyor moves the mattress in the
reverse direction toward the Mattress Flipper. If the Setting is set to "1" (outfeed) the conveyor waits
until the Backstop is raised and then the conveyor moves the mattress in the forward direction toward
the Mattress Flipper.
The Mattress Flip Eye detects the end of the mattress and
turns on the Edge to Mattress Flip delay. If the Flip Eye
does not see the mattress within 5 seconds, the conveyor
turns off.
After the Edge to Mattress Flip Delay is reached the
Mattress Flip Lift solenoid turns on which extends the
mattress flip lift cylinders. The Mattress Flip Lift sensor is
then reached approx. half way up on the lift cylinders,
which turns on the Mattress Flip Pivot solenoid and the
Mattress Flip Pivot On Time setting. Once the Mattress
Flip Pivot On Time setting times out, the Mattress flip
pivot and lift cylinders retract and the conveyor turns off.
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Technical Manual & Parts Lists
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After the flip cycle has been completed the operator uses the
High Speed Sew pedal to bring the mattress back to the
middle of the conveyor. If the Mattress Flip Location setting
is set to "0" the conveyor pedal will move the conveyor in the
forward direction or if the setting is set to "1" the conveyor
pedal will move the conveyor in the reverse direction. Once
the operator releases the foot pedal, the push plate cycle is
then initiated. During the flipping cycle, the Push Plate
transfer 1 cylinder is extended. (if the Push Plate Enable
setting is disabled, the transfer cylinder will not extend during
the flipping cycle)
After the Push plate cycle is initiated, the Push plate lift cylinders extend until the lift sensor is true.
Once the sensor is true, the Push plate transfer 1 cylinder retracts and the Push plate transfer 2 cylinder
extends. The software now looks at the Mattress edge detect eye to see that the mattress has been pushed
all the way back to the sewing head.
Once the Mattress edge detect eye is covered for a short time, the Push plate transfer 2 cylinder retracts
until the Push plate transfer 2 retract sensor is true. The Push plate lift cylinders are now retracted to
lower the Push plate tray.
The operator is now ready to sew the other side of the mattress.
Notes:
1. There is also a Manual Corner Sew Mode setting
that can be enabled. If this setting is enabled it allows the
operator to choose when to rotate for corner sewing instead of
using the mattress edge detect eye. Once the eye uncovers,
the sewing head and
conveyor stop. The operator can now use the Head &
Platform Down pedal to sew in low speed to allow the
operator to accurately stop where they want to rotate. Once
the operator reaches the point where they want to rotate they
can now use the High Speed Sewing pedal to start the rotate
for corner sewing.
2. The operator can use the buttons on the Operator Functions page to adjust the Sew Head
Column, Sew Head Tilt and the Operator Platform individually for the correct ergonomic height
relationship between the operator and the sewing head. After this is set, the operator can now use the
Head & Platform Up and Down pedals to move the platform and the sew head up and down together for
adjustment between different thickness mattresses.
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Technical Manual & Parts Lists
14
Efka Control Box
The sewing machine is powered by the Efka motor controller. It has
its own on/off switch which should be left on at all times. It also has
some small buttons and LED's on the front to indicate the enabled
functions. The only LED that should be on is the second to last from
the bottom which sets the control to stop the machine needle down at
neutral treadle and needle up after full heal back. The functions can be
changed upon power up or after a full heal back. The control box has
been programmed to operate specifically with the 1315A unit. If the
box is later replaced, the new box will need to be programmed
according to the included parameter list in order to function properly.
Notice that the sewing head does not stop at normal needle up
(lockstitch heads) position after full heal back, but stops at needle top
dead center to allow more room for loading thicker material
General Machine Maintenance
Daily
•Clean machine at the end of every shift.
•Clean lint etc. from the looper area on the sewing head.
•Remove any threads wrapped around moving parts.
•Wipe all photo eye lenses with a clean nonabrasive dry cloth.
•Use a blow-off hose to get rid of excess lint, thread and other clippings.
•Open conveyor door and inspect belt for debris and remove with broom or air hose.
•Follow manufactures recommendations and guidelines for daily maintenance and
lubricating of sewing head.
Weekly
•Check sewing head drive belt for tightness and condition.
•Inspect reflective tape on handwheel and replace if dirty or worn.
•Inspect conveyor bearings and remove thread and debris if needed.
Monthly
•Inspect conveyor bearings and apply one shot of bearing grease to each bearing as needed.
From the library of: Diamond Needle Corp