Clinton AS-895E User manual

ML895E-14
CLINTON
MODEL AS-895E
VARIABLE SPEED DC SERVO MOTOR
FOR
OVEREDGE AND CHAINSTITCH MACHINES
WITH INTERMITTENT LCD AIR SAVER,
NEEDLE COOLER & STACKER OUTPUTS
SERVICE MANUAL
40-0255-01

TABLE OF CONTENTS
ML895E-15
®
SECTION I - INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
SECTION II - INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
A.
B.
C.
D.
E.
F.
G.
CONTROL BOX TO MOTOR . . . . . . . . . . . . . . . . . . . . . . . . .
MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SYNCHRONIZER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LCD DISPLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . .
SWITCH BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
POWER AND CABLE CONNECTIONS . . . . . . . . . . . . . . . . . .
MOTOR ROTATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-1
2-1
2-2
2-2
2-2
2-3
2-3
SECTION III - SYNCHRONIZER TIMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
SECTION IV - PROGRAMMABLE LCD DISPLAY . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
A.
B.
C.
D.
E.
F.
G.
MAXIMUM SEWING SPEED . . . . . . . . . . . . . . . . . . . . . . . . .
DIRECT ACCESS PARAMETERS . . . . . . . . . . . . . . . . . . . .
HIDDEN PARAMETERS . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MASTER RESET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PULLEY RATIO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
STACKER OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TEST PROGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1. TREADLE TEST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2. SYNCHRONIZER TEST. . . . . . . . . . . . . . . . . . . . . . . . . . .
3. ENCODER TEST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4. DIVIDER TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-1
4-1
4-3
4-3
4-4
4-4
4-4
4-4
4-4
4-5
4-5
SECTION V - CONNECTOR DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
SECTION VI - DRAWINGS AND PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
A.
B.
C.
D.
E.
F.
G.
H.
I.
J.
MAJOR ASSEMBLIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MOTOR ASSEMBLY, DC SERVO . . . . . . . . . . . . . . . . . . . .
CONTROL BOX ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . .
POWER SUPPLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SYNCHRONIZER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PROGRAMMABLE DISPLAY . . . . . . . . . . . . . . . . . . . . . . . . .
MISCELLANEOUS PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . .
E-PROM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AIR CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AIR CONTROL ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . .
6-1
6-2
6-4
6-5
6-6
6-7
6-7
6-8
6-8
6-9

INTRODUCTION
Clinton's Model 895E is an electronically controlled variable speed drive for industrial sewing
machines. The system consists of a brushless DC Servo motor, a microprocessor powered
controller, a synchronizer, speed control, and programmable LCD display. No clutches or brakes
are used. All components interact to give a fast accurate and reliable sewing machine drive. The
components of the system are shown in figure below.
The model 895E has outputs for air saver, foot lift, needle cooler and stacker. It can be used to
operate all Clinton chain cutters, as well as various make and model chain cutters.
The programmable LCD display is used to select the desired mode. In addition, the display box is
used to select or change all parameters such as Speeds, Timers, Counters, Toggle Switches, etc.
1-1
SECTION I
®
ML895E-16

INSTALLATION
A. CONTROL BOX TO MOTOR
Refer to the control box assembly parts drawing in page 6-4. Attach the mounting brackets to
the control box then, mount the control box to the motor with the hardwareprovided.
B. MOTOR
1. Drill three holes in the sewing machine table as shown in figure 2-1.
2. Mount the motor to the table using the spacers, carriage bolts, nuts, washers, and flanged
spacers supplied (See page 6-2). Install pulley and belt then check the following:
a. The motor is mounted so that the motor drive pulley and sewing machine drive pulley are
properlyaligned.
b. The V-belt connecting the motor to the sewing machine should be tensioned properly. It
should be possible to pull a correctly tensioned belt together between two fingers within
approximately 2 cm (3/4"). Excessive tension may not onlyshorten the life of the bear-
ings, but could also affect the operation of the sewing machine. A loose belt will affect
positioning accuracy.
c. Install the belt guard.
2-1
ML895E-17
SECTION II
®
MOTOR INSTALLATION
FIG. 2-1

C. SYNCHRONIZER
Two methods are used to attach the synchronizer to the handwheel. They are (1) handwheel turned down to
accept synchronizer and (2) an adapter that is mounted to a machined handwheel.
Refer to figure 2-2 and install the synchronizer as follows:
SYNCHRONIZER INSTALLATION
UNIVERSAL MOUNT
FIG. 2-2
1. Install adapter if used.
2. Mount and secure synchronizer to handwheel or adapter.
3. Position the synchronizer retaining rod and clamp as shown in figure 2-2. Make sure that the rod
clears the sewing machine belt.
4. Using the mounting clamp hole as a guide, drill and tap a 10-32 hole in the machine casting. Secure
clamp and rod with a 10-32 X 1/2 B.H.M.S.
5. Drill a 1-1/4" Dia. hole in table to route synchronizer cable to logic box. Check that cable has adequate
slack when tilting machine for service.
D. LCD DISPLAY
Mount the LCD display console at a convenient location on the table top as shown in figure 2-3. Route cable
through same hole that synchronizer cable passes through.
E. SWITCH BOX
Install switch box at a convenient location under the table. See figure 2-3.
2-2
ML895E-18
®
FIG. 2-3

F. POWER AND CABLE CONNECTIONS
Refer to figure below and connect all cables as shown. The system can be operated from 230V, 3
phase or 230V, single phase power.
Caution: It is important that the ground wire be connected between the motor and sewing
machine to prevent a static charge buildup at the sewhead.
2-3
G. MOTOR ROTATION
Temporarily remove the "V" belt. Turn power on then move the pedal forward and note
the direction of motor pulley rotation. If incorrect, do the following:
1. Turn power off.
2. Refer to section V-B, Hidden Parameters, and follow the instructions to change
motor rotation. The parameter is in the "**** Toggle Switches" group.
3. Install the "V" belt.
ML895E-19
®
FIG. 2-4

SYNCHRONIZER TIMING
Turn the power off before making synchronizer adjustments. Refer to figure below for all adjust-
ments and perform the steps below to time the synchronizer.
1. Remove cover from synchronizer, then loosen the disc locking screw.
2. Rotate the handwheel so that the needle is at its highest position.
3. Rotate the UP sensor disc until the notch is centered in the photo interrupter module.
4. Rotate the down sensor disc until the notch is centered in the photo interrupter module.
5. Rotate the trim disc until the notch is centered in the photo interrupter module.
6. Tighten the disc locking screw and replace the cover.
NOTE: After power is turned on a fine adjustment may be necessary and can be made by
positioning the needle under power and noting the actual needle UP and needle DOWN
stopping positions. If any of the positions are not correct, readjust the appropriate disc.
3-1
SECTION III
®
ML895E-20

PROGRAMMABLE LCD DISPLAY
A. MAXIMUM SEWING SPEED
Maximum sewing speed can be adjusted by changing the "MAXIMUM SPEED" parameter in the
"LCD" display.
The LCD display, shown below is used to program and set the various parameters of the 895 series,
such as; SPEEDS, TIMERS, COUNTERS, and TOGGLE SWITCHES.
Three (3) different modes of operation are available.
They are:
1. ManualMode
2. Operating Mode
3. Programming Mode
When power is turned on, the display reads
"OperatingMode".
There are two (2) groups of parameters that are accessed in different ways. They are : (1) parameters
with direct access and (2) hidden parameters with indirect access. In addition a master reset is avail-
able to reset all parameters to their default values.
B. DIRECT ACCESS PARAMETERS
The direct access parameters are divided into four (4) groups. They are (1) SPEEDS, (2) TIMERS,
(3) COUNTERS, and (4) TOGGLE SWITCHES. Table 4-1 describes each parameter, shows
the default value and range of adjustment for each parameter.
4-1
SECTION IV
®
ML895E-21
To change a parameter, follow the sequence described below.
1. Press the key to enter the programming mode. Continue pressing this key until the para-
meter group that is to be changed is displayed. As an alternative; press the key to enter
the programming mode and display the last changed parameter.
2. Press the key to step to the next parameter in the selected group.
3. Press the key to increase or the key to decrease the contents of the displayed para-
meter. Both keys are used to toggle parameters between states in the Toggle Switches group.
Hold the key closed to make the display step automatically.
4. Press the key to return to the operating mode and save the changed parameters.

4-2
®
ML895E-22
TABLE 4-1
PARAMETER DESCRIPTION DEFAULT RANGE
SPEED GROUP RPM RPM
MINIMUM
SLOW STRT
VENT.SPD
First speed when pedal is moved forward.
Initial speed at start of cycle (after trim).
This speed is maintained for No. of stitches set
by soft start count parameter.
Speed motor runs while venturi is active
180
500
2000
80-250
150-1000
100-9000
TIMER GROUP MS MS
STRT DEL
VENT TIME
WASTE REM
CUT TIME
STACKER
Delays machine start to allow presser foot to
drop.
Delays venturi shut off after stop.
Waste removal turned on in the seam when this
function is selected.
Cutter on time or pulse length
Stacker on time
120
500
80
80
80
0-500
10-2500
10-1000
10-250
10-1000
COUNTER GROUP STITCHES STITCHES
SOFTST
FRNT.CNT
END CNT
WASTE REM
Number of stitches sewn at soft start speed
after trim (EOC).
Number of stitches with venturi on and first cut if
enabled after eye is covered.
Number of stitches with venturi on and end cut if
enabled after eye is uncovered.
Number of stitches with venturi on in the seam if
the waste removal function is selected.
3
3
3
3
1-25
1-25
1-25
1-25
TOGGLE SWITCHES
PF/SEAM
PF/EOC
SOFT STRT
HEEL 2
POSITION
TREADLE
START EYE
Pr. Ft. up or down in seam, treadle neutral.
Pr. Ft. up or down after trim, treadle neutral.
Used to turn soft strt "on" or "off".
If on, needle up. If off footlifter up with heel 2.
Selects the needle position in the seam to UP
or DOWN.
Neutral: Position before cycle starts
Continue: Cycle starts without releasing treadle
Uncov: Cycle starts independent of eye
Covered: Cycle starts only if eye is covered
DOWN
DOWN
OFF
ON
DOWN
NEUTRAL
UNCOVERED
UP/DOWN
UP/DOWN
ON/OFF
ON/OFF
UP/DOWN
NEUTRAL/
CONTINUE
COVERED/
UNCOVERED

®
ML895E-23
C. HIDDEN PARAMETERS
The parameters in this section are separated from the Direct Access parameters because they are
infrequently changed and should not be changed by the operator. The parameters are listed in
TABLE 4-2
To enable access to Hidden Parameters, follow the sequence described below.
1. Turn power off, if it is on, then wait until the display goes blank.
2. Press the key and the key simultaneously. Keep pressed then,
3. Turn power on. A series of "***" will appear on the display. They will slowly dissapear.
4. Release the keys then press the key before all the stars dissapear.
5. Press the key repeatedly, until the first hidden parameter group (****SPEEDS) is dis
played.Note that 4 stars (*) as described in section "A".
6. Parameters may then be changed by following the procedure described under DIRECT
ACCESS PARAMETERS (Page 5-1).
D. MASTER RESET
In some cases it may be necessary to reset all parameters to their default values. This is done as
follows:
1. Turn power off, if it is on, then wait until the display goes blank.
2. Press the key, key and key simultaneously. Keep pressed then,
3. Turn power on. The display alternates between "Push Set" and "For Reset".
4. Push the key within 10 cycles.
5. The word "Programming" is displayed. The parameters will be reset to their default values after
a few seconds.
4-3
PARAMETER DESCRIPTION DEFAULT RANGE
****SPEEDS RPM RPM
MAXIMUM Maximum sewing machine speed. The speed
cannot go higher than 3500 times the pulley
ratio.
4200 1000-9900
****TOGGLE SWITCHES
DIRECTION
AUTO MODE
STACKER
Direction of motor rotation viewed from pulley.
Maximum speed until eye is uncovered.
Stacker operates after EOC or alternate EOC
CCW
DISABLE
FIX
CCW/CW
ENABLE/DISABLE
FIX/FLEX

E. PULLEY RATIO (RATIO BETWEEN MOTOR AND MACHINE PULLEYS)
During the initial setup and after power is first turned on. The pulley ratio must be calculated. The
pedal must be moved forward to do this. While the ratio is being taken, the machine speed is
limited for several stitches. After the ratio is taken, the machine will then accelerate to maxi
mum speed.
Each time power is turned off then back on, the ratio is checked when the pedal is moved forward
the first time. If the ratio has changed, because of a pulley change, then the ratio will be recalcu-
lated. The ratio can be displayed by pressing the and keys simultaneously. If the ratio
is correct, a star (*) will be displayed after the ratio number.
F. STACKER OPERATION
The stacker can be operated after each trim cycle or after every other cycle.
G. TEST PROGRAM
A test program is available to test the treadle, synchronizer, encoder, and divider for proper
operation. To select the program, press the and keys simultaneously. The display will
show "SYSTEM TEST". Press the key to toggle between each test, i.e. Treadle,
Synchronizer, Encoder, or Divider. Press the key to activate whichever test is selected.
1. Treadle Test
Press the button until "TEST TREADLE" is displayed. Press the button once. The
display should show "NEUTRAL".
a. Move the pedal from neutral to heel 1 then to heel 2. The display should show each positon.
b. Move the pedal forward slowly. As the pedal is moved, a number (0 to 255, see NOTE#4)
will be displayed.
This number is proportional to how far the pedal is moved. The lowest number should be no
more than "8" and the highest number greater than "250".
(NOTE: the maximum speed pot should be in the full cw position.)
c. Press the pedal full forward. Turn the maximum speed pot ccw. The displayed count should
decrease as the pot is turned. Return the pot to its maximum cw position.
2. Synchronizer Test
Press the button. The display will read "TEST SYNCHRONIZER". Press the
button.Rotate the machine pulley by hand. The display will show the position. The positions
are as follows: "UP", "DOWN", and "TRIM".

4-5
3. Encoder Test
CAUTION: Remove the sewing machine belt. The belt has to be removed because the
motor may not develop suffient torque to turn the machine.
Press the button. The display will read "TEST ENCODER". Press the button. The
display will read "PUSH TREADLE". Press the pedal fully forward for approximately three
seconds then release the treadle. Do not heel. The result will be displayed, either "OK" or
"NOT OK".
Heel the pedal. The display shows the number of counts. The number should be between 795
and 800 pls.
4. Divider Test
NOTE: This test will not function properly if the encoder test fails. Also, remove the sewing
machine belt.
Press the button, the display will read "TEST DIVIDER". Press the button. The
displayreads "PUSH TREADLE". Press the treadle fully forward for 3 seconds, then release
the treadle. If the test works the display will read "DIVIDER OK". If the test fails the display will
show the test which failed, ie. "PASS 1", "PASS 2", "PASS 3", "PASS 4", "PASS 5", or "PASS
6".
®
ML895E-25

5-1
®
CONNECTOR DIAGRAMS
Listed below are the pinouts for the Model 895E control box connectors.
ML895E-26
SECTION V
NO. TOTAL PINS CONNECTOR PIN NO. FUNCTION
1 6 SYNCHRONIZER 1
2
3
4
5
6
+5
DOWN SENSOR
UP SENSOR
TRIM SENSOR
GND
LED
2 6 AUX INPUTS 1
2
3
4
5
6
+5
GND
CHASSIS GND
I 1 SAFETY SWITCH
I 2 INCHING/CHANGE POSITION
I 3
3 4 AUX OUTPUTS 1
2
3
4
+48 V
R1
+48 V
R2
4 2 FOOTLIFT 1
2FOOTLIFT SOL. +48V
5 9 VENTURI, CHOPPER,
AND NEEDLE COOLER 1
4
2
5
3
6
7
8
9
VENTURI SOL. -
VENTURI SOL. +(48V)
CHOPPER SOL. -
CHOPPER SOL. +(48V)
NEEDLE COOLER SOL. -
NEEDLE COOLER SOL. +(48V)
NOT USED
NOT USED
NOT USED

5-2
®
ML895E-27
NO. TOTAL PINS CONNECTOR PIN NO. FUNCTION
8 8 COMMUTATOR 1
2
3
4
5
6
7
8
+5V
ENCODER (S1)
ENCODER (S2)
SIG. GND
PHASE C
PHASE B
PHASE A
-5V
916 LCD DISPLAY 1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
EXT1
CHASSIS GND
+5V
GND
D0
D1
D2
D3
D4
D5
D6
D7
CA1
E
ERD
CA0
10 4AC POWER 220V 3 1
2
3
4
PHASE A
PHASE B
PHASE C
CHASSIS GND
1 1 4MOTOR VOLTAGE 1
2
3
4
PHASE A
PHASE B
PHASE C
CHASSIS GND

DRAWINGS AND PARTS LIST
MODEL 895E
81-0863-02
6-1
A. MAJOR ASSEMBLIES
®
ML895E-28
SECTION VI

ITEM DESCRIPTION PART NO. QUANTITY
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
COVER
SCREW
SCREW, S.S.S.
FAN
PC BOARD, ENCODER
SCREW
SPACER
ENCODER DISC
SCREW
ENCODER SENSOR
MOTOR, DC
SCREW, S.S.S.
MOTOR/ENCODER ASSEMBLY
BELT GUARD, FIXED
PULLEY - 50MM
PULLEY - 60MM
PULLEY - 65MM
PULLEY - 70MM
PULLEY - 75MM
PULLEY - 80MM
PULLEY - 85MM
PULLEY - 90MM
PULLEY - 95MM
PULLEY - 100MM
PULLEY - 105MM
PULLEY - 110MM
PULLEY - 115MM
PULLEY - 120MM
PULLEY - 125MM
PULLEY - 130MM
PULLEY - 140MM
PULLEY - 150MM
BELT GUARD, ADJUSTABLE
KEY, PULLEY
SCREW M5 X 10 HEX HD.
BOLT, CARRAIGE
SPACER
WASHER, FLAT
WASHER, SPLIT LOCK
NUT, HEX
HARDWARE KIT, MOTOR MOUNT
PIN
BRACKET, MOTOR MOUNT
SNAP RING
BOLT, ADJUSTING
NUT, HEX
WASHER, SPLIT LOCK
GROMMET
30-4433-01
30-4434-01
30-4435-01
30-4436-01
30-4437-01
30-4438-01
30-4439-01
30-4440-02
30-4441-01
30-4442-01
30-4443-01
30-4444-01
81-0732-01
30-4445-01
30-4204-50
30-4204-60
30-4204-65
30-4204-70
30-4204-75
30-4204-80
30-4204-85
30-4204-90
30-4204-95
30-4204-100
30-4204-105
30-4204-110
30-4204-115
30-4204-120
30-4204-125
30-4204-130
30-4204-140
30-4204-150
30-4203-01
30-4227-01
30-4206-01
30-4298-01
30-4332-01
30-4300-01
30-4301-01
30-4229-01
30-4337-01
30-4219-01
30-4446-01
30-4220-01
30-4205-01
30-4210-01
30-4218-01
30-4472-01
1
3
2
1
1
3
3
1
1
1
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
3
3
3
3
3
1
1
1
1
1
1
1
1
MOTOR ASSEMBLY PARTS LIST, DC SERVO
81-0731-01
6-3
®
ML895E-29-2

E. SYNCHRONIZER
6-6
ITEM DESCRIPTION PART NO. QUANTITY
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
SYNCHRONIZER
COVER, SYNCHRONIZER
SCREW M5 X 12 F.H.M.S.
SPACER DISC RETAINING
LED
DISC POSITIONER
SPACER, DISC
DISC, TRIM
SCREW M3.5 X SELF TAP
SPACER
HOUSING
SCREW M4 X 10
SHAFT, SYNCHRONIZER
SCREW M6 X 8 S.S.S.
PC BOARD, SYNCHRONIZER
SCREW, PC BOARD MOUNT
WASHER, SPLIT LOCK
BASE
SCREW M3 X SELF TAP
SCREW M3 X 10
BEARING
81-0733-01
30-4262-02
30-4263-01
30-4264-01
30-4428-01
30-4266-01
30-4267-01
30-4268-01
30-4270-01
30-4271-01
30-4272-02
30-4273-01
30-4429-01
30-4275-01
30-4430-01
30-4209-01
30-4277-01
30-4278-02
30-4279-01
30-4280-01
30-4281-01
1
1
1
1
1
2
3
1
3
1
1
2
1
2
1
4
4
1
2
2
1
®
ML895E-31