Efka AB611A5021 User manual

FRANKL & KIRCHNER EFKA OF AMERICA INC. EFKA ELECTRONIC MOTORS
GMBH & CO KG SINGAPORE PTE. LTD.
CONTROL AB611A5021
AB611A5022
Operating manual
With parameter list
-Putting into Service
-Settings
-Functional Description
-Connection Diagrams
-Timing Diagrams
No. 402442 English

Important Notes
The particulars used in various figures and tables, such as type, program number, speed, etc.,
serve as examples. They may differ from those in your display.
For current versions of the Instructions for Use and Lists of Parameters, necessary for operating EFKA drives
in accordance with regulations, please refer to the EFKA web site www.efka.net, page “Downloads”.
On our web site, you will also find the following supplementary instructions for this control:
General instructions for use and programming
Use with USB Memory Stick
Adapter cords

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CONTENTS Page
1Range of Applications 5
1.1 Use in Accordance with Regulations 5
2Scope of Supply 6
2.1 Special Accessories 6
2.1.1 Adapter Cords for Special Machines 7
3Putting into Service 7
4Setting and Putting into Service with the Aid of the Fast Installation Routine (SIR) 8
5Setting the Basic Functions 11
5.1 Direction of motor rotation 11
5.2 Use of a HSM001 Hall Sensor Module or IPG... Pulse Encoder 11
5.3 Transmission Ratio 12
5.4 Selection of Functional Sequences (Thread Trimming Operations) 12
5.5 Functions of the Keys Inputs in1...in7 12
5.6 Positioning speed 12
5.7 Maximum Speed Compatible with the Sewing Machine 13
5.8 Maximum speed 13
5.9 Positions 13
5.9.1 Setting the reference position (Parameter 170) 14
5.9.2 Setting the positions (Parameter 270 = 0 or 6) 14
5.10 Control display of signal position and stop position 15
5.11 Positioning shift 15
5.12 Braking Characteristics 15
5.13 Braking Power at Standstill 15
5.14 Starting Characteristics 16
5.15 Operating hours counter 16
5.15.1 Set and Reset Operating Hours Counter 17
5.15.2 Total Operating Hours Display 17
6Functions 17
6.1 First Stitch after Power On 17
6.2 Softstart 17
6.2.1 Softstart speed 17
6.2.2 Softstart stitches 18
6.3 Sewing foot lifting 18
6.4 Reverse motor rotation 19
6.5 Unlocking the Chain (Mode 5/6/7) 19
6.6 Machine run blockage 20
6.7 Thread trimming operation 20
6.7.1 Thread Trimmer/Thread Wiper (Lockstitch Modes) 20
6.7.2 Trimming speed 21
6.7.3 Chainstitch thread cutter (var. modes) 21
6.7.4 Chainstitch Machine Trimming Signal Times 21
6.8 Overlock Machine Functions (Mode 7) 21
6.8.1 Start and End Counts 22
6.9 Tape Cutter/Fast Scissors (Modes 6/7) 22

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6.9.1 Tape Cutter/Fast Scissors in Mode 6 22
6.9.2 Tape Cutter/Fast Scissors in Mode 7 22
6.10 Manual Tape Cutter/Fast Scissors 23
6.11 Seam with Stitch Counting 23
6.11.1 Number of Stitches for a Seam with Stitch Counting 23
6.11.2 Stitch Counting Speed 23
6.11.3 Seam with Stitch Counting When Light Barrier Is On 24
6.12 Free Seam and Seam with Light Barrier 24
6.13 Light barrier 24
6.13.1 Speed after Light Barrier Sensing 24
6.13.2 General Light Barrier Functions 24
6.13.3 Reflection Light Barrier LSM002 25
6.13.4 Automatic Start Controlled by Light Barrier 25
6.13.5 Light barrier filter for knitted fabrics 25
6.13.6 Functional Variations of the Light Barrier Input 26
6.14 Switching Functions of Inputs in1...i13 26
6.15 Software Debouncing of All Inputs 27
6.16 Special pedal function Single stitch / Full stitch 27
6.17 Signal “Machine Running“ 27
6.18 Signal Output Position 1 28
6.19 Signal Output Position 2 28
6.20 Signal Output 512 Impulses per Rotation 28
6.21 Actuator 28
6.21.1 Analog actuator 28
7Signal Test 29
7.1 Signal Test Using the Incorporated Control Panel 29
7.1.1 Inputs to the control 29
7.1.2 Outputs of control 29
8Table of Machine Functions and Adapter Cords 30
9Operating Elements and Socket Connectors 32
9.1 Positions of the Front Side 32
9.2 Positions of the rear side 32
9.3 Connection Diagrams 33
10 Timing Diagrams 38
11 Parameterlist 55
11.1 Operator Level 55
11.2 Technical level (Code no. 1907) 58
11.3 Supplier level (Code No. 3112) 63
12 Error Displays 69

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1 Range of Applications
The drive is suitable for lockstitch, chainstitch and overlock machines of various manufacturers.
With the help of adapter cords (adapter cords see Special Accessories), the drive can be used in replacement of
the controls listed in the table below, as long as backtacking, stitch condensing, and chain suction are not used.
Machine
manufacturer
Replacing
Machine
Model
Thread
trimming
mode
Adapter cord
Aisin
AB62AV
Lockstitch
AD3XX, AD158, 3310,
EK1
0
1112815
Brother
AB62AV
Lockstitch
737-113, 737-913
0
1113420
Brother
AC62AV
Chainstitch
FD3 B257
5
1112822
Dürkopp Adler
DA62AV
Lockstitch
210, 270
0
1112845
Global
Chainstitch
CB2803-56
5
1112866
Juki
AB62AV
Lockstitch
5550-6
14
1112816
Juki
AB62AV
Lockstitch
5550-7, 8500-7, 8700-7
14
1113132
Kansai
AC62AV
Chainstitch
RX 9803
5
1113130
Pegasus
AC62AV
Chainstitch
W500/UT, W600/UT/MS,
with/without stitch
condensing
5
1112821
Pegasus
AB60C
Backlatch
8
1113234
Pfaff
PF62AV
Lockstitch
563, 953, 1050, 1180
0
1113746
Rimoldi
Chainstitch
F27
5
1113096
Singer
SN62AV
Lockstitch
212 UTT
2
1112824
Union Special
AC62AV
Chainstitch
34700 with stitch lock
5
1112844
Yamato
AC62AV
Chainstitch
VC series
5
1113345
Yamato
Chainstitch
VG series
5
1113345
Yamato
AB60C
Backlatch
ABT3
9
1112826
Yamato
Backlatch
ABT13, ABT17
9
1113205
Medium-duty sewing machine,
general
Lockstitch
e.g. Dürkopp Adler, Juki,
Pfaff, Sunstar, Golden
Wheel
3
Suitable
adapter, upon
request
1.1 Use in Accordance with Regulations
The drive is not an independent functional machine. It has been designed for integration into other machines by
trained specialists.
It must not be put into service until the machinery into which it is to be incorporated has been declared in
conformity with the provisions of the EC Directive (Appendix II, paragraph B of the Directive 89/392/EEC and
supplement 91/368/EEC).
The drive has been developed and manufactured in accordance with the relevant EC standards:
IEC/EN 60204-31 Electrical equipment of industrial machines:
Particular requirements for industrial sewing machines, sewing units and sewing systems.
Operate the drive only in dry areas.
ATTENTION
When selecting the installation site and the layout of the connecting cable, the Safety
Instructions must be followed with no exceptions.
Particular attention should be paid to maintaining the proper distance from moving parts!

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2 Scope of Supply
Standard Scope of Supply
1
Direct current motor
DC1200 optional DC1250
1
Electronic control/Power supply unit
AB611A5021/N214
1
Set of accessories (standard)
B156
1
Actuator
EB401
Consisting of:
Plastic bag for B156 + documentation
and
1
Set of accessories
Z55
Consisting of:
37-contact SubminD plug,
potential equalization cord
Option 1
1
Actuator
EB401
and
1
Set of accessories
Z66
Consisting of:
37-contact SubminD plug, tension rod,
potential equalization cord
Additional options
Below table assembly set
Z71 AB6..-DC12.. Below table assembly
Pulse encoder IPG001
Z72 AB6..-DC12.. IPG
NOTE
If there is no metallical contact between drive (motor) and machine head, the potential equalization cord
supplied with the unit is to be wired from the machine head to the terminal provided on the control box!
2.1 Special Accessories
The special accessories available ex works allow the augmentation and enhancement of functions, operating,
connecting, and mounting options.
Since the range of available components is continually expanded, we kindly ask you to contact us in case of
need.
Designation
Material No.
Reflection light barrier module LSM002
6100031
Hall sensor module HSM001
6100032
Pulse encoder IPG001
6100033
Adapter cord for the connection of light barrier module and/or Hall sensor module
HSM001 and/or pulse encoder IPG001
1113229
Extension cable approx. 1000 mm long for commutation transmitter DC12.. + DC15..
1113151
Extension cable approx. 1000 mm long for Netz DC12.. line + DC15..
1113931
Potential equalization cord 700 mm long, LIY 2.5 mm2, gray, with spades on both
sides
1100313
Foot control type FB302B with three pedals for standing operation, with
approx. 1400 mm connecting cable and plug
4170025
Fitting piece for position transmitter
0300019
Knee switch type KN19 (pushbutton) with cord of approx. 450 mm length and
western plug (RJ11)
5870021
Knee switch type KN20 (pushbutton + selector switch ) with cord of approx.
1640 mm length and Western plug (RJ11)
5870022
Adapter set for DC12. + DC15.. on PEGASUS model W600
1113125
Adapter set for DC12. + DC15.. on PEGASUS Ex/Ext
1113126
Adapter set for DC12. + DC15.. on PEGASUS model W1500N, W1600
1113647
Undertable mounting kit for DC1200/DC1250
1113956
Undertable mounting kit for DC1500/DC1550
1113427
9-contact SubminD male connector
0504135

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9-contact SubminD female connector
0504136
Half-shell housing for 9-contact SubminD
0101471
37-contact SubminD male connector, complete
1112900
Single pins for 37-contact SubminD with strand of 50 mm length
1112899
Adapter set direct drives DC1210 & DC1230
Mounting kit for DC1210 on JUKI M067, M069
1114085
Mounting kit for DC1210 on JUKI M068
1114093
Mounting kit for DC1210 on PEGASUS EX
1114082
Mounting kit for DC1210 on PEGASUS M900
1114088
Mounting kit for DC1210 on YAMATO AZ, CZ
1114084
Mounting kit for DC1230 on PEGASUS chainstitch
1114119
Mounting kit for DC1230 on YAMATO VC, VE, VF, VG
1114102
2.1.1 Adapter Cords for Special Machines
For interconnection diagrams of the adapter cords, please refer to our web site at www.efka.net/downloads.
Machine / Type / Model
Material No.
AISIN high-speed seamer AD3XX, AD158, 3310 and overlock machine EK1
1112815
BROTHER models 737-113, 737-913
1113420
BROTHER Lockstitch machines, with 100 Ω selective resistance,
cl. 7xxx, B84xx, 877B, B87xx, 878B (mode 31)
1113420
BROTHER chainstitch machines, with 150 Ω selective resistance,
cl. FD3-B257, 25xx, 26xx, 27xx (mode 32)
1112822
BROTHER models B721, B722, B724, B737, B748, B772, B774, B778, B842, B845,
B872, B875
Connection of the position sensor incorporated in the hand wheel
1113433
DÜRKOPP ADLER models 210 and 270
1112845
GLOBAL model CB2803-56
1112866
JUKI high-speed seamer with index -6
1112816
JUKI high-speed seamer with index -7
1113132
JUKI lockstitch machines
Connection of the position sensor incorporated in the hand wheel
1113157
JUKI DNU1541, LU2210, LU1510
1114023
JUKI LU2810-6
1114024
JUKI PLC 2760
1114025
KAISER models 1245 & 335
1114003
KANSAI machines model RX 9803
1113130
PEGASUS models W500/UT, W600/UT/MS with or without stitch condensing
1112821
PEGASUS backlatch machine
1113234
PFAFF models 563, 953, 1050, 1180
1113746
PFAFF models 1245 & 335
1114003
SINGER models 211, 212U, 212UTT and 591
1112824
TYPICAL models 1245 & 335
1114003
UNION SPECIAL lockstitch machine model 63900AMZ (in replacement of US80A)
1112823
UNION SPECIAL model 34700 with stitch lock
1112844
UNION SPECIAL models 34000 and 36200 (in replacement of US80A)
1112865
UNION SPECIAL models CS100 and FS100
1112905
YAMATO VC/VG series chainstitch machines + stitch lock
1113345
YAMATO backlatch machine ABT3
1112826
YAMATO backlatch machine ABT13, ABT17
1113205
MAUSER models 1245 & 335
1114003
MITSUBISHI lockstitch machines
Connection of the position sensor incorporated in the hand wheel
1113411
3 Putting into Service
Before putting the control into service, the following must be ensured, checked and/or adjusted:
Designation
Material No.

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Selection of motor type using parameter 467
The correct installation of the drive, position transmitter and accompanying devices, if necessary
The correct selection of the trimming operation using parameter 290
If necessary, the correct adjustment of the direction of motor rotation using parameter 161
The correct selection of the functions of keys (inputs) using parameters 240...246
The setting of the transmission ratio between motor shaft and machine shaft using parameter 272
The setting of the type of position sensor using parameter 270
If necessary, the adjustment of the positions using parameter 171
if necessary, the setting of the positions using parameter 171 (possible with all settings of parameter 270)
The correct positioning speed using parameter 110
The correct maximum speed compatible with the sewing machine using parameter 111
The setting of the remaining relevant parameters
Begin sewing in order to save the set values
4 Setting and Putting into Servicewith the Aid of the Fast Installation
Routine (SIR)
Function with or without control panel
Parameters
Call-up of the Fast Installation Routine SIR
(Sir)
500
The Fast Installation Routine (SIR) passes through all parameters necessary for programming the functional
sequence and the positions.
With SIR you can do the most important settings for initial operation with menu prompting.
For safety reasons, the menu must be executed point by point. This ensures correct setting of all important
parameters.

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Input of the code number for the fitting level. 
Parameter 500 is displayed. 
Parameter 290 for functional sequence of the cutting procedures. 
Parameter 467 for selection of motor. 
Parameter 111 for the maximum speed. 
Parameter 161 for direction of motor rotation. 
Parameter 270 for type of position sensor. 
Parameter 272 for transmission ratio. 
Important! The transmission ratio should be determined and
indicated as precisely as possible.
If parameter 270 =0 or 5, continue with input of 451.
Check the transmission ratio.

Move pedal forwards. Let the drive run until ready (rdy) is displayed.
Press pedal to position 0. The check is complete.

if parameter 270 = 6, set the reference position. 
Turn hand wheel until symbol odisplay goes off. 
Set reference position (e.g. height of the stitch plate, lower dead point).
Parameter 451 for position 1. 
Parameter 453 for position 2. 
To repeat the cycle from parameter 290, push button E. 
Or end with button P(2x). 
The values can be varied by pressing key +/-.
The input of the code number is described in the general operating manual!

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Setting on the operating part of the controls (onboard)
1
Input code number 3112!
2
Press the Ekey

Parameter 5.0.0. displayed
3
Press the Ekey

Sir displayed. The 2 lower segments of the right 7 segment display flash.
4
Press the >> key

Parameter 2.9.0. appears
(Functional cycle cutting
processes)
5
Press the Ekey

Parameter value e.g. 05 appears.
6
Press the +/-key

The parameter value can be changed.
7
Press the Ekey

Parameter 4.6.7. appears
(Selection of motor)
8
Press the Ekey

Parameter value e.g. 3appears.
9
Press the +/-key

The parameter value can be changed.
10
Press the Ekey

Parameter 1.1.1. appears
(Maximum speed)
11
Press the Ekey

Value of the set speed appears.
12
Press the +/-key

The parameter value can be changed.
13
Press the Ekey

Parameter 1.6.1. appears
(Direction of motor rotation)
14
Press the Ekey

Parameter value e.g. 1appears.
15
Press the +/-key

The parameter value can be changed.
16
Press the Ekey

Parameter 2.7.0. appears
(Type of position sensor)
17
Press the Ekey

Parameter value e.g. 0appears.
18
Press the +/-key

The parameter value can be changed.
19
Press the Ekey

Parameter 2.7.2. appears
(Transmission Ratio)
20
Press the Ekey

Parameter value e.g. 1000 appears.
21
Press the +/-key

The parameter value can be changed.
22
If parameter 270 =0 or 5, or the check of the
transmission ratio is already done, continue with
Point 30.
23
Press the Ekey

PULY is displayed.
(Check the transmission ratio)
24
Move pedal forwards
Let the drive run until ready (rdy) is displayed.
For a maximum speed that is too high, an error
message A12 is generated. Push button Eas
often as needed until parameter 111 (Point 12) is
reached again to set the permitted maximum
speed.
25
Press pedal to position 0
(neutral)
The check is complete.
26
When parameter 270 ≠ 6, continue with Point
31.
27
P0 o is displayed (oin red).
(Setting the reference position)
28
Rotate the hand wheel in the running direction until oextinguishes *.
Set reference position (e.g. height of the stitch plate, lower dead point).
29
Press the Ekey

Parameter 4.5.1. appears
(Position 1 leading edge,
position 1 trailing edge is
automatically set 60° higher)
30
Press the Ekey

Angle from position 1 is displayed.
31
Turn the hand wheel

Set position 1 (at least 1 rotation *).
32
Or press the +/-key

The parameter value can be changed.
33
Press the Ekey

Parameter 4.5.3. appears
(Position 2 leading edge,
position 2 trailing edge is
automatically set 60° higher)
34
Press the Ekey

Angle from position 2 is displayed.
35
Turn the hand wheel

Set position 2 (at least 1 rotation *).
36
Or press the +/-key

The parameter value can be changed.
37
Upon pressing the Ekey once more the program returns to parameter 2.9.0.!
38
Press the Pkey twice

The system exits the SIR routine.
*) All operations carried out by turning the hand wheel must always be carried out in the direction of rotation set up on the
machine. Under no circumstances should you turn against the machine direction.