Efka AB620A5035 User manual

FRANKL & KIRCHNER EFKA OF AMERICA INC. EFKA SINGAPORE PTE. LTD.
GMBH & CO KG
CONTROL AB620A5035
Operating manual
With parameter list
-Putting into Service
-Settings
-Functional Description
-Connection Diagrams
-Timing Diagrams
No. 402446 English

- AB620A5035
- 2 -
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

- AB620A5035
- 3 -
CONTENTS Page
1Range of Applications 6
1.1 Use in Accordance with Regulations 6
2Scope of Supply 7
2.1Special Accessories 7
2.1.1 Adapter Cords for Special Machines 8
3Putting into Service 8
4Setting and Putting into Service with the Aid of the Fast Installation Routine (SIR) 9
5Quick access 13
5.1 Parameter back up 13
5.1.1 Parameter backup 13
5.1.2 Restoring parameters from the backup 13
5.1.3 Save the parameter backup on a USB stick 14
5.1.4 Restoring the parameter backup from the USB stick 15
5.2 Setting the reference position 16
6Setting the Basic Functions 17
6.1 Direction of motor rotation 17
6.2 Use of a HSM001 Hall Sensor Module or IPG... Pulse Encoder 17
6.3 Transmission Ratio 18
6.4 Selection of Functional Sequences (Thread Trimming Operations) 18
6.5 Functions of the Keys Inputs in1...in7 18
6.6 Positioning speed 18
6.7 Maximum Speed Compatible with the Sewing Machine 19
6.8 Maximum speed 19
6.9 Positions 19
6.9.1 Setting the reference position (Parameter 170) 20
6.9.2 Setting the Positions 21
6.10 Display of the Signal and Stop Positions 21
6.11 Positioning shift 22
6.12 Braking Characteristics 22
6.13 Braking Power at Standstill 22
6.14 Starting Characteristics 23
6.15 Actual Speed Display 23
6.16 Operating hours counter 23
6.16.1 Set and Reset Operating Hours Counter 25
6.16.2 Total Operating Hours Display 25
7Functions with or without Control Panel 25
7.1 First Stitch after Power On 25
7.2 Softstart 25
7.2.1 Softstart speed 25
7.2.2 Softstart stitches 26
7.3 Sewing foot lifting 26
7.4 Start Backtack/Start Stitch Condensing 27
7.4.1 Speed n3 at the Start of the Seam 27
7.4.2 Stitch Counting for Start Backtack/Start Stitch Condensing 28
7.4.3 Stitch Correction and Speed Release 28
7.4.4 Double start backtack 28

- AB620A5035
- 4 -
7.4.5 Single Start Backtack / Start Stitch Condensing 28
7.5 End Backtack / End Stitch Condensing 28
7.5.1 Speed n4 at the Seam End 29
7.5.2 Stitch Counting for End Backtack/End Stitch Condensing 29
7.5.3 Stitch Correction and Last Stitch Backward 29
7.5.4 Double End Backtack/End Stitch Condensing 29
7.5.5 Single End Backtack / End Stitch Condensing 30
7.5.6 Backtack Synchronization 30
7.6 Start Ornamental Backtack/Stitch Condensing 30
7.7 End Ornamental Backtack/Stitch Condensing 30
7.8 Intermediate Backtack 31
7.9 Stitch Regulator Suppression/Recall 32
7.10 Holding Power of the Stitch Regulator Solenoid 32
7.11 Reverse motor rotation 32
7.12 Unlocking the Chain (Mode 5/6/7) 33
7.13 Machine run blockage 34
7.14 High lift for walking foot / flip-flop 1 34
7.14.1 High lift walking speed 34
7.14.2 High Lift Walking Speed Run-Out Time 35
7.14.3 High Lift Walking Stitches 35
7.14.4 HighLift forWalkingFoot Operational ModeNotStored (Parameters 240...246=13) 35
7.14.5 High Lift for Walking Foot Operational Mode Stored /Flip-Flop 1 (Parameters 240...246 =
14) 35
7.15 Speed Limitation Depending on High Lift 35
7.15.1 Programming the measurement value of the poti 36
7.16 Speed Limitation n9 36
7.17 Thread trimming operation 36
7.17.1 Thread Trimmer/Thread Wiper (Lockstitch Modes) 37
7.17.2 Trimming speed 37
7.17.3 Chainstitch thread cutter (var. modes) 37
7.17.4 Chainstitch Machine Trimming Signal Times 37
7.18 Functions for bag sewing machines 38
7.19 Overlock Machine Functions (Mode 7) 38
7.19.1 Chain Suction Signal 38
7.19.2 Start and End Counts 40
7.20 Tape Cutter/Fast Scissors (Modes 6/7) 40
7.20.1 Tape Cutter/Fast Scissors in Mode 6 40
7.20.2 Tape Cutter/Fast Scissors in Mode 7 40
7.21 Manual Tape Cutter/Fast Scissors 41
7.22 FlipFlop functions (AFF) 42
7.23 Seam with Stitch Counting 43
7.23.1 Number of Stitches for a Seam with Stitch Counting 43
7.23.2 Stitch Counting Speed 43
7.23.3 Seam with Stitch Counting When Light Barrier Is On 43
7.24 Free Seam and Seam with Light Barrier 44
7.25 Light barrier 44
7.25.1 Speed after Light Barrier Sensing 44
7.25.2 General Light Barrier Functions 44
7.25.3 Reflection Light Barrier LSM002 45
7.25.4 Automatic Start Controlled by Light Barrier 45
7.25.5 Light barrier filter for knitted fabrics 45
7.25.6 Functional Variations of the Light Barrier Input 46
7.26 Switching Functions of Inputs in1...i13 47
7.27 Software Debouncing of All Inputs 48
7.28 F1/F2 Function Key Assignment on the V810/V820 Control Panels 48
7.29 Special pedal function Single stitch / Full stitch 49
7.30 Signal “Machine Running“ 49
7.31 Signal Output Position 1 49
7.32 Signal Output Position 2 49

- AB620A5035
- 5 -
7.33 Signal Output 512 Impulses per Rotation 49
7.34 Actuator 50
7.34.1 Analog actuator 50
8Signal Test 50
8.1 Signal Test Using the Incorporated Control Panel or the V810/V820 51
8.1.1 Inputs to the control 51
8.1.2 Outputs of control 51
9Table of Machine Functions and Adapter Cords 52
10 Operating Elements and Socket Connectors 54
10.1 Positions of the Front Side 54
10.2 Positions of the rear side 54
10.3 Connection Diagrams 55
11 Timing Diagrams 60
11.1 Operator Level 80
11.2 Technical level (Code no. 1907) 83
11.3 Supplier level (Code No. 3112) 88
12 Error Displays 96

- AB620A5035
- 6 -
1 Range of Applications
The drive is suitable for lockstitch, chainstitch and overlock machines of various manufacturers.
It can be operated with or without control panel.
The easy-to use V810 or V820 control panels extend the range of functions.
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!

- AB620A5035
- 7 -
2 Scope of Supply
Standard Scope of Supply
1
Direct current motor
DC1200 optional DC1250
1
Electronic control/Power supply unit
AB620A5035N214
1
Set of accessories (standard)
B156
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.
Control panel Variocontrol V810
5970153
Control panel Variocontrol V820
5970154
Control panel Variocontrol V860
5990164
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

- AB620A5035
- 8 -
9-contact SubminD male connector
0504135
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
Designation
Material No.

- AB620A5035
- 9 -
Before putting the control into service, the following must be ensured, checked and/or adjusted:
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 Service with 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.

- AB620A5035
- 10 -
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!