Jack 6040-D Technical manual

Automatic Sewing Control
System
Operation Instruction
(Human Machine Interface)
October 2014, Version V3.1
©All rights reserved Shenzhen Xing Huo CNC Co., Ltd.

星火全自动缝纫控制系统使用说明书
Operation Instruction for Xing Huo Automatic Sewing Control System
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Table of Contents
Chapter I Introduction to Control System....................................................................4
1.1 Overview...................................................................................................................................... 4
1.2 Functional Description................................................................................................................. 4
1.3 Notes.............................................................................................................................................6
1.3.1 Safety Instruction..................................................................................................................6
1.3.2 Work Environment................................................................................................................7
1.3.3 Power Supply Requirement..................................................................................................7
1.3.4 Grounding Requirement....................................................................................................... 7
Chapter II Main Interface Specification....................................................................... 8
2.1 System Powered on...................................................................................................................... 8
2.2 Processing Main Interface............................................................................................................8
2.2.1 Display Specification of Processing Main Interface............................................................8
2.2.2 Display Specification of Processing Auxiliary Interface................................................... 10
2.2.3 Display Specification of Manual Frame Moving Interface............................................... 12
2.2.4 Display Specification of Base Settings Interface............................................................... 13
2.2.5 Display Specification of Processing Statistics Interface....................................................15
2.3 Main Menu Interface..................................................................................................................17
Chapter III File Management...................................................................................... 18
3.1 Memory File Management.........................................................................................................18
3.2 U Disk File Management........................................................................................................... 19
Chapter IV File Collection............................................................................................21
4.1 Main Interface of File Collection...............................................................................................21
4.2 Empty Sending Collection......................................................................................................... 24
4.3 Single Needle Collection............................................................................................................24
4.4 Straight Line Collection............................................................................................................. 25
4.5 Arc Collection............................................................................................................................ 26
4.6 Round Collection........................................................................................................................27
4.7 Multi-Segment Collection..........................................................................................................28
4.8 Curve Collection........................................................................................................................ 29
4.9 Zig-zag Sewing (Bartack).......................................................................................................... 30
4.10 Multiple Sewing and Complementary Sewing........................................................................ 31
4.11 Reinforcing Sewing..................................................................................................................32
4.11.1 Forward and Backward Reinforcing................................................................................ 33
4.11.2 Closed Reinforcing........................................................................................................... 34
4.12 Collection Speed and Stitch..................................................................................................... 35

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4.13 Insert Functional Code............................................................................................................. 36
4.14 Save File................................................................................................................................... 37
Chapter V Modify File.................................................................................................. 39
5.1 Main Interface of Modify File................................................................................................... 39
5.2 Add Needle Point....................................................................................................................... 41
5.3 Delete Needle Point....................................................................................................................42
5.4 Forward and Backward Reinforcing..........................................................................................43
5.5 Closed Reinforcing.....................................................................................................................44
5.6 Delete Multi-Needle...................................................................................................................45
5.7 Append Needle Point..................................................................................................................47
5.7.1 Append Single Needle........................................................................................................ 47
5.7.2 Append Multi-Needle......................................................................................................... 48
5.8 Modify Functional Code............................................................................................................ 49
5.9 Modify Needle Position............................................................................................................. 50
5.9.1 Modify Current Point Needle Position...............................................................................51
5.9.2 Modify All Needle Positions after Current Point...............................................................52
5.10 Section Offset........................................................................................................................... 52
5.11 Section Speed Modification..................................................................................................... 54
5.12 Overall Offset........................................................................................................................... 55
5.13 Secondary Origin Modification............................................................................................... 56
5.14 Section Modification................................................................................................................57
Chapter VI User Settings.............................................................................................. 59
6.1 User Settings Interface............................................................................................................... 59
6.2 User Settings Parameters Introduction.......................................................................................61
Chapter VII Auxiliary Operation................................................................................ 66
7.1 Auxiliary Operation Interface.................................................................................................... 66
7.2 Combine File.............................................................................................................................. 67
7.3 Export Parameters...................................................................................................................... 68
7.4 Output Detection........................................................................................................................ 68
7.5 Input Detection...........................................................................................................................69
7.6 Lock Machine Settings...............................................................................................................70
7.7 Date Settings...............................................................................................................................71
7.8 Version Information....................................................................................................................71
7.9 System Update............................................................................................................................71
Chapter VIII Ex-Factory Parameters......................................................................... 73
Appendix I: Description and Solution of Information Tips...................................... 75
Appendix II: Introduction to Quick Start...................................................................78

星火全自动缝纫控制系统使用说明书
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Chapter I Introduction to Control System
1.1 Overview
Thank you very much for using the automatic template sewing machine control system of
our company!
This system can match with the various types of template machine, satisfying different
sewing requirements with satisfactory sewing effect for all sorts of cloth!
Before using, please read the Instruction carefully to ensure the correct use of this system.
Please keep the instruction appropriately in order to check at any time.
In case of discrepancies between actual machine and this Instruction due to different
machine configurations and software update, the operating functions shall prevail.
1.2 Functional Description
(1) One machine with multi-purpose, simple operation
Full automatic template sewing machine can replace many kinds of special machinery
such as traditional flat sewing machine, long arm sewing machine, bartack sewing
machine, embroidery machine, etc. in certain circumstances to achieve multi-usage
After placing the template well, the operating personnel only needs to press the start key,
automatic processing can be completed, the operation is quite simple
With standardized operation; the machine can work out amazing effects for a variety of
stitches and a variety of fabric!
(2) The man-machine interface is friendly and easy to use
7 inches color LCD touch screen, with clear display, easy to touch
Support display in both Chinese and English
Up to 256M (or 128M) file storage space, to store and process many files
Convenient file Collection (template making), modification, management functions

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(3) Precise motion control technology with efficient sewing
Using international advanced DSP chip, fast system run speed, high hardware integration,
stable performance
Support step-by-step, closed loop step-by-step, brushless DC, servo drive, using smooth
curve for speed governing, smooth operation
Compact mechanical structure, good rigidity, high sewing position precision, low noise
(4) The upper computer graphics editing software is easy to use
Such files in dxf, dst, dsb, ai, plt, edi, tzf format that are generated by software such as
Autocad, Coredraw are easily converted into processing files
The software has comprehensive graphics editing functions, supports layer editing and
adding various kinds of special sewing stitch lines
With common control instruction set, customizable control instruction (functional code),
high dexterity of action
For each layer, each graphic, each stitch point, a variety of mechanical control commands
can be inserted into, to meet the diversified and precise automatic sewing requirement
(5) Rich user parameter settings, comprehensive auxiliary functions
Detail settings can be carried out for various mechanical actions
Point position, painting line, automatic mold slot opening function of some equipment
can be extended
Support automatic identification of template, U Disk system updates, broken threads
detection, continue sewing in power down, processing statistics, forecast for lack of
bobbin thread, system self-test, parameter backup and recovery, encryption lock
machine...

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1.3 Notes
1.3.1 Safety Instruction
In order to avoid the possible risk and prevent damage to the device, please observe the
following safety matters:
Note:
Please don't carry out maintenance and debugging to electric system by
non-specialists, this will reduce the safety performance of equipment, enlarge the
fault, and even cause harm to the personnel and property losses.
Some parts inside the case have high pressure; after the system is powered on, please
do not open the case cover, in order to avoid accidental injury.
Please do not pile up sundry around the control box, and in the process of using;
remove dust on the surface of control box and the filter regularly, so as to keep good
ventilation for the system, which is good for heat dissipation.
Without authorization of the company, please do not make any change to the product
arbitrarily, and the company shall not hold any responsibility for the consequences!
Warning:
If it really needs to open the case cover, it must be carried out5 minutes after
cutting off power and guided by professionals to contact components inside the
electrical cabinet!
Danger:
When the machine is at work, it is forbidden to contact with any moving part
or open the control equipment, plug or pull out motor interface, otherwise it
may cause personal injury or the machine not to work!
It is forbidden for electrical equipment to work in places with humidity, dust,
corrosive gas, flammable and explosive gas, otherwise it may cause electric
shock or fire!

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1.3.2 Work Environment
Solid, level ground installation
Good ventilation, healthy environment, less dust
Temperature in work space: 5 to 40 ℃
Relative humidity in work space: 30% to 90% without condensation
1.3.3 Power Supply Requirement
Single-phase AC220V/50 to 60 HZ
It needs to be equipped with the voltage regulation equipment when the power grid
voltage fluctuation is more than 10%
Equipment power is between 1.0 to 2.0KW according to different machine
configuration
1.3.4 Grounding Requirement
In order to prevent electric shock or fire accident of electrical equipment due to
causes such as electric leakage, over voltage, insulation, etc., please make sure the
electronic control with reliable grounding
The grounding resistance should be less than 100 ohms, conductor length within 20
meters, conductor cross-sectional area greater than 1.0 square millimeters

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Chapter II Main Interface Specification
2.1 System Powered on
After the system is powered on, the man-machine interface will display the boot interface,
spindle will carry out rotational detection automatically, and then reset other parts. The
specific reset actions are related to the settings of power on reset parameters.
2.2 Processing Main Interface
2.2.1 Display Specification of Processing Main Interface
After boot LOGO is displayed, the processing main interface will be entered
automatically. Processing main interface is shown as below.
Figure 2-1 Processing Main Interface
Functions of keys on processing main interface are introduced as follows:
Processing file preview area: displays the currently selected graphical file, when clicked,
switches between "Full Figure" (zoom to best display) and "In Proportion" (actual proportion
with processing range) modes.
Memory file list: displays the memory file list, when clicked, selects different processing
Name and length and
width size of the
current processing file
Lock file icon
Memory file list
Total number of
needles of
processing file and
current processing
number of needles
Pause machine icon
Spindle work speed
Used bobbin thread
length
Finished number
Processing file
preview area
Current time
Prompt information
area

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files. If the automatic identification function of template identifies the template number before
processing, file with this number will be taken as the current processing file automatically.
Lock file key: locks the current processing file to prevent wrong operation, other
processing files can't be chosen after the lock, and icon will appear in preview area.
Click it once to lock, and click it again to unlock.
Note: only in the locking condition of "Lock file", the automatic template identification
function will work. After identification of the template, it will display on the "Prompt
information area" and the "Current time" interface, and selects the file with corresponding
number automatically.
Acceleration key: rises spindle speed at 100 r/min ascending, increases
continuously if long press (press and hold), until the set maximum speed. It sews one
stitch by one round of the spindle. It can be prohibited to modify rotational speed
arbitrarily through setting a password.
Slow down key: reduces the spindle speed at 100 r/min decreasing, reduces
continuously if long press, until the set minimum speed. It can be prohibited to modify
rotational speed arbitrarily through setting a password.
Bobbin thread statistics key: shows the used length of the current bobbin
thread, press the key to enter the processing statistics interface.
Processing statistics key: displays the number of current completed
processing, press the key to enter the processing statistics interface.
Main menu: press the key to enter the main menu interface.
Manual empty retreat key: press the key to start single step empty retreat
backwards, long press for continuous empty retreat. Empty retreat is that the spindle is
fixed, and XY axis move only, which can be used to preview the position of specified
processing needle, or to start processing from the position of specified needle.
Manual empty advance key: press the key to start single step empty advance

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forward, long press for continuous empty advance.
Processing number of needle setting key: number on the upper line is the total
number of needle of processing files, number on the lower line is the current processing
number of needle. Press the key to pop up "Move to the Specified Needle" setting
window.
Note: the "Move to the Specified Needle" window shows: ... : the set value by
digital input; : the set value returns to zero;
: add 1 to the set value; : minus 1 to the set value; : restore
to the set value before modifying; : cancel the current modification;
confirm the current modification.
Left page key: turn to the left page to check memory file.
Right page key: turn to the right page to check memory file.
Reset key: press the key to make each axis return to the absolute origin.
Base key: press the key to enter setting page of XY axis base point.
Manual presser frame rise/fall key: every press to switch the presser frame
between rise and fall.
Manual presser foot rise/fall key: every press to switch the presser foot between
rise and fall.
Next interface key: press the key to enter the processing auxiliary interface.
2.2.2 Display Specification of Processing Auxiliary Interface
In the processing auxiliary interface, the bobbin thread winding and other manual
operations can be undertaken.

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Figure 2-2 Processing Auxiliary Interface
Functions of keys on auxiliary interface are introduced as follows:
Bobbin thread winding switch: every press to switch between "Allow" and
"Forbid". Press the start running switch after "Allow", winding operation can be
performed, and the spindle will start winding at the set speed of this page. Press the start
running switch again or , or winding duration is over, winding will stop.
"Forbid" shows that winding is prohibited.
: shows the spindle winding speed.
Spindle inversion key: press the key then the spindle starts inversion and slow
moving.
Spindle corotation key: press the key then the spindle starts corotation and slow
moving.
Needle bar up/down key: every press to switch needle bar between upper
positioning (highest point of needle) and lower positioning (lowest point of needle); press
this key for more than 1 second, the spindle starts corotation and slow moving (same as
the function of spindle corotation key).
Trim key: press the key then the machine takes sewing once, to achieve full
trimming action.

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, , : press the keys then the corresponding
electromagnetic valve open once and close again.
, , , … : press the keys then the
corresponding IO output function is always on, press again then the output is closed.
Note: please do not hold the solenoid valve control keys such as Trim key for a long time
without loosening, otherwise it may lead to damage of the electromagnetic valve connected
on this output due to overheat!
Last interface key: press the key to return to processing main interface.
Manual frame moving key: press the key to enter manual frame moving operation
interface.
2.2.3 Display Specification of Manual Frame Moving Interface
In the processing main interface, click , and then click , it can enter the manual
frame moving interface. In the manual frame moving interface, operations such as manual
frame moving, controlling the rotation of each axis and so on can be undertaken.
Functions of keys on manual frame moving interface are introduced as follows:
, , Frame moving speed switch key: click them to switch among low,
Direction keys: they can
move to eight directions
Key speed switch can
adjust three kinds of
speeds
X/Y/Z coordinates
display
Spindle angle position
display

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medium, high speed. Correspond to the pattern making speed 1, 2, 3 in "User Parameters".
Eight direction keys such as : move in the X, Y axis direction.
"Z+", "Z-", "Axis 1+"... "Axis 3-": manually turns the corresponding axis, some axis is
invalid to parts of the machine.
Return key: press the key to return to the previous operation interface.
2.2.4 Display Specification of Base Settings Interface
In the processing main interface, click to enter the base point settings interface.
In this interface, template base point can be set up.
?
Reasons of base point settings:
As to the processing files edited and generated using upper computer software, in the
import into memory and preview show for the first time, the system will place this file at the
right middle position within the scope of processing (visible when clicking on the "Processing
File Preview Area" to switch display mode), specific as follows: center of Y axis direction of
file is center of Y axis direction of processing range axis; The rightest side of X axis direction
of file is 70 mm apart from the rightest side of processing range. The system will write the
position information into the processing file. As shown in the figure below
Base Point Settings
Set Base 1
Set Base
1

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While position of the template actually made on the workbench may be as follow:
So align base point 1 and A, base 2 and B, and adjust the position of processing pattern in
the system to correspond to the position of template slotting.
Detailed steps are as follows:
1) Select the file which needs to be aligned with the base point in the processing main
interface, and place the corresponding template. Click to enter the base point
settings interface, the system will move the frame to the base point 1 position
automatically.
2) If upper computer editing software has set double base points, “Set the First Base
Point” will be prompted the top left of the interface; check whether base point 1 is in
template slot position A at this time; if there is any deviation, click the direction keys
to move for overlap.
3) Click on , and complete base point 1 setting. The system will move the frame
to the base point 2 position automatically, and “Set the Second Base Point” will be
prompted the top left of the interface; click the direction keys to make the positions
of base point 2 and template B overlapping. If it needs to return to reset base point 1,
click to switch to the base point 1 setting.

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4) Click on , complete base point 2 settings, and return to main interface
automatically. System will write this position into processing file, and the processing
preview area pattern will adjust to the corresponding template position.
After aligning to the base point, as long as it doesn't modify the file and the template,
there is no need to align to base again. If the upper computer software does not set double
base points to file, it tacitly approves the sewing start point as the base point 1, and will return
to processing main interface after aligning to the base point 1.
At the same time, through setting system parameters, there is no need to align to base
when used for the first time. Please consult the manufacturer for the detail settings.
2.2.5 Display Specification of Processing Statistics Interface
In the processing main interface, click or to enter processing
statistics interface. In this interface, you can check information such as processing quantity,
time, and bobbin thread length.
Interface specification is as follows:
: "ON" is to enable the processing statistics, press it again then "OFF" closed.
When "User Parameter" - "Statistics Settings" - "Count Work Time: Yes", it will enable
processing always, this key can't be used to close.
Initial Len of Bobbin Thread
(mm)

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"Cur. File All": refers to the total completed number of current processing files all the
time. Click on "Clear All" for zero clearing.
"Cur. File Now": refers to the total completed number of current processing files on the
same day. Click on "Clear Now" for zero clearing.
"Initial Value of Statistics": refers to the total number of completed processing files. No
matter what kind of the file is, as long as finishing processing once, this value will add 1
automatically.
"Total Number of Packages": refers to the total number of preprocessing of all kinds of
files.
Note: if you enable processing statistics, and "User Parameters" - "Statistics Settings" -
"Continue to Work after the Counter Achieves: No", when the "Initial Value of Statistics"
achieves "Total Number of Packages", restart the processing, "Full Counting" will be
prompted.
: Press the key to enable the bobbin thread statistics: press it again then shut down.
If "User Parameters" - "Count Setting" - "Counter Setting Valid: Yes", it will enable the
bobbin thread statistics always, this key can't be used to close.
"Initial Len of Bobbin Thread (mm)": refers to the bobbin thread length which has been
used up; when a file is finished processing, it will reduce the corresponding length of the
bobbin thread.
"Total Len (mm)": refers to the initial bobbin thread length in the rotating shuttle. It can
be estimated during winding to be: total length = average circumference of rotating shuttle x
revolving speed x winding time,
Note: if you enable the bobbin thread statistics, the system will calculate the length
required by the bobbin thread of preprocess files before processing; when the length is greater
than (total length - the initial length of bobbin thread), "bobbin thread is used up" will be
prompted to prevent changing bobbin thread in the processing midway. After popping up,
press "OK" for zero clearing of the initial length.

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“Work Time”: sum total of the processing time for all time.
2.3 Main Menu Interface
In the processing main interface, press key to enter the main menu interface, as
shown in the figure:
File management: manages memory files and the U Disk files, carries out input/output
file operations.
Collect File: generates processing files through track collection (pattern making).
Modify File: modifies the currently selected processing file.
User Param: sets the parameters need to be adjusted in the user processing.
Machine Param: only for the use by machine assembly personnel.
Auxiliary Setting: used for processing auxiliary setting and testing, etc.
Factory Param: manages parameters set by factory.

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Chapter III File Management
File management is used for operations such as input, output, and deletion for U Disk
and memory files. System identifies processing files with .FLW and .HLW suffix only.
Processing files are created by attached PC graphics editing software, or generated using the
file collection function.
3.1 Memory File Management
In the main menu interface, press the key to enter the file management
interface, into memory file management by default, as shown in figure:
The memory can store 999 processing files at most, the total size of no more than 256 M
(or 128 M) total storage space. It supports Chinese and English names display. It uses 8.3
naming rules, that is, the primary file name cannot be more than eight characters (not more
than four Chinese characters if Chinese characters); If more than that, it will take the first 6
characters of the file name plus ~1 (if the first 6 characters are the same, use ~2, ~3... in turn)
for display.
Click to select file, the selected file name will be changed into red, carry out operations
for the selected file according to the need.
Keys descriptions: copy file: copies the currently selected file or the last file of

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multiple selected files and rename it.
Delete the selected file: deletes the currently selected file or the last
file of multiple selected files.
Batches delete selected files: deletes the currently selected multiple
files.
Move files: moves the currently selected file or the last file of
multiple selected files to the specified position. For example, select "002:TEST2.FLW", click
on , in the pop-up dialog box, amend the current sequence number "2" to be "1", click
on "Confirm". It will change to be "001:TEST2.FLW".
Output file: copies selected single or multiple files from memory files
to the root directory of U Disk. If there is any file of the same name in U Disk, it will be
replaced.
Memory, U Disk switch: press the key once switch between
memory and U Disk.
3.2 U Disk File Management
After inserting U Disk, in the memory management interface, press key to
switch to the U Disk file management interface, as shown in figure:

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U Disk file management uses 8.3 rules for naming display, displays .FLW format files
and subfolder names in U Disk root directory by default, and .DIR suffix means that this is a
folder. It supports multistage folder operation, and it is suggested to adopt the way of
subfolders for classification management when there are a lot of files.
Click to select file, the selected file name will be changed into red, carry out operations
for the selected file according to the need.
Keys descriptions: input file: copies the selected single or multiple files from U
Disk to memory space, files with the same names will be replaced.
Return key: back to the main menu interface or the parent folder.
Note: if processing files in .HLW format can't be identified, please update control system
version, see Section 7.9.