JUKI AW-3S User manual

1
INSTRUCTION MANUAL
AW-3S

i
CONTENTS
1. GENERAL............................................................................................... 1
1-1. Specications of AW-3....................................................................................................... 1
1-2. Conguration...................................................................................................................... 2
2. INSTALLATION....................................................................................... 4
2-1. Installing the AW-3S........................................................................................................... 4
2-2. Installation location ........................................................................................................... 4
2-3. Installing the bobbin thread remaining amount detection sensor (optional)............... 4
3. OPERATION PROCEDURE ................................................................... 5
3-1. Opening/closing the cover door....................................................................................... 5
3-2. How to thread the device with the bobbin thread........................................................... 6
3-3. How to set a bobbin........................................................................................................... 8
3-4. Length of remaining thread to be removed................................................................... 11
3-5. Device operation lamp..................................................................................................... 12
3-6. To use the AW-3................................................................................................................ 13
3-7. Behavior of the AW-3 device when the power is turned ON ........................................ 14
3-8. Memory switch data list................................................................................................... 15
3-9. Basic operation and setting............................................................................................ 16
3-10. Operating the AW ........................................................................................................... 17
3-11. Setting the AW number-of-stitches input mode, AW operation mode and
remaining-thread allowance length ................................................................................ 20
3-12. Example of operation..................................................................................................... 27
3-13. Turning OFF of the power ............................................................................................. 32
3-14. Error display and error handling procedure................................................................ 32
3-15. Detection of errors related to the AW........................................................................... 34
3-15. List of errors................................................................................................................... 36
4. MAINTENANCE.................................................................................... 38
4-1. Attaching / removing the cover ...................................................................................... 38
4-2. Cleaning............................................................................................................................ 39
4-3. Replacing the fuse ........................................................................................................... 41
4-4. Replacing the gripper tube.............................................................................................. 41
4-5. Corrective measure against idling of the bobbin.......................................................... 42
4-6. Adjusting the air ow for the remaining thread guide ................................................. 42
4-7. Attaching/removing the AW main body ......................................................................... 43
5. TROUBLESHOOTING.......................................................................... 44

– 1 –
1. GENERAL
1 Applicable bobbin, bobbin
case
Exclusive double-capacity bobbin and bobbin case.
2 Applicable thread count #5 to #30 (Japan), 135 to 45 (TEX), 020 to 060 (TKT)
3 Applicable type of thread Synthetic thread
4Remaining-thread removal and
bobbin winding operation
Possible while the sewing machine is in operation.
5 Condition setting according
to the thread type
Conditions to be met to unravel the thread at the beginning of
winding a bobbin can be set.
6Line voltage 100,120/200,220,240 Vac ±10 %, Single phase 50/60 Hz
7 Power consumption 100 VA
8 Air pressure used 0.5 to 0.55 MPa
9 Air consumption 156 Nℓ / min (max. value)
10 Dimensions 700 mm (W ) × 650 mm (L ) × 430 mm (H ) (Accessories includ-
ed)
11 Mass of the device 38 kg
12 Operating temperature range 5 ˚C to 35 ˚C
13 Operating humidity range 35 % to 85 % (No dew condensation)
14 Noise - Equivalent continuous emission sound pressure level (LpA) at
the workstation : A-weighted value ≦ 75 dB ; (Includes KpA =
2.5 dB) ; according to ISO 10821- C.6.2 -ISO 11204 GR2 at
remaining-thread removal length = 2 m; Bobbin-thread winding
length (22 m).
Conventionally, a series of operations including the replacement of a bobbin in the sewing machine
hook, removal of thread remaining on a bobbin, winding of a bobbin, threading of the bobbin case ten-
sion spring and trimming of thread have been carried out manually. Now, this device has been devel-
oped to carry out the series of operations full-automatically. This device not only helps increase e󰀩cien-
cy of sewing work but also ensures stable product making in such processes that require high seam
quality.
Refer to the Instruction Manual for the AMS-221EN/AMS224EN/IP-420 for information about the main
body of the sewing machine.
1-1. Specications of AW-3

– 2 –
1-2. Conguration
❸
❹
❺
❻
❷
󱢴
󱢵
󱢷
❶
❾
󱢶
❽
❼
󱢳
* The illustration shows the AMS-221EN.

– 3 –
Name Function
❶Main body of device It is mounted under the sewing machine bed and is the mechanical
section of the device which carries out replacement of the bobbin,
removal of thread remaining on the bobbin, winding of thread on a
bobbin, threading, thread trimming and thread unraveling automatical-
ly.
❷Angle section It connects the main body of the AW device to the sewing machine
bed.
❸Carrier arm It is the mechanism for carrying a bobbin case to the hook, bobbin
setting section, remaining thread removal section and bobbin winding
section.
❹Bobbin setting section It serves as an intermediary place used in the case of putting/removing
a bobbin on/from the device.
❺Remaining thread removal
section
It is the mechanism for removing the thread remaining on the bobbin
taken out from the hook. It consists of the remaining thread removal
roller, suction vacuum, etc.
❻Thread unraveling section It is the mechanism for unraveling the tip of thread to be wound on a
bobbin at the beginning of bobbin winding. It consists of the bobbin
unraveling roller, etc.
❼Nozzle Thread from the bobbin thread cone comes from the tip of the noz-
zle by way of the thread path. The thread coming out of the nozzle is
wound on a bobbin.
❽Bobbin thread winding
section
It is the mechanism for winding thread on a new bobbin, threading the
bobbin case and trimming the thread. It consists of the clutch plate,
threader, thread trimming knife, etc.
❾Thread feeding unit It is used to feed the thread bit by bit from the tip of the nozzle and
accurately measure the length of thread wound on a bobbin during
bobbin winding.
󱢳Electrical control box of
the device
It is the box which contains the PCB for controlling the operation of
the device. This electrical control box is di󰀨erent from the one for the
sewing machine.
󱢴Device operation lamp It indicates that the device is in operation.
󱢵Dust bag It is the place to store the remaining thread removed from the bobbin.
󱢶Cover It is used to prevent the operator from coming in contact with the mov-
ing part of the device.
󱢷Remaining thread detec-
tion section (optional)
It controls the amount of thread which remains on the bobbin with its
micro-laser distance measurement sensor.

– 4 –
2. INSTALLATION
2-1. Installing the AW-3S
For details, refer to the "Retrot Instructions for the AW-3SB" in the case of installing the AW-3S to the
AMS-221EN or "Retrot Instructions for the AW-3SC" in the case of installing it to the AMS-224EN.
2-2. Installation location
For the installation location, carefully check the following points.
(1) This device uses an optical sensor. In order to protect the optical sensor from malfunctioning, do
not install the device near a window or in any other location where it is likely to be exposed to direct
sunlight. Alternatively, install the device in a direction where it will not be exposed to direct sunlight.
(2) In order to avoid malfunctioning, do not use the device near any equipment that generates large
electrical noise. In addition, it is preferable to keep the power supply line away from the aforemen-
tioned equipment.
2-3. Installing the bobbin thread remaining amount detection sensor
(optional)
DANGER :
1. There will be a risk of vision impairment if laser light directly enters the eye. Do not look into the
laser output port.
2. Never attach/remove the sensor unit with the power remained ON. In addition, do not use the
sensor for any purpose other than for detecting the bobbin thread remaining amount.
Temporarily secure bobbin thread remaining
amount detection sensor unit ❶to base ❷with
supplied screws ❸.
Specications of the bobbin thread remaining
amount detection sensor
Class 2 sensor product
Maximum output : 1mW
Wave length : 655 nm (red)
Safety standards
JIS / IEC60825-1 2014
For details, refer to the "Retrot Instructions for the AW-3SB" in the case of installing the AW-3S to the
AMS-221EN or "Retrot Instructions for the AW-3SC" in the case of installing it to the AMS-224EN.
❶❸ ❷

– 5 –
3. OPERATION PROCEDURE
3-1. Opening/closing the cover door
It is necessary to open front cover door ❶in order to set up the bobbin thread. When you want to open
front cover door ❶, open it while pushing both snaps ❷in the direction of the arrow simultaneously
with both hands.
Be sure to close cover door ❶ for the sake of safety whenever you carry out sewing.
WARNING :
Turn OFF the power before starting the work so as to prevent accidents caused by abrupt start of
the sewing machine.
❷ ❶

– 6 –
3-2. How to thread the device with the bobbin thread
In order to accurately measure the length of thread from the bobbin thread cone ❶to be wound on a
bobbin, guide the thread from the bobbin thread cone ❶through the bobbin thread feeding unit and
draw the thread out from the nozzle as illustrated in the gure.
Install the spool holder disk to the lowest possible position. If it is installed at a high position, an exces-
sive tension will be applied to the thread drawn from the bobbin thread cone ❶, causing a trouble.
1) Insert the power plug to a receptacle and turn ON the power to the device. Press . Wait until
initialization operation of the device is completed. (Approx. 10 seconds)
2) Pass the thread drawn from bobbin thread cone ❶through thread tension controller ❷.
3) Wind the thread on thread length measuring roller ❸by one layer.
4) Pass the thread through thread guide ❻by way of tension controllers ❹and ❺.
It should be noted that the tube extending between thread tension controllers ❹and ❺is intended
to prevent thread from tangling on the shaft of the respective thread tension controllers. Pass the
thread through the space inside the curved part of tube ❾.
5) Pass the thread through the hole in the tip of thread feed arm ❼.
6) When the data input screen is displayed
on the operation panel, press A.
When the AW operation screen is dis-
played, press B.
<Data input screen> <AW operation screen>
B
A
Be aware that the thread feed arm
❼ may operate when B is
pressed.
❶
❽
❼
❷
❸
❺
❻
❹
❾

– 7 –
When the thread is put in thread path tube ❽,
it is sucked. Put the thread in the tube, while
pulling the thread from the bobbin thread
cone, until the length of thread coming out of
the tip of nozzle 󱢳becomes approximately
13 cm. If the thread stops halfway, pull it back
slightly several times.
At this time, the bobbin winder nozzle is at
its advanced position. In this state, adjust the
length of thread while observing the scale on
label 󱢴as a guide.
󱢴
󱢳
7) Suction is stopped by pressing B
again.
Basically, adjustment of the thread ten-
sion controlled by the thread tension
controller is not required.
It should be noted, however, that you
need to re-adjust the tension setting of
the thread tension controller whenever
you replace the bobbin thread with a
larger-count thread.
Adjust the tension setting of the thread
tension controller to 300 to 350 gf.
Tension gauge
Thread
[How to thread the sewing machine head in the case a thread winding error occurs when non-
slip thread is used]
Thread tension
controllers ❹
Thread tension
controllers ❺
Do not thread thread tension controller ❹.

– 8 –
3-3. How to set a bobbin
This device uses two bobbin cases each of which is tted with a bobbin.
(1) How to t a bobbin in the bobbin case
2) Fit a bobbin in the bobbin case so that clutch
holes ❷(at two locations) of bobbin are
brought to the open side.
Before tting a bobbin in the bobbin
case, wipe the bobbin case to remove
oil and dust. In particular, wipe the
shaft section of bobbin case to remove
oil and dust. In addition, blow out, with
an air gun, oil and dust gathering under
the bobbin idling prevention spring in
the bobbin case.
❷
1) Put a drop of oil No. 2 in the bobbin case
before placing bobbin ❶in it.
❶

– 9 –
(2) How to load a bobbin in the device
Load the bobbin case tted with a bobbin, as
described in (1), in bobbin setting section ❺of the
device.
Load the bobbin case tted with a bobbin while
putting your hand from under the right side of the
cover located this side of the device.
Set the bobbin case in such a way that its opening
section ❸aligns with lock member ❹.
Place the bobbin case in the device with the claw
of bobbin case raised. Push the bobbin case in
the device fully until it will go no further.
If the bobbin case is not correctly placed in the bobbin setting section ❺ of the device, an
error such that the gripper fails to catch the bobbin case can occur.
If the bobbin case is not correctly placed in the device, the bobbin case can drop from the
device without raising its claw.
Keeping the bobbin case lever held opened widely with your ngers, insert the bobbin
case into the hook as far as it will go. If the lever is not opened widely enough, the bobbin
may interfere with the claw part of the hook to prevent the bobbin case from being inserted
to its locking position. If the bobbin case is not correctly inserted in the hook, it may drop
during sewing to cause needle breakage or bobbin case breakage.
❹
❺
❸
In order to set the bobbin case in the hook section without fail, do not carry out attach-
ment, removal or setting of the bobbin case directly by hand but place the bobbin case
rstly on the standby position.
After you have set the bobbin case in the device, make sure that the bobbin case has not
dropped from the device.
Interference The state that the bobbin case is correctly
placed in the hook
Lever is not
opened su󰀩ciently

– 10 –
(3) How to remove/set the bobbin from/in the hook section
< Data input screen >
<AW operation screen>
1) Turn the power ON.
2) When you press Aon the data input screen, the AW
operation screen is displayed.
When you want to take out the bobbin that is placed in
the hook, be sure to rstly press B to carry the
bobbin from the hook to the bobbin setting section.
Then, take out the bobbin from the bobbin setting sec-
tion. If you directly remove the bobbin from the hook,
the sewing machine may run with no bobbin placed in
the hook.
B
❷
3) Take out the bobbin from bobbin setting sec-
tion ❷by hand.
4) When you press Bbutton on the AW operation screen,
the bobbin placed in the device (or in the hook) is carried to
the bobbin setting section ❷.
5) Take out the bobbin from bobbin setting section ❷by hand.
A

– 11 –
<Bobbin check screen>
C
D
6) Place the rst bobbin in bobbin setting section ❷by hand.
・ In the case of an empty bobbin, press C .
・ In the case of a bobbin that has already been wound with
thread, press A rstly, then press D.
The bobbin is carried to the hook.
7) Subsequently, place the second bobbin in bobbin setting sec-
tion ❷.
・ As with step 6), press Cin the case of an empty
bobbin.
・ Press Din the case of a bobbin that has already
been wound with thread.
8) Press Eto return the screen to the data input screen.
If one of the bobbins placed in the bobbin setting section is an
empty bobbin, the device will wind thread on the bobbin. After the
device completes winding of the bobbin, it will enter the standby
state in preparation for bobbin replacement.
3-4. Length of remaining thread to be removed
During the remaining-thread removal operation,
bobbin clutch holes ❶turn as the bobbin rotates.
The device recognizes that the remaining thread
is being removed by detecting turning of the bob-
bin clutch holes ❶.
The maximum length of remaining
thread that can be removed in 8 m.
Be aware that a remaining-thread re-
moval error may occur if the bobbin is
wound with thread to such an extent
that the bobbin clutch holes ❶ are
hidden by the thread. If the length of
thread remaining on the bobbin ex-
ceeds 8 m, it is necessary to remove
the thread from the bobbin by hand.
❶
E

– 12 –
3-5. Device operation lamp
Lamp ❶mounted next to the power switch indi-
cates that the device is in operation.
Lamp status Meaning
Light up (ON state) Indicates that the device is in operation. While the lamp lights up, the device is en-
gaged in removal of remaining thread from the bobbin or winding of a bobbin. Do not
turn the power OFF unless there is an emergency.
Light o󰀨 (OFF state) Indicates that the device is in the standby state. Make sure that the lamp has gone out
before turning the power OFF.
1. In the case the power is turned OFF while the lamp is in the ON state intentionally or
unintentionally due to power failure or the like, it is necessary to remove the cover to
check whether or not the device is tangled with thread. ( Refer to "3-1. Opening/closing
the cover door" p.5.)
2. If the device is tangled with thread, remove the thread and draw out thread from the
bobbin winder nozzle by approximately 13 cm. Then, attach the cover back. ( Refer to "3-
2. How to thread the device with the bobbin thread" p.6.)
❶

– 13 –
3-6. To use the AW-3
When using the AW-3, the memory switch (level 2) " " (AW-3 enable/disable setting) must be set
to "enable".
No. Description Initial value
Enabled Disabled
Disabled (AW-3 is not installed)
Disabled (AW-3 is installed/with communication) *
Disabled (AW-3 is installed/no communication) *
* Select when the AW-3 is installed but not operated.
If the memory switch is set to "With communication", the version of AW-3 software can be
conrmed and rewritten.
When the memory switch is initialized, the AW-3 is disabled. Re-set the memory switch
" " to "enable".
[ How to change the memory switch (level 2) ]
(1) Displaying the memory switch data (level 2) list screen
<Mode changeover screen>
B
When switch is held pressed by approximately six seconds, Ais displayed on the up-
per section of screen.
When Ais pressed to display next page on the screen, memory switch (level 2) Bis
displayed. When the button of Bis pressed, the memory switch (level 2) list screen is dis-
played.
A
<Mode changeover screen>

– 14 –
3-7. Behavior of the AW-3 device when the power is turned ON
The AW-3 device operates when the power is turned ON, on the assumption that bobbins
wound with thread are loaded in the hook and in the bobbin setting section. If the power to
the device is turned ON in other situation, it is necessary to operate the AW-3 to load the
bobbins. (Refer to "3-9. Basic operation and setting" p.16 for details.)
When or is pressed after the power is turned ON, the AW-3 carries out its initialization op-
eration if it is operated for the rst time.
<Memory switch data
(level 2) list screen>
Press Cto select data item Dyou want to
change.
For the memory switch data (level 2) other than " " ,
refer to the Engineer's Manual.
(2) Selecting the button of memory switch to be changed
DC

– 15 –
No. Item Setting
range
Editing
unit
Initial val-
ue
U166 Thread consumption margin 0 to 25 111
U167 Selection of enable/disable of ignorance
of remaining thread removal error
(0: Enable, 1: Disable)
0 to 1 1 0
U168 Insu󰀩cient remaining bobbin thread
amount determination timing
(0: For each thread trimming, 1: For
each pattern)
0 to 1 1 0
U169 Remaining amount detection angle 0 to 3 1 3
U170 Remaining amount threshold 0 to 1023 1 0
U171 Remaining thread length at thread
breakage detection
0 to 50 1 0
U172 Sensor value correction -200 to
200
1 0
K200 Selection of enable/disable of optional AW device
--- ---
Disable Enable Communi-
cation only
Neither operation
nor communica-
tion
Disable
K201 Selection of enable/disable of AW device operation at
power-ON
--- ---
Disable Enable Disable
3-8. Memory switch data list

– 16 –
3-9. Basic operation and setting
The AMS-221EN or AMS-224EN is provided with the independent operation function for carrying out
setup of the AW-3S and the setting function related to automatic bobbin changing.
Open up the AW operation screen for carrying out the independent operation, or the AW setting screen
for carrying out setting.
* The AW operation screen can be opened up from the data input screen or sewing screen.
The AW setting screen can be opened up from the data input screen.
A
B
Button and
display Description
A
The AW operation screen is opened up.
On the AW operation screen, setup of the AW such as loading/changing of bobbins
can be carried out.
B
The AW setting screen is opened up.
On the AW setting screen, setting of data related to the automatic bobbin changing
such as the bobbin-thread winding quantity can be carried out.
<Data input screen>
A
<Sewing screen>
While the AW3 is in operation and while the sewing machine is running (engaged in sew-
ing), there will be no response if you press AW operation button A. (Button opera-
tion is disabled.)

– 17 –
A
3-10. Operating the AW
When Ais pressed on the data input screen, the AW opera-
tion screen is displayed.
At this time, the bobbin check screen is displayed when no bobbin
is loaded in the device, or the error screen is displayed when an
AW error has occurred. On these screens, the error will be reset by
completing loading of a bobbin.
The AW operation screen is displayed after resetting the error.
Ⓐ Ⓑ
Ⓒ
Ⓔ
Ⓓ
BWhen one of the following buttons is pressed on the AW operation
screen, the corresponding independent operation of AW can be
carried out.
Press Bto close the screen.
Ⓐ: Bobbin change button
Ⓑ: Bobbin take-out button
Ⓒ: Empty bobbin loading button
Ⓓ: Threaded bobbin loading button
Ⓔ: Nozzle air button
Detailed explanation will be given from the next page.
<Data input screen>
<AW operation screen>
Be aware that an error can be caused if the bobbin in
hook ❶ is directly changed, etc. by hand without oper-
ating the AW operation screen after turning the power
ON.

– 18 –
Ⓐ: Bobbin change button
This button is used for winding a bobbin with new
thread in the case of changing the thread, etc.
When Ⓐ is pressed, the bobbin tted in
hook ❶is replaced by another bobbin which is
present at bobbin case standby position ❷. Then,
the thread remaining on the bobbin in hook ❶is
removed and new thread is wound on the empty
bobbin.
Ⓑ: Bobbin take-out button
This button is used for taking out the bobbin load-
ed in hook ❶. Take out the bobbin that is pres-
ent at bobbin case standby position ❷by hand
before pressing Ⓑ. Then, when Ⓑis
pressed, the bobbin loaded in hook ❶is brought
to bobbin case standby position ❷.
Place an empty bobbin at bobbin case standby position ❷and press Ⓒ.
• If no bobbin is present in hook ❶, the empty bobbin placed as described above will be brought
to hook ❶. Then, the device waits until the display is restored to the previous one and the next
bobbin is placed. The device starts winding a bobbin when Ⓒor Ⓓis pressed after
placing the next bobbin in the hook ❶.
• If a bobbin is already present in hook ❶, the device will start winding of the bobbin.
Be sure to check that the bobbin to be loaded in the hook ❶ is empty before pressing
Ⓒ. If a threaded bobbin is loaded in the hook ❶, a malfunction can occur when
winding the bobbin or removing the thread remaining on the bobbin.
Ⓒ: Empty bobbin loading button
This button is used for loading an empty bobbin in the hook ❶.
❶
❷