Mitsubishi Electric MP-J25-AD User manual

INDUSTRIAL SEWING MACHINE
Attachment
MODEL
MP-J25-AD
TECHNICAL MANUAL
Abnormal Stitch Detector
A180E839P01

FOR SAFE USE
Before the installation, operation, and inspection for this product, read the “FOR SAFE USE” and the
technical manuals carefully. Also read the other technical manuals, “Sewing Machine Head”, “Control
Unit” and “Operation Panel” describing some instructions, which are not in this manual, and use the
sewing machine properly.
SAFETY INDICATIONS
CAUTION
Indicates that incorrect handling may cause hazardous conditions, resulting
in medium or slight personal injury or physical damage. Note that CAUTION
level may lead to a serious consequence according to the circumstances.
Always follow the instructions of both levels because they are important to
personal safety.
CAUTION INDICATIONS
No.
Caution indication
Description
1
Precaution for sewing machine operation:
Indicates that removing the safety and operating the sewing
machine for some other purposes with power-on are prohibited.
Please do not operate the sewing machine without
protective equipment such as a needle guard, an eye guard,
a belt cover or the others.
Please turn off the power switch when threading, changing
a needle and a bobbin, cleaning, and lubricating.
2
Caution for fingers injury:
Indicates a possibility of fingers (hands) injury in a certain
condition.
3
Caution for squeezing fingers:
Indicates a possibility of squeezing fingers in a certain condition.
Introduction
It is not possible for this device to detect all abnormal stitch. Please use this device after reading this
technical manual a lot and being sure to adjust depend on threads and sewing materials.
Note If you use this device without adjusting, there are risk that it causes the yet to be detected
and misdetection.

- 1 -
1. Configuration
The Fig. numbers in the drawing correspond to the part numbers given in the following explanations.
When ordering service parts, please specify in the Parts No. (M********).
1-1. Abnormal stitch detector parts, Fiber amp parts
1-2. Solenoid valve parts, Accessories
119
120
121
122
125
126
127
124
123
101
102
104
2
108
2
106
105
2
107
2
103
2
(106)
(105)
109
2
111
2
110
2
112
2
113
2
114
2
115
116
117
118
7
119
120
121
122

- 2 -
1-1. Abnormal stitch detector parts, Fiber amp parts (Parts list)
Fig
部品コード
品名
Description
数量
No.
Parts No.
Amt. Req.
101
M90605010
ｻﾗﾈｼﾞ 3/32(56)X2.8
Countersunk screw
3/32(56)X2.8
2
102
MJ61A2339
ｶﾊﾞｰ
Cover
1
103
MJ61A0476
ﾍﾞｰｽｽﾍﾟｰｻ
Base spacer
1
104
MJ61A0758
ﾌﾞﾗｹｯﾄ
Bracket
1
105
M90858004
Pｻﾗﾈｼﾞ M3X6
Countersunk screw M3X6
4
106
M92000010
ｻﾗﾈｼﾞ M2.5X3
Countersunk screw M2.5X3
4
107
MJ61A0601
ﾄﾘﾂｹｲﾀ
Adapter
1
108
MJ61A0770
ﾊｲｾﾝﾍﾞｰｽ
Wiring base
1
109
MJ61A0567
ﾋﾞﾆｰﾙﾁｭｰﾌﾞ
Tube
2
110
MJ61A0757
ﾌｧｲﾊﾞﾕﾆｯﾄ
Optical fiber unit
1
111
MJ61A1770
ﾒｲﾝﾍﾞｰｽ
Main base
1
112
M92004020
ﾛｯｶｸｱﾅﾂｷﾄﾒﾈｼﾞ M2X2
Set screw M2X2
2
113
MJ61A0571
ｶﾝﾂｷﾞﾃ
Connector
1
114
MJ61A1476
ｽﾍﾟｰｻ
Spacer
2
115
MJ61A1742
ﾍﾞｰｽﾌﾀ
Base cover
1
116
MJ40A0626
ｶﾞｰﾄﾞ
Guard
1
117
MJ40A0257
ﾊｻﾐｲﾀ
Plate
1
118
M93000022
ﾛｯｶｸｱﾅﾂｷﾎﾞﾀﾝﾎﾞﾙﾄ M3X6
Button bolt M3X6
2
119
MJ61A1757
ﾌｧｲﾊﾞｱﾝﾌﾟｸﾐﾀﾃ
Optical fiber amplifier assy.
1
120
M90859004
SW-PW ﾌﾟﾗﾏｲﾅﾍﾞﾈｼﾞ M3X6
SW-PW pan screw M3X6
2
121
MJ61A0602
ﾄﾘﾂｹｶﾅｸﾞ
Holder
1
122
MJ61A1601
ｱﾝﾌﾟﾄﾘﾂｹｲﾀ
Amplifier adapter plate
1
1-2. Solenoid valve parts, Accessories (Parts list)
Fig
部品コード
品名
Description
数量
No.
Parts No.
Amt. Req.
123
MJ25D0599
ﾃﾞﾝｼﾞﾍﾞﾝｸﾐﾀﾃ
Solenoid valve
1
124
MA30A0757
ﾌﾟﾗｸﾞ
Plug
1
125
MS14A1620
ﾅｲﾛﾝｸﾘｯﾌﾟ 4N
Nylon clip 4N
1
126
MB60A2620
ﾅｲﾛﾝｸﾘｯﾌﾟ 10N
Nylon clip 10N
1
127
MF06A1620
ｹｯｿｸﾊﾞﾝﾄﾞ
Cable tie
5

- 3 -
2. Assembly procedures
2-1. Installing the Abnormal stitch detector
(1) Loosen the screw <1>, and remove the thread guide <2>.
Note Thread guide is attached to only shuttle hook type machines.
(2) Install the base spacer (Fig.No.103) and the bracket (Fig.No.104) by two screws (Fig.No.105)
to the face plate <3>.
(3) Install the Abnormal stitch detector (consist of Fig.No.117 etc.) to the bracket (Fig.No.104) by two
screws (Fig.No.106).
(4) Install the cover (Fig.No.102) to the bracket (Fig.No.104) by two screws (Fig.No.101).
<2>
<1>
★To work in the presence of residual pressure in the pneumatic circuit It is dangerous.
Please work after you remove the residual pressure always. The method of removing the
residual pressure, and pull up the handle of the pressure regulating filter regulator, can be
done by turning counter-clockwise until the pressure gauge shows 0.
★When installing removal of parts, please go to turn off the power before. In addition,
qualified personnel of electrical work, please be performed by wiring work.
★Because the fiber unit (Fig.No.110) is very thin, It may causes break it if applying strong
shock. Please handle with care.
CAUTION
103
104
105
<3>
(104)
101
102
(104)
117
106

- 4 -
2-2. Installing the Fiber amp assy
(1) Remove two screws <2> installed in back word the control box <1>,
and install the amp bracket (Fig.No.122).
(2) Install the bracket (Fig.No.121) to the amp bracket (Fig.No.122) by two screws (Fig.No.120).
(3) Catch the Fiber amp assy on lower edge of the bracket (Fig.No.121), and install it while pushing up
2-3. Setting of Connector
(1) Remove five screws <2>, and MIF board cover <1>.
(2) Pass the fiber amp assy’s connector cable
(Fig.No.119) through the side hole of MIF board
bracket <3>.
Note If it is difficult to through the connector cable,
through it after loosening two screws <5>.
While being careful not to damage cables,
close the shatter <4> and tighten two
screws<5> again.
(3) Connect the connector to CON6 (CH) on the MIF board.
(4) Attach MIF board cover <1> with Screws <2> again.
<1>
<2>
<2>
120
122
121
<1>
119
(121)
119
<3>
<5>
<4>
<6>

- 5 -
2-4. Installing Solenoid valve
(1) Pull up the adjustment handle of the Filter regulator <1> located under the table, and
Turn counterclockwise until the pressure gauge shows 0.
(2) Remove five screws <3>, and motor cover <2>.
(3) Remove two screws <6> from Solenoid valve <4>, and blanking plate assy.
Note If two or more blanking plate assy are attached, please remove any one.
(4) Install the solenoid valve through gasket with two screws as shown in the figure, where the blanking
plate assy <5> was removed (2).
Insert the plug (Fig.No.124) completely the hole on the left side of the solenoid valve.
123
124
<2>
<3>
<5>
<6>
<4>
<1>

- 6 -
(5) Unplug 15 pin connector <7> from MIF board.
(6) Pass lead wires (red and black) of the Solenoid
valve (Fig.No.123) through the UL tube <8>
which the 15 pin connector is connected.
(7) Pass lead wires of the Solenoid valve
(Fig.No.123) through the connector cap <9>.
Completely insert the lead wire (red) into 15 pin
connector 4, lead wire (black) into 5.
(8) Insert the 15 pin connector <7> into MIF board
again.
2-5. Piping
Piping two φ4 tubes (One contains a fiber unit) connected to the abnormal stitch detector installed in
[2-1] [Installing the Abnormal stitch detector].
(1) Remove seven screws <3>, head cover <1>, and cover <2>.
<7>
<3>
<1>
<2>
赤
黒
赤
黒
追加ピン
<9>
(
既
存
ピ
ン
)
<8>
コネクタ挿入面
<8>
(123)

- 7 -
(2) Pull two φ4 tubes <4> to the left through the bottom of the sewing machine arm.
(3) Remove the left screw of the wiper bracket <5> on the left side of the sewing machine.
(4) Pass two φ4 tubes <4> through the nylon clip. Fix the nylon clip (Fig.No.125) to the wiper bracket
<5> by using the screw removed in (3).
Note At this time, manually move the clamp adapter <6> to the front of the sewing machine.
Make sure that the clamp adapter and φ4 tubes <4> don’t touch each other and fix with the nylon clip.
(5) Pass two φ4 tubes from the right side of the motor <7>. Bundle it with the existing tubes using a
cable tie (Fig.No.127), and pipe it to the back of the sewing machine.
Note If the existing nylon clip is small, change the nylon clip (Fig.No.126).
(6) Insert the end of φ4 tube (One without a fiber unit)
completely into the right side of
the solenoid valve (Fig.No.123) installed earlier.
Note If φ4 tube is long, cut and insert
(7) In the reverse order of [2-4] [Installation of solenoid
valve] (1), turn the Filter regulator <1> handle
clockwise to adjust the air pressure to
0.4 MPa (4kgf/cm2) and push down the handle.
<4>
(123
)
<4>
125
<5>
<6>
<4>
<7>
<4>
126
127

- 8 -
(8) Pass the other φ4 tube <4> (One with a fiber unit
(Fig.No.110)) down through the hole in the table,
Insert the fiber unit into the Fiver amp assy (Fig.No.119)
mounted on the control box in [2-2] [Installing the Fiber amp
assy] in the following procedure.
1. Open the protective cover.
2. Raise the lock lever.
3. Insert the fiber unit completely into the fiber unit insertion slot.
4. Return the lock lever and put the protective cover.
(9) Pipe the φ4 tube passed under the table as same as other cables refer to PLK-J2516-YU/
J2516R-YU technical manual [SEWING MACHINE HEAD] [3-10-7] [Fixing of the cables]
(10) Attach the motor cover removed in [2-4] [Installation of Solenoid valve],
the head cover <1>, and the cover<2>.
3．How to use
3-1. How to thread the upper thread
Pass the upper thread through the abnormal stitch detector as shown
on the right figure. How to pass the upper thread through other parts
is different depends on the model, so confirm the technical manual
[SEWING MACHINE HEAD] of each model.
3-2. Setting of output customize
(1) Press to to (need password) on the standard screen,
open the Output Customize Setting screen.
(2) Set SKAR for output O8.
Note Please refer to the technical manual [Operation Panel] [16] [Input/output setting mode] for
details on how to setting of custom output.
3-3. Setting of Fiver amp assy
Please set up of Fiver amp assy (Fig.No.119) as follows.
When resetting, turn the power switch on.
3-3-1. Changing of output signal
Change output method to output when a workpiece is in the detection area.
(1) Press button.
(2) Change to .
119
119
110
<4>

- 9 -
3-3-2. Smart tuning [Easy sensitivity setting]
Detect for thread Presence/Absence.
(1) Thread the Abnormal stich detector (consist of Fig.No.117 etc.) attached in right side of machine arm.
(2) Press to to on the standard screen, and open the output signal
confirmation panel.
(3) Change the panel of [Status reference mode] to [Test output mode]
Note Please refer to the technical manual [Operation Panel] [16] [Input/output setting mode] for
checking detail of operation method (2), (3).
(4) On the operation panel, output the port set SKAR,
and blow air. Loosen thread as shown on the right figure,
and obstruct the sensor light<1> by thread.
In this state, press button.
Note If red value of Fiver amp assy decrease,
It is the state obstructing the sensor light.
(5) On the operation panel, Stop blowing air by cancelling output SKAR, and pull thread as shown on the
upper right figure.
Check separating thread and sensor light.
In this state, press button again.
3-3-3. Setting of threshold level
Press button and set threshold level “8000”.
3-3-4. Setting of DPC function
DPC is the function restores changing of inner incident light if changing incident light by dust, and keep
incident light display constant.
Please set up DPC function after setting 3-3-2[Smart tuning [Easy sensitivity setting]]
(1)Hold button for 3 seconds or more to enter SET mode.
(2)Press button few times to change display to “dPc oFF”.
(3)Press button to change to change display to “dPc on”.
(4)Hold button for 3 seconds or more again to finish setting.
Threshold level (green)
Incident light (red)
117
<1>
110
Air ON
Air OFF

- 10 -
3-3-5. Checking of incident light
Check incident light (refer to the figure of 3-3-3[Setting of threshold level]) value is “9999” when
separating thread and sensor light. If value decrease, set incident light to “9999” as follows.
Note If incident light value decrease, erroneous detection may occur.
1. Connect the Fiber Unit again
Please refer to 2-5 [Piping] (8), Make sure the Fiber Unit is fully inserted into the Fiber amp assy.
2. Clean the abnormal stitch detector
Clean as follows because sensor light is obstructed
by collecting the thread waste in the abnormal stitch
detector.
(1) Remove two button bolts (Fig.No.118),
the plate (Fig.No.117), the guard (Fig.No.116),
the base cover (Fig.No.115),
and two spacers (Fig.No.114).
(2) Clean inside the abnormal stitch detector
(Hatched area), and remove the thread waste.
(3) Attach spacers (Fig.No.114),
the base cover (Fig.No.115),
the guard (Fig.No.116), and the plate (Fig.No.117),
with button bolts (No.118) again.
When seeing the abnormal stitch detector from
above, attach the guard (Fig.No.116) with making
an edge of the guard (No.116) contact a protrusion
of the base cover (No.115) as shown on the right
figure.
Note If an edge of the guard doesn’t contact
a protrusion of the base cover, thread may
be off from the abnormal stitch detector.
3-4. How to use the abnormal stitch detector
When using the abnormal stitch detector, set as follows.
(1) Press to on the standard screen, and open the Program Mode panel.
(2) Press the icons to change the page, and press Traceability
(3) Set SKCF, S2CF to “ON”.
Note If you don’t use the abnormal stitch detector, set the above setting to “OF”.
118
116
115
117
114
116
115
118
114
117

- 11 -
3-5. Adjustment of the abnormal stitch detector gap
When sewing by thin thread, reduce a gap in the abnormal stitch detector by removing spacers.
Checking procedure：
(1) Press to to on the standaed screen, and open the Motor
angle・Home position Sensor・Temperature panel.
(2) Press the icon, and open the Motor angle・Home position Sensor・Temperature panel 2.
(3) In this state, start sewing, and can check
thread obstructing sensor light if “SENSOR
INPUT” CH repeats ON/OFF.
Adjustment of a gap procedure
(1) Remove two button bolts (Fig.No.118), the plate (Fig.No.117), the guard (Fig.No.116),
and the base cover (Fig.No.115).
(2) Remove two spacers (Fig.No.114), and attach the base cover (Fig.No.115), the guard (Fig.No.116),
the plate (Fig.No.117) with button bolts (Fig.No.118) again.
Note When attaching the guard, pay attention to installation position by referring to [3-3-5,2] [Clean the
abnormal stitch detector].
Note After adjusting a gap, be sure to check that sensor amp unit receive the light normally by doing
[3-3-2] [Smart tuning [Easy sensitivity setting]], [3-3-3] [Setting of threshold level], [3-3-5] [Checking of
incident light] again.
118
116
117
115
114

- 12 -
3-6. Setting of the abnormal stitch detection function
Please refer to the technical manual [Operation Panel] [22] [Program mode list] 23[Traceability] for
checking detail of the abnormal stitch detection function.
3-6-1. Setting change example of the abnormal stitch detection1
When changing setting of the abnormal stitch detector1, refer to the following example.
Open the Traceability in the Program Mode refer to [3-4] [How to use the abnormal stitch detector].
(1) In the case of erroneous detection occurring without occurring the abnormal stitch.
->Adjust that erroneous detection doesn’t occur by increasing set value of SKCS little by little.
Note If it is difficult to adjust, use test output of the abnormal stitch detection SKTS.
Checking procedure:
1. Press to to (need password) on the standard screen,
open the Output Customize Setting screen.
2. Set output signal is not used to SKTS.
Note Please refer to the technical manual [Operation Panel] [16][Input/output
setting mode] for checking detail of operation 1,2.
3. Connect output terminal is set in 2 to the outside lamp.
-> It is possible to substitute for outside lamp by changing Halt signal being on
output SSW to SKTS.
4. In this state, Sew while working the abnormal stitch detector.
And adjust that lamp doesn’t light while standard sewing by increasing set value of
SKCS little by little.
(2) In the case of not detecting when the abnormal stitch occur.
-> Adjust that erroneous detection doesn’t occur while standard sewing by decreasing set value of
SKCS little by little.
(3) If you want not to detect while sewing at less than 1,000rpm.
-> Change set value of SKSP to “1000”.
(4) If you want not to detect from start sewing to 6 stitches latter, and from end sewing to 8 stitches former.
-> Change set value of SKN1 to “6” and SKN3 to “8”.
(5) If you want to change sewing stop timing by the abnormal stitch detector to when stop upper shaft next
time.
-> Change set value of SKTP to “ED”.
3-6-2. Setting change example of the abnormal stitch detection2
When changing setting of the abnormal stitch detector2, refer to the following example.
Note It is mentioned only about explanation different from the abnormal stitch detection1.
Open the Traceability refer to [3-5] [Adjustment of the abnormal stitch detector gap].
(1) Change set value of S2CE to the same value as SKCS set at “3-6-1(1), (2).
(2) In the case of erroneous detection occurring without occurring the abnormal stitch.
-> Adjust that erroneous detection doesn’t occur by increasing set value of S2FL little by little.

Printed in Japan