Pegasus W500 Series User manual

AI
Device
Thank you for purchasing Pegasus' labor saving device.
Study this manual very carefully before beginning any
of the procedures and then use the device correctly and
safely.
Keep this manual in a convenient place for quick refer-
ence when needed.
Automatic differential feed amount switching
device
INSTRUCTIONS
W500 Series
Models: AI 100
AI 110

1.Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2.Indications of dangers, warnings & cautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
3.Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
4.Notes for each procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Applications and performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Installing the AI device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
Installing the console box and the power box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Description of power box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Replacing the fuse for the power box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Connecting cords . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Description of AI console box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Adjusting the sensitivity of sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Before entry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Programming the sewing mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Function selecting mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-20
To change and/or enter sewing data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-24
Change of Item number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Programming sewing data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-24
To enter data during sewing (Teaching) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25-27
Testing mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
AI Trouble shooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29-30

Indicates an immediate hazard to life or limb.
Indicates a potential hazard to life or limb.
Indicates a possible mistake that could result in injury or damage.
DANGER
WARNING
CAUTION
1.Introduction@@@@@@@@@@@@@@
●This manual describes the instructions for using this device safely.
●Study this manual very carefully and understand fully how to operate, check, adjust and maintain the labor
saving device before beginning any of the procedures.
●You always perform operations close to moving parts such as needles when using industrial sewing machines.
Therefore you have to keep in mind you could easily touch them. To prevent accidents, it is essential that you
use the safe products supplied by Pegasus correctly.
All the people who will use sewing machines must study this manual and the instruction manual for sewing
machines very carefully and then take necessary safety measures before beginning any of the procedures.
2. Indications of dangers, warnings and cautions @
To prevent accidents, indications (symbols and/or signs) which show the degree of danger are used on our
products and in this manual. Study the contents very carefully and follow the instructions.
Indication labels should be found easily.
Attach new labels when they are stained or removed.
Contact our sales office when new labels are needed.

Be sure to follow the instructions when you operate the machine and/or labor saving device.
If you use the machine and/or labor saving device incorrectly, you may get an electrical shock.
If you use the machine and/or labor saving device incorrectly, your hands and/or fingers may
be injured.
If you use the machine and/or labor saving device incorrectly, you may cause fire.
Never do this.
Unplug the machine or shut off the power when checking, adjusting and/or repairing the
machine and/or labor saving device, or when lightning may strike.
Be sure to ground the machine and labor saving device securely.
If you use the machine and/or labor saving device incorrectly, your fingers and/or hands
may be caught in them or it, causing trouble.
Indicates a danger of burn injury due to high temperature.
3.Safety precautions
①Applications, purpose
The labor saving device is designed to increase quality and
productivity according to you needs.
Therefore never use the device for the applications which may
defeat the above purpose.
②Circumstances
Some circumstances when you are using the labor saving device
may affect its life, function, performance, and safety.
For safety, do not use the labor saving device under the
circumstances below.
1.Do not use the device near objects which make noise such as a
high-frequency welder, etc.
2.Do not use or store the device in the air which has vapor from
chemicals, or do not expose the device to chemicals.
3.Do not leave the device outside, in high temperatures or the
direct sun.
4.Do not use the device in high humidity or ambient temperatures
which may affect them.
5.Do not use the device on the condition that the voltage fluctua-
tion range is more than ±10% of the rated voltage.
6.Do not use the device at the place where the supply voltage
specified for the control motor cannot be properly obtained.
7.Do not use the device at the place where the air supply specified
for the device cannot be properly obtained.
8.Do not expose the device to the water.

③Safety measures
(1)Safety precautions when you perform maintenance on
the labor saving device.
●When performing maintenance such as when checking, repairing,
cleaning the labor saving device, turn off the power, disconnect
the power plug from the outlet and press the machine treadle in
order to make sure the machine does not run.
If you have to perform maintenance on the machine and/or labor
saving device with the power on, always be careful because the
machine and/or device could start operating unexpectedly.
To prevent accidents caused by incorrect operation, you should
establish your own procedures for safe operation and follow
them.
●Only well-trained people should perform routine daily
maintenance and/or repair the machine and/or device.
●Do not modify the machine and device yourself.
※Consult you local Pegasus' sales office or representative for
modification.
(2)Before operating the device
●Before operating the device, check the machine head, machine
unit and device to make sure they do not have any damage
and/or defects.
Repair or replace any defective parts immediately.
●To prevent accidents, always make sure the safety covers and
safety guards are properly secured.
Never remove the safety covers and safety guards.
(3)Training
●To prevent accidents, operators and service/maintenance
personnel should have proper knowledge and skills for safe
operation.
To ensure so, managers must design and conduct training for
these people.
4.Notes for each procedure
CAUTION
CAUTION
①Unpacking
The machine and device are packed in boxes (and plastic bags) in
the factory before shipment. Unpack the boxes and bags properly
and sequentially by following the instructions shown on them.
②Installation, preparation
CAUTION
CAUTION
Connecting the air lines
1.Always turn off the power first and then connect the air lines to
the joints. Be sure to connect all the air lines before connecting
them to the air source.
2.When connecting the air lines to the joints, be sure to insert the
joints to the proper depth of the air lines and fasten securely.
3.Do not allow excessive force to be exerted on the air lines while
using the device.
4. Do not bend the air lines too much.
5.If necessary, protect the air lines by positioning them safely
and/or using the cover.
6. Do not use staples to secure the air lines. Otherwise it may
cause damage.
W
WARNING ARNING
Connecting the cords
1. When connecting the power cord, be sure to turn off the
power and disconnect the power plug from the outlet.
2. Check the voltage designation to make sure the power
relay cord matches the local supply voltage. The use of wrong
cord may cause damage to parts and/or fire.
3.Do not allow excessive force to be exerted on the cords while
using the device.
4. Do not bend the cords too much.