Porter PALS 4000 Instruction Manual

[;ffl[ffll ®
Catalog# PALS 4000 8/96
INTERNATIO N AL
P ALS 4000 & 500 0
Auton.1.atic Labe l Sewers
1
Porter International• 97 Rantoul Street• Beverly, MA 01915 • [phone] • [phone] • FAX [phone]

From the library of Superior Sewing Machine & Supply LLC - www.supsew.com
PALS 4000 & 5000
Automatic
Label
Sewers
CONTENTS
Instructions
I.
Unpacking and Check
of
Contents
.................................
.4
1.1
Cautions
at
Unpacking . . . . . . . . . . . . . . . . . . . . . . . . • . . . . . . . . . ••
...
.4
1.2
Confirmation
of
Contents
. . . . . . .
....
.•..
...
..
....................
.4
1.3
Please
Check
following Points Before Starting
the
Operation
..............
.4
2.
Construction
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.....
S
3
Features
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.....................
6
4.
Specifications
....................................•...............
7
4.1
General Specifications . . . . . .
...
...............
.
...................
.7
5.
Installation
................................................
.
....
I0
5.1
Securing
the
Sewing Machine Table . . . . . . . . . . . . . . . . . . . . . . . • . . • ,
...
I0
5.2 Securing
the
Cotton
Stand . . . .
......
....
...
..•...
................
I0
5.3 Connecting
the
AirTube
..
, . •••
...................................
I I
5.4
Wire
Connections
............................................
.
...
12
5.5 Power
Cord
for
Work
Lamp . . . . . . . . . . . . . . . . . • . • . . . . . . . .
...
...
13
5.6 Connecting
the
Power Cable
...
, . . . . . . . • . . . . •. . •
................
13
5.7 Changing
the
Direction
of
the
Motor
Rotation
.........................
14
6.
Checkpoints
for
Operation
........................................
I5
7.
Handling
the
Sewing Machine
Head
............
.
..................
.
17
7.1
Turning
the
Arm Shaft Driving Pulley . . . . . • . . . . . . . . . .
.................
17
7.2 Lubrication . • •, . . . . . . . • .
.•
....................................
17
7.3 Installing
the
Needle
..........................................
.
....
18
7.4 Threading
the
NeedleThread . . . . . . . . . . . . . . . . . . . •. . . . . . . . .
......
.
19
7.5 Winding
the
Bobbin Thread . • . . . . . . . . • • .
...
•.•..
.................
20
7.6 Installing
the
Bobbin . . . . • .
...
.....................................
21
7.7 Installing
the
Bobbin Case
..........................................
21
7.8 Removing
the
Inner
Hook
. . . . . . . . . . . . . . . . . . . . . . . •. . . . . . •• . . •
.....
21
7.9 ThreadTension
....................
•.
....
.•...
.....
•••.
.........
22
7.10 Adjusting
the
Work
Holder •. . . . . . . . . .
...........................
23
7.1
I Adjusting
the
Presser
Foot
.........................................
24
7.12 Replacing
the
Lower Clamp Frame . . . . . . . . . . . . . . . . . . . . . . •. . . .
....
25
7.13 Lubrication with Silicon Oil . . . . . . . . . . . •. . . . • • •
......
.
............
25
7.14 Air Piping
to
Cylinders for
Work
Holder,
Presser
Foot
...................
25
8.
Adjustment
and
Maintenance
.....................................
26
8.1
Adjusting
the
Bobbin
Winder
. . . . . . . . . . . . . . . . . . . . . . . . . . . • • ,
.......
26
8.2 Adjusting
the
Height
of
the
Needle Bar . . . . . • . . • . . . . . . . • . •
..
.......
26
8.3 Adjusting
the
Driver and
Hook
. . . . . • . •
............
.
...............
27
8.4 Adjusting
the
Thread Guide
........................................
28
8.5 Adjusting
the
Presser
Foot
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
•••
......
, .29
8.6 Adjusting
the
Home
Position
.......
.
..
....
...•
,
.....
, . • . . .
......
. .3 I
8.7 Maintaining and Inspecting
the
X-YTable .
....
..•
......................
34
8.8 Adjusting
the
X-Y Table BeltTension
.................................
36
8.9 Adjusting
the
Synchronizer
..........................
..•..
,
.......
• .38
8.10 Adjusting
the
ThreadTrimmer . . . . . . . . . . . . . . .
.....
.......
......
..
.40
8.1
I Adjusting
the
TrimmerThread
Tail
Length • . . . . . • .
....................
.43
8.12 Adjusting
the
Thread Release
....
..•.
..............................
.44
8.13 Adjusting
the
Stroke
of
the
Take-up Spring
...............
.
....
.
.....
.•
.45
8.14 Adjusting
the
LIMI-STOP
Z
Motor
Belt
......
. ,
..
.....
.•
, . .
.......
.•
.45
Porter
International•
97
Rantoul
Street•
Beverly,
MA
OJ
915

From the library of Superior Sewing Machine & Supply LLC - www.supsew.com
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CONTENTS
Parts
ARM
BED
&
ITS
ACCESSORIES
(I)
. . • . • • . . . . • . • .
..•.....•...•....•....
.46
SEWING
MECHANISM
..............................................
.48
THREAD
TRIMMING
MECHANISM
•.•.....••..••...•.•••.....•.•....••
.49
NEEDLE
BAR
MECHANISM
. . . •. . . • • . •. . . . •. . . • . . . •• • . . • • • • . • . • . • . . .50
PRESSER
BAR
LIFTING
MECHANISM
..•.......•...•.....•....•.•.•.••..
52
X-YTABLE
MECHANISM
(I)
......•...•.•........•...•.....•.....•.•....
54
X-YTABLE
MECHANISM
(II).
.
.•..••..•..••...•..•....•...••..•.••••.•
55
WORK
HOLDER
MECHANISM
• • . . . • •
..•...••.•...••.•.
.
•.•.•.•......
56
WIPER
&
DETECTOR
MECHANISM
. • . • . • . . . . .
.•..•.....••..•.•...•...
57
OIL
LUBRICATION
MECHANISM
..•••••...•.•..•......••...•...•...••.
58
CONTROL BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.........
.59
PNEUMATIC
CONTROL
UNIT
.•...•.....•......•.•.•...•••••.••.•..•.•
60
TABLE
&
STAND
. . . . . . . . . . . . . . . . .
..................................
.
61
ACCESSORIES
.............................................
.
........
.62
ORDERING
INFORMATION
......••..•...•......•..•......•...•.•....•
63
Telephone [phone]
or
508-922-2611 •Fax [phone]

From the library of Superior Sewing Machine & Supply LLC - www.supsew.com
4 PALS 4000
&
5000
Automatic
Label
Sewers
1. Unpacking and Check
of
Content
Before unpacking the content, please read carefully following cautions in order to conduct the
preparation for operation effectively and satisfactorily.
1.1
Cautions at Unpacking
Fig. 1.1
(1)
Since the machine head is heavy, pay attention when carrying.
(2)
Use a crane or a fork lift truck to carry the sewing machine table.
• When carrying with a fork
lift
truck, be sure
to
place the sewing machine table on a pallet.
Sufficient care should be taken not to drop the table from the pallet during carrying.
(3)
In order to prevent unexpected deform or damage, please be sure not to hold such
vulnerable section as the slide plate, Motor cover, Table top, Detector, etc.
Otherwise,
it
may cause accident by falling, etc.
-----
. ,- ~
--
..
-~-•~-Motor
cover
I
-
/;
SJido
p/alo
(L)N
,
Al,
Table top
Slide plate
(M)
/
I
I
---=----=---=---=---:.....--
--
------
~--
---
I/
Packing attitude
~
_y
1.2 Confirmation of Content
Slide plate
(R)
First of
all,
please refer to the attached parts list (List of component parts) to confirm the standard
composition of the product.
If
you need any optional accessories, please place orders consulting
with the parts catalogue.
1.3 Please Check Following Points before Starting the Operation.
(1)
Check if the power supply
is
adequate to operate the machine.
(2)
The needle must be set such that it comes down
at
the center of presser foot.
(3)
LIMI-STOP
Z motor must turn
in
the direction as specified. (Refer to section 5.
5.)
Porter
International•
97Rantoul Street• Beverly,
MA
01915

From the library of Superior Sewing Machine & Supply LLC - www.supsew.com
PALS 4000 & 5000 Automatic
Label
Sewers 5
2. Construction
Machine Head
Control
Panel
Work
Holder
Telephone [phone]
or
S08-922-2611 •
Fax
617-599-7081

From the library of Superior Sewing Machine & Supply LLC - www.supsew.com
6 PALS 4000 & 5000
Automatic
Label
Sewers
3.
Features
1. Increased Productivity
• High speed sewing.
Increased speed at large stitch length.
• Large-sized shuttle hook.
The adoption
of
a large-sized shuttle hook (1.8 times larger than the size featured
in the
PALS
3000)
makes
it
possible
to
drastically reduce the frequency with which
the bobbin thread
is
replaced, and
it
enhances the
work
efficiency
as
well.
• Wide variety
of
needles and patterns
Up
to
1
50
patterns featuring the data
for
8000
stitches
per
pattern
can
be stored
on a single floppy disk
to
meet the requirements
of
fancy stitching
or
embroidery
involving a large number
of
stitches.
2.
Increased sewing
area
(15.75
X 11.81)
3.
Optional clamping configuration
(Pins
vs.
Saw
Tooth)
4.
Improved
operator
loading access
to
allow
better
material handling
5.
Less
dependency
on special skills
or
training
• Simple input and operation thanks
to
interactive system.
The
LCD
(liquid crystal display) vastly simplifies the preparation
of
the sewing
patterns and the preparations made
for
operation, and
it
also displays operating
errors in the form
of
messages. The teaching playback type
of
input makes
it
possible
to
create sewing patterns which match the clamp frame.
•
Easy
maintenance.
The full line-up
of
troubleshooting functions make the pinpointing
of
trouble and
its display on the
LCD
an
easy task.
• Adding/subtracting counters provided
as
a standard feature.
The subtracting counter sounds a buzzer when the bobbin thread should be replaced.
The adding counter makes
it
possible
to
verify the output.
6.
Attractive seams
and
stitching
• Stable feed system.
The fabric feed mechanism features both a travel system which uses races and
backlash-free timing belts.
It
enables reliable intermittent feed drive and produces
clear,
well-defined seams and stitches.
• Resolution in 0.1
mm
units.
By
bringing the resolution
of
the fabric feed mechanism accurately down
to
a
0.1
mm
pitch
it
is
now
possible
to
sew smoothly and precisely.
• Maximum stitch length
of
12.7mm.
The variable stitch length accommodates everything from delicate stitches such
as
embroidery
to
large-pitch sewing
of
such articles
as
container bags.
• Home position return function.
As
the stitching
of
one pattern
is
completed, the
work
holder returns
to
the
home position
so
there
is
no accumulation
of
mechanical displacement.
• Cloth feed
can
be adjusted in 3 levels depending on the thickness
of
cloth.
Further, the cloth feed
can
be adjusted in 2 levels in adaptation
to
the weight
of
work holder such
as
the attachment, etc.
Porter
International
•97RantoulStreet •Beverly,
MA
O1915

From the library of Superior Sewing Machine & Supply LLC - www.supsew.com
PALS 4000 &5000
Automatic
Label
Sewers 1
4.
Specifications
4.1
General Specifications
(1)
Specifications
of
mechanisms
(Figures
In
( )
Indicate
PALS
5000)
Item
Specification
Type of stitching Single-needle lockstitch
*
Needle
bar
stroke
41.2
mm
Take-up lever stroke
68
mm
Needle
135x17
#22
Wiper Lengthwise thread wiping drive
(With wiper release switch)
Work
holder lift
70mm
Tilting
*
Presser
foot
&
needle
lift
38mm
Presser foot stroke 4 to 10 mm
Hook Large-sized shuttle hook
Bobbin case With slip prevention spring
Bobbin
Aluminum bobbin for large-sized hook
Thread trimmer Combination of fixed knife and movable knife
(Plane scissoring)
Lubrication system Manual oiling and replenishment with oil braid (Tank type)
Oil used White spindle oil No.2
Sewing area
350
[400]
mm(15.75
STD)
in
X
direction
300mm
in
Y
direction
(
11.812
STD)
Speed setting 200 to 2000 spm, 10 levels selectable
Max.
sewing speed 2000 stitch/min. (for feed length of less than 2.0 mm)
Stitch length
0.1
to 12.7 mm
Dimensions 1535(W)
x
1430(L)
x
121
0(H) mm
{Excluding cotton stand)
Wefght 470 kgf (Total weight including head, table)
*
Patent
Pending
Telephone [phone]
or
508-922-2611 •Fax [phone]

From the library of Superior Sewing Machine & Supply LLC - www.supsew.com
8 PALS 4000 &5000
Automatic
Label
Sewers
(2)
Specifications of control
unit
(Figures
In
( ) indicate
PALS
5000 )
Item Specification
Control system All-electronic control system with microcomputer
Sewing area
350X300
(400X300)
mm
Pattern storage medium 3.5-inch floppy disks and
P-ROM
(option)
Number of programs stored 150 patterns
Number of stitches stored 360000 stitches
Number of stitches per 8000 stitches
pattern
Length of stitch
0.1
to
12.
7 mm (resolution:
0.1
mm)
Speed setting 200 to 2000 stitch/min.
1
a levels selectable
Enlargement/reduction 10 to
200%
in
0.1
% steps
Mechanical home position Set by optical sensor, insulator
Mechanical home position
0.1
to
12.
7
mm,
adjustable in
0.1
mm units
correction
Secondary home position Set by input program
Halt Set by input program
Reverse rotation support Set by input program
output
Baste stitching Set by input program
Test function Jog switch
Error display Display of errors on
LCD
Check
of
input switch signals
Troubleshooting functions Check
of
output signals
Verification and adjustment of sewing speed
Phases
Frequency Voltage Input
(Hz) (V) (kVA)
Power Single-phase
50,60
100 110 120
l
200 220 230 240
Three-phase
50,60
200 220 380 415
1
Ambient temperature/ 5 to
4D°C
humidity 30 to
80%
(no condensation)
Porter
International•
97Rantoul
Street•
Beverly,
MA
01915

From the library of Superior Sewing Machine & Supply LLC - www.supsew.com
PALS 4000 &5000
Automatic
Label
Sewers 9
(3)
Teaching specifications (Figures
In
( )
indicate
PALS
5000 )
Item Specification
Input method Point input and
P-P
(Point to Point) input by teaching
Pattern input area
350X300
(400X300)
mm
Length of stitch
0.1
to
12.
7 mm (resolution:
0.1
mm)
Enlargement/reduction 100% only
No. of input stitches 8000 stitches
Stitch data, feed data, thread trimming data, end data,
Input data secondary home position data, halt data, reverse turn
support output data, baste stitch data
4-step setting:
Stitch speed command High speed (H), medium speed (MD1), medium to
low speed (MD2), low speed
(L)
Correction:
Stitch
number
reduction 1 or N stitches reduced from last stitch; 1 or N stitches
reduced from middle stitch; deletion of data from
assigned position
to
the last stitch
Stitch
number
addition 1 stitch added at assigned position
1 stitch correction 1 stitch corrected at assigned position
Speed change Speed change of N stitches from assigned position;
speed change from assigned position to the last stitch
Function change Addition/deletion of function codes
Test function Jogging at pattern input
Jogging at correction (input data verification)
Data write Written onto floppy disk and P-ROM
Delete Deletion of assigned patterns (floppy disk only)
(4) LIMI-STOP Z motor specifications
Model
CA-Z402E
CB-Z402E
CB-Z402E
Output
(W)
·
400
400
400
Phases Single phase 3phase 3phase
Poles
2 2 2
Voltage(V)
110
220
220/380/415
Drive motor Frequency (
Hz)
50
60
50
60
50
60
Full-load current(A)
5.8
5.6
2.2
2.0
1.
9/1.
3/1.
2
1.7/1.1/1.0
Full-load
speed(spm)
2870
3470
2920
3500
2860
3440
Type
approval Obtained
Clutch
Output
torque
(
kgf-m)
0.
13
o.
11
0.
13
o.
11
0.
13
0.
11
Telephone [phone]
or
508-922-2611 •Fax [phone]

From the library of Superior Sewing Machine & Supply LLC - www.supsew.com
10 PALS 4000 & 5000
Automatic
Label
Sewers
5.
Installation
5.1
Securing the Sewing Machine Table
(1)
After placing the table
in
the prescribed
position, turn the adjustors mounted
underneaththe table to secure the table so
1
that
it
will not move.
(See
Fig.
5.
1)
(2)
Install the table on a level and stable floor
so that
it
will not shake or rock from side to
side.
5.2 Installing the Cotton Stand
Adjuster 0
Fig. 5.1
'-.....
Castor
Assemble the separately packed tension thread guide into the cotton stand, installing
it
at
the
right rear
of
the table.
Fig.
5.2
Porter
International•
97Rantoul
Street•
Beverly,
MA
01915
Thread
tension
guide