Sunstar Precision SWF/TA-WL910-120 User manual

MANUAL
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1. THIS IS AN INSTRUCTION FOR SAFE USE OF AUTOMATIC
EMBROIDERY MACHINES. READ THOROUGHLY BEFORE USE.
2. CONTENTS IN THIS INSTRUCTION MAY CHANGE, WITHOUT
PRIOR NOTICE, FOR IMPROVEMENT OF MACHINE QUALITY AND
THUS MAY NOT CORRESPOND TO THE MACHINE YOU
PURCHASED. CONTACT YOUR SALES AGENT FOR INQUIRIES.
3. THIS IS DESIGNED AND MANUFACTURED AS AN INDUSTRIAL
MACHINE. IT SHOULD NOT BE USED FOR OTHER THAN
INDUSTRIAL PURPOSE.

4
Contents
1. MACHINE TYPE AND SPECIFICATIONS .............................................................................6
1.1) MACHINE TYPE ...........................................................................................................................6
1.2) MODEL TYPE .................................................................................................................................6
1.3) PRODUCT SPECIFICATIONS........................................................................................................6
1.4) ACCESSORIES ..............................................................................................................................6
1.5) OPTIONS ........................................................................................................................................6
2. SAFETY RULES ......................................................................................................................7
2.1) SAFETY INDICATIONS ..................................................................................................................7
2.2) MACHINE DELIVERY .....................................................................................................................8
2.3) MACHINE INSTALLATION .............................................................................................................9
2.4) MACHINE OPERATION..................................................................................................................9
2.5) REPAIR .........................................................................................................................................10
3. PRODUCT FEATURES ........................................................................................................11
4. MACHINE INSTALLATION AND PRECAUTIONS ..............................................................14
4.1) INSTALLATION CONDITION.......................................................................................................14
4.2) ELECTRICITY INSTALLATION ENVIRONMENT.........................................................................15
4.3) LEVELING THE MACHINE ..........................................................................................................15
5. NOTICES RELATED TO OPERATION .................................................................................17
5.1) SAFETY LABEL TYPES ..............................................................................................................17
5.2) LOCATION OF SAFETY LABELS ................................................................................................18
6. NAMES OF MACHINE PARTS..............................................................................................19
7. ACCESSORIES AND THEIR ASSEMBLY ..........................................................................20
7.1) STAND ..........................................................................................................................................20
7.2) OP BOX.........................................................................................................................................20
8. FUNCTIONS OF EACH PART AND MACHINE OPERATION..............................................21
8.1) BASIC OPERATION .....................................................................................................................21
8.2) NEEDLE-HOOK TIMING AND RELATED TIPS ..........................................................................41
8.3) THREAD BREAK DETECTOR ASSEMBLY AND ITS FUNCTIONS ............................................46
8.4) TYPE AND NAME OF ACCESSORIES .......................................................................................47
8.5) DIRECTION OF BOBBIN BY EMBROIDERY MODE ...................................................................50
8.6) REPLACEMENT OF VARIOUS GUIDES .....................................................................................53
8.7) TYPE OF GUIDES ........................................................................................................................54
9. EMBROIDERY METHODS ....................................................................................................55
10. ERROR DISPLAY AND TROUBLESHOOTING..................................................................56

5
Contents
10.1) MAIN SHAFT MOTOR ................................................................................................................56
10.2) X, Y-AXIS MOTORS ...................................................................................................................56
10.3) COLOR CHANGE .......................................................................................................................57
10.4) ENCODER ..................................................................................................................................57
10.5) REPETITION WORK...................................................................................................................57
10.6) FLOPPY DISK.............................................................................................................................58
10.7) MEMORY ....................................................................................................................................59
10.8) COILING-RELATED ERROR......................................................................................................59
11. CONTROL BOX ...................................................................................................................60
11.1) MAIN CONTROL BOX ................................................................................................................60
11.2) MAIN SHAFT & X-Y MOTOR DRIVE (SANYO)..........................................................................62
11.3) LIST OF ERRORS AND CAUSES IN MAIN SHAFT DRIVER & X,Y SERVO MOTOR DRIVERS .......63
11.4) TRIMMING MOTOR DRIVE........................................................................................................64
12. MAINTENANCE AND INSPECTION ...................................................................................65
12.1) CHECK POINTS FOR REGULAR INSPECTION .......................................................................65
12.2) CLEANING ..................................................................................................................................65
12.3) OIL SUPPLY ...............................................................................................................................67
13. ADJUSTING MAJOR PARTS OF THE MACHINE..............................................................75
13.1) ADJUSTING THE TRIMMERS....................................................................................................75
13.2) ADJUSTING THE UPPER THREAD HOLDING UNIT................................................................77
13.3) PICKER ADJUSTMENT..............................................................................................................78
13.4) ADJUSTING UPPER THREAD HOLDER ..................................................................................79
13.5) ADJUSTING LOW-NOISE PRESSER FOOT .............................................................................81
13.6) RELATIONSHIP BETWEEN PRESSER FOOT AND NEEDLE ..................................................82
13.7) CORRECT POSITION OF NEEDLE ...........................................................................................83
13.8) ADJUSTING HALF-TURN FILM FOR COLOR CHANGE ..........................................................84
13.9) ENCODER ADJUSTMENT ........................................................................................................84
13.10) NEEDLE BAR ADJUSTMENT ..................................................................................................85
13.11) JUMP MOTOR ADJUSTMENT .................................................................................................87
13.12) ADJUSTING DRIVE BELT TENSION .......................................................................................88
13.13) ADJUSTING X, Y SCOPE LIMITS ............................................................................................91
14. TROUBLESHOOTING ........................................................................................................94
15. AUTOMATIC OILING DEVICE .........................................................................................106
15.1) PRECAUTIONS .......................................................................................................................106
15.2) CHARACTERISTICS ................................................................................................................106
15.3) BLOCK DIAGRAM ....................................................................................................................107
15.4) AUTOMATIC OILING PUMP.....................................................................................................108
15.5) JUNCTION AND MOS-TYPE QUANTITY-SET VALVE............................................................109
15.6) UNDERSTANDING OILING CONTROL BOX...........................................................................110

BOBBIN WINDER Normal STANDARD
COILING STANDARD
UPPER THREAD HOLING UNIT STANDARD
OPERATION BOX STANDARD : COLOR TOUCH SCREEN
LUBRICATION STANDARD : AUTO LUBRICATION SYSTEM
MEMORY CAPACITY STANDARD : 2,000,000
6
MACHINE TYPE AND SPECIFICATIONS
01
1.1) MACHINE TYPE
1.2) MODEL TYPE
1.3) PRODUCT SPECIFICATIONS
SWF / TA - W L (X) 9 10 - 120
Series
Machine Type
Head Interval
Alternate
Y-Stroke
No. of Coiling Head (10)×
No. of Standard Head (10)
No. of Needles on Standard Head
1.4) ACCESSORIES
Model Head Color
HEAD
INTERVAL
(MM) All Head(Alternate)
(X××Y)
Board××Continuous
(X××Y)
TABLE SIZE (mm)
EMBROIDERY SPACE (mm)
SWF/TA-WL910-120 10+10 9+1 550 550 ×1200 5500 ×1200 7850 ×2848.5
SWF/TA-WL912-120 12+12 9+1 550 550 ×1200 6600 ×1200 8950 ×2848.5
SWF/TA-WJ614-120 14+14 6+1 450 450 ×1200 6300 ×1200 8465 ×2848.5
SWF/TA-WL912-75 12+12 9+1 550 550 ×750 6600 ×750 6750 ×1958.5
SWF/TA-WL912-100 12+12 9+1 550 550 ×1000 6600 ×1000 8950 ×2498.5
SWF/TA-WJ614-100 14+14 6+1 450 450 ×1000 6300 ×1000 8465 ×2498.5
SWF/TA-WJ614-75 14+14 6+1 450 450 ×750 6300 ×1000 8465 ×1958.5
STITCH LENGTH 0.1~12.7mm
SPEED Standard : Max. 1200rpm, Coiling : 450rpm, Tapping & Zigzag : Max. 850rpm
MAIN MOTOR AC SERVO MOTOR
X-Y MOTOR AC SERVO MOTOR ×2
ELECTRICITY 1-Phase : 200V, 220V, 240V (50Hz/60Hz)
3-Phase : 200V, 220V, 240V, 340V, 380V, 415V (50Hz/60Hz)
POWER CONSUMPTION 1.5Kw
1.5) OPTIONS
1) Standard heads: sequin device, boring device, coding device, 1.7x hook, frame clip for thin materials
2) Coiling heads: special attachments (standing, blind, and frill embroidery), double bobbin

SAFETY RULES
02
7
2.1) SAFETY INDICATIONS
The following set of safety rules categorized as , , and indicates
possibilities of physical or property damages if not fully observed.
DANGERWARNINGCAUTION
No. Names Content
CAUTION
WARNING
DANGER
CAUTION
Users may be subject to physical or property damages if
not fully observe the CAUTION.
Users may be subject to death or severe damages if not
fully observe the WARNING.
Users may be subject to death or severe damages and
emergency if not fully observe the DANGER.
WARNING
DANGER

8
2.2) MACHINE DELIVERY
DANGER
ONLY TRAINED AND EXPERIENCED PERSONS, FAMILIAR WITH THE
RELEVANT SAFETY INSTRUCTIONS, SHOULD HANDLE THE MACHINE. MAKE
SURE TO FULLY OBSERVE THE FOLLOWING INSTRUCTIONS.
2.2.1) Delivery using a crane
1) The crane used should be strong enough to lift the machine.
The nylon rope used should also be durable enough to support the machine weight.
2) Please hang the nylon rope on the rope hangers on the right and left sides of the body.
3) When hanging a rope to the crane, the slant angle of the rope should not exceed
40°at the maximum.
2.2.2) Delivery using a forklift
1) Make sure that size and weight of the forklift is sufficient to support the machine.
2) Place the machine so that its center is on the fork arm. Lift the machine carefully
from behind so that the machine does not tilt to either side.
Make sure all
persons and
obstacles are out
of the way of the
moving
machine.
Danger mark Description
Max 40。
Nylon rope
When unloading the machine from forklift or crane, make sure to
maintain the weight balance in order to prevent injury or machine
damages.
WARNING

9
2.3) MACHINE INSTALLATION
CAUTION
2.3.1) Machine malfunctions or physical damages may occur due to
condition of the installation environment. Make sure to meet the
following conditions.
1) The foundation (floor) under the machine must be strong enough to support the
weight of the machine (approximately 3.5 tons).
2) Air conditioning can eliminate dust and humidity, which may cause pollution and
corrosion of the machine. Make sure your machine is regularly maintained.
3) Do not expose the machine to direct sunlight. (Long exposure to direct sunlight
can fade the machine paint or deform the machine shape.)
4) Allow at least 50cm space on each side of the machine (right, left, rear) from the
wall for convenient maintenance.
2.4) MACHINE OPERATION
2.4.1) The machine has and labels on each risky
parts. Pay careful attention to the labels and make sure to observe
them during operation.
1) Read thoroughly and fully understand the manual before operating the machine.
2) Dress for safety. Long and unbound hair, jewelry such as necklaces, bracelets, and
wide sleeves can get caught in the machine. Wear shoes with non-slip soles to
prevent slip-off accidents.
3) Check the scope of machine operation to see if there is no problem.
4) Keep your hands or head away from the moving parts of the machine such as
needle, hook, take-up lever, and pulley when the machine is in operation.
5) Do not remove the safety covers on the pulley or shaft when the machine is in
operation for your safety.
6) Be sure the main power is turned off and the power switch is OFF before opening
the cover of any electrical components such as control box.
7) Be sure the main switch is OFF before manually turning the main shaft.
8) Turn OFF the machine when you thread needles or inspect the finished
embroidery.
9) Do not lean against the cradle or place your fingers near the pantograph guide
grooves. You may hurt your fingers when the frame moves.
10) The machine noise may exceed 85db when it runs at the maximum speed.
WARNINGCAUTION
WARNING

10
2.5) REPAIR
2.5.1) Only SWF-trained and designated engineers should perform repair
work.
1) Turn OFF the power before cleaning or repair. Wait for 4 minutes so the machine
electricity is completely discharged.
2) Do not change the settings or any parts on the machine without consulting with
SWF.
3) Use only official SWF parts when repairing your machine or replacing parts.
4) Re-install all safety covers when you are finished with the repair.
It takes approximately 10 minutes after turning off the main switch
before the electricity is fully discharged from main shafts and the
X/Y drive box.
CAUTION
Machine changes without consultation with SWF may cause risks
to your safety when you operate the machine.
DANGER
DANGER

PRODUCT FEATURES
03
11
(1) EXPANDED MEMORY SIZE
The machine can store a maximum of 100 designs. The basic memory size is 2 million stitches.
(2) MIRROR IMAGE CONVERSION AND DESIGN DIRECTION
You can turn the design from 0°to 359°in the increments of 1°and also reverse the design in the X direction
(mirror image).
(3) ENLARGING AND REDUCING DESIGN
You can reduce or enlarge the embroidery design in size from 50% to 200% by 1% along the X and Y axis.
(4) AUTOMATIC SELECTION OF NEEDLE BAR
You can select the order of the needle bars up to the 99th bar.
(5) GENERAL REPETITION WORK
The same design can be repeated up to 99 times along the X and Y axis.
(6) SPECIAL REPETITION WORK
Several designs can be repeated freely at different turns (mirror) and angles up to 63 times.
(7) AUTOMATIC OFFSET
The frame automatically returns to the offset point when the embroidery is finished to make it easier for you
to switch the frames. You can select AUTOMATIC OFFSET at PARAMETER SELECT MODE to move the
frame automatically to the desired point, making it easier to do appliqués and to switch the frames.
(8) MANUAL OFFSET
You can manually move the frame to the pre-selected point to do appliqués or change the frames during
embroidery work. The frame can be moved back to its original place by simply pressing the right buttons.
(9) RETURN TO START
The frame can be moved back to the start point of the design during the embroidery work.
(10) NON-STITCHING
The frame and the needle bar can move back and forth by the units of 1, 100, 1000, and 10000 stitches and by
color without stitching.
(11) FRAME REVERSAL
When the thread breaks or runs out of track, you can move the needle bar back to the starting point of the
design in the units of one to ten stitches.
(12) AUTOMATIC TRIMMING
The automatic trimming function, determined by the design and the machine set-up, enhances work
productivity and quality of the finished product.

12
(13) AUTOMATIC DETECTION OF UPPER AND LOWER THREAD BREAKS
The machine detects when the upper thread breaks or the lower thread is out of the needle and automatically
stops the machine.
(14) UPPER THREAD HOLDING DEVICE
Prevents thread escape on unused heads during sample embroidery as well as escape of upper thread during
change of embroidery materials.
(15) AUTOMATIC RETURN TO STOP POINT IN UNEXPECTED BLACKOUT
When the power fails unexpectedly, the frame moves back to the exact point where the stitching stopped. This
helps reduce the number of defects.
(16) 3.5″″ FLOPPY DRIVE (EMBEDDED)
A 3.5″floppy drive is embedded in the operation panel for you to read or store designs. Both 2DD and 2HD
disks can be used.
(17) EDITING
You can delete, change, or insert stitch data and function codes (jump, finish, trimming).
(18) INDIVIDUAL HEAD OPERATION
You can work on the specific head with a broken thread.
(19) MACHINE STOPPAGE
The screen will indicate why the machine has stopped.
(20) RPM
The screen indicates rpm.
(21) FRAME SPEED SET-UP
You can adjust the frame speed to high, medium, or low.
(22) UNUSED MEMORY
The screen indicates the memory available for use.
(23) TAPE CODE COMPATIBILITY
2-binary and 3-binary tape codes can be edited.
(24) 10.4″″ COLOR LCD MONITOR
A 10.4″color LCD monitor helps you read all work-related information at once.
(25) CODES FROM OTHER BRANDS
The machine can automatically read designs of various formats stored in the floppy disk.
[Compatible formats]
1. SST
2. DST, DSB, DS
3. TAP
4. FMC, FDR
5. ZSK
6. 10O
7. EXP

13
(26) Automatic Embroidery Mode Selection
This function enables easy operation of the OP box when taping (coding), coiling, zigzag swing embroidery
and standard embroidery works need to be mixed arbitrarily.
The embroidery machine having both the coiling (taping) head and the standard head can automatically
switch between the coiling (taping) head and the standard head by changing the embroidery mode.
(27) Accessory Assembly
The accessories for taping (coding), coiling, and zigzag swing embroidery could be easily replaced and
assembled.
(28) Accurate M-shaft Driving
The M-shaft driving is always adjusted and controlled so that delicate embroidery is possible under the
accurate control.
(29) Automatic Nipple Return
When embroidery work is finished, the nipple returns to the stand-by position. Therefore, the embroidery
frame or material exchange can be easily conducted.

MACHINE INSTALLATION AND PRECAUTIONS
04
14
4.1) INSTALLATION CONDITION
4.1.1) Temperatures
1) When machine in operation: 0 ~ 40℃(32 ~ 104℉)
2) When machine is idle: －25 ~ 55℃(－13 ~ 131℉)
4.1.2) Humidity
1) relative humidity : 45~85%
4.1.3) Grounding
Ensure the electricity is properly grounded.
4.1.4) Surrounding environment
Close any doors or windows near the machine to prevent direct sunlight, dust, and humidity.
4.1.5) Place of installation
Foundation (floor) under the machine must be sufficiently strong and flat concrete to support the weight of
the machine.
4.1.6) Industrial environment classification
Installation and use of the machine must be performed in an industrial area.
(SWF machines should be used in Class A environment)
Meet the conditions described in the manual when installing the machine. Failure to follow
the directions may result in unexpected machine malfunctions.
CAUTION
1) Do not let moisture drops on the machine.
2) Provide air conditioning to control humidity and to prevent dust and corrosion.
CAUTION
Ensure properly grounding of the machine to avoid the possibility of electric shock.
Use three-wire grounding (grounding resistance below 100 ohms).
DANGER

15
4.2) ELECTRICITY INSTALLATION ENVIRONMENT
4.2.1) Input voltage (to be adjusted at installation)
3-Phase 200V, 220V, 240V, 340V, 380V, 415V (50~60Hz)
4.2.2) Allowed voltage range
Within 10% of the voltage set
4.2.3) Electric capacity and power consumption
3KVA 1.4∼1.6KW
4.2.4) Insulation resistance
Over 10M ohms (measured with 500V insulation tester)
4.3) LEVELING THE MACHINE
4.3.1) Leveling the device
1) leveling
－Use the adjusting bolts installed at the four
stands to level the machine (front, rear, left,
and right). Use a level gauge.
Adjusting bolts
Level gauge
Stand
Level base
Check if the input voltage of the machine corresponds with the voltage supply before
installing or operating the machine.
WARNING
1) Make sure to check the voltage supply where the machine will be installed.
2) Install the cable away from the operator’s work space to prevent accident or injury.
WARNING
The machine must be accurately leveled (especially front-back) to prevent machine from
deformation or needle from moving out of position.
CAUTION

16
2) Locations of level gauge
– Place the level gauges at the locations as in the figure below to maintain the balance of the machine.
3) Leveling fixation
– When the left and right balancing is completed, turn the supporting bolt of the frame until it reaches the
level base and loosen it by turning in the reverse way by a 1/4 circle.
– When the supporting bolt adjustment is completed, tightly fasten the nut for fixation.
Level Gauge
Supporting bolt
Nut
Level Gauge
Until the height difference between the four adjusting bolts becomes 10mm, use the spacer
by holding it against the lower balancing base.
CAUTION
Do not place the level gauges on the square pipes and the table for maintaining the balance
of the machine.
CAUTION
The supporting bolt at the center reduces the machine vibration and maintains its
horizontal balance.
CAUTION

NOTICES RELATED TO OPERATION
05
17
5.1) SAFETY LABEL TYPES
※※NEEDLE
Injury may be caused by moving needle.
Ensure that the machine is in a stop condition before changing, threading
or rethreading of needies or changing of needles.
※※HIGH VOLTAGE
Fire or death may be caused by high voltage electric shock.
Don’t open the cover except for service man assigned by SWF.
When open the cover turn off power and wait for 6 minutes.
※※Watch out for chink!
Don’’ t put your finger in a groove on the table.
※※HAND
Physical damage may be caused by interposition.
While embroidery frame is running according to the direction of
embroidery frame may be injured your hands by gap between fixed body
and embroidery frame.
※※MACHINE MOVE
Injury may be caused by winding.
Be sure to turn off the power before cleaning, lubricating, adjusting or
repairing.
※※MACHINE MOVE
Physical damage may be caused by winding.
Don’t put your hands near the needle bar & take-up lever while machine is
running.
Have a full understanding of the labels attached to the machine to prevent any possible
accidents.
CAUTION
Injury may be caused by moving
needle.
Ensure that the machine is in a
stop condition before changing,
threading or rethreading of
needies or changing of needles.
WARNING
WARNING
Fire or death may be caused by
high voltage electric shock.
Don’t open the cover except for
service man assigned by SWF.
When open the cover turn off
power and wait for 6 minutes.
WARNING
Physical injury may be caused
by crevice.
Don’t put your finger in a groove
on the table.
Physical damage may be caused
by interposition.
While embroidery frame is running
according to the direction of
embroidery frame may be injured
your hands by gap between fixed
body and embroidery frame.
WARNING
Injury may be caused by winding.
Be sure to turn off the power
before cleaning, lubricating,
adjusting or repairing.
WARNING
Physical damage may be caused by
winding.
Don’t put your hands near the
needle bar & take-up lever while
machine is running.
WARNING

18
5.2) LOCATION OF SAFETY LABELS
[Front]
[Side]
Injury may be caused by moving
needle.
Ensure that the machine is in a
stop condition before changing,
threading or rethreading of
needies or changing of needles.
WARNING
Physical damage may be caused by
winding.
Don’t put your hands near the
needle bar & take-up lever while
machine is running.
WARNING
Injury may be caused by winding.
Be sure to turn off the power
before cleaning, lubricating,
adjusting or repairing.
WARNING
Make sure that the power is turned off
before conducting cleaning, oil supply,
adjustments or repairs. Otherwise, you
may hurt your hands.
WARNING
Physical damage may be caused
by interposition.
While embroidery frame is running
according to the direction of
embroidery frame may be injured
your hands by gap between fixed
body and embroidery frame.
WARNING
WARNING
Fire or death may be caused by
high voltage electric shock.
Don’t open the cover except for
service man assigned by SWF.
When open the cover turn off
power and wait for 6 minutes.
Injury may be caused by moving
needle.
Ensure that the machine is in a
stop condition before changing,
threading or rethreading of
needies or changing of needles.
WARNING
Physical damage may be
caused by winding.
Don’t put your hands near the
arrow while the main shaft is
rotating
WARNING

NAMES OF MACHINE PARTS
06
19
A. Machine Body Ass’y
B. Work Table
C. Spool
D. Main Drive System
E. Bed
F. Thread Trimming System
G1. Arm I
H1. Arm I(Coiling)
I. Color Change System
J. Wiper Set
K. Head
L1. Thread Tension Unit
L2. Thread Tension Unit(Coiling)
M. Sub-Control Unit & lamp
N. X-Axis Drive System
O. Y-Axis Drive System
P. Bar Switch
Q. Frame
R. Main Controller
S. Operation Box
M
S
Q
B
DJ
G1
K
L1 L2
H1
FEA
I
C
R
ON
P

ACCESSORIES AND THEIR ASSEMBLY
07
20
7.1) STAND
1) Assembling Upper Thread Stand
7.2) OP BOX
30
Thread holding bar
Supporter
Spool plate
Bolts for supporter
①Sequin cable connection (optional)
: When the sequin device is installed, the sequin cable shall
be connected.
②Thread sensing board cable connection
③Joint board cable connection
①②
③

FUNCTIONS OF EACH PART AND MACHINE OPERATION
08
21
8.1) BASIC OPERATION
8.1.1) Power on
1) Plug in the power cord of the embroidery machine.
2) Turn on the power switch.
3) Press the operation switch attached on the bar switch.
4) When the main power switch is “OFF”, the power is not supplied, although the operation switch is turn
“ON”.
Power operation switch
Main power switch
※※Power Switch
※※When the emergency switch develops errors, the power switch detects them and ensure
that the machine remains turned off. This is designed to detect the breakdown of the
emergency switch and prevent related accidents.
NOTE