Sunstar Precision SWF G Series User manual

●LCD
Monitor Operation
SSUUNNSSTTAARR PPRREECCIISSIIOONN CCOO..,, LLTTDD..
MANUAL
SWF/G-Series
MULTI-HEAD AUTOMATIC
EMBROIDERY MACHINE
MMMMEE--

THIS IS AN INSTRUCTION FOR SAFE USE OF
MULTI-HEAD AUTOMATIC EMBROIDERY MACHINES.
READ THOROUGHLY BEFORE USE.

I
CHAPTER 1 SAFETY RULES ................................................................................................................................. 1-1
CHAPTER 2 MACHINE INSTALLATION AND ASSEMBLY ....................................................................... 2-1
2-1) INSTALLATION ENVIRONMENT .................................................................................... 2-1
2-2) ELECTRICITY INSTALLATION ........................................................................................ 2-1
2-3) LEVELING THE MACHINE ................................................................................................ 2-2
2-4) PERIPHERALS ASSEMBLY ............................................................................................... 2-4
CHAPTER 3 NAMES OF MACHINE PARTS ...................................................................................................... 3-1
CHAPTER 4 FEATURES AND SPECIFICATIONS ........................................................................................... 4-1
CHAPTER 5 FUNCTIONS FOR BASIC MACHINE OPERATION .............................................................. 5-1
5-1) NAMES AND FUNCTIONS OF PARTS IN OPERATION BOX ....................................... 5-1
5-2) EMERGENCY POWER AND START/STOP BUTTONS .................................................. 5-3
5-3) BAR SWITCH ....................................................................................................................... 5-4
5-4) LAMP ON THREAD TENSION ADJUSTMENT BOARD ................................................ 5-6
5-5) NEEDLE STOP CLUTCH ..................................................................................................... 5-7
5-6) LAMP ON COLOR CHANGE BOX .................................................................................... 5-8
5-7) UPPER THREADING AND TENSION ADJUSTMENT .................................................... 5-9
5-8) LOWER (BOBBIN) THREADING AND TENSION ADJUSTMENT .............................. 5-12
5-9) BOBBIN WINDER .............................................................................................................. 5-13
5-10) FLOPPY DISKS ................................................................................................................ 5-16
5-11) IN AND OUT OF DESIGNS ............................................................................................. 5-17
5-12) RETURN TO PREVIOUS LOCATION IN UNEXPECTED BLACKOUTS .................. 5-17
5-13) NEEDLE- HOOK TIMING CONTROL ........................................................................... 5-18
5-14) ASSEMBLY AND FUNCTIONS OF THREAD DETECTOR ........................................ 5-23
CHAPTER 6 BASIC MACHINE OPERATION .................................................................................................... 6-1
CHAPTER 7 OPERATION BOX .............................................................................................................................. 7-1
CHAPTER 8 ERROR MESSAGES AND CORRECTION ................................................................................ 8-1
8-1) MAIN SHAFT MOTOR ........................................................................................................ 8-1
8-2) X, Y PULSE MOTORS ......................................................................................................... 8-1
8-3) COLOR CHANGE ................................................................................................................. 8-1
8-4) ENCODER ............................................................................................................................. 8-2
8-5) FLOPPY DRIVE & COMMUNICATION ............................................................................ 8-2
8-6) MEMORY .............................................................................................................................. 8-3
8-7) TAPE READER & TRANSMISSION .................................................................................. 8-3
CHAPTER 9 CONTROL BOX .................................................................................................................................. 9-1
9-1) MAIN CONTROL BOX ........................................................................................................ 9-1
9-2) MAIN SHAFT MOTOR DRIVE ........................................................................................... 9-3
9-3) X, Y MOTOR DRIVE ........................................................................................................... 9-4
TABLE OF CONTENTS

II
CHAPTER 10 MAINTENANCE AND INSPECTION ....................................................................................... 10-1
10-1) CHECK POINTS FOR REGULAR INSPECTION .......................................................... 10-1
10-2) CLEANING ....................................................................................................................... 10-1
10-3) OIL SUPPLY ..................................................................................................................... 10-3
10-4) DRIVE BELT TENSION ................................................................................................... 10-6
CHAPTER 11 MAJOR MACHINE ADJUSTMENTS ........................................................................................ 11-1
11-1) ADJUSTING THE TRIMMERS ....................................................................................... 11-1
11-1-1) ADJUSTING THE INSERT ANGLE OF MOVABLE BLADE ....................... 11-1
11-1-2) ADJUSTING SPACE BETWEEN MOVABLE BLADE AND HOOK ............ 11-1
11-1-3) ADJUSTING BLADE TENSION ...................................................................... 11-2
11-1-4) ADJUSTING TRIMMER RETURN SPRING ................................................... 11-3
11-2) PICKER ADJUSTMENT .................................................................................................. 11-3
11-3) ADJUSTING UPPER THREAD HOLDER .......................................................................11-4
11-4) ADJUSTING HEIGHT OF THE PRESSER FOOT .......................................................... 11-5
11-5) CORRECT POSITION OF NEEDLE ................................................................................ 11-7
11-6) ADJUSTING HALF-TURN FILM FOR COLOR CHANGE ........................................... 11-8
11-7) ENCODER ADJUSTMENT .............................................................................................. 11-8
11-8) JUMP SOLENOID ADJUSTMENT ................................................................................. 11-9
11-9) ADJUSTING DRIVE BELT TENSION .......................................................................... 11-10
11-9-1) X, Y TIMING BELT ....................................................................................... 11-10
11-9-2) MAIN SHAFT MOTOR AND UPPER/LOWER SHAFT BELT .................... 11-10
11-10) ADJUSTING X, Y SCOPE LIMITS ............................................................................. 11-11
CHAPTER 12 TROUBLESHOOTING .................................................................................................................... 12-1
CHAPTER 13 GREASING ......................................................................................................................................... 13-1
13-1) WHERE AND HOW TO GREASE ................................................................................... 13-1
13-2) GREASING THE LM GUIDE ON OLD TYPE MACHINES .......................................... 13-1
13-3) GREASING LM GUIDE RAIL ON HEAD ...................................................................... 13-2
13-4) GREASING CYCLE .......................................................................................................... 13-3
13-5) GREASE SPECIFICATION .............................................................................................. 13-3
13-6) PRECAUTIONS ................................................................................................................ 13-3
CHAPTER 14 BLOCK DIAGRAM ......................................................................................................................... 14-1

1-1
The following set of safety rules categorized as , , and indicates possibilities of
physical or property damages if not fully observed.
: These safety instructions MUST be observed to be safe from danger when installing, delivering, or
repairing the machine.
: These safety instructions MUST be observed to be safe from machine injuries.
: These safety instructions MUST be observed to prevent predictable machine errors.
CAUTION
WARNING
DANGER
CAUTIONWARNINGDANGER
SAFETY RULES
CHAPTER 1
ONLY TRAINED AND EXPERIENCED PERSONS, FAMILIAR WITH THE
RELEVANT SAFETY INSTRUCTIONS, SHOULD HANDLE THE MACHINE.
MAKE SURE TO FULLY OBSERVE THE FOLLOWING INSTRUCTIONS.
1) Using a Crane
Make sure that the crane is large enough to hold the machine. Use a nylon
rope of sufficient strength. Place a wooden block at either side of the
machine before tying the rope. The angle should be 40�or less. Make sure
that the rope does not touch the table.
※Make sure all persons and
obstacles are out of the way
of the moving equipment.
[Fig.1-1]
1-1) MACHINE
DELIVERY
DANGER
Nylon rope
Wooden
block
Bolt
Nut
Max. 40�
Max. 40�

1-2
2) Using a Forklift
Make sure that size and weight of the forklift is sufficient to support the
machine. Use the pallet to place the machine so that its center is on the
forklift arm (see [Fig.1-2]). Lift the machine carefully so that the machine
does not tilt to either side.
[Fig.1-2]
Installation environment may incur machine malfunction or breakdown.
Make sure to meet the following conditions.
1) The foundation under the machine, i.e. table or desk, must be strong enough
to support the weight of the machine (approximately 3.5 ton).
2) Air conditioning can eliminate dust and humidity that can cause pollution
and corrosion of the machine. Make sure your machine is regularly cleaned.
3) Long exposure to direct sunlight can cause the paint of the machine to fade
or change of the machine shape.
4) Allow at least 50cm (20 inches) of space on each side of the machine for
convenient maintenance.
※Please refer to for installation details.
2. Machine Installation and Assembly
1-2) MACHINE
INSTALLATION
CAUTION
[WARNING]
Make sure to maintain the weight balance in machine deliveries,
especially when unloading the machine from a forklift or crane, in
order to prevent injury or machine damages.

1-3
Only SWF-trained and selected repair engineers should do repair work.
1) Turn OFF the power before cleaning or repairing the machine. Wait for 4
minutes so the machine electricity is completely discharged.
2) Do not change the settings or any parts on the machine without confirmation
from SWF. Such change may cause safety accidents.
3) Use only SWF parts when repairing your machine.
4) Replace all safety covers when you are finished with your repair.
1-4) REPAIR
DANGER
WARNING
The SWF Automatic Embroidery Machine is designed for applying
embroidery to fabric and other similar materials.
Pay careful attention to the and stickers on certain
parts of the machine. Make sure to observe the following when operating
the machine:
01) Read thoroughly and fully understand the manual before operating the
machine.
02) 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.
03) Clear all persons from the machine before turning on the power.
04) 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.
05) Do not remove the safety cover on the pulley or shaft when the machine is
in operation.
06) Be sure the main power is turned off and the power switch is set to OFF
before opening the cover of any electrical component or control box.
07) Be sure the main switch is OFF before manually turning the main shaft.
08) Turn the machine off when threading needles or inspecting the finished
embroidery.
09) Do not lean against the cradle or place your fingers near the guide grooves
of the frame.
10) The machine noise may exceed 85db when it is run at a maximum speed. It
is not higher than the standard level, but you may need earplugs or sound-
proof facilities for the operator and other workers.
CAUTIONWARNING
1-3) MACHINE
OPERATION
[CAUTION]
It takes about 10 minutes after turning off the main switch before the
electricity is fully discharged from X/Y main shafts and the drive box.

1-4
Observe the directions on ALL warning stickers placed on the machine as
reminders for your safety.
1-5) Placement of
Warning Sticker
[Front]
[Side]
[Back]
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
winding.
Be sure to turn off the power
before cleaning, lubricating,
adjusting or repairing.
Physical damage may be
caused by winding.
Don’t put your hands near the
arrow while the main shaft is
rotating
Physical injury may be caused
by crevice.
Don’t put your finger in a groove
on the table.
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.
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.
①Turn off the main power before rotating the
main shaft by hand!
②Do not remove covers during operation!
③Turn off the main power before opening
electricity-related boxes!
WARING
WARING
WARING
WARING
WARING
WARING
WARING

1-5
A) WARNING
1-6) Contents of
Warning Stickers
WARNING
WARNING
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.
[CAUTION]
Safety cover refers to all covers near the operating parts
of the machine.
Injury may be caused by winding.
Be sure to turn off the power before
cleaning, lubricating, adjusting or
repairing.
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.

2-1
Install your machine in an appropriate environment and with adequate electrical supply. Failure to follow the
directions may result in machine malfunction.
2-1) INSTALLATION ENVIRONMENT
1) Temperature: 0 ~ 40℃(32 ~ 104℉) when the machine is in operation
－25 ~ 55℃(－13 ~ 131℉) when the machine is not in operation
2) Humidity: 45 ~ 85% (relative)
3) Grounding: Ensure the electricity is properly grounded.
4) Close any doors and windows near the machine to prevent direct light, dust, and humidity.
5) Foundation under the machine must be a sufficiently strong and flat concrete to support the weight of the
machine.
6) The machine must be installed and used in an industrial environment (Class A).
2-2) ELECTRICITY INSTALLATION
Check if the input voltage of the machine is in the right range of the voltage supply before installing or operating the
machine. The voltage required is as follows:
1) Allowed range of voltage: within ±10% of the voltage set
2) Electric capacity and voltage consumption: 3KVA, 1.4-1.6 KW
3) Insulation resistance: over 10M ohms (measured with 500V insulation tester)
MACHINE INSTALLATION AND ASSEMBLY
CHAPTER 2
[CAUTION]
①Do not let moisture drops on the machine.
②Provide air conditioning to control humidity and to prevent dust and corrosion.
DANGER
WARNING
Properly ground the machine to avoid the possibility of electric shock. Use three-wire
grounding (grounding resistance below 100 ohms).
①Check the voltage supply where the machine will be installed.
②Install the cable away from the operator’s work space to prevent accident or injury.

2-2
2-3) LEVELING THE MACHINE
The machine must be accurately leveled (especially front and back) to prevent the needle from moving out of position
as well as machine error.
1) Use the adjusting bolts installed at the four stands to level the machine (front, rear, left, and right). Use a level
gauge.
①Check the voltage supply where the machine will be installed.
②Install the cable away from the operator’s work space to prevent accident or injury.
③If the difference in heights of the four bolts is over 10mm, place spacers beneath the lower adjusting bolts to
make the heights even.
2) Make sure to level the machine front-back and left-right.
[Fig.2-2]
[Fig.2-1]
Level gauge
Adjusting bolts
Stand
Level base

2-3
3) Using the level gauge
③Fasten the bolts snugly when the machine is horizontally leveled.
④Install the supporting bolt as shown in [Fig.2-4]. Turn the bolt until it touches the machine and turn additional
1/4 round. Close the bolt with a nut.
[Fig.2-3]
[Fig.2-4]
Nut
Supporting
bolt
[CAUTION 1]
The level gauge does not measure accurately on a pipe or a table.
[CAUTION 2]
The supporting bolt reduces machine vibration and balances the machine weight. However, avoid using
the bolt too high, which may lift the machine body.
Level gauge

2-4
2-4) PERIPHERALS ASSEMBLY
1) Assembling Upper Thread Stand
2) Assembling Operation Box
[Fig.2-5]
[Fig.2-6]
Thread holder
structure
Support
Operation box
Frame contact line
FDD
Spool plate

3-1
NAMES OF MACHINE PARTS
CHAPTER 3
1) Machine Body
2) Table
3) Upper thread stand
4) Main shaft drive motor
5) Rotary hook base
6) Trimming motor box
7) Arm
8) Color Change box
9) Upper thread holder
10) Head
11) Thread tension adjustment board
12) Sub-controller
13) X-axis driving system
14) Y-axis driving system
15) Bar switch
16) Frame
17) Main controller box
18) Operation box
19) X, Y driver box
20) Main power switch
21) Lamp
22) Leveling base
23) Supporting bolt
24) Thread detector
[Front]
[Back]
4
9
13 21 14
12
16
2
7
24
11
10
6
1
523 19 17 15
20
22
8
3
18
[Fig.3-1]
[Side]

4-1
01) EXPANDED MEMORY SIZE
The machine can store a maximum of 100 designs. The basic memory size is 2 million stitches.
02) 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).
03) 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.
04) AUTOMATIC SELECTION OF NEEDLE BAR
You can select the order of the needle bars up to the 99th bar.
05) GENERAL REPETITION WORK
The same design can be repeated up to 99 times along the X and Y axis.
06) SPECIAL REPETITION WORK
Several designs can be repeated up to 63 times at different angles and directions.
07) 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 appliques and to switch the frames.
08) MANUAL OFFSET
You can manually move the frame to the pre-selected point to do appliques or change the frames during
embroidery work. The frame can be moved back to its original place by simply pressing the right buttons.
09) 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.
FEATURES AND SPECIFICATIONS
CHAPTER 4

4-2
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.
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) 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.
15) 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.
16) EDITING
You can delete, change, or insert stitch data and function codes (jump, finish, trimming).
17) INDIVIDUAL HEAD OPERATION
You can work on the specific head with a broken thread.
18) MACHINE STOPPAGE
The screen will indicate why the machine has stopped.
19) RPM
The screen indicates rpm.
20) FRAME SPEED SET-UP
You can adjust the frame speed to high, medium, or low.
21) UNUSED MEMORY
The screen indicates the memory available for use.
22) TAPE CODE COMPATIBILITY
2-binary and 3-binary tape codes can be edited.
23) 10.4 INCH COLOR LCD MONITOR
A 10.4 inch color LCD monitor is installed on your operation panel for easier reading of the work data.
24) CODES FROM OTHER BRANDS
The machine can automatically read designs of various formats stored in the floppy disk.
These formats include:
1. SST 2. DST, DSB, DSZ
3. TAP 4. FMC, FDR
5. ZSK 6. 10O
7. EXP

5-1
5-1) NAMES AND FUNCTIONS OF PARTS IN OPERATION BOX
FUNCTIONS FOR BASIC MACHINE OPERATION
CHAPTER 5
LCD Menu Screen
A color monitor that shows all data related to work.
Number Buttons
This is used to input numbers when setting parameters.
Frame Movement Key
Moves the frame left, right, up, and down.
Frame Speed Button
Sets the speed of the frame movement to low, medium, or high.
Main Shaft Speed Button
Changes the speed of the main shaft during machine operation. Press [UP] to increase and [DOWN] to
decrease the speed.
Function Menu
Selects the function displayed on the screen.
START
STOP
[Fig.5-1]







[Front]

5-2
[Right]
Acryl cover: protects the floppy disk drive
Disk Out: takes the disk out
FDD: runs and reads the floppy disk
Work Lamp: blinks when FDD is in operation
COM2: serial port-2
Parallel port
Keyboard connector
VGA Card connector
COM1: serial port-1
[Back]
[Fig. 5-2]
[Fig.5-4]




[Bottom]
[Fig. 5-3]

[CAUTION] CHANGING NEEDLE BAR WITH “CL” KEY
If you want to change the order of the needle bar during operation.
Input the desired needle number and press “CL”.





5-3
[Fig.5-5]
Emergency power switch
Main power switch
5-2) EMERGENCY POWER AND START/STOP BUTTONS
1) Emergency Power Switch
When starting the machine from initial stage,
Turn on the main power.
Press the emergency power switch (blue color).
Emergency power switch will not turn on if the main power is off.
[NOTE]
Emergency power switch detects emergency stop failures and prevents accidents.
Emergency power function detects the failure of the emergency stop function and prevents the machine
from being switched on.

5-4
5-3) BAR SWITCH
Refer to [Fig.5-6] for use of the bar switch.
Use the bar switch to:
For starting embroidery and stopping the machine
Bar switch during machine stop
[Fig.5-6]
Bar switch
Left
Start the embroidery work or stop the machine during operation.
Move the frame back during machine stop.
Move forward/backward in design during machine stop (non-stitching)
Do work other than embroidery
BUTTON OPERATION
Push to right
Hold to right
Push to left
Machine starts and embroidery work begins.
Machineinches (see Note1)until you release the switch.
Machine stops.
MACHINE OPERATION
BUTTON OPERATION
Push to left
Hold to left
Push to left again
Frame moves backward in selected movement units (see Note 2).
Frame starts to move backward.
If you release the switch before the machine goes 10 of the selected
stitches, the machine will stop immediately (the machine moves back in
the selected movement units). If you release the switch after the machine
traveled 10 of the selected stitches, the machine will continue to move
back.
Push the bar to the left again and the machine will stop moving backward.
MACHINE OPERATION
[CAUTION]
You cannot perform non-stitching (floating) at the start of the embroidery because the function is not in
the start menu. To perform floating at the start of the embroidery, push the bar switch to the left. The
machine will go into STOP MODE. Select FLOAT and set the desired number of non-stitching in
the sub menu.
Right