SunStar Fortuna 5 Series User manual

1) FOR AT MOST USE WITH EASINESS,
PLEASE CERTAINLY READ THIS MANUAL
BEFORE STARTING USE.
2) KEEP THIS MANUAL IN SAFE PLACE
FOR REFERENCE WHEN THE MACHINE
BREAKS DOWN.
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USER’’ S MANUAL
PARTS BOOK
FORTUNA
series 5
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Version 1.0
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Best Quality
Best Price
Best Service
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1. Thank you for purchasing our product. Based on the rich expertise and
experience accumulated in industrial sewing machine production, SUNSTAR
will manufacture industrial sewing machines, which deliver more diverse
functions, high performance, powerful operation, enhanced durability, and
more sophisticated design to meet a number of user’s needs.
2. Please read this user’s manual thoroughly before using the machine. Make
sure to properly use the machine to enjoy its full performance.
3. The specifications of the machine are subject to change, aimed to enhance
product performance, without prior notice.
4.
This product is designed, manufactured, and sold as an industrial sewing
machine. It should not be used for other than industrial purpose.

USER’S
MANUAL

1. Safety instruction 6
2. Precautions before use 8
3. Locating and using parts of the controller box 10
4. Installation 11
1) Mounting your Servo Motor on the table 11
2) Assembling the belt cover and adjusting the belt tension 12
3) Mounting and adjusting the foot-lift solenoid 13
4) Mounting the position sensor (Synchronizer) and setting the film 14
5) How to equip and adjust a built-in location detector(synchronizer) 16
6) Mounting the Program Unit(P/U) 18
7) An example of installing the SunStar sewing machine 19
5. Wiring and grounding 20
1) Specification of the power plug 20
2) Specification of electric current in wiring of power plug 20
3) Name and description on the outside connector of control box 21
4) How to change the electric voltage supplied for solenoid(The factory installed setting is:J2) 21
6. Connection the earth wire of the sewing machine and motor 23
7. Things to be checked after installation 23
8. Program unit part names and method of use 24
1) Program unit part names 24
2) Program Unit Method of Use 24
3) Start and End Backtack Stitch Correction Method 35
4) Method of Use: Inertia Tuning Function 38
5) How to Use Edge Sensor 39
6) Motor Controller Setting 42
7) Advanced Pattern Sewing Functions 46
8) Automatic Change Function of Twin Needles (applicable to the models supporting twin needles) 48
9. Simple operation unit part names and method of use 50
1) Names of Each Part in the Simple Operation Unit 50
2) Simple Program Unit Method of Use 50
10. Fortuna series 5 full function software method of use 55
1) Basic Functions of the Fortuna Series 5 Full Function Software 55
2) Fortuna Series 5 Full Function Software Specific Parameters 56
3) Method of Use and Explanations for Specific Items of the Parameter 71
4) Thread Trimming Sequence Function Method of Use (Items no. 54, 55, 56 of Group B) 75
11. Breakdown and troubleshooting 84
12. How to place for controller 85
13. Block diagram 86
※Parts Book 87
CCOONNTTEENNTTSS

6
Be sure to read and keep in mind the following instructions before you install and use
thr FORTUNA SERVO MOTOR.
1) Use and Purpose
This product is designed, manufactured, and sold as an industrial sewing machine. It should not be used for
other than industrial purpose.
2) Working Environment
①Power Source
•It is desirable that voltage of the power source be kept within the range of ±10% of the rated voltage.
•It is desirable that frequency of the power source be kept within the rage of ±10% of the rated frequency.
(50/60㎐)
•The SERVO MOTOR can be expected to work normaly only in case the foregoing things are kept.
②Electromagnetic Noise
•It is desirable that those equipments causing strong electromagnetic field or high frequency not use the
same electrical outlet as this on and stay away from it.
③Temperature and Humidity
•Keep the ambient temperature above 5 degrees and below 40 degrees Centigrade.
•Never use it outdoors and avoid direct ray of light.
•Keep it away from an hot object like a stove.
•Keep the ambient humidity above 30% and below 95%.
④Never use it near gases and explosives.
⑤Do not use it at a spot located 1,000m or higer above sea-level.
⑥Keep the storage temperature higher than 25 degrees below zero and lower than 55 degrees Centigrade when
not in use.
3) Installation
Follow the instruction carefully when installing it.
①Be sure to start installing it after pulling the power plug off the outlet.
②Fix the cable so that it may not move, and do not allow the moving parts like belts to be interfered with.(keep
distance of at least 25mm from them.)
③Be sure to have the Controller, the Motor and the sewing Machine grounded.
④Be sure that the voltage of power source fits the specification of the Controller before the power is on
⑤Be sure to use Safety Extra Low Voltage when an extra item or an accessory is fitted into the Controller.
4) Disassembly
①Indisassembling it, be sure to wait at least 360 seconds before taking any action after pulling the plug off the
power source after turning it off.
②When pulling off the plug from the power source, be sure to hole the plug itself instead of the wire connected
to the plug.
SAFETY INSTRUCTION
11

5) Service and Maintenance
①Make sure that service and maintenance are carried out by a skilled technician.
②Never try to operate with the Motor and the Controller open.
③When inserting a thread into or touching the machine, be sure to turn the power off and step down from the
platform.
④Be sure to use standard products specified for replacement of parts.
6) Other Safety Instructions
①Tack care not to let your fingers touch any moving parts including belts.
②In case of remodelling or fitting of additional device, be sure to follow safety standards and do not ever try to
go ahead based on your own judgments.
③Do not try to operate with the safety device removed.
④Take care not to let water or coffee or something like those admitted into the Controller or the Motor.
⑤Never drop the Controller or the Motor to the ground.
※The instructions presented above are for the safer and more proper operation of the Fortuna Servo
Motor. Ignoring such instructions could cause damage to the machine or physical injury of the user.
Please follow all the instructions when operating the machine.
7

8
PRECAUTIONS BEFORE USE
1. Do not turn on the power while stepping on the pedal.
22
2. Turn off the power when leaving the servomotor overnight.
3. Turn off the power when servicing the servomotor or changing
the needle. 4. Be sure to keep the servomotor securely grouned.
5. Do not connect multiple servomotor power plugs to the same
power strip. 6. Install the servomotor away from noise sources, such as high- frequency equipments and welding machines.
7. Avoid electrical shock when servicing the controller box. (Wait for 6
minutes before opening the cover after turning off the power.)
8. When an error message“Er”sppears on the digital display,
take a note of the“Er”code, and then turn on and off before
resuming operation(Contact the local dealer if“Er”message
persists on the display)

9
9. Adjust the belt tension to the optimum level.
Belt-tension adjustment should
be performed after the motor is
mounted on the table : First,
loosen both the upper and
lower anchoring bolts(①, ②).
The belt tension will then be
adjusted by the weight of
servo motor itself. Fasten both
anchoring bolts.
10. Clean it every two or three weeks so that no dirt or a dirty
substance may be piled up.
11. When replacing the fuse, use a standard item, opening the
cover as shown in the diagram. 12. Make the length of the cable connected with an outside parts like stand-up pedal as short as possible.
F1
F2
F3
F4 250V/1A
250V/6.3A
250V/15A
250V/15A
①
②

Control box right sideControl box left side
10
LOCATING AND USING PARTS OF THE CONTROLLER BOX
1) Left and right side of control box
2) Rear panel
①Caution
②Motor
③AC INPUT
②
③
33
Motor Power Cable
AC Power switch
Standard Solenoid
Connector
Switch and Lamp
Foot-lift Solenoid(Green)
Right lift Solenoid(Blue)
Tension-release and
Auxiliary solenoid(White)
Hazardous voltage will cause injury.
Be sure to wait at least 360 seconds before
opening this cover after turn off main switch and
unplug power cord.
고압 전류에 의해 감전될 수 있으므로 커버를 열 때
는 전원을 내리고 전원 플러그를 뽑고 나서 360초간
기다린 후 여십시오.
WARNING
경고
Encoder Connector
(Green)
OPTION
Connector for Position
Sensor(Black)
Program Unit
Connector(White)
①

11
1) Mounting your Servo Motor on the table
②Insert three motor-fixing bolts through the three holes on the table. Attach the motor base padded with vibration-proof rubber, and slide
flat and spring washers over the bolt stems, and then fasten the bolts with nuts.
③Make sure that the center of motor pulley is matched to that of the sewing machine before tightening the motor-fixing bolts and nuts.
①Make sure that the holes are bored on the table as shown in the
figure.
INSTALLATION
44
Table
Belt Hole
ф41 Cable-Hole
R
Motor-Fixing Bolts
Motor-Fixing Bolts(3ea)
Motor-Fixing Bolts(3ea)
Controller Box
Vibration-Proof rubber
Table
Flat Waser
Spring Waser
Nut
Base

12
2) Assembling the belt cover and adjusting the belt
tension
(1) Belt cover assembling procedure
①Upon the completion of the motor mounting, bring the two
pulleys of motor and sewing machine closer to each other, by
pulling back the sewing machine. You can then mount the belt
easily as shown in the figure.
②Place the belt cover‘B’, making sure that the belt cover does
not contact the belt, and then fasten the cover with the fixing
screw.
(2) Adjusting the belt tension
①Optimum Tension Level：The optimum tention level is
achieved when the belt is pushed by 5-10mm when the top
surface portion of the belt at about 30-50mm above the tabletip
is pressed by a finger with a force of~1㎏m/sec2or 1 Newton.
②Adjusting the Tension Level：If the tension level is out of the
optimum range, adjust the tension as follows. First, loosen both
the upper and lower nuts for the anchor bolt, letting the belt be
stretched by the motor weight itself. Second, tighten the upper
nut only to the extent that the motor does not move. Third,
fasten the bottom nut tightly so that the motor is securely fixed.
Controller Box
Belt Cover“A”
Belt Cover“B”
Belt
Belt Guide Fixing Screw
Belt Cover Fixing Screw
Belt Guide
Pulley
Belt Guide
Fixing
Screw
Upper Nut for the Anchor Bolt
Lower Nut for the Anchor Bolt
Warning
Do not remove the belt cover.
If a finger slips into the belt, it might be broken or
cut off.
Warning
Make sure that the power is off before
assembly.
5~10mm 1kg
30~50mm
→←
↕

13
3) Mounting and adjusting the foot-lift solenoid
(1) SunStar KM-235 Model
①Attach the main power switch first since the power switch is
located normally in between the solenoid brackets.
②By referring to the figure on the right and the mounting
instructions enclosed in the packaging box, locate the insertion
surface of the oil pan, and then attach the foot-lift solenoid.
(2) SunStar KM-250 Model
①First, assemble a panel for the attachment of presser foot
solenoid on the back of KM-250.
②Attach the presser foot solenoid to a bracket“A”.
③Attach the bracket“A”with the presser foot solenoid to the
panel above.
④Attch a crank to a solenoid shaft and then connect it to a
sewing machine.
⑤Place a cover on the solenoid.
(3) SunStar Special-specification models
The same mounting procedure for KM-235 model is applicable
for other models listed below.
(4) Adjusting the stroke(Gap) of the automatic foot-lift
solenoid
①Check point
Check to make sure that the stroke-adjusting screw is
located at the center of the solenoid axis, i.e., the solenoid
should be assembled in parallel with the bottom surface of
the table. If the solenoid is not in paralle, make an
adjustment so that the screw is in parallel with the center of
the solenoid axis using the connection link-fixing screw.
②Adjusting Procedure
The verical travel distance of the presser foot can be adjusted by
the stroke-adjusting screw. First, Loosen the two fixing screws,
and adjsut the vertical stroke using the stroke-adjusting screw.
loosening and tightening the stroke-adjusting screw will decrease
and increase the verical stroke of the presser foot respectively.
After the adjustment, fasten the fixing screw tightly.
No.
1
Solenoid No.
SPF-2
Applicable Models
KM-235A, B
Oil Pan Insertion Surface
Mounting Position
for Legs(4)
Mounting Position(4)
for Automatic
Foot-Lift Solenoid
Oil Pan Insertion Surface
Mounting Position(4)
for Automatic
Foot-Lift Solenoid
Belt Holes
Belt Holes
Oil Pan
Fixing Nuts Solenoid Axis
Stroke-Adjusting Screw
Connection Link-
Fixing Screw
※Specification viewed from the table bottom
※Specification viewed from the table bottom
※KM-250 Rear Panel
Solenoid Bracket A Cover for Foot-Lift Solenoid
No.
1
2
3
4
5
6
7
Solenoid No.
SPF-3
SPF-4
SPF-6
SPF-8
SPF-9
Applicable Models
KM-750-7, KM-750BL-7
KM-790-7, KM-790BL-7
KM-857-7, KM-867-7
KM-560-7
KM-957-7, KM-967-7
KM-757-7
KM-640BL-7

14
4) Mounting the position sensor (Synchronizer) and
setting the film
(1) Mounting the position sensor(Synchronizer)
①SunStar thread-cutting sewing machine.
All SunStar thread-cutting sewing machines are equipped
with a position sensor. Users, therefore, are required to the
adjust the film position, if necessary, as shown in the figure.
②All other sewing machines(including other manufacturers’ brands)
First, attach the position sensor-mounting adapter to the upper shaft of the sewing machine. Second, attach the position sensor-fixing
plate to the body of the sewing machine as shown below in the figure. Third, secure the position sensor to the adapter with the fixing
screws.
L Wrency
Pulley
Synchro shaft-fixing screw(2)
Synchro shaft
Photo film
(Adjusted left and right)
Photo INTERRUPT
COVER
Upper Shaft
P.C.B Holder
Adapter
Position Sensor-Fixing Bolts
Position Sensor
Cable
Position Sensor-Fixing Plate(Type B)
Nylon Cable Tie Fiixing Bolt for Position
Sensor-Fixing Plate
Position Sensor-
Fixing Plate(Type A)
Pulley

15
(2) Adjusting the film of the position sensor
①Assemble the films and position sensor in the order as shown
in the figure.
②Upon the completion of the assembling, position the needle shaft tight at the rising point from the lowest needle position by manually
rotating the pulley. Loosen the film-fixing screw, and adjust the DOWN film so that the film-adjsting line and the sensor housing
calibration line are matched. Tighten the film-fixing screw just to the extent that the film can not be rotated. Likewise, position the thread
take-up at the highest position. Loosen the film-fixing screw, and adjust the UP film as shown in the figure, while using caution not to
move the DOWN film which is already adjusted earlier. Tighten the adjusted film with the fixing screw.
(3) Adjustion the films of reverse rotation sewing machines
※For reverse-rotation sewing machines, the film-adjusting lines located at right edge of the“UP”and“DOWN”film should be matched to
the center line of the sensor.
Fixing Washer Fixing Bushing
Film-Fixing Screw
Position Sensor Shaft
Fixing Nut Fixing Nut
Fixing NutFixing Nut
Setting Position
Setting Position
Sensor Calibration Line
Sensor Calibration Line
Film-Adjusting Line
Film-Adjusting Line(Reverse Rotation)
Sensor Housing
Sensor Housing
The highest position
of take-up lever
The highest position
of take-up lever
Up Film Adjustment
Up Film Adjustment
Down Film Adjustment
Down Film Adjustment
2mm turning around
from the lowest
position of needle bar
2mm turning around
from the lowest
position of needle bar
Caution
After adjustment the film of the position detector, be sure to rotate the motor for 3~5 seconds by pedalling so
that the Controller may remember location of the film.

16
5) How to equip and adjust a built-in location
detector(synchronizer)
(1) How to equip the built-in location detector
(synchronizer)
▶In case of a SunStar thread trimmer
When a built-in location detector(synchronizer) for the
sewing machine with the SunStar thread trimmer is
equipped, all that the users need to do is to simply adjust the
location of magnetic for detection according to their needs.
Locate detector
(synchronizer) Position magnetic up
Upper
Shaft
Position magnetic down
Position magnetic up
Sewing machine
pulley
Locate detector
(synchronizer)
Position
magnetic down
Sewing machine

17
(2) How to adjust the magnet of the location detector
①Assemble the detector in order following the pictures.
②Once assembling is completed, power the controller on and step on the pedal. At this time, make sure that the needle moves up and down.
Stop the needle at a desired location by moving the magnet back and forth along the location where the needle stops.
(3) How to adjust a location detector in case of a reverse rotation sewing machine
※It is the same as that used for the normal rotation direction
Locate detector(synchronizer)
Normal rotation
direction
Reverse rotation
direction Reverse rotation direction
Normal rotation
direction
The highest position
of take-up lever
The highest position
of take-up lever
Locate detector
(synchronizer)
Locate detector
(synchronizer)
2mm turning around
from the lowest
position of needle bar
2mm turning around
from the lowest
position of needle bar
Caution
After adjusting a location detector, rotate the motor by stepping on the pedal for 3~5 seconds so that a
controller can remember the location.

18
6) Mounting the Program Unit(P/U)
(1) SunStar KM-235 Sewing Machine
First, attach the P/U bracket to the P/U using three fixing screws
and a supporting bolt with nut attached on it as shown in the
figure. Second, securely attach the P/U to the head of the sewing
machine using two fixing screws and washers, keeping a 3~4mm
distance between the bottom surface of the nut and the base of the
supporting bolt.
(2) Other SunStar thread-machine
First, attach the P/U bracket to the P/U using the four fixing screws. Second, attach the P/U to the main body of the sewing machine using the
three bracket-fixing screws as shown in the figure.
Program Unit
Program Unit
P/U Bracket
P/U Bracket-Fixing
Screw(3)
Caution Fix the cable using the cable tie so that cable is not in the way of the belt.

19
7) An example of installing the SunStar sewing machine

20
1) Specification of the power plug
(1) Single phase 100V~120V
(2) Single phase 200V~240V
(3) Three phase 200V~240V
※Be sure to connect Protective Earth
2) Specification of electric current in wiring of power plug
Be sure to use wiring materials which can stand electric current of higher than 15A.
WIRING AND GROUNDING
55
110V
220V
220V
EARTHV
EARTHV
EARTHV
Switch Box
Control Box
Control Box
Control Box
Switch Box
Switch Box