SunStar Fortuna IV Series User manual

USER’S MANUAL
PARTS BOOK
Version 03
AC Servo Motor series
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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SSUUNNSSTTAARR MMAACCHHIINNEERRYY CCOO..,, LLTTDD..

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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 12
5. Wiring and grounding 17
6. Connection the earth wire of the sewing machine and motor 20
7. Things to be checked after installation 20
8. Program unit part names and method of use 21
9. Simple operation unit part names and method of use 41
10. Fortuna series 4 full function software method of use 46
11. Breakdown and troubleshooting 70
12. How to place for controller 71
13. Block diagram 72
※Parts Book 73
CCOONNTTEENNTTSS

6
Be sure to read and keep in mind the following instructions before you install and use
the 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
Power 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.
Electromagnetic 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.
Temperature 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%.
Never use it near gases and explosives.
Do not use it at a spot located 1,000m or higer above sea-level.
Keep 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.
Be sure to start installing it after pulling the power plug off the outlet.
Fix 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.)
Be sure to have the Controller and the sewing Machine grounded.
Be sure that the voltage of power source fits the specification of the Controller before the power is on.
Be sure to use Safety Extra Low Voltage when an extra item or an accessory is fitted into the Controller.
4) Disassembly
Indisassembling 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.
When pulling off the plug from the power source, be sure to hole the plug itself instead of the wire connected
to the plug.

7
5) Service and Maintenance
Make sure that service and maintenance are carried out by a skilled technician.
Never try to operate with the Motor and the Controller open.
When inserting a thread into or touching the machine, be sure to turn the power off and step down from the
platform.
Be sure to use standard products specified for replacement of parts.
6) Other Safety Instructions
Tack care not to let your fingers touch any moving parts including belts.
In 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.
Do not try to operate with the safety device removed.
Take care not to let water or coffee or something like those admitted into the Controller or the Motor.
Never 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.

8
1. Do not turn on the power while stepping on the pedal. 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.
Motor
P/U
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. Clean it every two or three weeks so that no dirt or a dirty
substance may be piled up.
10. When replacing the fuse, use a standard item, opening the
cover as shown in the diagram.
11. Make the length of the cable connected with an outside parts
like stand-up pedal as short as possible.

10
Control box back (Full Option Type)Control box front (Full Option Type)
1) Front and back of control box
AC Power switch
AC Power Input Power Cable
Control box grounding part
Option 2 Connector
Pedal Connector
Encoder Connector
Motor Power Connector
Position Detector Connector
P/U Connector
Option 1 Connector
A/B Button Connector
Solenoids Connector
Option 3
Button
A/B
Option1
Option3
S/M
Synchro
P/U
Motor
Encoder
Pedal
Option2
SUNSTAR ELECTRIC CO., LTD.
Control box back (Economic Type)Control box front (Economic Type)
AC Power switch
Simple Controller Board
AC Power Input Power Cable
Control box grounding part
Option 2 Connector
Pedal Connector
Encoder Connector
Motor Power Connector
Position Detector Connector
P/U Connector
Option 1 Connector
A/B Button Connector
Solenoids Connector
Button
A/B
Option1
S/M
Synchro
P/U
Motor
Encoder
Pedal
Option2
SUNSTAR ELECTRIC CO., LTD.

11
2) Control box side
Caution
Specification
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

12
1) Attaching controller to table
2) Attaching pedal unit
As in the figure, attach pedal unit bracket to the underside of table with 15mm fixing screws.
Attach pedal unit to the fixing holes on one side of pedal unit bracket.
Pedal unit bracket should be fixed to the area where the bar linked to the pedal that is to be attached to table leg becomes vertical.
(The area where pedal unit bracket is attached depends on where the pedal is.)
As in the figure, attach control box to the lower right of the table with 15mm fixing screws.
Area where control box is
to be attached
The underside of the table, front part
Right table leg

13
3) Installing and adjusting knee lifter solenoid
(1) For Sunstar KM-2300 Sewing Machine
Assemble Ornamental panel of knee lifter solenoid on the back
of KM-2300 body
Attach knee lifter solenoid on bracket A.
Attach the bracket A fixed on the knee lifter solenoid.
After attaching crank on the solenoid shaft, connect to the
machine.
Put cover over solenoid.
Connect grounding cable.
4) Installing Position detector (Synchronizer) and adjusting Film
(1) Installing Position detector (KM-2300Series, SC-7300Series)
Synchronizer is attached on the machine upon shipment.
When changing and fixing synchronizer, see the manual.
(2) Setting needle bar up-/down- stop position with using program unite (KM-2300Series, SC-7300Series)
- Fortuna Series IV allows a user set up-down stop position by using program unite without changing setting of synchronizer.
Setting needle bar up-down stop with using optional program unite.
Turn on the down-stop icon lamp by pressing needle bar up-/down-stop
button on the program unit to set needle bar down-stop position.
When the up stop lamp on, press needle bar up-down stop button
with pressing the button. After that, as in the figure letter showing
information on the setting target and number pointing the current position
will blink.
Turn the pulley forward manually to move the needle bar to the desired
position. The screen displays changing position of needle bar.
When the needle bar moves to the desired position, save the position by
pressing key. Then, the screen automatically returns to the initial screen
with a buzzer.
[Caution]
Returning to the initial screen by pressing button without pressing button will not save reset values.
KM-2300 Back
Solenoid bracket A
Grounding Cable
Presser foot Solenoid Cover
Solenoid Crank
Solenoid Cover

14
Furthermore, turn on the down-stop icon lamp by pressing needle bar up-
/down-stop button on the program unit to set needle bar down-stop position.
When the down-stop lamp turns on, press button while pressing needle
bar up-/down-stop button. Then, as in the figure right, the information
on what is to be set and the numbers that tell the current position of needle
bar will be shown.
Turn the pulley forward manually to move the needle bar to the desired
position. The screen displays changing position of needle bar.
When the needle bar moves to the desired position, save the position by
pressing key. Then, the screen automatically returns to the initial screen
with a buzzer.
[Caution]
Returning to the initial screen by pressing button without pressing button will not save reset values.
Setting needle bar up-/down-stop position by using simple controller board (front OP).
Turn on the up-stop icon lamp by pressing needle bar up-/down-stop button
on the simple controller board to set needle bar up-stop position.
When the up-stop lamp turns on, press “E” button while pressing needle bar
up-/down-stop button ( C). Then, as in the figure right, the numbers that tell
the current position of needle bar will be displayed.
The operator turns the pulley forward manually to move the needle bar to the
desired position. The screen displays changing position of needle bar.
When the needle bar moves to the desired position, save the position by
pressing Ckey. Then, the screen automatically returns to the initial screen
with a buzzer.
[Caution]
Returning to the initial screen by pressing Ebutton without pressing Cbutton will not save reset values.

15
To set needle bar down stop position, press needle bar up-down stop button
of simple controller board to make on the icon lamp of needle bar up stop.
When the down stop lamp on, press needle bar up-down stop button C
with pressing Ebutton. After that, number pointing the current needle bar
position will blink.
Turn the pulley forward manually to move the needle bar to the desired
position. The screen displays changing position of needle bar.
When the needle bar moves to the desired position, save the position by
pressing Ckey. Then, the screen automatically returns to the initial screen
with a buzzer.
[Caution]
Returning to the initial screen by pressing Ebutton without pressing Cbutton will not save reset values.
[Caution]
The names of buttons on simple controller board are as follows.
①A Button switch( Switch for initial Reverse)
②B Button switch (Switch for end reverse)
③C Button switch (Switch for needle bar up-down stop when the machine
stops)
④D Button switch (Switch for automatic presser foot ascending when the
machine stops)
⑤E Button switch (Switch for program)
①
②
③
④
⑤

16
6) Installing program unit
As in the figure below, attach program unit bracket to program unit with three fixing screws. As in the figure, attach the bracket with
program unit to the head of machine firmly with two fixing screws.
7) SunStar machine installed with program unit

17
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.

18
3) Names and Explanation of external connector in control box
[ Pin Number ]
[ Pin Number ] [ Pin Number ]
[ Pin Number ]
5,13: Left needle control
solenoid
6,14: Right needle control
solenoid
7,15: Thread release solenoid
8,16: Auxiliary solenoid
1, 9: Back Tack solenoid
2,10: knee lifter solenoid
3,11: Trimming solenoid
4,12: Wiper solenoid
1,5: Manual Back tack
button
2,6: Back tack Insert/Delete
Button
3,7: Knee lifter solenoid switch
4,8: Safety Switch
Solenoid Connector (5566-16P) Basic switch connector (5566-8P)
Switch and lamp connector (5566-14P) Extension connector (5566-20P)
4) Changing solenoid supply voltage (Basic setting values upon shipment: J19)
It is for a good operation of solenoid when AC input voltage changes.
Setting values of solenoid supply voltage against input voltage (input voltage 220V series)
Solenoid with the rating current of 30V Solenoid with the rating current of 24V
Input Voltage Setting Values
Less than 210V J20
210V~230V J19
More than 230V J18
Input Voltage Setting Values
Less than 180V J20
180V~190V J19
More than 190V J18
1, 2, 9, 10 : 12[V] 13 : Output 12
3~8 : GND 14 : Output 13
11, 12, 19, 20 : VCC (5[V]) 15 : Output 14
13~18: Extension Port 16 : Output 15
17 : External Input 00
18 : External Input 01
1, 2, 7 : GND 9 : 4/4
3 : Left switch LED 10 : 3/4
4 : Right switch LED 11 : 2/4
5 : Left switch 12 : 1/4
6 : Right switch 13 : Switch-CNT
8 : VCC (5[V]) 14 : Switch-HALF

19
Setting values of supplied voltage to solenoid against input voltage (Input voltage: 110V)
Setting supplied voltage
Solenoid with rating current of 30V Solenoid with rating current of 24V
Input Voltage Setting Values
Less than 100V J20
100V~120V J19
More than 120V J18
Input Voltage Setting Values
Less than 90V J20
90V~100V J19
More than 100V J18
J22
J20
J19
J18
P5 P4

20
Method
As in the figure, connect grounding conductors (green or
green/yellow) that link the machine and the controller. Check if
grounding part of power is connected to the grounding conductors.
1) Before the power is on...
Make sure that the incoming voltage is in accordance with that shown in the name plate of the Control box.
Check whether the following connectors are connected.
Check to see the fixing nuts for pulley are tightly fastened.
Check whether the sewing machines are right kinds (Chain Stitch S/M, Lock Stitch S/M)
Check the rated voltage for Solenoid (Refer to How to change the electric voltage supplied for Solenoid ))
2) After the power is on...
Check whether the program unit is working.
Check the direction of rotation of the Sewing Machine.
In case the direction of rotation is not right, action shall be taken to change set it right, referring to the methods of changing the
program and the list of changing functions (N. 65 in Group A )
Check to see whether there are abnormal heat, smell or noise nearby.
In case there are, turn the power off and call our regional office.
SUNSTARELECTRIC CO., LTD.
Option3
Motor
P/U
S/M
Option1
A/B
Button
Encoder
Synchro
Option2
Pedal
Caution
Failure to ground the motor can cause abnormal
operations, such as overspeed rotation or unwanted
stitching.